-

n,1ce nual

..~
~
.~ ·~ .
..
. ~=:

•
EAS20003

IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Please refer to "BASIC INFORMATION" (separate volume, YOA-28197-1 O*) for basic instructions that
must be observed during servicing. Repair and maintenance work attempted by anyone without this
knowledge is likely to render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the vehi-
cle will operate as designed. If there is any question about a service procedure, it is imperative that you
contact a Yamaha dealer for any service information changes that apply to this model. This policy is
intended to provide the customer with the most satisfaction from their vehicle and to conform to federal
environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• * If the contents of the manual are revised, the last digit of the manual number will be increased by
one.
• This Service Manual contains information regarding periodic maintenance to the emission control sys-
tem. Please read this material carefully.
• Designs and specifications are subject to change without notice.

EAS30001

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential personal inju-
ry hazards. Obey all safety messages that follow this symbol to avoid possible
injury or death.

A WARNING indicates a hazardous situation which, if not avoided, could result

A WARNING in death or serious injury.

~
A NOTICE indicates special precautions that must be taken to avoid damage to
NOTICE , the vehicle or other property.

ITIP I A TIP provides key information to make procedures easier or clearer.

EAS20002

MTT9K/MTT9KC/MTT9GTK/MTT9GTKC
SERVICE MANUAL
©2019 by Yamaha Motor Corporation, U.S.A.
First edition, April 2018
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
P/N LIT-11616-32-10
 SERVICE MANUAL

BA I INF RMATI N

LIT-11616-MC-BO YOA-28197-10
IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics.
Th is manual contains only basic instructions that must be observed during servicing. Refer to the ap-
plicable service manual for detailed information on checking, adjustment, and replacement.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Designs and specifications are subject to change without notice.

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential personal
& injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.

A WARNING indicates a hazardous situation which, if not avoided, could

~ WARNING result in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid

NOTICE damage to the vehicle or other property.

TIP A T IP provides key information to make procedures easier or clearer.

BASIC INFORMATION
SERVICE MANUAL
©2017 by Yamaha Motor Corporation, U.S.A.
First edition, January 2017
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
P/N LIT-11616-MC-BO
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 w ith engine mounted 1

- Gear oil
~
1
~ Filling fluid
~
- Brake fluid

1
-
m
I Lubricant Silicone fluid

)b Special tool ~ Wheel bearing grease

~~ Tightening torque ... Lithium-soap-based grease

~ Wear limit, clearance

~ Molybdenum disulfide grease

C) Engine speed ~ Silicone grease

-'
~ Electrical data
A Apply locking agent (LOCTITE®).

1
m Engine oil Replace the part with a new one.

-1 Molybdenum disu lfide oil

~
 CONTENTS

IMPORTANT INFORMATION ............................................................................ 1

PREPARATION FOR REMOVAL AND DISASSEMBLY .............................. 1
REPLACEMENT PARTS .............................................................................. 1
GASKETS, OIL SEALS AND 0 -RINGS ....................................................... 1
LOCK WASHERS/PLATES AND COTTER PINS ........................................ 1
BEARINGS AND OIL SEALS ....................................................................... 2
CIRCLIPS ... .............. ........................... .............. ........................... .............. .. 2
RUBBER PARTS ..... .............. .............. .............. .............. ............ .............. ... 2

BASIC SERVICE INFORMATION ...................................................................... 3

QU ICK FASTENERS .............. ............. ............. ....................................... ..... 3
ELECTRICAL SYSTEM ................................................................................ 4
GENERAL TIGHTENING TORQUE SPECIFICATIONS .............................. 8
ADJUSTING THE WHEEL STATIC BALANCE ............................................ 9
CHECKING THE SWITCHES .................................................................... 10
CHECKING THE BULBS AND BULB SOCKETS ...................................... 10
CHECKING AND CHARGING THE BATTERY .......................................... 12

TROUBLESHOOTING ...................................................................................... 16
GENERAL INFORMATION ........................................................................ 16
TROUBLESHOOTING OF ENGINE (fault code not detected) ................... 16
TROUBLESHOOTING OF CLUTCH .......................................................... 27
TROUBLESHOOTING OF TRANSM ISSION ............................................. 30
TROUBLESHOOTING OF COOLING SYSTEM ........................................ 31
TROUBLESHOOTING OF BRAKE ............................................................ 32
TROUBLESHOOTING AT ABS WARNING LIGHT .................................... 33
TROUBLESHOOTING OF SUSPENSION ................................................. 34
TROUBLESHOOTING OF STEERING/HANDLING .................................. 36
TROUBLESHOOTING OF CHARG ING SYSTEM ..................................... 37
TROUBLESHOOTING OF LIGHTING SYSTEM ........................................ 37
TROUBLESHOOTING OF SIGNALING SYSTEM ..................................... 37
 IMPORTANT INFORMATION

IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.

GASKETS, OIL SEALS AND 0-RINGS

1. When overhauling the engine, replace all
gaskets, seals and 0-rings. All gasket surfac-
es, oil seal lips and 0-rings must be cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
2. Use only the proper tools and cleaning equip-
lips with grease.
ment.
Refer to "SPECIAL TOOLS" in the applicable
service manual.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders,
pistons and other parts that have been "mat-
ed" through normal wear. Mated parts must
always be reused or replaced as an assem- 4
bly.

,,,_._ -==--
'--~.~ f'? 1 - -=- 1 . Oil
2. Lip
3. Spring
4. Grease

LOCK WASHERS/PLATES AND COTTER

PINS
After removal, replace all lock washers/plates
"1" and cotter pins. After the bolt or nut has been
4. During disassembly, clean all of the parts and
tightened to specification, bend the lock tabs
place them in trays in the order of disassem-
along a flat of the bolt or nut.
bly. This will speed up assembly and allow for
the correct installation of all parts.
5. Keep all parts away from any source of fire.

REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by Ya-
maha for all lubrication jobs. Other brands may
be similar in function and appearance, but inferi-
or in quality.

1
 IMPORTANT INFORMATION

BEARINGS AND OIL SEALS RUBBER PARTS

Install bearings "1" and oil seals "2" so that the
manufacturer marks or numbers are visible.
When installing oil seals, lubricate the oil seal
lips with a light coat of lithium-soap-based
grease. Oil bearings liberally when installing, if
appropriate.
ECA13300
Check rubber parts for deterioration during in-
spection. Some of the rubber parts are sensitive
to gasoline, flammable oil, grease, etc. Do not al-
low any items other than the specified one to
contact the parts.

NOTICE
- - - - - - - - - - - - -
Do not spin the bearing with compressed air
because this will damage the bearing surfac-
es.

CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al-
ways replace piston pin clips after one use.
When installing a circlip "1", make sure the
sharp-edged corner "2" is positioned opposite
the thrust "3" that the circlip receives.

1
3
2

2
 BASIC SERVICE INFORMATION

BASIC SERVICE INFORMATION

QUICK FASTENERS

Rivet type
1. Remove:
• Quick fastener
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
a
To remove the quick fastener, push its pin with a
screwdriver, then pull the fastener out.

Screw type 1
1. Remove:
• Quick fastener
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
.-,.• I
To remove the quick fastener, loosen the screw
(j with a screwdriver, then pull the fastener out.

2. Install:
• Quick fastener
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
To install the quick fastener, push its pin so that
it protrudes from the fastener head, then insert
the fastener into the part to be secured and push
the pin "a" in with a screwdriver. Make sure that
the pin is flush with the fastener's head. 2. Install:
• Quick fastener
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
To install the quick fastener, insert the fastener

1Ir.. into the part to be secured and tighten the screw .

l1l

3
 BASIC SERVICE INFORMATION

Screw type 2
1. Remove:
• Quick fastener
,-
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
To remove the quick fastener, loosen the screw
with a screwdriver, then pull the fastener out.
~ .~.) 1J

ELECTRICAL SYSTEM

Electrical parts handling

ECA16600

NOTICE
-------------
Never disconnect a battery lead while the en-
gine is running; otherwise, the electrical
components could be damaged.

2. Install:
• Quick fastener ECAt 6751

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
To install the quick fastener, insert the fastener
into the part to be secured and tighten the screw
"a".
NOTICE
-------------
When disconnecting the battery leads from
the battery, be sure to disconnect the nega-
tive battery lead first, then the positive bat-
tery lead. If the positive battery lead is
disconnected first and a tool or similar item
contacts the vehicle, a spark could be gener-
ated, which is extremely dangerous.

4
 BASIC SERVICE INFORMATION

e e

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ ECAt66t0

NOTICE
If a battery lead is difficult to disconnect due to --:--------------
Turn the main switch to "OFF" before dis-
rust on the battery terminal, remove the rust us-
connecting or connecting an electrical com-
ing hot water.
ponent.

ECA16760
ECAt 6620
NOTICE
-------------
Be sure to connect the battery leads to the
NOTICE
~--=------------
Handle electrical components with special
correct battery terminals. Reversing the bat-
care, and do not subject them to strong
tery lead connections could damage the
shocks.
electrical components.

ECAt 6630
ECAt6n1
NOTICE
NOTICE -------------
----=-=---=----------
When connecting the battery leads to the
Electrical components are very sensitive to
and can be damaged by static electricity.
battery, be sure to connect the positive bat-
Therefore, never touch the terminals and be
tery lead first, then the negative battery lead.
sure to keep the contacts clean.
If the negative battery lead is connected first
and a tool or similar item contacts the vehi-
cle while the positive battery lead is being
connected, a spark could be generated
which is extremely dangerous. '

5
 BASIC SERVICE INFORMATION

ECAt 6640
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
NOTICE _ _ _ _ _ _ _ _ _ _ _ __
When resetting the ECU by turning the main
For waterproof couplers, never insert the
switch to "OFP', be sure to wait approximately 5
tester probes directly into the coupler. When
seconds before turning the main switch back to
performing any checks using a waterproof
"ON".
coupler, use the specified test harness or a
suitable commercially available test har-
ness.

..
Checking the electrical system
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Before checking the electrical system, make
Checking the connections
sure that the battery voltage is at least 12 V.
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
• Lead
• Coupler
• Connector
ECAt 6780

NOTICE
-------------
• When disconnecting a coupler, release the
coupler lock, hold both sections of the cou-
pler securely, and then disconnect the cou-
ECAt4371

-
NOTICE _ _ _ _ _ _ _ _ _ _ _ __
pler.
• There are many types of coupler locks;
Never insert the tester probes into the cou- therefore, be sure to check the type of cou-
pler terminal slots. Always insert the probes pler lock before disconnecting the coupler.
from the opposite end "a" of the coupler, tak-
ing care not to loosen or damage the leads.

6
 BASIC SERVICE INFORMATION

• Make sure all connections are tight.

ECAt6790

NOTICE
-------------
When disconnecting a connector, do not pull
the leads. Hold both sections of the connec-
:
tor securely, and then disconnect the con-
nector.

:
4. Check:
• Continuity
(with the digital circuit tester (CD732))

Digital circuit tester (CD732)

90890-03243
2. Check:
Model 88 Multimeter with ta-
chometer
• Lead
YU-A1927
• Coupler
• Connector TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Moisture ➔ Dry with an air blower.
• If there is no continuity, clean the terminals.
Rust/stains ➔ Connect and disconnect sev-
• When checking the wire harness, perform
eral times.
steps (1) to (4).
•Asa quick remedy, use a contact revitalizer
available at most part stores.

D
<==Q>

3. Connect:
• Lead
• Coupler
• Connector
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• When connecting a coupler or connector, push
both sections of the coupler or connector to-
gether until they are connected securely.

7
 BASIC SERVICE INFORMATION

GENERAL TIGHTENING TORQUE

SPECIFICATIONS
D
(C>C> Ql
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread pitch.
Refer to the applicable service manual for tight-
ening torque specifications of special compo-
nents or assemblies. To avoid warpage, tighten
multi-fastener assemblies in a crisscross pattern
and progressive stages until the specified tight-
ening torque is reached. Unless otherwise spec-
5. Check: ified, tightening torque specifications require
• Resistance clean, dry threads. Components should be at
room temperature .
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927
0
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ A
The resistance values shown were obtained at
the standard measuring temperature of 20 °C
(68 ° F). If the measuring temperature is not 20
°C (68 °F), the specified measuring conditions A. Distance between flats
will be shown. B. Outside thread diameter

General tightening
Intake air temperature sensor re- B
A (nut) torques
sistance (bolt)
5.40-6.60 kQ at o °C (32 °F) N-m kgf-m lb-ft
290-390 n at 80 °c (176 °F)
10 mm 6mm 6 0.6 4.4
12 mm 8mm 15 1.5 11
14 mm 10 mm 30 3 22
~ 17 mm 12 mm 55 5.5 41
1

-- I
,~-
I
7
«=>= lJ)

,~ 19 mm
22 mm
14 mm
16 mm
85
130
8.5
13
63
95.9
•I
- . if). 0
- - },

8
 BASIC SERVICE INFORMATION

ADJUSTING THE WHEEL STATIC BALANCE TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ Start with the lightest weight.
• After replacing the tire, wheel or both, the
wheel static balance shou ld be adjusted.
• Adjust the wheel static balance with the brake
disc installed.

1. Remove:
• Balancing weight(s)
2. Find:
• Wheel's heavy spot
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Place the wheel on a suitable balancing stand.
b . Turn the wheel go 0 so that the heavy spot is
a. Spin the wheel. positioned as shown .
b . When the wheel stops, put an "X/' mark at
the bottom of the wheel.

X •

c. If the heavy spot does not stay in that posi-

tion, install a heavier weight.
d. Repeat steps (b) and (c) until the wheel is
c. Turn the wheel go 0 so that the "X/' mark is
balanced.
positioned as shown .
d. Release the wheel. 4. Check:
e. When the wheel stops, put an "X2" mark at • Wheel static balance
the bottom of the wheel. a. Turn the wheel and make sure it stays at
each position shown .
X
•
x.
X X

f. Repeat steps (c) through (e) several times

until all the marks come to rest at the same b . If the wheel does not remain stationary at all
spot. of the positions, rebalance it.
g. The spot where all the marks come to rest is
the wheel's heavy spot "X".

3. Adjust:
• Wheel static balance
a. Install a balancing weight "1" onto the rim
exactly opposite the heavy spot "X".

9
 BASIC SERVICE INFORMATION

CHECKING THE SWITCHES

Check each switch for continuity with the digital b
circuit tester. If the continuity reading is incor-
rect, check the wiring connections and if neces-
,
------
ON
R/W Br/l Br/R
( )- -(}- 1-( )
sary, replace the switch. a OFF
ECAt4371
p :: (; ')
NOTICE -
-------------
Never insert the tester probes into the cou- .r
R/W
Br/R
pler terminal slots. Always insert the probes Br/L V

from the opposite end "a" of the coupler, tak-

ing care not to loosen or damage the leads.
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Before checking for continuity, set the digital
circuit tester to the "Q" range.
• When checking for continuity, switch back and
forth between the switch positions a few times.
D
eoo
The terminal connections for switches (e.g.,
main switch, engine stop switch) are indicated in
an illustration as shown in the following exam-
ple.
The switch positions "a" are shown in the far left
column and the switch lead colors "b" are shown
in the top row in the switch illustration.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
"0---0" indicates a continuity of electricity be-
tween switch terminals (i.e., a closed circuit at
the respective switch position).
CHECKING THE BULBS AND BULB
SOCKETS
Check each bulb and bulb socket for damage or
wear, proper connections, and also for continuity
between the terminals.
Damage/wear ➔ Repair or replace the bulb,
bulb socket or both.
Improperly connected ➔ Properly connect.
No continuity ➔ Repair or replace the bulb, bulb
socket or both.
Types of bulbs
The bulbs used on this vehicle are shown in the
following illustration.
• Bulbs "a" and "b" are used for the headlights
and usually use a bulb holder that must be de-
tached before removing the bulb . The majority
of these types of bulbs can be removed from
their respective socket by turning them coun-
terclockwise.
• Bulbs "c" are used for turn signal lights and can
be removed from the socket by pushing and
turning the bulb counterclockwise.
• Bulbs "d" and "e" are used for license plate and
auxiliary lights and can be removed from their
respective sockets by carefully pulling them
out.

The example illustration below shows that:

There is continuity between red/white, brown/
blue and brown/red when the switch is set to
"ON".
There is continuity between red/white and
brown/red when the switch is set to" p,('.

10
 BASIC SERVICE INFORMATION
a 90890-03243
C minal "2", and check the continuity.
d e
Checking the condition of the bulbs
The following procedure applies to all of the
bulbs.
1. Remove:
• Bulb
EWA13320
AwARNING
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
ECA14381
NOTICE - -------------
• Be sure to hold the socket firmly when re-
moving the bulb. Never pull the lead, other-
wise it may be pulled out of the terminal in
the coupler.
• Avoid touching the glass part of a headlight
bulb to keep it free from oil, otherwise the
transparency of the glass, the life of the
bulb, and the luminous flux will be adverse-
ly affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
2. Check:
• Bulb (for continuity)
(with the digital circuit tester)
No continuity ➔ Replace .
11
Digital circuit tester (CD732)
Model 88 Multimeter with ta-
chometer
YU-A1927
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Before checking for continuity, set the digital cir-
cuit tester to the "Q " range.
a. Connect the positive tester probe to termi-
nal "1" and the negative tester probe to ter-
b . Connect the positive tester probe to termi-
nal "1" and the negative tester probe to ter-
minal "3", and check the continuity.
c. If either of the readings indicate no continu-
ity, replace the bulb.
x 1
0 /::.:\
2
2
Checking the condition of the bulb sockets
The following procedure applies to all of the bulb
sockets.
1. Check:
• Bulb socket (for continuity)
(with the digital circuit tester)
No continuity ➔ Replace.
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Check each bulb socket for continuity in the
same manner as described in the bulb section;
however, note the following.
a. Install a good bulb into the bulb socket.
b . Connect the digital circuit tester probes to
the respective leads of the bulb socket.
 BASIC SERVICE INFORMATION
c. Check the bulb socket for continuity. If any
of the readings indicate no continuity, re-
place the bulb socket.
CHECKING AND CHARGING THE BATTERY
EWA13290
jl WARNING
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of poi-
sonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
• Wear protective eye gear when handling or
working near batteries.
• Charge batteries in a well-ventilated area.
• Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
• DO NOT SMOKE when charging or han-
dling batteries.
• KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
• Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
•Skin-Wash with water.
• Eyes- Flush with water for 15 minutes and
get immediate medical attention.
INTERNAL
• Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg or
vegetable oil. Get immediate medical atten-
tion.
VRLA type battery
ECA13661
NOTICE
• This is a-------------
VRLA (Valve Regulated Lead Acid)
battery. Never remove the sealing caps be-
cause the balance between cells will not be
maintained and battery performance will
deteriorate.
• Charging time, charging amperage and
charging voltage for a VRLA (Valve Regu-
lated Lead Acid) battery are different from
those of conventional batteries. The VRLA
(Valve Regulated Lead Acid) battery should
be charged according to the appropriate
charging method. If the battery is over-
charged, the electrolyte level will drop con-
12
siderably. Therefore, take special care
when charging the battery.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Since VRLA (Valve Regulated Lead Acid) bat-
teries are sealed, it is not possible to check the
charge state of the battery by measuring the
specific gravity of the electrolyte . Therefore, the
charge of the battery has to be checked by mea-
suring the voltage at the battery terminals.
1. Check:
• Battery charge
a. Connect a digital circuit tester to the battery
terminals.
• Positive tester probe ➔
positive battery terminal
• Negative tester probe ➔
negative battery terminal
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• The charge state of a VRLA (Valve Regulated
Lead Acid) battery can be checked by measur-
ing its open-circuit voltage (i.e., the voltage
when the positive battery terminal is discon-
nected) .
• No charging is necessary when the open-cir-
cuit voltage equals or exceeds 12.8 V.
b. Check the charge of the battery, as shown
in the charts and the following example.
Example
Open-circuit voltage = 12.0 V
Charging time = 6.5 hours
Charge of the battery = 20- 30%
A
13.0
12.5
12.0 - .... - - - - - - -
11.5
5 6.5 10 B
D
A. Open-circuit voltage (V)
B. Charging time (hours)
C. Relationship between the open-circuit volt-
age and the charging time at 20 °C (68 °F)
D. These values vary with the temperature, the
condition of the battery plates, and the elec-
trolyte level.
 BASIC SERVICE INFORMATION

ulated Lead Acid) battery stabilizes about

A
14 30 minutes after charging has been com-
I
13 pleted. Therefore, wait 30 minutes after
12
-::::::::::~
I
C
charging is completed before measuring
I
~ the open-circuit voltage.
I I
11 I
I
I I
I A .. -·-•
C
10 I
I I 18
D
I I
I 17
100 75 50
'
302520 0 B 16
15
A. Open-circuit voltage (V) 14
\
B. Charging condition of the battery (0/o) 13
12
C. Ambient temperature 20 °C (68 °F) 11
10
o 10 20 30 40 so 60 B
2. Charge : 4E
• Battery
A. Open-circuit voltage (V)
(refer to the appropriate charging method)
EWA13300 B. Time (minutes)
~ WARNING C. Charging
Do not quick charge a battery. D. Ambient temperature 20 °C (68 °F)
E. Check the open-circuit voltage.
ECA13671

NOTICE Charging method using a variable-current

-------------
• Do not use a high-rate battery charger
since it forces a high-amperage current
into the battery quickly and can cause bat-
tery overheating and battery plate damage.
• If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
• When charging a battery, be sure to remove
it from the vehicle. (If charging has to be
done with the battery mounted on the vehi-
cle, disconnect the negative battery lead
from the battery terminal.)
• To reduce the chance of sparks, do not
plug in the battery charger until the battery
charger leads are connected to the battery.
• Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.
• Make sure the battery charger lead clips are
in full contact with the battery terminal and
that they are not shorted. A corroded bat-
tery charger lead clip may generate heat in
the contact area and a weak clip spring may
cause sparks.
• If the battery becomes hot to the touch at
any time during the charging process, dis-
connect the battery charger and let the bat-
tery cool before reconnecting it. Hot
batteries can explode!
• As shown in the following illustration, the
open-circuit voltage of a VRLA (Valve Reg-
(voltage) charger
a. Measure the open-circuit voltage prior to
charging.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Voltage should be measured 30 minutes after
the engine is stopped.
b . Connect a charger and ammeter to the bat-
tery and start charging .
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Set the charging voltage to 16-17 V. If the set-
ting is lower, charging will be insufficient. If too
high, the battery will be over-charged.
c. Make sure that the current is higher than
the standard charging current written on the
battery.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
If the current is lower than the standard charging
current written on the battery, set the charging
voltage adjust dial at 20- 24 V and monitor the
amperage for 3- 5 minutes to check the battery.
• Standard charging current is reached
Battery is good.
• Standard charging current is not reached
Replace the battery.
d. Adjust the voltage so that the current is at
the standard charging level.

13
 BASIC SERVICE INFORMATION
e . Set the time according to the charging time
suitable for the open-circuit voltage.
f . If charging requires more than 5 hours, it is
advisable to check the charging current af-
ter a lapse of 5 hours. If there is any change
in the amperage, readjust the voltage to ob-
tain the standard charging current.
g . Measure the battery open-circuit voltage af-
ter leaving the battery unused for more than
30 m inutes.
12.8 V or more --- Charging is complete .
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
Charging method using a constant volt-
age charger
a . Measure the open-circuit voltage prior to
charging .
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Voltage should be measured 30 minutes after
the engine is stopped.
b . Connect a charger and ammeter to the bat-
tery and start charging .
c. Make sure that the current is higher than
the standard charging current written on the
battery.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
If the current is lower than the standard charging
current written on the battery, this type of battery
charger cannot charge the VRLA (Valve Regu-
lated Lead Acid} battery. A variable voltage
charger is recommended .
d . Charge the battery until the battery's
charging voltage is 15 V.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Set the charging time at 20 hours (maximum) .
e . Measure the battery open-circuit voltage af-
ter leaving the battery unused for more than
30 m inutes.
12.8 V or more --- Charging is complete .
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
14
Open type battery
1. Check:
• Electrolyte level
The electrolyte level shou ld be between the
minimum level mark "a" and the maximum
level mark "b".
Below the min imum level mark ➔ Add dis-
tilled water to the proper level.
ECA136 t0
NOTICE
-------------
Add only distilled water. Tap water contains
minerals which are harmful to the battery.
- UPPERl EVEL -
e
2. Check:
• Specific gravity
Less than 1.28 ➔ Recharge the battery.
Specific gravity
1.28
3. Charge :
• Battery
Battery charging amperage and time
Refer to "ELECTRICAL SPEC IFICATIONS"
in the applicable service manual.
EWA13300
jl WARNING
Do not quick charge a battery.
ECA 13620
NOTICE -- - - - - - - - - - - - - -
• Loosen the battery sealing caps.
• Make sure the battery breather hose and
battery vent are free of obstructions.
• To ensure maximum performance, always
charge a new battery before using it.
• Do not use a high-rate battery charger.
They force a high-amperage current into
the battery quickly and can cause battery
overheating and battery plate damage.
• If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
 BASIC SERVICE INFORMATION

• When charging a battery, be sure to remove

it from the vehicle. (If charging has to be
done with the battery mounted on the vehi-
cle, disconnect the negative lead from the
battery terminal.)
• To reduce the chance of sparks, do not
plug in the battery charger until the battery
charger leads are connected to the battery.
• Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.
• Make sure the battery charger lead clips are
in full contact with the battery terminal and
that they are not shorted. A corroded bat-
tery charger lead clip may generate heat in
the contact area and a weak clip spring may
cause sparks.
• If the battery becomes hot to the touch at
any time during the charging process, dis-
connect the battery charger and let the bat-
tery cool before reconnecting it. Hot batter-
ies can explode!
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Replace the battery whenever:
• battery voltage does not rise to specification or
bubbles fail to rise during charging,
• sulphation of one or more battery cells occurs
(as indicated by the battery plates turning white
or material accumulating in the bottom of the
battery cell),
• specific gravity readings after a long, slow
charge indicate that one battery cell's charge is
lower than the rest,
• warpage or buckling of the battery plates or in-
sulators is evident.

4. Check:
• Battery breather hose and battery vent
Obstruction ➔ Clean.
Damage ➔ Replace.

15
 TROUBLESHOOTING

TROUBLESHOOTING
GENERAL INFORMATION
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Troubleshooting information provided here does not cover all the trouble symptoms, possible causes,
and remedial actions. Some items may not apply depending on the model. Use this information as a
guide and quick reference matrix when performing basic troubleshooting. Refer to the applicable Ser-
vice manual for detailed information on checking, adjustment, and replacement.

TROUBLESHOOTING OF ENGINE (fault code not detected)

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
If a fau lt code is detected, refer to the "ECU SELF-DIAGNOSTIC FUNCTION" under "FUEL INJEC-
TION SYSTEM" (ELECTRICAL SYSTEM) in the Service manual.

Engine does not crank.

Symptom
Starter motor does not operate
Starter motor operates, but the
engine does not crank.
Possible cause Actions
Refer to "TROUBLESHOOTING" under "ELECTRIC STARTING
SYSTEM" (ELECTRICAL SYSTEM) in the Service manual.
Starter clutch malfunction Replace the starter clutch .
Improper oil grade (starter Change to recommended en-
clutch slipping) gine oil.
Stuck piston or seized crank- Disassemble and check the en-
shaft gine . Replace defective parts.

Engine will not start or is difficult to start, but it cranks (fuel injection models).
Symptom Possible cause Actions
Spark plug does not produce a Refer to "TROUBLESHOOTING" under "IGN ITION SYSTEM"
spark (ELECTRICAL SYSTEM) in the Service manual.
Fuel not supplied - Measure the fuel pressure .
Empty fuel tank Fill the fuel tank with fuel.
Clogged fuel tank cap breather Clean the fuel tank cap.
hole
Clogged or damaged fuel hose Clean, repair, or replace the
fuel hose .
Fuel leakage Check the fuel passage . Repair
or replace as necessary.
Clogged fuel pump Clean or replace the fuel pump.
Cracks or damage in fuel pump Replace the fuel pump.
Fuel pump malfunction Refer to "TROUBLESHOOT-
ING" under "FUEL PUMP SYS-
TEM" (ELECTRICAL SYSTEM)
in the Service manual.
Failed or clogged fuel injector Replace the fuel injector.
ECU failure Replace the ECU .
- Water or foreign material in fuel, Change fuel.
degraded fuel

16

Symptom
Compression pressure is low
TROUBLESHOOTING
Possible cause Actions
- Measure the compression pres-
sure .
Loose spark plug Tighten the spark plug to the
specified torque .
Loose cylinder head or cylinder Tighten bolts or nuts on cylinder
head and cylinder to the speci-
tied torque.
Damaged cylinder head gasket Replace the cylinder head gas-
ket.
Incorrect valve timing Adjust the valve tim ing .
Incorrect valve clearance Adjust the valve clearance.
Worn valve gu ide Replace the valve guide.
Bent, damaged, or stuck valve Replace the valve .
Poor contact between valve Reface the valve-to-valve-seat
and valve seat contact.
Fatigued or broken valve spring Replace the valve spring .
Worn, damaged, or stuck piston Replace the piston and piston
nng rings as a set.
Seized or damaged piston Replace the piston and piston
rings as a set.
Worn or damaged cylinder bore Replace the cylinder, piston,
and piston rings as a set.
17
 TROUBLESHOOTING

Engine will not start or is difficult to start, but it cranks (carburetor models).
Symptom Possible cause Actions
Spark plug does not produce a Refer to "TROUBLESHOOTING" under "IGNITION SYSTEM"
spark (ELECTRICAL SYSTEM) in the Service manual.
Fuel not supplied Empty fuel tank Fill the fuel tank with fuel.
Clogged fuel tank cap breather Clean the fuel tank cap.
hole
Clogged or damaged fuel hose Clean, repair, or replace the
fuel hose.
Fuel leakage Check the fuel passage. Repair
or replace as necessary.
Clogged fuel cock strainer Clean or replace the fuel cock
strainer.
Clogged fuel cock Clean or replace the fuel cock.
Cracked, damaged or worn fuel Replace the fuel cock.
cock.
Clogged carburetor fuel pas- Clean the carburetor.
sage
Clogged needle valve or needle Clean the needle valve or nee-
valve seat die valve seat.
Damaged float Replace the float.
Clogged pilot jet Clean the pilot jet.
Clogged starter jet Clean the starter jet.
Bent or damaged starter plung- Replace the starter plunger.
er
Incorrectly adjusted starter ea- Adjust the starter cable.
ble
- Water or foreign material in fuel, Change fuel.
degraded fuel

18

Symptom
Compression pressure is low
Incorrect idling speed or mid-to-high speed (fuel injection models)
Symptom
Spark plug does not produce a
spark
Low fuel pressure
Fuel not supplied
Compression pressure is low
TROUBLESHOOTING
Possible cause Actions
- Measure the compression pres-
sure.
Loose spark plug Tighten the spark plugs to the
specified torque.
Loose cylinder head or cylinder Tighten bolts or nuts on cylinder
head and cylinder to the speci-
tied torque.
Damaged cylinder head gasket Replace the cylinder head gas-
ket.
Incorrect valve timing Adjust the valve timing.
Incorrect valve clearance Adjust the valve clearance.
Worn valve guide Replace the valve guide.
Bent, damaged, or stuck valve Replace the valve.
Poor contact between valve Reface the valve-to-valve-seat
and valve seat contact.
Fatigued or broken valve spring Replace the valve spring.
Worn, damaged, or stuck piston Replace the piston and piston
nng rings as a set.
Seized or damaged piston Replace the piston and piston
rings as a set.
Worn or damaged cylinder bore Replace the cylinder, piston,
and piston rings as a set.
Possible cause Actions
Incorrect spark plug gap Adjust the spark plug gap.
Worn or damaged spark plug Replace the spark plug.
Defective spark plug cap Replace the spark plug cap.
Defective ignition coil Replace the ignition coil.
ECU failure Replace the ECU.
- Measure the fuel pressure.
Fuel leakage Check the fuel passage. Repair
or replace as necessary.
Clogged fuel pump Clean or replace the fuel pump.
Cracks or damage in fuel pump Replace the fuel pump.
Fuel pump malfunction Refer to "TROUBLESHOOT-
ING" under "FUEL PUMP SYS-
TEM" (ELECTRICAL SYSTEM)
in the Service manual.
Failed or clogged fuel injector Replace the fuel injector.
ECU failure Replace the ECU.
Refer to "Engine will not start or is difficult to start, but it cranks (tu-
el injection models)".
19

Symptom Possible cause
- Worn camshaft lobe
Water or foreign material in fuel, Change fuel.
degraded fuel
Contaminated throttle body or
clogged internal passage
Incorrectly adjusted throttle ea-
ble
Improperly synchronized throt-
tie bodies
Incorrectly adjusted idling
speed (idle adjusting screw)
Contaminated idle speed con-
trol {ISC) valve
Damaged idle speed control
{ISC) valve
Incorrect idle speed control
{ISC) valve position
Incorrect throttle position sen-
sor angle
Incorrect acceleration position
sensor angle
Faulty ECU
Failed air induction system
Clogged vacuum hose
Cracks and damage in vacuum
hose
Damaged throttle body joint
Loose throttle body joint
Clogged air filter element
Incorrect oil level (high)
20
TROUBLESHOOTING
Actions
Replace the camshaft.
Clean the throttle body.
Adjust the throttle grip free play.
Adjust synchronization of throt-
tie bodies.
Adj ust the idle adjusting screw.
Clean the idle speed control
(ISC) valve .
Replace the idle speed control
(ISC) valve .
Reset the learning value of idle
speed control (ISC) valve .
Adjust the throttle position sen-
sor angle.
Adjust the acceleration position
sensor angle.
Replace the ECU .
Check the air induction system .
Repair or replace fau lty parts.
Clean the vacuum hose.
Replace the vacuum hose .
Replace the throttle body joint.
Tighten the throttle body joint
bolts to the specified torque.
Clean or replace the air fi lter el-
ement.
Adjust the oil level to the speci-
fied level.

Incorrect idling speed (carburetor models)
Symptom
Spark plug does not produce a
spark
Fuel not supplied
Compression pressure is low
TROUBLESHOOTING
Possible cause Actions
Incorrect spark plug gap Adjust the spark plug gap .
Worn or damaged spark plug Replace the spark plug.
Defective spark plug cap Replace the spark plug cap.
Defective ign ition coil Replace the ignition coil.
CD I un it failure Replace the CD I un it.
Fuel leakage Check the fuel passage . Repair
or replace as necessary.
Clogged carburetor fuel pas- Clean the carburetor.
sage
Clogged needle valve or needle Clean the needle valve or nee-
valve seat die valve seat.
Damaged float Replace the float.
Refer to "Engine w ill not start or is difficu lt to start, but it cranks
(carburetor models)".
21
 TROUBLESHOOTING

Symptom Possible cause Actions

- Worn camshaft lobe Replace the camshaft.
Water or foreign material in fuel, Change fuel.
degraded fuel
Clogged carburetor air passage Clean the carburetor.
Incorrectly adjusted throttle ea- Adjust the throttle grip free play.
ble
Improperly synchronized carbu- Adjust synchronization of car-
retors buretors.
Incorrectly adjusted idling Adjust the throttle stop screw.
speed {throttle stop screw)
Incorrectly adjusted pilot screw Adjust the pilot screw.
Incorrectly adjusted pilot air Adjust the pilot air screw.
screw
Clogged pilot jet Clean the pilot jet.
Loose pilot jet Tighten the pilot jet to the spec-
ified torque .
Damaged or worn needle valve Replace the needle valve seat.
seat
Loose needle valve seat Tighten the needle valve seat to
the specified torque.
Damaged or worn needle valve Replace the needle valve .
Incorrect fuel level Adjust the fuel level to the prop-
er level.
Bent, worn, or damaged starter Replace the starter plunger.
plunger
Incorrectly adjusted starter ea- Adjust the starter cable.
ble
Clogged or damaged carbure- Clean, repair, or replace the
tor breather hose carburetor breather hose .
Incorrect throttle position sen- Adjust the throttle position sen-
sor angle sor angle.
Failed air induction system Check the air induction system .
Repair or replace fau lty parts.
Clogged vacuum hose Clean the vacuum hose.
Cracks and damage in vacuum Replace the vacuum hose .
hose
Damaged carburetor joint Replace the carburetor joint.
Loose carburetor joint Tighten the carburetor joint
bolts to the specified torque.
Clogged air filter element Clean or replace the air fi lter el-
ement.
Incorrect oil level {high) Adjust the oil level to the speci-
fied level.

22

Incorrect mid-high speed (carburetor models)
Symptom
Spark plug does not produce a
spark
Fuel not supplied
Compression pressure is low
TROUBLESHOOTING
Possible cause Actions
Incorrect spark plug gap Adjust the spark plug gap .
Worn or damaged spark plug Replace the spark plug.
Defective spark plug cap Replace the spark plug cap.
Defective ign ition coil Replace the ignition coil.
CD I un it failure Replace the CD I un it.
Fuel leakage Check the fuel passage . Repair
or replace as necessary.
Clogged carburetor fuel pas- Clean the carburetor.
sage
Clogged needle valve or needle Clean the needle valve or nee-
valve seat die valve seat.
Damaged float Replace the float.
Refer to "Engine w ill not start or is difficu lt to start, but it cranks
(carburetor models)".
23
 TROUBLESHOOTING

Symptom Possible cause Actions

- Worn camshaft lobe Replace the camshaft.
Water or foreipn material in fuel, Change fuel.
degraded fue
Clogged carburetor air passage Clean the carburetor.
Incorrectly adjusted throttle cable Adjust the throttle grip free play.
Improperly synchronized carbu- Adjust synchronization of car-
retors buretors.
Incorrectly adjusted pilot screw Adjust the pilot screw.
Incorrectly adjusted pilot air screw Adjust the pilot air screw.
Clogged pilot jet Clean the pilot jet.
Loose pilot jet Tighten the pilot jet to the spec-
ified torque.
Clogged main nozzle Clean the main nozzle.
Loose main nozzle Tighten the main nozzle to the
specified torque.
Clogged main jet Clean the main jet.
Loose main jet Tighten the main jet to the spec-
ified torque.
Bent, damaged, or worn jet needle Replace the jet needle.
Cracks or damage in the piston Replace the piston valve dia-
valve diaphragm phragm.
Problem with piston valve move- Replace the piston valve.
ment (movement is not smooth)
Damaged or worn needle valve seat Replace the needle valve seat.
Loose needle valve seat Tighten the needle valve seat to
the specified torque.
Damaged or worn needle valve Replace the needle valve.
Incorrect fuel level Adjust the fuel level to the prop-
er evel.
Bent, worn, or damaged starter Replace the starter plunger.
plunger
Incorrectly adjusted starter cable Adjust the starter cable.
Clogged or damaged carbure- Clean, repair, or replace the
tor breather hose carburetor breather hose.
Incorrect throttle position sen- Adjust the throttle position sen-
sor angle sor angle.
Failed air induction system Check the air induction system.
Repair or replace faulty parts.
Clogged vacuum hose Clean the vacuum hose.
Cracks and damage in vacuum hose Replace the vacuum hose.
Damaged carburetor joint Replace the carburetor joint.
Loose carburetor joint Ti~hten the carburetor joint
bots to the specified torque.
Clogged air filter element Clean or replace the air filter element.
Incorrect oil level (high) Adjust the oil level to the speci-
tied level.

24

Excessive noise from engine
Symptom Possible cause
Noise heard from around cylin- Incorrect valve clearance (too
derhead w ide)
Fatigued or broken valve spring Replace the valve spring .
Worn or damaged camshaft
lobe
Worn or damaged valve lifter
Worn or damaged rocker arm
Worn or damaged rocker arm
shaft
Worn or damaged camshaft
journal
Worn or damaged cylinder
head (camshaft journal)
Noise heard from around timing Worn or damaged timing chain
chain
Worn or damaged camshaft
sprocket
Worn or damaged timing chain
guide
Cracked, damaged, or fau lty
tim ing chain tensioner
Noise heard from around piston Worn or damaged piston ring
Worn or damaged piston
Worn piston (piston pin hole)
Worn or damaged piston pin
Worn or damaged cylinder bore Replace the cylinder, piston,
and piston rings as a set.
Carbon bu ildup in piston head
and combustion chamber
25
TROUBLESHOOTING
Actions
Adjust the valve clearance.
Replace the camshaft.
Replace the valve lifter and cyl-
inder head as a set.
Replace the rocker arm .
Replace the rocker arm shaft.
Replace the camshaft.
Replace the cylinder head .
Replace the timing chain and
camshaft sprocket as a set.
Replace the timing chain and
camshaft sprocket as a set.
Replace the timing chain guide.
Replace the timing chain ten-
s1oner.
Replace the piston and piston
rings as a set.
Replace the piston and piston
rings as a set.
Replace the piston and piston
pin as a set.
Replace the piston pin.
Clean the piston head and corn-
bustion chamber.
 TROUBLESHOOTING

Symptom Possible cause Actions

Noise heard from around crank- Worn or damaged camshaft
shaft journal or crank pin
Cracked, worn, or damaged
balancer shaft
Worn or damaged balancer
drive gear.
Worn or damaged big end bear- Replace the big end bearing .
1ng
Worn or damaged crankshaft
journal bearing
Worn or damaged balancer
shaft journal bearing
Replace the crankshaft.
Replace the balancer drive
gear and balancer shaft as a
set.
Replace the balancer drive
gear and balancer shaft as a
set.
Replace the crankshaft journal
bearing.
Replace the balancer shaft
journal bearing.

26

TROUBLESHOOTING OF CLUTCH
Manual clutch
Symptom Possible cause
Clutch slippage Improperly assembled clutch
Improperly adjusted clutch ea-
ble
Improperly assembled clutch
master cylinder (hydraulic
clutch)
Improperly assembled clutch
fluid reservoir (hydraulic clutch) reservoir.
Improperly assembled clutch
release cylinder (hydraulic
clutch)
Damaged clutch release cylin-
der {hydraulic clutch)
Incorrect clutch fluid level {low)
(hydraulic clutch)
Damaged clutch hose (hydrau-
lie clutch)
Loose union bolt (hydraulic
clutch)
Loose clutch spring
Fatigued clutch spring
Warped pressure plate
Worn friction plate
Warped or worn clutch plate
Incorrect oil level
Incorrect oil viscosity (low)
Deteriorated oil
27
TROUBLESHOOTING
Actions
Reassemble the clutch.
Adjust the clutch lever free play.
Reassemble the clutch master
cylinder.
Reassemble the clutch fluid
Reassemble the clutch release
cylinder.
Replace the clutch release cyl-
inder.
Add clutch fluid to the specified
level.
Replace the clutch hose.
Tighten the union bolt to the
specified torque.
Tighten the clutch spring bolts
to the specified torque.
Replace the clutch springs as a
set.
Replace the pressure plate.
Replace the friction plates as a
set.
Replace the clutch plates as a
set.
Adjust the engine oil level to the
specified level.
Change to recommended en-
gine oil.
Change to recommended en-
gine oil.
 TROUBLESHOOTING

Symptom Possible cause Actions

Clutch drags A ir in hydraulic c lutch system Bleed the hydraulic clutch sys-
(hydrau lic clutch) tern .
Fluid leakage from hydrau lic Check the hydrau lic clutch sys-
clutch system (hydraulic clutch) tern and repair or replace faulty
parts as necessary.
Faulty clutch spring Replace the clutch springs as a
set.
Warped pressure plate Replace the pressure plate.
Swollen friction plate Replace the friction plates as a
set.
Warped clutch plate Replace the clutch plates as a
set.
Bent pull rod (outer pull type) Replace the pull rod .
Worn pu ll rod tooth (outer pull Replace the pull rod and pull le-
type) ver shaft as a set.
Bent push rod (inner push type) Replace the push rod.
Damaged or worn clutch boss Replace the clutch boss .
Seized clutch housing bush ing Replace the clutch housing.
Improperly installed pull lever Align the match mark on the pull
lever before installation.
Incorrect oil level Adjust the engine oil level to the
specified level.
Incorrect oil viscosity (high) Change to recommended en-
gine oil.
Deteriorated oil Change to recommended en-
gine oil.
Clutch noise Damaged or worn primary driv- Replace the primary drive gear
en gear or crankshaft, and the c lutch
housing as a set.
Loose clutch boss nut Tighten the clutch boss nut to
the specified torque.
Fatigued clutch damper Replace the clutch housing.
Worn clutch housing bearing Replace the clutch housing
bearing.
Worn pressure plate bearing Replace the pressure plate
bearing.

28

V-belt automatic transmission
Symptom
Possible to start engine but im-
possible to drive motorcycle
Clutch slippage
Poor starting performance
Poor speed performance
Possible cause
Damaged or worn V-belt
Damaged primary sliding
sheave (slider rib)
Loose primary fixed sheave nut Tighten the primary fixed
sheave nut to the specified
torque .
Damaged
. . secondary compres-
s1on spring
Damaged transm ission gear
Damaged clutch shoe spring
Damaged or worn clutch shoe
Damaged or worn clutch hous-
1ng
Damaged or worn V-belt
Oil or grease on the V-belt
Faulty primary sliding sheave
Damaged or worn clutch shoe
Damaged or worn clutch hous-
1ng
Damaged or worn V-belt
Oil or grease on the V-belt
Faulty primary sliding sheave
Damaged or worn primary
sheave weight
Worn primary fixed sheave
(pulley side)
Worn primary sliding sheave
(pulley side)
29
TROUBLESHOOTING
Actions
Replace the V-belt.
Replace the primary sliding
sheave.
Replace
. the .secondary corn-
press1on spring .
Check the transm ission gear.
Replace defective parts.
Replace the clutch shoe
springs as a set.
Replace the clutch shoes and
springs as a set.
Replace the clutch housing.
Replace the V-belt.
Clean the V-belt, primary
sheave, and secondary
sheave.
Check the primary sliding
sheave, cam, and slider. Repair
or replace faulty parts as neces-
sary.
Replace the clutch shoes and
springs as a set.
Replace the clutch housing.
Replace the V-belt.
Clean the V-belt, primary
sheave, and secondary
sheave.
Check the primary sliding
sheave, cam, and slider. Repair
or replace faulty parts as neces-
sary.
Replace the primary sheave
weight as a set.
Replace the primary fixed
sheave.
Replace the primary sliding
sheave.

Symptom
Noise from clutch and transmis- Damaged or worn transmission
s1on
TROUBLESHOOTING OF TRANSMISSION
Symptom
Difficult or impossible to shift
transmission gear
Jumps out of gear
Transmission noise
Possible cause
gear
Worn main axle spline
Worn drive axle spline
Damaged or worn transmission
bearing
Possible cause
Clutch drags
Improperly adjusted shift rod
Bent shift shaft
Foreign object in a shift drum
groove
Damaged shift drum
Seized shift fork
Bent shift fork guide bar
Foreign object between trans-
m1ss1on gears
Seized transmission gear
Improperly assembled trans-
. .
m1ss1on
Incorrect shift pedal position
Improperly returned stopper le- Replace the stopper lever
ver
Bent or worn shift fork
Shift drum incorrect axial play
Worn shift drum groove
Worn transmission gear dog
Damaged or worn transmission
gear
Worn main axle spline
Worn drive axle spline
Worn bearing
30
TROUBLESHOOTING
Actions
Check the transmission gear.
Replace defective parts.
Replace the main axle.
Replace the drive axle.
Replace the transmission bear-
1ng.
Actions
Refer to "Clutch drags".
Adjust the shift rod installation
length .
Replace the shift shaft.
Remove foreign object from
shift drum groove.
Replace the shift drum.
Replace the shift fork and shift
fork guide bar as a set.
Replace the shift fork guide bar.
Remove foreign object from
transmission gears.
Replace the seized gear and
the axle as a set.
Reassemble the transmission
axle assembly.
Adjust the shift pedal position.
spring.
Replace the shift fork.
Replace the shift drum.
Replace the shift drum.
Replace the transmission gear.
Replace the transmission gear.
Replace the main axle.
Replace the drive axle.
Replace the bearing.

TROUBLESHOOTING OF COOLING SYSTEM
Symptom Possible cause
Overheating Carbon buildup in piston head
and combustion chamber
Clogged engine cooling water
passages
Incorrect oil level
Incorrect oil viscosity
Inferior oil quality
Low coolant level
Damaged or leaking radiator
Faulty radiator cap
Clogged radiator fin
Bent or damaged radiator fin
Faulty radiator fan motor
Damaged or faulty water pump
Thermostat stays closed
Clogged or damaged oil cooler
Damaged hoses or pipes
Improperly connected hoses or
pipes
Damaged throttle body joint
Loose throttle body joint
Clogged air filter element
Brake drags
Incorrect spark plug gap
Incorrect spark plug heat range Replace the spark plug with the
Faulty ECU
Over cooling Thermostat stays open
31
TROUBLESHOOTING
Actions
Clean the piston head and corn-
bustion chamber.
Check and clean the engine
cooling water passages.
Adjust the oil level to the speci-
fied level.
Change to recommended en-
gine oil.
Change to recommended en-
gine oil.
Add recommended coolant to
the specified level.
Replace the radiator.
Replace the radiator cap.
Clean the radiator fin.
Repair the radiator fin or re-
place the radiator.
Refer to "TROUBLESHOOT-
ING" under "COOLING SYS-
TEM" (ELECTRICAL SYSTEM)
in the Service manual.
Replace the water pump.
Replace the thermostat.
Replace the oil cooler.
Replace the hose or pipe.
Connect the hoses and pipes
properly.
Replace the throttle body joint.
Tighten the throttle body joint
bolts to the specified torque.
Clean or replace the air fi lter el-
ement.
Check the brake system and re-
pair or replace faulty parts as
necessary.
Adjust to the specified spark
plug gap.
one of the specified type.
Replace the ECU .
Replace the thermostat.

Symptom Possible cause
Noise from water pump Contact between the water Disassemble the water pump
pump housing cover and impel- and replace fau lty parts.
ler
Worn water pump housing
bearing
TROUBLESHOOTING OF BRAKE
Symptom Possible cause
Poor performance of disc brake Worn brake pad
Worn or deflected brake disc
Air in hydrau lic brake system
Brake fluid leakage
Incorrect brake flu id level (low)
Stuck brake caliper piston
Stuck brake caliper and slide
pin
Loose union bolt
Damaged brake hose and
brake pipe
Oil or grease on the brake disc
or brake pad
Insufficient lubrication of brake
lever or brake pedal pivot
32
TROUBLESHOOTING
Actions
Replace the water pump hous-
ing bearing .
Actions
Replace the brake pads as a
set.
Replace the brake disc.
Bleed the hydrau lic brake sys-
tern .
Check the hydrau lic brake sys-
tern and repair or replace faulty
parts as necessary.
Add brake fluid to the specified
level.
Replace the caliper piston seal.
Lubricate the caliper slide pin.
Tighten the union bolt to the
specified torque .
Replace the brake hose and
brake pipe .
Clean the brake disc or brake
pad .
Lubricate the brake lever or
brake pedal pivot.

Symptom Possible cause
Poor performance of drum Worn brake shoe
brake
Corroded or worn brake drum
Incorrect brake pedal position
Incorrect brake pedal free play
Incorrect brake camshaft lever
position
Incorrect brake shoe position
Damaged or fatigued brake
shoe tension spring
Damaged brake torque rod
Oil or grease on the brake drum
or brake shoe
Insufficient lubrication of brake
camshaft
Insufficient lubrication of brake
pedal pivot
TROUBLESHOOTING AT ABS WARNING LIGHT
Refer to "TROUBLESHOOTING" under "ABS" (ELECTRICAL SYSTEM) in the Service manual.
33
TROUBLESHOOTING
Actions
Replace the brake shoes and
brake shoe tension springs as a
set.
Replace the brake drum .
Adjust the brake pedal to the
specified position .
Adjust the brake pedal free play
to specification .
Install the brake camshaft lever
to the correct position .
Install the brake shoe to the cor-
rect position .
Replace the brake shoe tension
springs as a set.
Replace the brake torque rod.
Clean the brake drum or brake
shoes.
Lubricate the brake camshaft.
Lubricate the brake pedal pivot.

TROUBLESHOOTING OF SUSPENSION
Symptom
Front fork is hard
Front fork is soft
Leaking oil from front fork
Possible cause
Bent or damaged inner tube
Bent or damaged outer tube
Damaged or worn outer tube
bushing
Bent or damaged damper rod
Bent wheel axle
Incorrect oil viscosity (high)
Incorrect oil level (high)
Improperly adjusted spring pre- Adjust the spring preload.
load (hard)
Improperly adjusted rebound
damping (hard}
Improperly adjusted compres-
sion damping (hard}
Fatigued or broken fork spring
Incorrect oil viscosity (low)
Incorrect oil level (low)
Improperly adjusted spring pre- Adjust the spring preload.
load (soft)
Improperly adjusted rebound
damping (soft}
Improperly adjusted compres-
sion damping (soft}
Bent, damaged, or corroded in- Replace the inner tube.
ner tube
Cracked or damaged outer tube Replace the outer tube.
Improperly installed oil seal
Damaged oil seal lip
Incorrect oil level (high)
Loose damper rod assembly
bolt
Damaged damper rod assem-
bly bolt copper washer
Cracked or damaged cap bolt
0-ring
34
TROUBLESHOOTING
Actions
Replace the inner tube.
Replace the outer tube.
Replace the outer tube bush-
1ng.
Replace the damper rod.
Replace the wheel axle.
Change to recommended fork
oil.
Adjust to the specified oil level.
Adjust the rebound damping.
Adjust the compression damp-
1ng.
Replace the fork spring.
Change to recommended fork
oil.
Adjust to the specified oil level.
Adjust the rebound damping.
Adjust the compression damp-
1ng.
Replace the oil seal.
Replace the oil seal.
Adjust to the specified oil level.
Tighten the damper rod assem-
bly bolt to the specified torque.
Replace the damper rod as-
sembly bolt copper washer.
Replace the cap bolt 0-ring.

Symptom
Rear suspension is hard
Rear suspension is soft
Oil leaking from rear shock ab-
sorber
TROUBLESHOOTING
Possible cause Actions
Bent or damaged rear shock Replace the rear shock absorb-
absorber rod er.
Bent swingarm pivot shaft Replace the swingarm pivot
shaft.
Damaged or worn swingarm Replace the swingarm bearing
bearing or bushing or bushing.
Damaged or worn relay arm Replace the relay arm bearing.
bearing
Damaged or worn connecting Replace the connecting arm
arm bearing bearing.
Improperly adjusted rear shock Adjust the spring preload.
absorber spring preload (hard)
Improperly adjusted rear shock Adjust the rebound damping.
absorber rebound damping
(hard)
Improperly adjusted rear shock Adjust the compression damp-
absorber compression damping 1ng.
(hard)
Oil leaking from rear shock ab- Replace the rear shock absorb-
sorber er.
Gas leaking from rear shock ab- Replace the rear shock absorb-
sorber er.
Fatigued or damaged rear Replace the rear shock absorb-
shock absorber spring er.
Improperly adjusted rear shock Adjust the spring preload.
absorber spring preload (soft}
Improperly adjusted rear shock Adjust the rebound damping.
absorber rebound damping
(soft}
Improperly adjusted rear shock Adjust the compression damp-
absorber compression damping 1ng.
(soft}
Bent, damaged, or corroded Replace the rear shock absorb-
rear shock absorber rod er.
Damaged oil seal lip Replace the rear shock absorb-
er.
35
 TROUBLESHOOTING

TROUBLESHOOTING OF STEERING/HANDLING
Symptom Possible cause Actions
Handlebar runout Loose lower ring nut Tighten the lower ring nut to the
specified torque .
Worn bearing or bearing race Replace the bearing and bear-
ing race as a set.
Warped front fork Repair or replace the front fork.
Bent front wheel axle Replace the front wheel axle.
Incorrect tire pressure Adjust to the specified tire pres-
sure .
Worn, deformed, or incorrect tire Replace the tire .
Heavy steering Lower ring nut is tightened too Tighten the lower ring nut to the
tight. specified torque .
Bent lower bracket Replace the lower bracket.
Broken bearing or bearing race Replace the bearing and bear-
ing race as a set.
Incorrect tire pressure Adjust to the specified tire pres-
sure .
Front wheel runout Incorrect wheel balance Adjust the wheel balance.
Deformed wheel (cast wheel, Replace the wheel.
pressed wheel)
Loose wheel (spoke wheel) Tighten the spoke and adjust
the runout.
Damaged or worn wheel bearing Replace the wheel bearing.
Worn, deformed, or incorrect tire Replace the tire .
Loose wheel axle or wheel axle Tighten the wheel axle or wheel
nut axle nut to the specified torque.
Loose wheel axle pinch bolt Tighten the wheel axle pinch
bolt to the specified torque.
Incorrect front fork oil level Adj ust to the specified front fork
oil level.
Rear wheel runout Incorrect wheel balance Adjust the wheel balance.
Deformed wheel (cast wheel, Replace the wheel.
pressed wheel)
Loose wheel (spoke wheel) Tighten the spoke and adjust
the runout.
Damaged or worn wheel bearing Replace the wheel bearing.
Worn, deformed, or incorrect tire Replace the tire .
Loose wheel axle nut Tighten the wheel axle nut to
the specified torque.
Loose swingarm pivot shaft Tighten the swingarm pivot
shaft to the specified torque.
Bent or damaged swingarm Replace the swingarm bearing.
Damaged or worn swingarm Replace the swingarm bearing
bearing or bushing or bush ing .

36

TROUBLESHOOTING OF CHARGING SYSTEM
Symptom
Battery is not charged
TROUBLESHOOTING OF LIGHTING SYSTEM
Symptom
Headlight does not come on
Tail light does not come on
License plate light does not
come on
Meter light does not come on
TROUBLESHOOTING OF SIGNALING SYSTEM
Symptom
Brake light does not come on or Refer to "TROUBLESHOOTING" under "SIGNALING SYSTEM"
go off (ELECTRICAL SYSTEM) in the Service manual.
Turn signal light or turn signal
indicator light or both fail to
blink, blink too early or too late,
or fail to go off
Indicator lights do not come on
properly
Horn does not sound
Speedometer fails to operate
correctly
TROUBLESHOOTING
Possible cause Actions
Refer to "TROUBLESHOOTING" under "CHARGING SYSTEM"
(ELECTRICAL SYSTEM) in the Service manual.
Possible cause Actions
Refer to "TROUBLESHOOTING" under "LIGHTING SYSTEM"
(ELECTRICAL SYSTEM) in the Service manual.
Refer to "TROUBLESHOOTING" under "LIGHTING SYSTEM"
(ELECT RICAL SYSTEM) in the Service manual.
Refer to "TROUBLESHOOTING" under "LIGHTING SYSTEM"
(ELECT RICAL SYSTEM) in the Service manual.
Refer to "TROUBLESHOOTING" under "LIGHTING SYSTEM"
(ELECT RICAL SYSTEM) in the Service manual.
Possible cause Actions
Failed front brake light switch or Adjust or replace the front brake
rear brake light switch light switch or rear brake light
switch.
Refer to "TROUBLESHOOTING" under "SIGNALING SYSTEM"
(ELECTRICAL SYSTEM) in the Service manual.
Refer to "TROUBLESHOOTING" under "SIGNALING SYSTEM"
(ELECTRICAL SYSTEM) in the Service manual.
Refer to "TROUBLESHOOTING" under "SIGNALING SYSTEM"
(ELECTR ICAL SYSTEM) in the Service manual.
Refer to "TROUBLESHOOTING" under "SIGNALING SYSTEM"
(ELECTR ICAL SYSTEM) in the Service manual.
37
EAS20003

IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Please refer to "BASIC INFORMATION" (separate volume, YOA-28197-1 O*) for basic instructions that
must be observed during servicing. Repair and maintenance work attempted by anyone without this
knowledge is likely to render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the vehi-
cle will operate as designed. If there is any question about a service procedure, it is imperative that you
contact a Yamaha dealer for any service information changes that apply to this model. This policy is
intended to provide the customer with the most satisfaction from their vehicle and to conform to federal
environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• * If the contents of the manual are revised, the last digit of the manual number will be increased by
one.
• This Service Manual contains information regarding periodic maintenance to the emission control sys-
tem. Please read this material carefully.
• Designs and specifications are subject to change without notice.

EAS30001

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential personal inju-
ry hazards. Obey all safety messages that follow this symbol to avoid possible
injury or death.

A WARNING indicates a hazardous situation which, if not avoided, could result

A WARNING in death or serious injury.

~
A NOTICE indicates special precautions that must be taken to avoid damage to
NOTICE , the vehicle or other property.

ITIP I A TIP provides key information to make procedures easier or clearer.

EAS20002

MTT9K/MTT9KC/MTT9GTK/MTT9GTKC
SERVICE MANUAL
©2019 by Yamaha Motor Corporation, U.S.A.
First edition, April 2018
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
P/N LIT-11616-32-10
EAS20004

HOW TO USE THIS MANUAL

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

CLUTCH CLUTCH

-
CLUTCH 1 111

I.~;

,,,.~--
• c;ucn IIOM nut
• Conall~wa...-

.... ..
--..
• W-
4 -t-- ..,.-2 "°"""'-
• TtwuM.,..,.
CH
.,
EQQNQ:ntE:CUJrCHPI.ATES- - - - = ' l - - + - 2

"°"""' .......
-• (lllpw!!p~CMln ' • a...
CIAcllll. . 1. 2
C...0- .......... lhtcUct't .,..• • • •

--·......
CHEOKIHO THIE FRK:TI()ff PU.TES
n . ~ ~ ..-......... ,,.. 2-..
•0 . 0 - , z ~
I CO...

~-
• Frnorq:1111» 1,2
~ - .. A'l,lllotflttnQIQnlM• ........
r--a_._pl,altMCl..,_p19•11
0.CdtP1(11111,c1110n .... ~ NWktl

.. ......
• Fnct,on pa,.i. t, 2 ~
Out d <C)eCIC&liol'I--,, ~ N WICIOft
~ ~s:
;:;;:;====~
--
. . . . . . . . . ~ p i . - .. towpltQN /4 ~ pi• I l.hktnus
r--+-7

_,...
, ~,t.~
_ ,_.2.40
lllffl (O.Ol7-0.09ol n>
6 -+--1~ -- -
........ U\.."'-
";:::....,
Fric11on pi• 11nklcnn.
2-fl,,,,3.0I mm {O.l tS-.0,121 In) ,- 0.10 lflffl (Q.004 11'1>
~ Clutm pi• 2 t:hidmes•
' ....,_ WNtllml1
2..t2 mm C0.111 11'1> U~2..10111ffl(0.075-0.0l:l n>

..Thi~--
,ric110n fll• 2 lttkllnt,N
2.~ .0I mm (0.1 IS-0.121 In) G.10mm(0.00411'1)
w.., IIMh
2.a2mm (0.11t I~
lflicknNI ~IIOn'-0
~ · - ........ #ffi ,._ aMdMI 11'\ck.-
""' ~ "•~--Wl1hcwieol ... w.
_ , , . . . ~ l t l ' I I W I.... UMI 10
50,.t
tllffl IOes-G 017 In) or 2 20440 mmto'81-

.....- -.,_..liOf'I
0 OM W lor N

-
aooGfOW'4 IOtil
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 -1 Gear oil

~
1
~ Filling fluid
~
- Molybdenum disulfide oil

I Lubricant -1 Brake fluid

~

~ Special tool
~ Wheel bearing grease

~~ Tightening torque
~ Lithium-soap-based grease

- ~

~ -«M>I
Wear limit, clearance Molybdenum disulfide grease

C) Engine speed
~ Silicone grease

-'
~ Electrical data
a Apply locking agent (LOCTITE®).

-1 ..
m
Engine oil Replace the part with a new one.

-1
m Silicone fluid
EAS10003

TABLE OF CONTENTS
GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND

ADJUSTMENTS

CHASSIS

ENGINE

COOLING SYSTEM

FUEL SYSTEM

ELECTRICAL SYSTEM

APPENDIX
 GENERAL INFORMATION

IDENTIFICATION .......... ......... ......... .......... ......... ........ .......... ......... ......... ......... 1-1
VEHICLE IDENTIFICATION NUMBER ..... ......... ......... .......... ......... ......... .. 1-1
MODEL LABEL .... .... ..... .... .... ..... ..... ..... .... ..... .... .... .......... ..... .... ..... .... ......... 1-1

FEATURES .......... .......... ......... ......... .......... ......... ........ .......... ......... ......... ......... 1-2
INSTRUMENT FUNCTIONS (MTT9K/MTT9KC) .......... ......... .......... ......... 1-2
INSTRUMENT FUNCTIONS (MTT9GTK/MTT9GTKC) ........... ......... ...... 1-11

SPECIAL TOOLS .......... ......... .......... ......... .......... ......... ......... ......... .......... ..... 1-22
 IDENTIFICATION

EAS20007

IDENTIFICATION
EAS30002

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number "1" is stamped
into the right side of the steering head pipe.

EAS30003

MODEL LABEL
The model label "1" is affixed to the battery box
under the passenger seat. This information will
be needed to order spare parts.

1-1
 FEATURES

EAS20008
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
FEATURES
• The select switch " A l v " and the menu switch
EAS30682 "MENU" are located on the left handlebar.
INSTRUMENT FUNCTIONS (MTT9K/ These switches allow you to control or change
MTT9KC) the settings of the multi-function meter unit.
• O S requires an accessory part and cannot be
Multi-function meter unit selected.
12 3 4 567 • The key must be turned to "ON" before you can
use the handlebar switches and buttons.

F.~~~
~
,fr~ I II IF/::: I
~a_~--
:@& a:
.; ,
l/
1!!!!!.i!J" I
1
- ~---,Q:_O. P~
a~
-ty-;:~~

12 11 10 9 8
1. "RESET" button
2
2. "TCS" button
3. Clock
4. Tachometer 1. Menu switch "MENU"
5. Speedometer 2. Select switch " A l v "
6. Transmission gear display
7. Information display selection function Speedometer
8. Information display 1
9. Fuel meter
10. Eco indicator "ECO" 1

11. Drive mode display

12. TCS display
I llilllil
The multi-function meter unit is equipped with
the following:
• speedometer
• tachometer
• clock 1. Speedometer
• fuel meter
• eco indicator The speedometer shows the vehicle's traveling
• transm ission gear display speed.
• drive mode display TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• TCS display To switch between kilometers and miles, refer to
• information display "Selecting the units".
• setting mode display
EWA12423

& WARNING
Be sure to stop the vehicle before making
any setting changes to the multi-function
meter unit. Changing settings while riding
can distract the operator and increase the
risk of an accident.

1-2
 FEATURES

Tachometer Fuel meter

1. Tachometer
2. High-r/min zone
The tachometer allows the rider to monitor the
engine speed and keep it within the ideal power
range.
When the key is turned to "ON", the tachometer
will sweep across the r/min range and then re-
turn to zero in order to test the electrical circuit.
ECA26220
1
1. Fuel meter
The fuel meter indicates the amount of fuel in the
fuel tank. The display segments of the fuel meter
disappear from "F" (full) towards "E" (empty) as
the fuel level decreases. When the last segment
of the fuel meter starts flashing , refuel as soon
as possible.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

NOTICE • When the key is first turned to "ON", all of the

------------- display segments of the fuel meter will appear
Do not operate the engine in the tachometer
for a few seconds before the fuel meter shows
high-r/min zone.
the actual fuel level.
• If a problem is detected in the fuel meter elec-
High-r/min zone trical circuit, the fuel meter will flash repeatedly.
11 250 r/min and above Refer to "CHECKING THE FU EL METER" on
page 8-197.
Clock
1 Eco indicator
1- - - - - - - - - - - - -
/0.]c' 6 1 8 9 0 1
88
II Ill Ill II I
AM
s.--:f_!
~
8 9 10 I
1111111
.-.~..~-\\\Ill~!!! llt11111111111111
~ ---"-°-=n---
..... . ~-- -- ---
I
/~
/~ -r-- _,_...,,, ..,,_..,
/;/f!: . -• • - • •- . MPH
kllh
ii~··~··
a
1I
~
s •--
---
•- ---
• •
•••
---
•
-r-- -r-- • MPH
km/h

:il--,OFF 1 2 l,l[•J•J#tASTD ,4.,,7

~ - - - - - - - - - -1-/
1. Clock 1
The clock displays time in 12-hour format. 1. Eco indicator "ECO"
To set the clock, refer to "Setting the clock".
The eco indicator comes on when the vehicle is
being operated in an environmentally friendly,
fuel-efficient manner. The indicator goes off
when the vehicle is stopped.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Consider the following tips to reduce fuel con-
sumption :
• Avoid high engine speeds during acceleration.
• Travel at a constant speed .

1-3
 FEATURES

• Select the transmission gear that is appropri- This display indicates which traction control sys-
ate for the vehicle speed. tem setting has been selected : "1", "2" or "OFF".

lnformation display
Transmission gear display

__,....,.I I m m~.
lB.!!:U mh
3J_
.,
3
TRIP-2/
I 11--..-1 77 4.3 4
;_;1--;1 I 1 ~ , Q@ mq
12
m~,
:ill@____7jl
' - - - --"

m~
@_7 m
7
N ™-7 •F I f.ELM'G/ MPG
:I Tll.lE TRIP/ Lo:1 7.6
u or=
: _____ !)_;!)_!?_: . . . . . . . . . '-----
MPG

7 ._6_/
CANT FUEL/

1 2
1. Information display
1. Neutral indicator light " N "
2. Display- 1
2. Transmission gear display
3. Display- 2
The transmission gear display shows the select- 4. Display- 3
ed gear. This model is equipped with 6 gears.
There are 3 information displays. Push the se-
The neutral position is indicated by the neutral
lect switch "Alv " to change the selected infor-
indicator light "N " and by the transmission gear
mation display.
display "N ".
The following items are shown in the information
Drive mode display displays:
• odometer
• two tripmeters
• fuel reserve tripmeter
• elapsed time
• air temperature
• coolant temperature
• average fuel consumption
• instantaneous fuel consumption
ll~l•J•J# ASTD B TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
' - - - - - - - - - -1
1-------"
1 You can select which items are shown in each
information display. Refer to "Setting mode" on
1. Drive mode display
page 1-7.
The drive mode display indicates which drive
mode has been selected: "STD", "A" or "B". Odometer and tripmeters

TCS display

88 5-, 6-1-8_9_L,!
ODO / mile
.-,t..~.,, llllllll(lll(lll(lllllll
3 ~ ><1 00 m
12
/~ ,_,,_,,_,km/h
2~ . -• •-
~/;:s --- --- --- MPH
•••

F
••,,,... f-_F_F_1_2__:t•_~•2_:f_A
_s_o
_ _ __,,
The odometer shows the total distance traveled
1 by the vehicle.
1. TCS display

1-4

TRI P-1 / mile
3.1
TRI P-2 / mile
4.3
The tripmeters ''TRIP-1 " and "TRIP-2" show the
distance traveled since they were last set.
To reset a tripmeter, use the select switch to dis-
play the tripmeter you want to reset. Then push
the "RESET' button briefly so that the tripmeter
flashes, and then push the "RESET' button
again for two seconds.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• The odometer will lock at 999999.
• The tripmeters will reset and continue counting
after 9999.9 is reached .
Fuel reserve tripmeter
When approximately 2.6 L (0.69 US gal, 0.57
Imp.gal) of fuel remains in the fuel tank, the last
segment of the fuel meter starts flashing . The
display will change to the fuel reserve tripmeter
mode ''TRIP- F" and start counting the distance
traveled from that point.
TRIP-F/ mile
2.1
In this case, push the select switch to switch the
display in the following order:
1-5
FEATURES
TRIP-F ➔ Display-1 ➔ Display-2 ➔ Display- 3
➔ TR IP-F
After refueling , you can manually reset the fuel
reserve tripmeter immediately, or allow it to reset
automatically after traveling 5 km (3 mi) . When
the fuel reserve tripmeter is reset, it will disap-
pear from the display.
Elapsed time
TIME TR IP/
0:06
This timer shows the time that has elapsed since
the key was turned to "ON". The timer automati-
cally resets when the key is turned to "OFF".
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
There are also ''TIME-2" and "T IME-3" elapsed
time displays, but they cannot be set to the infor-
mation display. Refer to "Setting mode" on page
1-7.
Air temperature
A.TEMP/ OF
77
This shows the air temperature from 16 °F to
199 °F in 1 °F increments. The temperature dis-
played may vary from the ambient temperature.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• 16 °F will be displayed even if the ambient tem-
perature falls below 16 °F.
• The accuracy of the temperature reading may
be affected when riding slowly (under 20 km/h
[13 mi/h]) or when stopped at traffic signals,
railroad crossings, etc.
 FEATURES

Coolant temperature • The "U1 OOkm" display shows the average

amount of fuel necessary to travel 100 km.
• The "MPG" display shows the average dis-
tance that can be traveled on 1.0 Imp.gal of fu-
el.
C.TEMF1/ OF To reset the average fuel consumption display,

Lo use the select switch to select the information

This shows the temperature of the coolant. The
coolant temperature varies w ith changes in the
weather and engine load .
If the message "Hi" flashes, stop the vehicle,
then stop the engine, and let it cool.
display that contains the average fuel consump-
tion display. Push the "RESET" button briefly so
that the average fuel consumption display flash-
es, and then push the "RESET' button again for
2 seconds while the display is flashing.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
After resetting the average fuel consumption dis-
play, "_--~' w ill be shown until the vehicle has
traveled 1 km (0.6 mi).

Instantaneous fuel consumption

C.TEMP/
CRNT FUEL/ MPG

7.6
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
The selected information display cannot be
switched while the message "Hi" is flashing .
This function calculates the instantaneous fuel
ECA10022
consumption (fuel economy) under current rid-
NOTICE ing conditions. The instantaneous fuel con-
-------------
Do not continue to operate the engine if it is sumption display can be set to "km/L" or "U
overheating. 1OOkm"; or when miles is selected "M PG" will be
displayed.
Average fuel consumption • The "km/ L" display shows the distance that can
be traveled on 1 .0 L of fuel.
• The "U1 OOkm" display shows the amount of
fuel necessary to travel 100 km .
• The "MPG" display shows the distance that
FUEL AVG/ MPG can be traveled on 1.0 Imp.gal of fuel.

7.6 TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
If traveling at speeds under 10 km/ h (6.0 mi/h),
"__._" will be displayed.

This function calculates the average fuel con-

sumption (fuel economy) of the vehicle since it
was last reset. The average fuel consumption
display can be set to "km/ L" or "U1 OOkm"; or
when miles is selected "MPG" w ill be displayed.
• The "km/L" display shows the average dis-
tance that can be traveled on 1.0 L of fuel.

1-6
 FEATURES

Setting mode Display Description

1 This function allows you to
Display change the items shown in 3 in-
formation displays.

·~
,------ ------
Maintenance
Time Trip
Brightness
This function allows you to ad-
just the brightness of the multi-
function meter unit panel.
Unit
Display This function allows you to set
Brightness Clock the clock.
Clock
___________
,_ All Reset _ This function allows you to re-
All Reset set all items, except the odome-
1. Setting mode display ter and the clock.

This mode allows you to set, select, or reset the

items shown in the information display. Resetting the maintenance counters
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ 1. Use the select switch to highlight "Mainte-
nance".
• The transmission must be in neutral and the
vehicle must be stopped to change settings in
this mode. f0ENU]
Maintenance
• Shifting the transmission into gear or turning
the key to "OFF" will exit the setting mode and .Time Trip
all changes will be saved. Unit
,Display
Push and hold the menu switch "MENU" for 2 .Brightness
seconds to enter the setting mode. To exit the Clock
setting mode and return to the normal display, All Reset
push and hold the menu switch again for 2 sec-
onds.
2. Push the menu switch, and then push the
Display Description "RESET' button to select the item to reset.
This function allows you to
check and reset the "OI L" oil
change interval (distance trav-
Maintenance eled), and the "FREE-1 " and
"FREE-2" maintenance inter-
vals. ,FREE-1 mile

This function allows you to I 6

check and reset the "TIME-2" ,FREE-2 mile
and "TIME-3" functions. These
time trips show the total I 6
elapsed time that the key has
been in the "ON" position. 3. While the selected item is flashing , push the
When the key is turned to "RESET' button for 2 seconds.
Time Trip "OFF", the time trips stop 4. Push the menu switch to return to the setting
counting but are not reset. The
maximum time that can be
mode menu.
shown is 99:59.
When the time trips reach 100 Checking and resetting ''TIME-2" and "TIME-3"
hours, they automatically reset
to 0:00 and continue counting.
This function allows you to
switch the display units be-
tween kilometers and miles.
Unit When kilometers are selected,
the fuel consumption units can
be switched between "L/
1OOkm" and "km/L".

1-7
 FEATURES

1. Use the select switch to highlight "Time Trip".

[Unit]
!MENU]
Maintenance km or mile
Time Tri km
Unit
km/L or L/1 00km
.Display
km/L
,Brightness
Clock
All Reset
TIP ________________
2. Push the menu switch to display "TIM E-2" • Keep kilometers selected: Skip to step 5.
and ''TIME-3". To reset a time trip, push the • Select miles or kilometers: Continue with step
"RESET" button to select the item to reset. 3.
3. Push the menu switch, then use the select
!Time Trip]
switch to toggle between "km" or "mile", and
then push the menu switch to confirm these-
TIME-2
lection.

TIME·3 (!)

km or mile

3. While the selected item is flashing, push the km/L or U100km

"RESET" button for 2 seconds. km/L
4. Push the menu switch to return to the setting
mode menu.

Selecting the units TIP ________________

1. Use the select switch to highlight "Unit". • When kilometers are selected , "U1 OOkm" or
"km/L" can be set as the fuel consumption dis-
!MENU] play units. Continue with step 4.
Maintenance • When miles are selected, the fuel consumption
.Time Trip display units will be set to "MPG". Skip to step
Unit 6.
.Display
.Brightness
Clock
All Reset

2. Push the menu switch. The unit setting dis-

play will be shown.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• When kilometers are already selected, "km/L
or U 1OOkm" will flash in the display.
• When miles are already selected, "km or mile"
will flash in the display.

1-8
 FEATURES

4. Use the select switch to move from "km or 3. Use the select switch to highlight the item to
mile" to "km/Lor U1 OOkm". change, and then push the menu switch .
5. Push the menu switch, then use the select
switch to toggle between "km/ L" and "U IDisplay-1 ) [!l
1OOkm", and then push the menu switch to
confirm the selection.
6. Use the select switch to highlight "I!]", and A.TEMP
then push the menu switch to return to the 1-2 7
setting mode menu. I C.TEMP
1-3 7
I TIME TRIP
D
km or mile 4. Use the select switch to select the item you
km want to display, and then push the menu
km/L or U100km switch.
km/L
[Display-1 ) [!l

Selecting the display items 1-2 7

1. Use the select switch to highlight "Display". I C.TEMP
1-3 7
!MENU]
I TIME TRIP
Maintenance
_Time Trip 5. When you are finished changing the settings,
Unit use the select switch to highlight "~", and then
Dis la push the menu switch to return to the previ-
.Brightness ous display.
Clock
All Reset IDisplay-1 ) D
2. Push the menu switch, then use the select 1-1 7
switch to highlight the display to change, and
I ODO
then push the menu switch again. 1-2 7
I C.TEMP

!Display) l!l 1-3 7

I TIME TRIP

Dis la -1
.Display-2 6. Use the select switch to highlight "~", and
.Display-3 then push the menu switch to return to the
setting mode menu .

[Display]

.Display-1
.Display-2
,Display-3

1-9
 FEATURES

Adjusting the meter panel brightness 2. Push the menu switch.

1. Use the select switch to highlight "Bright- 3. When the hour digits start flashing, use the
ness". select switch to set the hours.

!MENU] [Clock]
Maintenance
.Time Trip
Unit
.Display
Bri htness
Clock
All Reset

2. Push the menu switch.
3. Use the select switch to select the desired
brightness level, and then push the menu
switch to return to the setting mode menu.
IBrightness ]
4. Push the menu switch and the minute digits
start flashing.
5. Use the select switch to set the minutes.
6. Push the menu switch to return to the setting
mode menu.
Resetting all of the display items
1. Use the select switch to highlight "All Reset''.

[MENU]
Maintenance
.Time Trip
Unit
.Display
.Brightness
Setting the clock Clock
1. Use the select switch to highlight "Clock". All Reset

!MENU] 2. Push the menu switch.

Maintenance 3. Use the select switch to highlight "YES", and
.Time Trip then push the menu switch .
Unit
.Display !All Reset ]
.Brightness
Clock
All Reset NO
h4i

TIP _ _ _ _ _ _ _ _ _ _ _ _ __
The odometer and the clock cannot be reset.

1-10
 FEATURES

EAS32706 EWA18210

INSTRUMENT FUNCTIONS (MTT9GTK/ & WARNING

MTT9GTKC) Stop the vehicle before making any setting
changes. Changing settings while riding can
Display
distract the operator and increase the risk of
The following items can be found on the display.
an accident.
• Speedometer
• Tachometer
• Fuel meter Speedometer
• Information display The speedometer shows the vehicle's traveling
• Transmission gear display speed.
• Drive mode display TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• TCS display The display can be set to miles or kilometers.
• Air temperature display Use the "Unit" module on the MENU screen.
• Grip warmer display
• OS indicator
Tachometer
• Clock
The tachometer shows the engine speed, as
• Revolution peak hold indicator
measured by the rotational velocity of the crank-
• Eco indicator
shaft, in revolutions per minute (r/min). When
• Fuel level warning icon
the vehicle is first powered on , the tachometer
• Engine oil warning icon will sweep across the r/min range and then re-
• Coolant temperature warning icon
turn to zero.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
This model uses a thin-film-transistor liquid-crys-
The tachometer can be color-adjusted and has a
tal display (TFT LCD) for good contrast and
revolution peak hold indicator which can be
readability in various lighting conditions. Howev-
turned on or off.
er, due to the nature of this technology, it is nor-
ECA26220
mal for a small number of pixels to be inactive.
NOTICE
--------------
1 3 4 6 Do not operate the engine in the tachometer
high-r/min zone.

High-r/min zone
11250 r/min and above

Fuel meter
The fuel meter indicates the amount of fuel in the
13 12 7 fuel tank. The display segments of the fuel meter
1. Tachometer disappear from "F" (full) towards "E" (empty) as
2. QS indicator the fuel level decreases.
3. Speedometer
When the last segment starts flashing and the
4. Revolution peak hold indicator fuel level warning icon comes on, refuel as soon
5. Clock as possible.
6. Fuel meter
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
7. Eco indicator "ECO" If a problem is detected in the fuel meter electri-
8. Grip warmer display cal circuit, the fuel meter will flash repeatedly.
9. Air temperature display Refer to "CHECKING THE FUEL METER" on
10. Transmission gear display page 8-197.
11. TCS display
12. Drive mode display Clock
13. Information display The clock uses a 12-hour time system.

1-11

Information display
This section of the main screen is used to show
additional riding related information such as air
and coolant temperature readings, tripmeters,
and fuel consumption statistics. The information
display items can be set into four groups via the
MENU screen.
The information display items are:
A .TEMP: air temperature
C .TEMP: coolant temperature
TRIP-1: tripmeter 1
TRIP-2: tripmeter 2
F-TRI P: fuel tripmeter
ODO: odometer
FUEL CON: the amount of fuel consumed
FUEL AVG : average fuel consumption
CRNT FUEL: current fuel consumption
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• ODO w ill lock at 999999.
• TRIP-1 and TRIP-2 w ill reset and continue
counting after 9999.9 has been reached.
• When the fuel tank reserve level has been
reached, F-TRIP appears automatically and
begins recording distance traveled from that
point.
• After refueling and traveling some distance, F-
TRIP will automatically disappear.
• Refer to "Unit" on page 1-14 to change the fuel
consumption units, set the clock, and switch
between miles and kilometers, etc.
TRIP-1, TRIP-2, F-TRIP, FUEL CON , and FUEL
AVG items can be individually reset.
To reset information display items
1. Use the wheel switch to scroll through the dis-
play items until the item you want to reset ap-
pears.
2. Short push the wheel switch and the item will
flash for five seconds. If both items are reset-
table items, the top item will flash first. Scroll
down to select the bottom item .
3. While the item is flashing , press and hold the
wheel switch for one second.
Transmission gear display
This shows which gear the transmission is in.
This model has 6 gears and a neutral position .
The neutral position is indicated by the neutral
indicator light "N " and by the transmission gear
display "N ".
1-12
FEATURES
Revolution peak hold indicator
This small bar momentarily appears within the
tachometer to mark the most recent peak r/min
speed of the engine.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
The indicator comes on momentarily only if the
peak engine speed is 7000 r/min or higher.
QS indicator
When the key is turned to "ON", the quick shift
system turns on and this indicator comes on.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
If a problem is detected in the quick shift system,
this indicator will turn off and the quick shift sys-
tem will be unavailable.
Eco indicator
This indicator comes on when the vehicle is be-
ing operated in an environmentally friendly, fuel-
efficient manner. The indicator goes off when
the vehicle is stopped.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Consider the following tips to reduce fuel con-
sumption :
• Avoid high engine speeds during acceleration.
• Travel at a constant speed .
• Select the transmission gear that is appropri-
ate for the vehicle speed.
Drive mode display
This display indicates which drive mode has
been selected: "STD", "A" or "B".
TCS display
This display indicates which traction control sys-
tem setting has been selected: "1", "2" or "OFF".
Air temperature display
This display indicates the air temperature from
16 °F to 122 °F in 1 °F increments.
TIP ________________
• 16 °F will be displayed even if the air tempera-
ture falls below 16 °F.
• 122 °F will be displayed even if the ambient
temperature climbs above 122 °F.
• The temperature displayed may vary from the
actual ambient temperature.
 FEATURES

ECA10022
Grip warmer display
NOTICE
This grip warmers can used when the engine is --------------
running. There are 4 grip warmer settings. Do not continue to operate the engine if it is
overheating.
Display Setting
Engine oil warning " ~ "
~ OFF Off

~ .. Low
This icon comes on when the engine oil level is
low .
When the vehicle is turned on, this icon will
~ r6' Middle
come on for a few seconds, and then go off.
~ High ECA26400
..6 '..
NOTICE
--------------
Do not continue to operate the engine if the
To change the grip warmer setting oil level is low.
1. Select the grip warmer display.
2. Short push the wheel switch , and then rotate Fuel level warning "ill"
This icon comes on when approximately 2.6 L
the wheel switch up or down to change the
setting while the icon is flashing. Short push (0.69 US gal , 0.57 Imp.gal) of fuel remains in the
the wheel switch to confirm the setting. tank.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
MENU screen
Each grip warmer setting can be fine tuned in
"Grip Warmer Setting" (see page 1-19). Or,rPH MENU 12:00
ECA1 7932

NOTICE l Maintenance

--------------
• Be sure to wear gloves when using the grip
----------

- - - - Wallp
Unit
---------

- a-pe- ,- - - -
warmers. _ _ _ Shift lndi~
• Do not use the grip warmers in warm ----- - - - -
Display Setting
weather. ---- ------
Brightness
• If the handlebar grip or throttle grip be-
comes worn or damaged, stop using the
grip warmers and replace the grips. The MENU screen contains the following setting
modules. Select a module to make related set-
ting changes. Although some settings can be
Warning icons
changed or reset via the main screen, the MENU
screen offers access to all display and control
1 2 3 settings.
Module Description
View and reset three mainte-
t;'t;J & 'l'.::1' iu 12:00 Maintenance nance item intervals.
•1000r/min 5 6 7 8 9 10 11
3 4 Unit Set fuel consumption units.
2 iiiiiiiiiiiiiil Wallpaper Set background color.
Turn the shift indicator on/off
Shift Indicator and adjust tachometer set-
1. Coolant temperature warning ",1"
tings.
2. Engine oil warning "~"
3. Fuel level warning "ill" Set the multi-function display
Display Setting window items.
Coolant temperature warning "xt" Brightness Adjust screen brightness.
This icon comes on if the coolant temperature
Set the low, middle, and high
reaches 242 °F or higher. Stop the vehicle and Grip Warmer settings to 10 temperature lev-
turn off the engine. Allow the engine to cool. Setting
els.
Clock Adjust the clock.

1-13
 FEATURES

Module Description
2. Select the item you want to reset.

Return all settings to factory

All Reset default settings. O ,.,PH Maintenance 12:00

MENU access and operation - - - - - - ' I 123456 mile I

The following wheel switch operations are com-
INTERVAL 1 I 123456 mlle l
- - -

mon operations for accessing , selecting, and

INTERVAL2 I 123456 mlle l
-------

moving within the MENU screen and its mod-

- .... -
ules.
Long push - press and hold the wheel switch for
one second to access the MENU screen or exit
MENU entirely. 3. Long push the wheel switch to reset the item.
Select - rotate the wheel switch up or down to
highlight the desired module or setting item and O ,.,eH Maintenance 12:00
then short push the wheel switch (briefly press O mile
the wheel switch inward) to confirm the selec-
tion .
INTERVAL 1 I 123456 mllel
Triangle mark - certain setting screens have an
INTERVAL 2 I 123456 mllel
upward pointing triangle mark item. Select the
---------- ....
triangle mark to exit that screen and move back
one screen (or long push the wheel switch to exit
MENU entirely) .
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ TIP _ _ _ _ _ _ _ _ _ _ _ _ __

• The MENU screen can be accessed by long Maintenance item names cannot be changed .
pushing the wheel switch, except when the grip
warmer display is selected or the fuel tripmeter "Unit"
(F-TRIP) is displayed . This module allows you to switch the display be-
• Should vehicle motion be detected, the screen tween kilometers and miles.
will automatically exit MENU and change to the When using kilometers, the fuel consumption
main screen. units can be changed between km/L or U
100km. When using miles, MPG will be avail-
"Maintenance" able.
This module allows you to record distance trav-
eled between engine oil changes (use the OIL To set the distance or fuel consumption units
item) , and for two other items of your choice (use 1. From the MENU screen , select "Unit''.
INTERVAL 1 and INTERVAL 2).
O,,,eH MENU 12:00
To reset a maintenance item - - - - Maintenance
-------
1. From the MENU screen , select "Mainte- I Unit
nance". - - - - Wallp
- a-pe_r _ _ __

- - - Shift Indicator
-----
O ,,,PH MENU 12:00 - Display Setting
l Maintenance
- - - - - - -------
Brightness
Unit
- - - - Wallp
- a-pe_r _ _ __

Shift Indicator
- - - - - - -
Display Setting
---- ------
Brightness

1-14
 FEATURES

2. Select the distance or consumption unit item To set the wallpaper

you want to adjust. 1. From the MENU screen , select "Wallpaper''.

O,,,eH Unit 12:00 Or,<PH MENU 12:00

---- -------
Maintenance
1
! 111 W1111l111ls- - - -~
/qp11A,,11Q1.,1[ . m
_ll_
I __ _ e, I

Unit

Wallpaper
--- -----
Shift Indicator
-------
...
-------
Display Setting

Brightness

TIP _ _ _ _ _ _ _ _ _ _ _ _ __ 2. Select the mode you want to adjust (select

When "km" is selected "km/L" or "U1 OOkm" can DAY for daytime display settings or NIGHT
' for nighttime display settings).
be set as the fuel consumption units. To set the
fuel consumption units, proceed as follows. If
"mile" is selected, skip step 3. 0 MPH Wallpaper 12:00

3. Select the units you want to use. - - - - NIGHT- - - -

O,m'h Unit 12:00

km j
~

km or mile
I

~
km/L or L/100km km/L

3. Select the background color (select BLACK

for a black background or WHITE for a white
background).

4. Select the triangle symbol to exit. O,.,eH Wallpaper 12:00

STREET MODE (day)

"Wallpaper"
This module allows you to set the main screen BLACK

background color to black or white for both the WHlJEI

day and night settings. A photo sensor equipped
----- ------ ....
in the instrument panel detects lighting condi-
tions and will automatically change the display
between its day and night settings. The photo
sensor also controls a subtle automatic bright- 4. Select the triangle symbol to exit.
ness adjustment function within both the day 5. To set another background color, repeat from
and night modes to suit ambient light conditions. step 2 or select the triangle symbol to exit this
module.

"Shift indicator"
The shift indicator module contains the following
items.
Display Description
Set the shift indicator pattern
Shift IND to "ON" "Flash" or "OFF" and
' '
adjust at what r/min the indi-
Setting
cator will come on and go off.
1. Photo sensor
Shift IND Adjust the brightness of the
Brightness shift indicator.

1-15
 FEATURES

Display Description 3. Select "ON" to have the indicator light steadi-

ly, "OFF" to turn the indicator off, or "Flash" to
Set the tachometer color dis- have the shift indicator flash when the indica-
play to "ON" or "OFF" and ad-
Tach IND just at what r/m in the tor start threshold has been reached .
Setting
tachometer will be green and
orange. O,,,PH Shift Indicator 12:00
• 1000 r/min B 9 10 11 12 13
Set the tachometer revolution
Peak Rev IND peak hold indicator to "ON" or
V 6.7jiiiiliiiiiiiiiiiii
.......
Setting Shift IND Setting
"OFF". ----
INO Mode
-INO Start 6000 r/min I
O,,,PH MENU 12:00
-IND Stop 12000 r/min I
---- -------
Maintenance

Unit
- - - - Wallp
- a-pe_r _ _ __ 4. Select "IND Start".
Shift Indicator
L
Display Setting
O,,,PH Shift Indicator 12:00
• 1000 r/min 8 9 10 11 12 13
Brightness

V 6/jiiiiliiiiiiiiii
Shift IND Setting
· ~I ON I
To make setting changes
1. Select "Shift IND Setting". L-1wew,n 7000 r/min I
INO Stop 12000 r/min I
O,,,PH Sh ift Indicator 12:00

lt Shift IND Settina

- - - - - - - - 5. Rotate the wheel switch to adjust the r/min at
Shift INO Brightness
~
which the shift indicator light will come on .
Tach INO Setting
- "IND Start" operational range is 5000-12800
Peak Rev INO Setting
r/min.
----------------
.....---------------

O,,,PH Shift Indicator 12:00

v 6,--I-·------
• 1000 r/min 8 9 10 11 12 13

2. Select "IND Mode".

Shift IND Setting
- INO Mode I ON I
0 ,.,PH Shift Indicator 12:00 -INO Start 8000 r/min
• 1000 r/min 8 9 10 11 12 13
6.7jiiiiliiiiiiiiiiiii
-------

INO Stop 13000 r/min I

V ....... Shift IND Settlng
-.....-
\1NP¥w!n 11 oN I
-INO Start
I 6000 r/min I 6. Select "IND Stop" then rotate the wheel
12000 r/min I
-------------

IND Stop
-.....- I switch to adjust the r/min at which the shift in-
dicator will go off. "IND Stop" operational
range is 5500-13000 r/min.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
The blue area on the tachometer indicates the
currently set operational range of the shift indica-
tor light.

"Shift IND Brightness"

The shift indicator light has six brightness levels.

1-16
 FEATURES

3. Select ON to turn the tachometer color dis-

O,,,PH Shift Indicator 12:00 play mode on (or select OFF to turn this func-
Shift INO Setting tion off) .
Shift INO Briahtness
------- 0,,,PH Shift Indicator 12:00
Tach INO Setting
, 1000 r/min B 9 10 11 12 13

-- - ....
Peak Rev INO Setting
--- ----- -
5 6jiililiii!!!i!!•
- INO Mode
-Tach INO 1st 5000 r/min I
Select "Shift IND Brightness", then use the Tach INO 2nd 8000 r/min I
wheel switch to adjust the setting. Short push
the wheel switch to confirm the setting and exit.
4. Select ''Tach IND 1sf' to set the green zone
O,,,PH Shift Indicator 12:00 starting r/min .
Shift INO Brightness
0,,,PH Shift Indicator 12:00
,1000 r/min B 9 10 11 12 13

5 6jiililiii!!!i!!•
----
INO Mode I ON

1Itsft INR llf JI 5000 r/min I

I I
•----------...
Tach INO 2nd 8000 r/min
--------

"Tach IND Setting"

This module allows you to turn the tachometer
5. Set the starting r/min by rotating and then
col or display on or off. When turned off, the ta-
short pushing the wheel switch. All r/min
chometer will display all r/min levels below the
above this value up to the ''Tach IND 2nd"
red zone in black or white (depending on wallpa-
setting value (or the red zone) , will be dis-
per settings) . When turned on , the mid and mid-
played in green .
to-high r/min zones can be set to come on in
green and then orange colors. O,,,PH Shift Indicator 12:00
1. Select ''Tach IND Setting". , 1000 r/min B 9 10 11 12 13

O,,,PH Shift Indicator 12:00

5 6jiililiii!!!i!!•
- ----
----- - INO Mode I ON
- - - - - Shift INO Setting
- -- - - - - - -
-Tach INO 1st 5000 r/min
Shift INO Brightness -Tach INO 2nd 8000 r/min I
- ----
- - - Peak Rev INO Setting
----- ....
-----
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Green bar start setting range: 5000-11300 r/
2. Select "IND Mode". min.

0 ,.,PH Shift Indicator 12:00

S
6jiililiii!!!i!!•
, 1000 r/min B 9 10 11 12 13

ltNRMZ1n JI ON
-Tach INO 1st I 5000 r/min I
-Tach INO 2nd I 8000 r/min I

1-17
 FEATURES

6. Select ''Tach IND 2nd". 1. Select "Peak Rev IND Setting".

O,.,PH Shift Indicator 12:00

x1000 r/ min 8 9 10 11 12 13
0 MPH Shift Indicator 12:00

5 6jilliliii!!!!!•
-
----
Shift IND Setting
------
Shift IND Brightness
IND Mode I ON --- ----
Tach IND Setting
- ---
Tach IND 1st I 5000 r/min I
fwt we aoo/I 8000 ,,min I - - - - - -
...
Peak Rev IND Setting
--------

7. Set the orange color starting r/min by rotating 2. Select "IND Mode" and then select ON (to
and then short pushing the wheel switch . All turn on the indicator) or OFF (to turn off the in-
r/min above this figure until the red zone, w ill dicator).
be displayed in orange.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ O,.,PH Shift Indicator 12:00

Orange bar start setting range: 5000-11300 r/ Peak Rev IND Setting
min. hNo Mode J ~I- - -o- N
~I

O,.,PH
• 1000 r/min 8
Shift Indicator
9 10 11
12:00
12 13
---------- ...
7

5 6jiliiliiiiii!!!!!•
IND Mode I ON
---- 3. Select the triangle symbol to exit.
Tach IND 1st I 5000 r/min I
Tach IND 2nd 8000 r/min
"Display Setting"
This module allows you to set how the informa-
tion display items (like TRIP-1 , ODO, C . TEMP,
8. Select the triangle symbol to exit. etc.) are grouped on the main screen. There are
four display groups.
O,.,PH Shift Indicator 12:00
• 1000 r/ min 8 9 10 11 12 13
7

5 6jiliiliiiiii!!!!!•
- IND Mode I ON
Tach IND 1st I 5000 r/min I
Tach IND 2nd I 8000 r/min I

1
"Peak Rev IND Setting"
This module allows you to turn the revolution 1. Information display
peak hold indicator on or off.
To set the display groups

1-18
 FEATURES

1. From the MENU screen , select "Display Set- 6. Select 1-2 to set the remaining DISPLA Y-1
ting". group item.

O,,,PH MENU 12:00 O,.,PH Display Setting 12:00

---- -------
Maintenance DISPLAY-1
- - - - -
Unit 1•1 A.TEM P I
- - - - Wallp-ap_e_
r ----
.:.
l1.;.·:.2_ ..................iiiiiii1'1I C.TEM p I
--- -----
Shift Indicator

Display Setting
----- ------ ....
' Brightness

2. DISPLAY-1 , DISPLAY-2, DISPLAY-3 and 7. Select the triangle symbol to exit. To set the
DISPLAY-4 are displayed. other display groups, repeat from step 3.
3. For example, let's select DISPLAY-1 . 1-1 and
1-2 are displayed. "Brightness"
This module allows you to adjust the general
OMPH Display Setting 12:00
brightness level of the display screen.
DISPLAY-1
To set the brightness
.,.
l1_-_1_ _ _ _ _; I A.TEMP I
1. From the MENU screen , select "Brightness".
-1 • 2 I C.TEMP I

-....- 0 MPH MENU 12:00

- Uni~
- - - - Wallp
- a-pe-r - - - -
4. Select 1-1 .
~
- Display Setting
OMPH Display Setting 12:00
Brightness
DISPLAY-1
-
1·1
-- A.TEMP
2. Select the desired brightness level by rotating
C.TEMP I the wheel switch, and then short push the
- - - - -
...
- - - - - -
wheel switch to fix the setting.

0 MPH Brightness 12:00

5. Select the desired information display item

with the wheel switch.
• A.TEMP: air temperature
• C.TEM P: coolant temperature
• TRIP-1 : tripmeter 1
• TRIP-2: tripmeter 2
• ODO: odometer
• FUEL CON : the amount of fuel consumed
"Grip Warmer Setting"
• FUEL AVG : average fuel consumption
This module allows you to set the low, middle,
• CRNT FUEL: current fuel consumption
and high settings to 10 temperature levels.

To set the grip warmer temperature levels

1-19
 FEATURES

1. From the MENU screen , select "Grip Warmer 2. When "Clock" is selected, the hours figure will
Setting". be highlighted.

O ,,,PH MENU 12:00 O MPH Clock 12:00

---- ------
Shift Indicator

Display Setting
- - - -Brightn- e-ss_ _ __ ■

L Grip Warmer Setting ■

- Clock

All Reset

2. Select "LO", "MIDDLE", or "HIGH". 3. Set the hour by rotating and then short push
the wheel switch.
O MPH Grip Warmer Setting 12:00
0 MPH Clock 12:00
ILO Level 1
-MIDDLE -
Levels
HIGH
---------- ... Level 10
■
■

3. Set the temperature level.

4. The minutes figure will become highlighted.
0 MPH Grip Warmer Setting 12 :oo
O MPH Clock 12:00
Level 1
-------
MIDDLE Levels
-------
HIGH Level1 0
■
■

4. To set the temperature level for another grip

warmer setting, repeat from step 2 or select 5. Set the minutes figure by rotating and then
the triangle symbol to exit this module. short push the wheel switch .

"Clock" 0 MPH Clock 12:00

This module allows you to set the clock.

To set the clock ■

1. From the M ENU screen , select "Clock".
■

O,,,PH MENU 12:00

- Shiftlndi~
------ ------
Display Setting
- - - - Brightn
- e-ss_ _ __

Grip Warmer Setting

Clock
---- ------
All Reset

1-20
 FEATURES

6. Short push the wheel switch again to exit and

go back to the MENU screen.

"All Reset"
This module contains the all reset function which
resets everything , except the odometer and
clock, to its factory preset or default setting.
Select YES to reset all items. After selecting
YES, all items will be reset and the display will
automatically return to the MENU screen.

1-21
 SPECIAL TOOLS

EAS20012

SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• For U.S.A. and Canada, use part number starting with "YM-", "YU-", or "ACC-".
• For others, use part number starting with "90890-".

Reference
Tool name/Tool No. Illustration
pages
Yamaha diagnostic tool USB (US) 3-4 4-65 4-67
90890-03257 ' 8-156
8-50 ' '
8-177' '

Yamaha diagnostic tool (A/1) 3-4 4-65 4-67

90890-03262 ' 8-156
8-50 ' '
8-177' '

O YAMA!IA

Thickness gauge 3-6 4-26 4-34

90890-03268 ' 5-53
5-28 ' '
Feeler gauge set '
YU-26900-9

Valve lapper (014) 90890-04101

3-7
90890-04101
Valve lapping tool (14mm)
YM-A8998 0 14~
'

YM-A8998

Vacuum gauge 3-9

90890-03094
90890-03094
Vacuum mate
YU-44456

YU-44456

1-22
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Carburetor angle driver 2 3-10
90890-03173

Steering nut wrench 3-20 4-99

90890-01403 '
Exhaust flange nut wrench
YU-A9472

Oil filter wrench 3-26

90890-01426
Oil filter wrench
YU-38411

Pressure gauge 3-27 7-17 7-18

90890-03153 ' '
Pressure gauge
YU-03153

Oil pressure adapter H 3-27

90890-03139

M16XP1 .5

Fork spring compressor 055 4-87 4-93 4-94

90890-01441 ' '
Fork spring compressor
YM-01441

Rod holder 4-87 4-93 4-94

90890-01434 ' '
Damper rod holder double ended
YM-01434

Damper rod holder (027) 4-88 4-90

90890-01582 '
Damper rod holder
YM-01582

Fork seal driver 4-90 4-90 4-91

90890-01442 ' '
Adjustable fork seal driver (36-46 mm)
YM-01442

1-23
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Rod puller 4-91 4-93 4-94
90890-01437 90890-01437 ' '
Universal damping rod bleeding tool set
YM-A8703

YM-A8703

Rod puller attachment (M10 long) 4-91 4-93 4-94

90890-01578 90890-01578 ' '
Universal damping rod bleeding tool set
YM-A8703

YM-A8703

Ring nut wrench 4-99

90890-01268
Spanner wrench
YU-01268

Drive chain cut & rivet tool 4-114, 4-11 6

90890-01550
Drive chain cut & rivet tool
YM-01550

Compression gauge 90890-03081

5-7
90890-03081
Engine compression tester
YU-33223

YU-33223

1-24
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Compression gauge extension 122mm 5-7
90890-04136
Compression gauge extension 122mm
YM-04136

Pivot shaft wrench 5-13 5-13

90890-01485 '
Frame mount insert wrench
YM-01485

Pivot shaft wrench 5-13 5-14

90890-01518 '
Frame spanner socket
YM-01518

Pivot shaft wrench adapter 5-13 5-14

90890-01476 '

Camshaft wrench 5-20 5-22

90890-04162 '
Camshaft wrench
YM-04162

Valve spring compressor 5-32 5-37

90890-04019 '
Valve spring compressor
YM-04019

Valve spring compressor attachment (023) 5-32 5-37

90890-04179 '
Valve spring compressor adapter (023)
YM-04179

Valve guide remover (04.5) 5-34

90890-04116
Valve guide remover (4.5 mm)
YM-04116

Valve guide installer (04.5) 5-34

90890-04117
Valve guide installer (4.5 mm)
YM-04117

1-25
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Valve guide reamer (04.5) 5-34
90890-04118
Valve guide reamer (4.5 mm)
YM-04118

Sheave holder 5-41 5-41 5-42

90890-01701 5-42' ' '
Primary clutch holder
YS-01880-A

Flywheel puller 5-41

90890-01362
Heavy duty puller
YU-33270-B

Yamaha bond No. 1215 5-43 5-70

90890-85505 '
(Three bond No.1215®)

Digital circuit tester (CD732) 5-46 8-189

90890-03243 ' 8-192,
8-190, '
Model 88 Multimeter with tachometer 8-192, 8-192,
YU-A1927 8-193, 8-194,
8-194, 8-195,
8-196, 8-196,
8-197, 8-197,
8-199, 8-199,
8-200, 8-201,
8-201, 8-202,
8-202, 8-203,
8-204, 8-204,
8-204
Universal clutch holder 5-52 5-56
90890-04086 90890-04086 M8x P1 . '
Universal clutch holder
YM-91042

YM-91042

1-26
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Piston pin puller set 90890-01304 5-74
90890-01304
Piston pin puller
YU-01304

YU-01304

Piston installing tool 5-81

90890-04161
Piston installing tool
YM-04161

Radiator cap tester 90890-01325 6-5 6-5

90890-01325 '
Mityvac cooling system tester kit
YU-24460-A

YU-24460-A

Radiator cap tester adapter 6-5 6-5

90890-01352 90890-01352 '
Pressure tester adapter
YU-33984

YU-33984

Mechanical seal installer 6-14

90890-04078
Water pump seal installer
YM-33221-A

1-27
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Middle driven shaft bearing driver 6-14
90890-04058
Middle drive bearing installer 40 & 50 mm
YM-04058

Fuel injector pressure adapter 7-17

90890-03210
Fuel injector pressure adapter
YU-03210

Fuel pressure adapter 7-18

90890-03176
Fuel pressure adapter
YM-03176

OBD/ GST Leadwire kit 8-50

90890-03249

Ignition checker 8-194

90890-06754
Oppama pet-4000 spark checker
YM-34487

Test harness- lean angle sensor (6P) 8-195

90890-03209
Test harness- lean angle sensor (6P)
YU-03209

Test harness S- pressure sensor (3P) 8-201

90890-03207
Test harness S- pressure sensor (3P)
YU-03207

1-28
 SPECIAL TOOLS

1-29
 SPECIFICATIONS

GENERAL SPECIFICATIONS ........ .......... ......... ........ .......... ......... ......... ......... 2-1

ENGINE SPECIFICATIONS .. ......... .......... ........ ......... .......... ......... ......... .......... 2-2

CHASSIS SPECIFICATIONS ......... .......... ........ ......... .......... ......... ......... .......... 2-7

ELECTRICAL SPECIFICATIONS .. .......... ........ .......... ......... .......... ......... ....... 2-1 O

TIGHTENING TORQUES ....... .......... ......... .......... ......... ........ .......... ......... ...... 2-13
ENGINE TIGHTENING TORQUES ..... .......... ......... ......... ......... .......... ..... 2-13
CHASSIS TIGHTEN ING TORQUES ... ......... ......... ......... .......... ......... ...... 2-14

CABLE ROUTING ......... ......... .......... ......... .......... ......... ......... ......... .......... ..... 2-15
 GENERAL SPECIFICATIONS

EAS20013

GENERAL SPECIFICATIONS

Model
Model B5C7 (MTT9K)
B5C8 (MTT9KC)
B1J3 (MTT9GTK)
B1J4 (MTT9GTKC)

Dimensions
Overall length 2160 mm (85.0 in)
Overall width 850 mm (33.5 in)
Overall height 1375/1430 mm (54.1 /56.3 in)
Wheelbase 1500 mm (59.1 in)
Ground clearance 135 mm (5.31 in)
Minimum turning radius 3.0 m (9.84 ft)

Weight
Curb weight 214 kg (472 lb) (MTT9K, MTT9KC)
215 kg (474 lb) (MTT9GTK, MTT9GTKC)

Loading
Maximum load 180 kg (397 lb) (MTT9K, MTT9KC)
179 kg (395 lb) (MTT9GTK, MTT9GTKC)
Riding capacity 2 person

2-1
 ENGINE SPECIFICATIONS

EAS20014

ENGINE SPECIFICATIONS

Engine
Combustion cycle 4-stroke
Cooling system Liquid cooled
Valve train DOHC
Displacement 847 cm 3
Cylinder arrangement In line
Number of cylinders 3-cylinder
Bore x stroke 78.0 x 59.1 mm (3.07 x 2.33 in)
Compression ratio 11.5 : 1
Compression pressure 1331-1713 kPa/680 r/min (13.3- 17.1 kgf/cm 2/
680 r/min, 189.3-243.7 psi/680 r/min)
Starting system Electric starter

Fuel
Recommended fuel Premium unleaded gasoline (Gasohol [E1 O]
acceptable)
Fuel tank capacity 18 L (4.8 US gal, 4.0 Imp.gal)
Fuel reserve amount 2.6 L (0.69 US gal, 0.57 Imp.gal)

Engine oil
Recommended brand YAMALUBE
SAE viscosity grades 1OW-40, 1OW-50, 15W-40, 20W-40 or 20W-50
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Lubrication system Wet sump
Engine oil quantity
Oil change 2.40 L (2.54 US qt, 2.11 Imp.qt)
W ith oil filter removal 2.70 L (2.85 US qt, 2.38 Imp.qt)
Quantity (disassembled) 3.40 L (3.59 US qt, 2.99 Imp.qt)

Oil filter
Oil filter type Cartridge

Oil pump
Inner-rotor-to-outer-rotor-tip clearance 0.000-0.120 mm (0.0000-0.0047 in)
Limit 0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing clearance 0.09-0.19 mm (0.0035-0.0075 in)
Limit 0.21 mm (0.0083 in)
Oil-pump-housing-to-inner-and-outer-rotor
clearance 0.06-0.13 mm (0.0024-0.0051 in)
Limit 0.16 mm (0.0063 in)
Oil pressure 230.0 kPa/5000 r/min (2.30 kgf/cm 2/5000 r/min,
33.4 psi/5000 r/min)
Relief valve operating pressure 670.0- 810.0 kPa (6.70- 8.1O kgf/cm 2 , 97.2-
117.5 psi)

Cooling system
Coolant quantity
Radiator (including all routes) 1.93 L (2.04 US qt, 1. 70 Imp.qt)

2-2
 ENGINE SPECIFICATIONS

Coolant reservoir (up to the maximum level

mark) 0.25 L (0.26 US qt, 0.22 Imp.qt)
Radiator cap valve opening pressure 93.3-122.7 kPa (0.93-1 .23 kgf/cm 2 , 13.5-17.8
psi)
Thermostat
Valve opening temperature 69.0-73.0 ° C (156.20-163.40 ° F)
Valve full open temperature 85.0 ° C (185.00 ° F)
Valve lift (full open) 8.0 mm (0.31 in)

Spark plug(s)
Manufacturer/model NGK/CPR9EA9
Spark plug gap 0.8-0.9 mm (0.031-0.035 in)

Cylinder head
Warpage limit 0.1O mm (0.0039 in)

Camshaft
Camshaft cap inside diameter 24.500-24.521 mm (0.9646-0.9654 in)
Camshaft journal diameter 24.459-24.472 mm (0.9630-0.9635 in)
Camshaft-journal-to-camshaft-cap clearance 0.028-0.062 mm (0.0011-0.0024 in)
Limit 0.080 mm (0.0032 in)
Camshaft lobe dimensions
Lobe height (Intake) 36.290-36.390 mm (1 .4287-1 .4327 in)
Limit 36.190 mm (1 .4248 in)
Lobe height (Exhaust) 35.720-35.820 mm (1 .4063-1 .4102 in)
Limit 35.620 mm (1 .4024 in)

Valve, valve seat, valve guide

Valve clearance (cold)
Intake 0.11-0.20 mm (0.0043-0.0079 in)
Exhaust 0.26-0.30 mm (0.0102-0.0118 in)
Valve dimensions
Valve seat contact width (intake) 0.90-1 .1O mm (0.0354-0.0433 in)
Limit 1.60 mm (0.06 in)
Valve seat contact width (exhaust) 1.10-1 .30 mm (0.0433-o.0512 in)
Limit 1.80 mm (0.07 in)
Valve stem diameter (intake) 4.475-4.490 mm (0.1762-0.1768 in)
Limit 4.445 mm (0.1750 in)
Valve stem diameter (exhaust) 4.460-4.475 mm (0.1756-0.1762 in)
Limit 4.430 mm (0.1744 in)
Valve guide inside diameter (intake) 4.500-4.512 mm (0.1772-0.1776 in)
Valve guide inside diameter (exhaust) 4.500-4.512 mm (0.1772-0.1776 in)
Valve-stem-to-valve-guide clearance (intake) 0.010-0.037 mm (0.0004-0.0015 in)
Limit 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance
(exhaust) 0.025-0.052 mm (0.0010-0.0020 in)
Limit 0.100 mm (0.0039 in)
Valve stem runout 0.01 O mm (0.0004 in)

Valve spring
Free length (intake) 39.31 mm (1 .55 in)
Limit 37.34 mm (1 .47 in)
Free length (exhaust) 37.78 mm (1 .49 in)

2-3
 ENGINE SPECIFICATIONS

Limit 35.89 mm (1.41 in)

Cylinder
Bore 78.000-78.01 O mm (3.0709-3.0713 in)
Wear limit 78.060 mm (3.0732 in)

Piston
Diameter
Measuring point (from piston skirt bottom)
Piston-to-cylinder clearance
Piston pin bore inside diameter
Limit
Piston pin outside diameter
Limit
Piston-pin-to-piston-pin-bore clearance
77.975-77.990 mm (3.0699-3.0705 in)
12.0 mm (0.47 in)
0.010-0.035 mm (0.0004-0.0014 in)
17.002- 17.013 mm (0.6694-0.6698 in)
17.043 mm (0.6710 in)
16.990- 16.995 mm (0.6689-0.6691 in)
16.970 mm (0.6681 in)
0.007-0.023 mm (0.0003-0.0009 in)

Piston ring
Top ring
End gap limit 0.50 mm (0.0197 in)
Ring side clearance 0.030-0.065 mm (0.0012-0.0026 in)
Side clearance limit 0.115 mm (0.0045 in)
2nd ring
End gap limit 0.80 mm (0.0315 in)
Ring side clearance 0.020-0.055 mm (0.0008-0.0022 in)
Side clearance limit 0.115 mm (0.0045 in)

Connecting rod
Oil clearance 0.027-0.051 mm (0.0011-0.0020 in)
Bearing color code
Code 1 Blue
Code 2 Black
Code 3 Brown
Code 4 Green

Crankshaft
Runout limit 0.030 mm (0.0012 in)
Crankshaft journal diameter 32.000-32.024 mm (1.260-1.261 in)
Journal oil clearance 0.014-0.038 mm (0.0006-0.0015 in)
Bearing color code
Code O White
Code 1 Blue
Code 2 Black
Code 3 Brown
Code 4 Green

Balancer
Balancer shaft runout limit 0.030 mm (0.0012 in)
Bearing color code
Code 1 Blue
Code 2 Black
Code 3 Brown
Code 4 Green
Code 5 Yellow

2-4
 ENGINE SPECIFICATIONS

Balancer shaft journal to balancer shaft bearing

clearance 0.024-0.048 mm (0.0009-0.0019 in)

Clutch
Clutch type Wet, multiple-disc
Clutch lever free play 10.0-15.0 mm (0.39-0.59 in) (MTT9K,
MTT9KC)
5.0-10.0 mm (0.20-0.39 in) (MTT9GTK,
MTT9GTKC)
Assembly width 42.7-43.5 mm (1.68-1 .71 in)
Friction plate 1 thickness 2.92-3.08 mm (0.115-0.121 in)
Plate quantity 3 pcs
Wear limit 2.82 mm (0.111 in)
Friction plate 2 thickness 2.92-3.08 mm (0.115-0.121 in)
Plate quantity 6 pcs
Wear limit 2.82 mm (0.111 in)
Clutch plate 2 thickness 1.90-2.1 O mm (0.075-0.083 in)
Plate quantity 7 pcs
Warpage limit 0.1 O mm (0.004 in)
Clutch plate 1 thickness 2.20-2.40 mm (0.087-0.094 in)
Plate quantity 1 pcs
Warpage limit 0.1 O mm (0.004 in)
Clutch spring free length 45.23 mm (1.78 in)
Limit 42.97 mm (1.69 in)

Drivetrain
Primary reduction ratio 1.681 (79/47)
Transm ission type Constant mesh 6-speed
Gear ratio
1st 2.667 (40/15)
2nd 2.000 (38/19)
3rd 1.619 (34/21)
4th 1.381 (29/21)
5th 1.190 (25/21)
6th 1.037 (28/27)
Main axle runout limit 0.08 mm (0.0032 in)
Drive axle runout limit 0.08 mm (0.0032 in)
Secondary reduction ratio 2.813 (45/16)
Final drive Chain

Shifting mechanism
Installed shift rod length 256.9-258.9 mm (10.11-10.19 in)

Air filter
A ir filter element O il-coated paper element

Fuel pump
Pump type Electrical
Maximum consumption amperage 3.3 A

Fuel injector
Resistance 12.0 Q

2-5
 ENGINE SPECIFICATIONS

Throttle body
ID mark 1RC1 00 (MTT9K)
B904 1O (MTT9KC)
BD51 20 (MTT9GTK)
B1J4 10 (MTT9GTKC)

Throttle position sensor

Output voltage (at idle) 0.63-0.73 V

Accelerator position sensor

Resistance 1.08-2.52 k ..Q

Idling condition
Engine idling speed 1100-1300 r/min
Al system Inactive
02 feedback control Inactive
Coolant temperature 90-110 oc (
194-230 °F)
CO% 1.5-3.5 %
Fuel line pressure (at idle) 300-390 kPa (3.0-3.9 kgf/cm 2 , 43.5-56.6 psi)
Throttle grip free play 3.0-5.0 mm (0.12-0.20 in)

Air induction system

Solenoid resistance 20-24 .Q

2-6
 CHASSIS SPECIFICATIONS

EAS20015

CHASSIS SPECIFICATIONS

Chassis
Frame type Diamond
Caster angle 24.0 °
Trail 100 mm (3.9 in)

Front wheel
Wheel type Cast wheel
Rim size 17M/C x MT3.50
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)

Rear wheel
Wheel type Cast wheel
Rim size 17M/C x MTS.SO
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)

Front tire
Type Tubeless
Size 120/70ZR 17 M/C (58W)
Manufacturer/model DUNLOP/D222F

Rear tire
Type Tubeless
Size 180/SSZR 17 M/C (73W)
Manufacturer/model DUNLOP/D222

Tire air pressure (measured on cold tires)

Up to 90 kg (198 lb) load
Front 225 kPa (2.25 kgf/cm 2 , 33 psi)
Rear 250 kPa (2.50 kgf/cm 2 , 36 psi)
90 kg (198 lb) load - maximum load
Front 250 kPa (2.50 kgf/cm 2 , 36 psi)
Rear 290 kPa (2.90 kgf/cm 2 , 42 psi)

Front brake
Type Hydraulic dual disc brake
Disc outside diameter x thickness 298.0 x 4 .5 mm (11 .73 x 0.18 in)
Brake disc thickness limit 4.0 mm (0.16 in)
Brake disc runout limit (as measured on wheel) 0.1O mm (0.0039 in)
Brake pad lining thickness limit 0.5 mm (0.02 in)
Master cylinder inside diameter 15.00 mm (0.59 in)
Caliper cylinder inside diameter (Left) 30.23 mm, 27.00 mm (1 .19 in, 1.06 in)
Caliper cylinder inside diameter (Right) 30.23 mm, 27.00 mm (1 .19 in, 1.06 in)
Specified brake fluid DOT4

Rear brake
Type Hydraulic single disc brake
Disc outside diameter x thickness 245.0 x 5.0 mm (9.65 x 0.20 in)
Brake disc thickness limit 4.5 mm (0.18 in)

2-7
 CHASSIS SPECIFICATIONS

Brake disc runout limit (as measured on wheel) 0.15 mm (0.0059 in)
Brake pad lining thickness limit 1.0 mm (0.04 in)
Master cylinder inside diameter 12.7 mm (0.50 in)
Caliper cylinder inside diameter 38.18 mm (1 .50 in)
Specified brake fluid DOT4

Front suspension
Type Telescopic fork
Spring Coil spring
Shock absorber Hydraulic damper
Wheel travel 137 mm (5.4 in)
Fork spring free length 305.3 mm (12.02 in)
Limit 299.1 mm (11 .78 in)
Inner tube bending limit 0.2 mm (0.01 in)
Recommended oil Yamaha Suspension Oil 01
Quantity (left) 444.0 cm 3 (15.01 US oz, 15.66 Imp.oz) (MTT9K,
MTT9KC)
439.0 cm 3 (14.84 US oz, 15.48 Imp.oz)
(MTT9GTK, MTT9GTKC)
Quantity (right) 431 .0 cm 3 (14.57 US oz, 15.20 Imp.oz) (MTT9K,
MTT9KC)
443.0 cm 3 (14.98 US oz, 15.62 Imp.oz)
(MTT9GTK, MTT9GTKC)
Level (left) 174 mm (6.9 in) (MTT9K, MTT9KC)
175 mm (6.9 in) (MTT9GTK, MTT9GTKC)
Level (right) 175 mm (6.9 in)
Spring preload
Adjusting system Mechanical adjustable type
Adjustment value (Soft) 19.0 mm (0.75 in)
Adjustment value (STD) 16.0 mm (0.63 in)
Adjustment value (Hard) 4.0 mm (0.16 in)
Rebound damping
Adjusting system Mechanical adjustable type
Unit for adjustment Click
Adjustment value from the start position (Soft) 12 (MTT9K, MTT9KC)
11 (MTT9GTK, MTT9GTKC)
Adjustment value from the start position (STD) 7
Adjustment value from the start position (Hard) 1
Compression damping
Adjusting system Mechanical adjustable type (MTT9GTK,
MTT9GTKC)
Unit for compression damping adjustment Click (MTT9GTK, MTT9GTKC)
Adjustment value from the start position (Soft) 11 (MTT9GTK, MTT9GTKC)
Adjustment value from the start position (STD) 7(MTT9GTK, MTT9GTKC)
Adjustment value from the start position (Hard) 1 (MTT9GTK, MTT9GTKC)

Rear suspension
Type Swingarm (link suspension)
Spring Coil spring
Shock absorber Gas-hydraulic damper
Wheel travel 142 mm (5.6 in)
Spring preload
Adjusting system Mechanical adjustable type

2-8
 CHASSIS SPECIFICATIONS

Unit for adjustment Cam position

Adjustment value (Soft) 1
Adjustment value (STD) 4 (MTT9K, MTT9KC)
11 (MTT9GTK, MTT9GTKC)
Adjustment value (Hard) 7 (MTT9K, MTT9KC)
24(MTT9GTK, MTT9GTKC)
Rebound damping
Adjusting system Mechanical adjustable type
Unit for adjustment Turn (MTT9K, MTT9KC)
Click (MTT9GTK, MTT9GTKC)
Adjustment value from the start position (Soft) 3 (MTT9K, MTT9KC)
18(MTT9GTK, MTT9GTKC)
Adjustment value from the start position (STD) 1 1/2 (MTT9K, MTT9KC)
7 (MTT9GTK, MTT9GTKC)
Adjustment value from the start position (Hard) O (MTT9K, MTT9KC)
1 (MTT9GTK, MTT9GTKC)

Drive chain
Size DID525V11
Chain type Sealed type
Number of links 118
Drive chain slack (Maintenance stand) 35.0-45.0 mm (1 .38-1 .77 in)
Limit 50.0 mm (1 .97 in)
15-link length limit 239.3 mm (9.42 in)

2-9
 ELECTRICAL SPECIFICATIONS

EAS20016

ELECTRICAL SPECIFICATIONS

Voltage
System voltage 12 V

Ignition system
Ignition system TCI
Advancer type Digital
Ignition timing (B.T.D.C.) 5.0 °/1200 r/min

Engine control unit

Model TBD F2Z(MTT9K, MTT9KC)
TBD F3A(MTT9GTK, MTT9GTKC)

Ignition coil
Primary coil resistance 1.19-1 .61 Q
Secondary coil resistance 9.35-12.65 kQ

Lean angle sensor output voltage

Operating angle 65 °
Output voltage up to operating angle 0.4-1 .4 V
Output voltage over operating angle 3.7-4.4 V

Charging system
Charging system AC magneto
Standard output 14.0 V, 29.6 A at 5000 r/min
Stator coil resistance 0.152-0.228 Q

Rectifier/regulator
Regulator type Three-phase
Regulated voltage (DC) 14.3-14.7 V
Rectifier capacity (DC) 50.0 A

Battery
Model YTZ10S
Voltage, capacity 12 V, 8.6 Ah (10 HR)

Bulb wattage
Headlight LED
Brake/tail light LED
Front turn signal/position light 21 .0 W/5.0 W
Rear turn signal light 21 .0 W
Auxiliary light LED
License plate light 5.0 W
Meter lighting LED

Indicator light
Neutral indicator light LED
Engine oil and Coolant warning light LED(MTT9GTK, MTT9GTKC)
High beam indicator light LED
Oil level warning light LED (MTT9K, MTT9KC)
Turn signal indicator light LED

2-10
 ELECTRICAL SPECIFICATIONS

Engine trouble warning light LED

ABS warning light LED
Cruise control "SET' indicator light LED(MTT9GTK,MTT9GTKC)
Cruise control "ON" indicator light LED(MTT9GTK,MTT9GTKC)
Shift timing indicator light LED(MTT9GTK,MTT9GTKC)
Traction control system indicator light LED

Starter motor
Power output 0.70 kW
Brush overall length limit 6.5 mm (0.26 in)
Brush spring force 6.03-6.52 N (615-665 gf, 21.71-23.47 oz)
(MTT9K, MTT9KC)
6.02-6.51 N (614-664 gf, 21.69-23.45 oz)
(MTT9GTK, MTT9GTKC)
Mica undercut (depth) 0.70 mm (0.03 in)

Oil level switch

Oil level switch resistance (maximum level
position) 484.0-536.0 Q (MTT9K, MTT9KC)
484.5-535.5 Q (MTT9GTK, MTT9GTKC)
Oil level switch resistance (minimum level
position) 114.0- 126.0 Q

Fuel sender unit

Sender unit resistance (full) 9.0-11.0 Q
Sender unit resistance (empty) 213.0-219.0 Q

Grip warmer
Grip warmer resistance (L) 1.2- 1.5 Q (MTT9GTK, MTT9GTKC)
Grip warmer resistance (R) 1.2- 1.4 Q (MTT9GTK, MTT9GTKC)

Fuel injection sensor

Crankshaft position sensor resistance 228-342 Q
Intake air temperature sensor resistance 5400-6600 Q at O 0 c (5400-6600 Q at 32 °F)
Intake air temperature sensor resistance 290-390 Q at 80 °c (290-390 Q at 176 °F)
Coolant temperature sensor resistance 2513-2777 Q at 20 °c (2513-2777 Q at 68 °F)
Coolant temperature sensor resistance 210-221 Q at 100 °c (210-221 Q at 212 °F)

Fuse(s)
Main fuse 50.0 A
Headlight fuse 7.5 A
Fog lamp fuse 2.0 A
Brake light fuse 1.0 A (MTT9GTK, MTT9GTKC)
Signaling system fuse 7.5 A
Ignition fuse 15.0 A
Parking lighting fuse 10.0 A
Radiator fan motor fuse 15.0 A
Fuel injection system fuse 20.0 A
ABS control unit fuse 7.5 A
ABS motor fuse 30.0 A
ABS solenoid fuse 15.0 A
Cruise control fuse 1.0 A (MTT9GTK, MTT9GTKC)
Backup fuse 7.5 A

2-11
 ELECTRICAL SPECIFICATIONS

Electronic throttle valve fuse 7.5A

Seat heater fuse 7.5 A
Plug +12V fuse 2.0 A
Plug +12V fuse 2.0 A

2-12
 TIGHTENING TORQUES

EAS20017

TIGHTENING TORQUES
EAS30016

ENGINE TIGHTENING TORQUES

Thread
Item Q'ty Tightening torque Remarks
size
Exhaust pipe nut M8 6 20 N-m (2.0 kgf-m, 15 lb-ft)
Muffler protector bolt M6 3 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Spark plug M10 3 13 N-m (1.3 kgf-m, 9.6 lb-ft)
Cylinder head cover bolt M6 4 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Generator rotor bolt M12 1 75 N-m (7.5 kgf-m, 55 lb-ft) -,@
Generator cover bolt M6 2 12 N-m (1.2 kgf-m, 8.9 lb-ft) -G
Generator cover bolt M6 8 12 N-m (1.2 kgf-m, 8.9 lb-ft)
Stake.
Clutch boss nut M20 1 125 N-m (12.5 kgf-m, 92 lb-ft)
-G
Clutch spring bolt M6 3 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Clutch cover bolt M6 11 12 N-m (1.2 kgf-m, 8.9 lb-ft)
Oil filter cartridge M20 1 17 N-m (1.7 kgf-m, 13 lb-ft)
Oil filter cartridge union bolt M20 1 70 N-m (7.0 kgf-m, 52 lb-ft) - ,@
Water pump drain bolt M6 1 10 N-m (1.0 kgf-m, 7.4 lb-ft)
Engine oil drain bolt M14 1 43 N-m (4.3 kgf-m, 32 lb-ft)

2-13
 TIGHTENING TORQUES

EAS30017

CHASSIS TIGHTENING TORQUES

Thread
Item Q'ty Tightening torque Remarks
size
Front wheel axle M16 1 65 N-m (6.5 kgf-m, 48 lb-ft)
Front wheel axle pinch bolt M8 1 23 N-m (2.3 kgf-m, 17 lb-ft)
Rear wheel sprocket nut M10 6 80 N-m (8.0 kgf-m, 59 lb-ft)
Rear wheel axle nut M18 1 150 N-m (15 kgf-m, 111 lb-ft)
Rear brake caliper bolt (front) M12 1 27 N-m (2.7 kgf-m, 20 lb-ft) ~
~
Rear brake caliper bolt (rear) M8 1 22 N-m (2.2 kgf-m, 16 lb-ft) and
-CJ
Brake caliper bleed screw M8 3 5 N-m (0.5 kgf-m, 3.7 lb-ft)
Front brake caliper bolt M10 4 35 N-m (3.5 kgf-m, 26 lb-ft)
Upper handlebar holder bolt M8 4 22 N-m (2.2 kgf-m, 16 lb-ft)
Lower handlebar holder nut M10 2 40 N-m (4.0 kgf-m, 30 lb-ft)
Clutch cable locknut M8 1 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Lower bracket pinch bolt M8 4 23 N-m (2.3 kgf-m, 17 lb-ft)
Upper bracket pinch bolt M8 2 26 N-m (2.6 kgf-m, 19 lb-ft)
Lower ring nut M25 1 See TIP.
Stake.
Drive sprocket nut M22 1 95 N-m (9.5 kgf-m, 70 lb-ft)
- 1@
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Lower ring nut
1. Tighten the ring nut to approximately 52 N-m (5.2 kgf-m , 38 lb-ft) with a torque wrench , then loosen
the lower ring nut completely.
2. Tighten the lower ring nut to 18 N-m (1.8 kgf-m, 13 lb-ft).

2-14
 CABLE ROUTING

EAS20021

CABLE ROUTING
Handlebar (front view) (MTT9K/MTT9KC)

1 2 A B C

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2-15
 CABLE ROUTING

1. Throttle cable (decelerator cable)

2. Throttle cable (accelerator cable)
3. Clutch cable
4. Handlebar switch lead (left)
5. Main switch lead
6. Steering stopper
7. Horn lead
8. Handlebar switch lead (right)
9. Front brake hose
10. Upper bracket
11. Main switch
12. Front fork
A. Fasten the front brake hose and handlebar switch
lead (right) with the holder.
B. Route the handlebar switch lead (right) and
handlebar switch lead (left) to the front of the
handlebar.
C. Align the edge of the holder with the end of the clutch
cable protector.
D. Fasten the handlebar switch lead (left) and handlebar
switch lead (ri ght) with the clamp.
Face the opening of the clamp forward.
E. Route the main switch lead over the guide from the
rear of the vehicle.
Position the main switch lead to the right of the
throttle cables.
F. Insert the clamp of the handlebar switch lead (left)
into the hole in the headlight stay.
G. Route the handlebar switch lead (left) over the wire
harness.
H. Let the horn lead sag between them.
I. Fasten the horn lead to the bracket with the clamp so
that the mating section faces downward.
Route the horn lead on the front side from the hole in
the clamp.
J. Fasten the horn lead and the protector of the front
brake hose with the clamp. Align the position of the
clamp with the steering stopper with its opening
facing rearward.
K. Insert the clamp of the handlebar switch lead (right)
into the hole in the headlight stay.
L. Route the horn lead along with the front portion of the
brake hoses between the clamps shown.
M. Fasten the horn lead and the front brake hose with
the clamp and insert the clamp into the bracket.
Engage the clamp by at least three notches.
Face the opening of the clamp rearward.
N. Pass the throttle cables through the guide.
0. Fasten the protector of the throttle cable with the
clamp.
Face the opening of the clamp rearward.
P. Position the clamp within the range shown in the
illustration.
Q. Face the catch of the holder outward.
R. Align the holder with the end of the hose protector on
the front brake hose. The position of this holder does
not determine the length of the handlebar switch lead
(right).
S. Position the clamp to the boss of the upper bracket
with the plastic band. Route the clutch cable to the
outside of the boss. Align the plastic band with the
bottom end of the boss.
T. Point the end of the clamp rearward.

2-16
 CABLE ROUTING

Handlebar (front view) (MTT9GTK/MTT9GTKC)

G J a lII s[B]

2-17
 CABLE ROUTING

1. Throttle cable (decelerator cable) s. Route the handlebar switch lead (right) and front
2. Throttle cable (accelerator cable) brake light switch lead to the rear of the front brake
3. Grip warmer lead hose. Make sure that there is no slack in the
handlebar switch lead (right) and front brake light
4. Clutch cable
switch lead between the handlebar switch and this
5. Handlebar switch lead (left) holder.
6. Main switch lead T. Fasten the front brake hose, handlebar switch lead
7. Clutch switch lead (right), grip warmer lead, and front brake light switch
8. Horn lead lead with the holder. Align the holder with the end of
9 . Steering stopper the hose protector on the front brake hose. Face the
opening of the clamp rearward.
10. Handlebar switch lead (right)
11 . Front brake hose u. Fasten the brake hose and throttle cable (decelerator
cable) with the clamp. Position the clamp at the same
12. Front brake light switch lead height as the clamp on the clutch cable. Face the
13. Upper bracket opening of the clamp rearward.
14. Main switch V. Face the catch of the holder outward.
15. Front fork W. Position the clamp to the boss of the upper bracket
A. Route the handlebar switch lead (right) to the front of with the plastic band. Route the clutch cable to the
the handlebar. outside of the boss. Align the plastic band with the
B. Route the handlebar switch lead (left) to the front of bottom end of the boss.
the handlebar. X. Point the end of the clamp rearward.
C. Fasten the handlebar switch lead (left), handlebar
switch lead (right), clutch switch lead, grip warmer
lead and front brake light switch lead with the clamp.
Face the opening of the clamp forward.
D. Route the main switch lead over the guide from the
rear of the vehicle. Position the main switch lead to
the right of the throttle cables.
E. Insert the clamp of the handlebar switch lead (left)
into the hole in the headlight stay.
F. Fasten the clutch switch lead, and handlebar switch
lead (right) with the holder. Making sure not to twist
them.
G. Position the holder within the 10- 30 mm (0.39-1.18
in) range shown in the illustration.
H. Route the handlebar switch lead (left) over the wire
harness.
I. Let the horn lead sag between them.
J. Fasten the horn lead to the bracket with the clamp so
that the mating section faces downward. Route the
horn lead on the front side from the hole in the clamp.
K. Fasten the horn lead and the protector of the front
brake hose with the clamp. Align the position of the
clamp with the steering stopper with its opening
facing rearward.
L. Fasten the front brake light switch lead, handlebar
switch lead (right), and grip warmer leads with the
holder. Making sure not to twist them.
M. Insert the clamp of the handlebar switch lead (right)
into the hole in the headlight stay.
N. Route the horn lead along with the front portion of the
brake hoses between the clamps shown.
0. Fasten the horn lead and the front brake hose with
the clamp and insert the clamp into the bracket.
Engage the clamp by at least three notches. Face the
opening of the clamp rearward.
P. Pass the throttle cables through the guide.
Q. Fasten the protector of the throttle cable with the
clamp. Face the opening of the clamp rearward.
R. Position the clamp within the range shown in the
illustration.

2-18
 CABLE ROUTING

Handlebar (top view) (MTT9K/MTT9KC)

[g]

1 2

-- '
'

2-19
 CABLE ROUTING

1. Front brake master cylinder

2. Throttle cable
3. Rubber cover
4. Handlebar
5. Front brake light switch connector
6. Front brake light switch
7. Front brake hose
A. When installing the rubber cover, silicone water or
soapy water may be applied to the inside of the
rubber cover.
B. Connect the front brake light switch connector onto
the front brake light switch.
C. Detailed drawing of around the front brake master
cylinder
D. Straight line parallel to the front brake master cylinder
reservoir cap
E. 20- 30°
F. Center of the metal fitting for the front brake hose

2-20
 CABLE ROUTING

Handlebar (top view) (MTT9GTK/MTT9GTKC)

1 2 A

2 C 3

2-21
 CABLE ROUTING

1. Front brake master cylinder

2. Throttle cable
3. Grip warmer lead
4. Rubber cover
5. Handlebar
A. Align the holder with the edge of the front brake
master cylinder assembly as shown in the illustration.
B. When installing the rubber cover, silicone water or
soapy water may be applied to the inside of the
rubber cover.
C. Fasten the grip warmer lead to the throttle cable
(accelerator cable) with a plastic locking tie. Cut off
the excess end of the plastic locking tie.
D. Position the plastic locking tie 10-20 mm (0.39- 0. 79
in) from the end of the throttle cable protector.
E. Fasten the throttle cables with the holder. Face the
catch of the holder downward.

2-22
 CABLE ROUTING

Frame and engine (right side view)

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2-23
 CABLE ROUTING

1. Clamp W. Route 0 2 sensor lead inside to the protrusion of the

2. Rear brake light switch lead bracket.
3. 0 2 sensor coupler X. Inside vehicle
4. Radiator fan motor coupler
5. Handlebar switch coupler (right)
6. Inner panel
7. Front right turn signal/position light coupler
8. Fuse box 1
9. Front turn signal/position light lead (right)
10. Bracket
11 . Fuse box 2
12. Coupler cover
13. 0 2 sensor lead
14. Frame
15. Engine
16. Front brake light switch coupler
17. Grip warmer lead
18. Front brake light switch lead
19. Handlebar switch lead (right)
A. Insert the clamp into the long hole in the battery box.
B. Route the rear brake light switch lead outside the wire
harness branch to the 0 2 sensor lead.
C. To the ECU coupler
D. Connect the 0 2 sensor coupler, and then fasten to
the bracket. Make sure that the top of the coupler
does not protrude. It is okay if the cover is deformed.
E. Fasten the 0 2 sensor lead with the clamp, and then
install it on the bracket.
F. Route the 0 2 sensor lead and the rear brake light
switch lead through the bracket guide.
G. Route the rear brake light switch lead outside brake
fluid reservoir hose.
H. It does not matter whether the 0 2 sensor lead or the
rear brake light switch lead is on top (bottom) in the
area shown in the illustration.
I. Connect the radiator fan motor coupler and then
position it in front of the connector cover.
J. Insert the handlebar switch coupler (right) into the
bracket.
K. Secure the plastic locking tie by inserting the
projection on the tie into the hole in the bracket. Align
the front edge of the tape with the plastic locking tie.
L. The positioning tape
M. Insert the front right turn signal/position light coupler
into the inner panel.
N. Insert fuse box 1 into the bracket.
0. Route the front turn signal/position light lead (right)
under fuse box 1.
P. Insert fuse box 2 into the bracket.
Q. Make sure that the end of the plastic locking tie does
not contact the bracket.
R. For MTT9GTK/MTT9GTKC only
S. Place the slack in the front brake light switch lead in
the order shown in the illustration.
T. Make sure that the end of the plastic locking tie does
not contact the bracket. Route the grip warmer lead
over the front brake light switch lead.
U. Insert the clamp so that it touches the rim of the
frame.
V. Fasten the 0 2 sensor lead with the holder.

2-24
 CABLE ROUTING

Frame and engine (left side view) (MTT9K/MTT9KC)

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2-25
 CABLE ROUTING

1. Air induction system hose (air filter case to air cut-off Q. It does not matter whether the fuel tank drain hose or
valve) the fuel tank breather hose is on top but make sure
2. Air filter case that these hoses are not twisted each other.
3. Throttle cables R. Align the edge of the tape on the handlebar switch
4. Stator coil assembly lead lead with the holder in the direction shown in the
illustration.
5. Clamp
S. Install the clamp so that the end of clamp is aligned
6 . Positive battery lead
with the rib of the bracket as shown in the illustration.
7. Starter motor lead
T. Face the clamp opening upward.
8. Stator coil lead
U. Install the clamp so that the end of clamp is aligned
9 . Wire harness (to rectifier/regulator) with the center of the spring nut as shown in the
10. Gear position switch lead illustration.
11 . Sidestand switch lead V. The positioning tape
12. Oil level switch lead W. Make sure that the end of the plastic locking tie does
13. Boots not contact the bracket.
14. Clutch cable
15. Intake air temperature sensor coupler
16. Handlebar switch coupler (left)
17. Bracket
18. Front left turn signal/position light coupler
19. Inner panel
20. Front turn signal/position light lead (left)
21 . Handlebar switch lead (left)
A. Route the air induction system hose (air filter case to
air cut-off valve) inside the throttle cable.
B. Route the fuel tank drain hose/fuel tank breather
hose outside to the wire harnesses.
Route them inside to the brake hose.
C. Fasten the sidestand switch lead, stator coil assembly
lead, starter motor lead and oil level switch lead with
the clamp. The order of the leads does not matter.
Align the clamp with the tape on the starter motor
lead. Do not cut off the clamp end and point it
forward.
Pull the oil level switch lead when fastening.
D. Align the sidestand switch lead, oil level switch lead,
fuel tank drain hose, and fuel tank breather hose with
the bending edge of the hose, and then install them.
Face the clamp opening to the rearward.
E. Route the gear position switch lead inside to the shift
arm.
F. Hose bending edge
G. 30-50 mm (1.18-1.97 in)
H. Point the tips of fuel tank drain hose and fuel tank
breather hose as shown in the illustration.
I. Place the stator coil assembly lead so that bare
copper wires do not protrude from the boots.
J. Install the intake air temperature sensor coupler on
the rib of the bracket.
K. Insert the clamp of the wire harness into the hole in
the bracket.
L. Insert the handlebar switch coupler (left) into the
bracket.
M. Insert the front left turn signal/position light coupler
into the inner panel.
N. Insert the clamp of the handlebar switch lead (left)
into the hole in the bracket.
0. Align each rounded end of the sidestand switch lead,
oil level switch lead and drain hose, and clamp them.
The opening of the clamp should face toward the rear
side of the vehicle.
P. It does not matter whether the oil level switch lead or
the sidestand switch lead is on top.

2-26
 CABLE ROUTING

Frame and engine (left side view) (MTT9GTK/MTT9GTKC)

3 7

4 B 5 [QJ

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AC
AB

2-27
 CABLE ROUTING

1. Air induction system hose (air filter case to air cut-off N. Insert the clamp of the wire harness into the hole in
valve) the bracket.
2. Air filter case 0. Insert the handlebar switch coupler (left) into the
3. Throttle cables bracket.
4. Stator coil assembly lead P. Route the front turn signal/position light lead (left)
5. Clamp under the clutch switch lead.
6 . Positive battery lead Q. Insert the front left turn signal/position light coupler
into the inner panel.
7. Starter motor lead
R. Insert the clamp of the handlebar switch lead (left)
8. Stator coil lead
into the hole in the bracket.
9 . Wire harness (to rectifier/regulator)
S. Align each rounded end of the sidestand switch lead,
10. Gear position switch lead oil level switch lead and drain hose, and clamp them.
11 . Sidestand switch lead The opening of the clamp should face toward the rear
12. Shift switch lead side of the vehicle.
13. Oil level switch lead T. Fasten the shift switch lead at the tape to the shift
14. Boots switch with the holder. The catch of the holder may be
facing in any direction. Close the holder until two
15. Clutch cable
clicks or more are heard.
16. Intake air temperature sensor coupler
U. It does not matter whether the oil level switch lead or
17. Handlebar switch coupler (left) the sidestand switch lead is on top.
18. Bracket V. It does not matter whether the fuel tank drain hose or
19. Front left turn signal/position light coupler the fuel tank breather hose is on top but make sure
20. Inner panel that these hoses are not twisted each other.
21 . Shift switch W. The position tape
22. Front turn signal/position light lead (left) X. Install the clamp so that the end of taping rearward.
23. Handlebar switch lead (left) Y. The boss
24. Clutch switch lead Z. Route the clutch switch lead as shown in the
A. Route the air induction system hose (air filter case to illustration so that it is not positioned in front of the
air cut-off valve) inside the throttle cable. boss on the electrical components tray.
B. Route the fuel tank drain hose/fuel tank breather AA. Face the clamp opening upward.
hose outside to the wire harnesses. AS. Install the clamp so that the end of clamp is aligned
Route them inside to the brake hose. with the rib of the bracket as shown in the illustration.
C. Fasten the sidestand switch lead, stator coil assembly AC. Install the clamp so that the end of clamp is aligned
lead, starter motor lead and oil level switch lead with with the center of the spring nut as shown in the
the clamp. The order of the leads does not matter. illustration.
Align the clamp with the tape on the starter motor AD. Make sure that the end of the plastic locking tie does
lead. Do not cut off the clamp end and point it not contact the bracket.
forward.
Pull the oil level switch lead when fastening.
D. Align the sidestand switch lead, oil level switch lead,
fuel tank drain hose, and fuel tank breather hose with
the bending edge of the hose, and then install them.
Face the clamp opening to the rearward.
E. Route the gear position switch lead inside to the shift
arm.
F. Hose bending edge
G. 30-50 mm (1.18-1.97 in)
H. Point the tips of fuel tank drain hose and fuel tank
breather hose as shown in the illustration.
I. Fasten the shift switch lead to the bracket, and then
fasten the lead to the shift switch with the holder.
Align the upper edge of the holder with the upper
edge of the nut.
J. Place the stator coil assembly lead so that bare
copper wires do not protrude from the boots.
K. Secure the plastic locking tie by inserting the
projection on the tie into the hole in the bracket, and
then fasten the shift switch lead with the tie. Point the
end of the plastic locking tie downward and insert it
into the cutout in the bracket.
L. Route the shift switch lead to the inside of the brake
hose and drain hose.
M. Install the intake air temperature sensor coupler on
the rib of the bracket.

2-28
 CABLE ROUTING

Frame (right side view)

19 Q

12

-
2

2-29
 CABLE ROUTING

1. Guide K. Route the front wheel sensor lead rear side of the
2. Wire harness vehicle respect to the main switch lead.
3. Pipe (headlight stay) L. Install the clamp to the hole in the bottom of the
4. Clamp coupler cover.
5. Frame M. Make sure that the main switch coupler does not
protrude from the sponge edge.
6. Auxiliary DC jack coupler (color: natural)
N. Align the wire harness protector with the edge of the
7. Auxiliary DC jack coupler (color: black)
Velcro tape and wrap it. However, the tape surface
8. Auxiliary DC jack lead may protrude somewhat.
9. Headlight lead 0. For MTT9GTK/MTT9GTKC
10. Coupler cover P. Insert the clamp of the handlebar switch lead into the
11. Auxiliary light lead hole in the headlight stay.
12. Throttle cable Q. Route the handlebar switch lead, clutch switch lead,
13. Wire harness protector and grip warmer lead between the electrical
14. Main switch coupler components tray and the wire harness.
15. Front wheel sensor coupler R. Fasten the handlebar switch lead (right), front brake
light switch lead and grip warmer lead with the clamp.
16. Main switch lead
Align the clamp with the tape on the handlebar switch
17. Main switch coupler 1 lead (right), front brake light switch lead and grip
18. Main switch coupler 2 warmer lead and face the end of the clamp forward.
19.Sponge Then insert the clamp into the hole in the headlight
20. Sponge edge stay.
21 . Handlebar switch lead (left) S. Fasten the handlebar switch lead (left) and clutch
switch lead with the clamp.
22. Front brake light switch lead
Align the clamp with the tape on the handlebar switch
23. Main switch lead lead (left) and clutch switch lead. Align the plastic
24. Grip warmer lead locking tie with the headlight stay nut. Route the
25. Clutch switch lead handlebar switch lead (left) and clutch switch lead
26. Handlebar switch lead (right) above the wire harness.
A. Bring the wire harness into contact with the pipe T. Make sure that the leads are not twisted between the
(headlight stay), fasten them with the clamp and then clamps shown.
insert the clamp into the hole in the headlight stay. U. Do not cut off the excess end of the plastic locking tie.
Make sure that the end of the clamp faces forward Fit the excess end of the plastic locking tie between
when inserting it into the hole in the headlight stay. It the frame and the wire harness.
is not necessary to insert the end of the clamp further
into the hole opposite to the hole in which it has been
inserted.
B. Connect the coupler to the headlight unit.
C. Insert the clamp of the wire harness into the hole in
the headlight stay.
D. Fasten the main switch lead and handlebar switch
leads with the clamp. Make sure that the main switch
lead is positioned backward and the handlebar switch
leads are positioned forward. Then, insert the clamp
into the hole in the headlight stay.
Align the clamp with the tapes (red to the left and blue
to the right) on the handlebar switch lead and face the
end of the clamp forward.
E. Make sure that there is no slack in the main switch
lead between the clamps shown.
F. Make sure that the main switch lead and handlebar
switch leads are not twisted between the clamps
shown.
G. Fasten the wire harness and main switch lead with
the clamp.
The wire harness and main switch lead should be
fastened with the clamp at the color tape.
Point the tip of the clamp outward, and then cut it.
H. Connect the auxiliary DC jack to the auxiliary DC jack
coupler (color: natural) on the wire harness.
I. Fasten the auxiliary light lead and auxiliary DC jack
lead with the clamp and then insert the clamp into the
hole in the headlight stay.
J. Fasten the main switch lead to the coupler cover with
the clamp.

2-30
 CABLE ROUTING

Frame (top view)

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2-31
 CABLE ROUTING

1. Injector #1 coupler
2. Injector #2 coupler
3. Clamp
4. Ignition coil #1 coupler
5. Ignition coil #2 coupler
6. Air cut-off valve coupler
7. Ignition coil #3 coupler
8. Injector #3 coupler
9. Throttle position sensor coupler
10. Throttle servo motor coupler
11. Cross tube
12. Accelerator position sensor coupler
13. Intake air pressure sensor coupler
14. Air induction system hose (air filter case to air cut-off
valve)
15. Clutch cable
16. Air cut-off valve
17. Air filter case
18. ECU (Engine Control Unit)
19. ECU (engine control unit) coupler
A. Fold back the intake air pressure sensor lead by the
coupler, and then fasten it with tape.
B. Insert the clamp into the fuel rail hole.
C. Fold back the injector lead #1 by the coupler, and
then fasten it with tape.
D. Connect the sub-lead to the injector #2 coupler.
Fasten the injector coupler on the wire harness side
with tape.
E. For the air cut-off valve lead, ignition coil lead #3, and
fuel injector lead #3, it does not matter which is routed
above the others.
F. Route the coolant temperature sensor sub-lead
between the cross tube and the wire harness.
Fasten the coolant temperature sensor coupler on the
wire harness side with tape.
G. Fasten the fuel hose at the mark and the wire
harness at the positioning tape with the clamp. The
opening of the clamp can face either way.
H. Route the clutch cable above to the air induction
system hose (air filter case to air cut-off valve).
I. Route the ECU lead for the front of the vehicle
through the rib of the air filter case.

2-32
 CABLE ROUTING

Frame (top view)

3 [g

4 [Q]

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2-33
 CABLE ROUTING

1. Stator coil assembly lead

2. Oil level switch coupler
3. Rear brake light switch coupler
4. Sidestand switch coupler
5. Gear position switch coupler 1
6. Gear position switch coupler 2
7. Negative battery lead coupler
8. Lean angle sensor
9. Starter motor lead
10. Negative battery lead 2 coupler
11. ABS ECU coupler
12. Hydraulic unit
A. Leads on the front of the battery box are, from the top
of the vehicle, in the following order: starter motor
lead, stator coil assembly lead. The orders for other
leads do not matter.
B. Fasten the wire harness side of the oil level switch
coupler to the battery box.
C. Fasten the rear brake light switch coupler of the wire
harness with tape.
D. Fasten the sidestand switch coupler of the wire
harness to the battery box.
E. Route the negative battery lead inside to the branch
of the 0 2 sensor lead and the rear brake light switch
lead, and through between the wire harness and the
frame. For rear side of the vehicle, route it above the
wire harness.
F. Fasten the wire harness side of gear position switch
coupler 1 to the battery box.
G. Fasten the wire harness side of gear position switch
coupler 2 to the battery box.
H. Details around the hydraulic unit
I. Route the brake hose above all the other leads.

2-34
 CABLE ROUTING

Frame (top view) (MTT9K/MTT9KC)

R 18 21

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2-35
 CABLE ROUTING

1. Rear wheel sensor coupler Q. Instructional drawing for routes in the front of the
2. Negative battery lead coupler battery
3. Positive battery terminal R. Fasten the crankshaft position sensor coupler of the
4. Negative battery lead wire harness with tape.
5. Radiator fan motor relay
6. Negative battery terminal
7. Fuse box
8. Relay unit
9. Turn signal/hazard relay
10. Clamp
11. Rear turn signal light coupler (left/right)
12. Tail/brake light coupler
13. Tail/brake light lead
14. Seat warmer coupler
15. Yamaha diagnostic tool coupler
16. Starter motor lead
17. Starter relay
18. Battery
19. Positive battery lead
20. Shift switch coupler (option)
21 . Battery box
22. Stator coil lead
23. Wire harness (to rectifier/regulator)
24. Wire harness
A. Position the rear wheel sensor coupler under the
negative battery lead.
B. Position the negative battery lead coupler under the
negative battery lead.
C. Install the rubber bracket of the radiator fan motor
relay in the battery box. Make sure to route the lead
under the relay.
D. Fasten the fuse box onto the battery box.
E. Install the rubber bracket of the relay unit in the
battery box.
F. Install the rubber bracket of the turn signal/hazard
relay in the battery box.
G. Install the clamp into the hole in the battery box.
H. Connect each rear turn signal coupler to the coupler
with the same color. After connecting the license plate
light coupler, store the rear turn signal light coupler
(left/right) furthest to the bottom of the vehicle. After
connecting the other couplers, store them below the
tail/brake light lead.
I. Route the tail/brake light lead, turn signal light lead,
and license plate light lead through the cutout of the
battery box. The order of the leads does not matter.
J. Fasten the wire harness side of the tail/brake light
coupler to the battery box.
K. Route the turn signal light lead, and license plate light
lead through the cutout of the battery box. The order
of the leads does not matter.
L. Position the seat warmer coupler under the wire
harness.
M. Route the Yamaha diagnostic tool coupler lead at the
bottom of the battery box.
N. Insert the Yamaha diagnostic tool coupler to the
battery box.
0. Route the starter motor lead under the other leads.
P. Install the rubber bracket of the starter relay in the
battery box.

2-36
 CABLE ROUTING

Frame (top view) (MTT9GTK/MTT9GTKC)

9

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2-37
 CABLE ROUTING

1. Rear wheel sensor coupler N. Insert the Yamaha diagnostic tool coupler to the
2. Negative battery lead coupler battery box.
3. Positive battery terminal 0. Route the starter motor lead under the other reads.
4. Negative battery lead P. Install the rubber bracket of the starter relay in the
5. Radiator fan motor relay battery box.
6. Negative battery terminal Q. 10-20 mm (0.39-0.79 in)
7. Fuse box R. Fasten the shift switch lead protector to the brake
8. Relay unit hose with the holder. Point the end of the clamp
downward.
9. Turn signal/hazard relay
S. Route the shift switch lead under the brake hoses.
10. Clamp
T. Fasten the fuel hose and positioning tape of wire
11. Rear turn signal light coupler (left/right) harness and grip cancel switch lead with clamp. The
12. Tail/brake light coupler catch of the clamp may be facing in any direction.
13. Tail/brake light lead U. Route the grip cancel switch lead inside the fuel tank
14. Cruise control/rear brake light relay drain hose.
15. Seat warmer coupler V. The leads may be routed in any order.
16. Yamaha diagnostic tool coupler W. Instructional drawing for routes in the front of the
17. Starter motor lead battery.
18. Starter relay X. Fasten the crankshaft position sensor coupler of the
19. Battery wire harness with tape.
20. Positive battery lead
21 . Shift switch coupler
22. Fuel hose
23. Wire harness
24. Grip cancel switch lead
25. Battery box
26. Stator coil lead
27. Wire harness (to rectifier/regulator)
28. Grip cancel switch coupler
29. Fuel tank drain hose
A. Position the rear wheel sensor coupler under the
negative battery lead.
B. Position the negative battery lead coupler under the
negative battery lead.
C. Install the rubber bracket of the radiator fan motor
relay in the battery box. Make sure to route the lead
under the relay.
D. Fasten the fuse box onto the battery box.
E. Install the rubber bracket of the relay unit in the
battery box.
F. Install the rubber bracket of the turn signal/hazard
relay in the battery box.
G. Install the clamp into the hole in the battery box.
H. Connect each rear turn signal coupler to the coupler
with the same color. After connecting the license plate
light coupler, store the rear turn signal light coupler
(left/right) furthest to the bottom of the vehicle. After
connecting the other couplers, store them below the
tail/brake light lead.
I. Route the tail/brake light lead, turn signal light lead,
and license plate light lead through the cutout of the
battery box. The order of the leads does not matter.
J. Fasten the wire harness side of the tail/brake light
coupler to the battery box.
K. Route the turn signal light lead, and license plate light
lead through the cutout of the battery box. The order
of the leads does not matter.
L. Position the seat warmer coupler under the wire
harness.
M. Route the Yamaha diagnostic tool coupler lead at the
bottom of the battery box.

2-38
 CABLE ROUTING

Front brake (right side view and left side view)

10

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2-39
 CABLE ROUTING

1. Front brake hose assembly 1

2. Front wheel sensor lead
3. Clamp
4. Bracket
5. Brake caliper (right)
6. Front fender
7. Reflector (left and right)
8. Brake caliper (left)
9 . Clamp
10. Clamp
A. Make sure that the bracket has contact with the axle
bracket, and install it.
B. Install the brake pipe so that it contacts the projection
on the brake caliper.
C. Install the clamp at the position where the distance
between the upper end of the metal fittings of the
brake hose and bottom side of the clamp is 25-45
mm (0.98-1.77 in).
D. Route the front wheel sensor lead along the front
brake hose as shown in the illustration.
E. Route the front wheel sensor lead through the right
side of the vehicle along the brake hose.
F. The blue paint should face to the outside of the
vehicle.
G. Install the brake hose from the hydraulic unit so that
the brake pipe touches the projection on the brake
caliper.
Install the brake hose to the brake caliper (right) so
that it aligned with the direction of the brake pipe from
the hydraulic unit.
H. Insert the grommet of the front wheel sensor.
I. Right side of the vehicle
J. Route the front wheel sensor lead in front of the
vehicle along the brake hose, and clamp the white
tape portion. The center line should be within this
area.
K. 45°
L. Vehicle forward direction
M. Inside of the vehicle
N. Insert the clamp into the T-stud of the bracket.
0. Route the front wheel sensor lead in front of the
vehicle against the brake hose.
P. Make sure that the clamp has contact with the
bracket in the right rotation direction as shown in the
illustration, and install it.
Q. Same for four clamps
R. Insert the clamp securely.
S. Make sure the clamp is engaged by 3 or more
notches.
Engage the claws so that they face toward the rear
side of the vehicle.
T. When installing the reflector, make sure that the
reflector (left and right) contacts the brake caliper.

2-40
 CABLE ROUTING

Rear brake

H
2 D

2-41
 CABLE ROUTING

1. Brake fluid reservoir

2. Rear frame
3. Rear frame (welded portion)
4. Rear brake master cylinder
5. Rear wheel sensor
6. Rear wheel sensor lead
7. Rear brake caliper
8. Rear brake hose
9. Clamp
10. Brake fluid reservoir hose
A. Install the clamp on the brake fluid reservoir hose by
aligning it with the position of the welded portion of
the rear frame.
B. Install the brake pipe so that it contact with the
protrusion on the master cylinder at outside vehicle.
C. Fasten the rear wheel sensor lead and the brake pipe
with the clamp. Make sure that the clamp touches the
end of the brake pipe.
D. Make sure to install the clamp all the way in the rear
frame.
E. Install the clamp facing the direction in the illustration.
F. Face the engaging section (catch) of the clamp
downward.
G. Do not clamp the rear wheel sensor lead.
H. Fasten the grommet on the brake hose with the
holder. Make sure that the hose is not twisted. Face
the catch of the holder upward.
I. Make sure to install the clamp all the way in the
swingarm assembly.
J. Fasten the grommet on the rear wheel sensor lead
with the clamp.
K. Position the rear wheel sensor lead outside the brake
hose.
L. Install the brake pipe so that it aligned with the cutout
in the caliper.

2-42
 CABLE ROUTING

Hydraulic unit (top view and left side view)

Q ~/~ ii
""

[f]I ~ II
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2-43
 CABLE ROUTING

1. Wire harness
2. Battery box
3. Brake hose (front brake master cylinder to hydraulic
unit)
4. Brake hose (hydraulic unit to front brake calipers)
5. Brake hose (rear brake master cylinder to hydraulic
unit)
6 . Brake hose (hydraulic unit to rear brake caliper)
7. Plug
8. Rear wheel sensor lead
9 . Bracket
A. Make sure to insert the ABS ECU coupler all the way
in.
B. Install the brake hose (front brake master cylinder to
hydraulic unit) so that the protrusion contact to the
brake hose (hydraulic unit to front brake calipers).
C. In the plug hole, install the brake hose (rear brake
master cylinder to hydraulic unit), the brake hose
(hydraulic unit to rear brake caliper) and rear wheel
sensor lead.
D. 28- 34°
E. 17-21 °
F. 13-17°
G. When installing the rear wheel sensor lead, silicone
water or soapy water may be applied.

2-44
 CABLE ROUTING

Fuel tank (left and bottom view)

G) 2

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2-45
 CABLE ROUTING

1. Frame
2. Fuel tank
3. Fuel pump
4. Fuel tank drain hose
5. Fuel tank breather hose
6. Clip
7. Fuel hose assembly
A. Insert the fuel tank drain hose up to the section where
the fuel tank pipe increases in diameter. Install it so
that the white paint mark faces the rearward.
Position the hose so that its paint mark is visible from
the rear of the vehicle. (Within +45°)
B. Install the clip so that the end is on the paint mark. Do
not put it on the clip spool (guard). Point the end to
the rear, and store it inside to the hose.
C. Align the fuel pump positioning to the inner panel
marking (visual guide during installation).
D. Insert the fuel tank breather hose up to the section
where the fuel tank pipe increases in diameter. Install
it so that the yellow paint mark faces the rearward.
Position the hose so that its paint mark is visible from
the rear of the vehicle. (Within +45°)

2-46
 CABLE ROUTING

. C and left side view)

Air filler case and throttle body (top view

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2-47
 CABLE ROUTING

1. Air filter case joint clamp

2. ECU (Engine Control Unit)
3. Air filter case
4. Throttle body
5. Clip
6. Cylinder head breather hose
7. Throttle cable (decelerator cable) (white plating)
8. Throttle cable (accelerator cable) (black plating)
9. Injector lead
10. Injector coupler
11. Fuel rail
12. Fuel hose (black side)
13. Canister purge hose (for California only)
A. Install the breather hose on the yellow paint mark
side to the air filter case, with its yellow paint mark
facing toward left side of the vehicle.
Point the end of the clip toward left.
B. Install the breather hose so that the tip touches the
pipe of the cylinder head.
Install the breather hose on the white paint mark side
to the engine.
Install the breather hose so that the white paint mark
is in the rear of the vehicle and parallel to the cylinder
head mating surfaces.
Install the clip so that the end is in the rear of the
vehicle and parallel to the cylinder head mating
surfaces.
C. Install the ECU harness by storing it in the recess in
the air filter case.
D. Install the ECU so that the hooks on the air fi lter case
go over the ECU edges.
E. Store the throttle cables on the protrusion of the air
filter case.
F. Insert the injector coupler all the way in.
G. Instructive drawing for assembling the throttle cables
H. Install the throttle cable so that the nut of the throttle
cable touches the stay.

2-48
 CABLE ROUTING

Air cut-off valve (left side view)

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2-49
 CABLE ROUTING

1. Radiator fan cover

2. Air filter case
3. Clip
4. Air induction system hose (air filter case to air cut-off
valve)
5. Air induction system hose (air cut-off valve to reed
valve cover #1)
6. Air induction system hose (air cut-off valve to reed
valve cover #2/#3)
7. Air cut-off valve
8. Air cut-off valve holder
A. Install the air induction system hose (air filter case to
air cut-off valve) so that the tip of the hose contacts
the air filter case.
B. Insert the protrusion on the radiator fan cover into the
hole in the air cut-off valve holder.
C. Point the end of the clip for the air induction system
hose (air cut-off valve to reed valve cover #2/#3)
forward.
D. Point the end of the clip for the air induction system
hose (air filter case to air cut-off valve) to the left.
E. 45°
F. Point the end of the clip for the air induction system
hose (air cut-off valve to reed valve cover #1)
diagonally left forward.
G. Install the hose so that the tip of the hose touches the
protrusion of the pipe.

2-50
 CABLE ROUTING

Radiator (front side view and right side view)

--- - - -"'ls:

'

~
[g]---1 - ~ ~--..,__
I I ~
®

I H :.J-::;~~

+<v

2-51
 CABLE ROUTING

1. Radiator cap
2. Radiator
3. Radiator fan
4. Radiator outlet hose
5. Thermostat assembly
6. Water jacket joint
7. Coolant reservoir
8. Radiator inlet hose
A. Install the radiator outlet hose with its white paint
mark facing inward.
B. Install the radiator outlet hose up to the base of the
bend in the radiator pipe.
C. Point the hose clamp installation bolt inward.
D. Point the end of the hose clip downward.
E. Align the yellow paint mark of the radiator outlet hose
with the rib of the thermostat assembly, and then
install it.
F. Install the radiator outlet hose so that the tip of the
hose contacts the rib of the thermostat assembly.
G. Install the radiator inlet hose so that the tip of the
hose contacts the rib of the water jacket joint.
H. Install the radiator inlet hose with its yellow paint mark
facing downward.
I. Point the hose clamp installation bolt upward.
J. Install the radiator inlet hose up to the base of the
bend in the radiator pipe.
K. Install the radiator inlet hose with its white paint mark
facing inward.
L. Install the radiator hose up to the base of the bend in
the radiator pipe.
M. Point the end of the clip outward.
N. Install the coolant reservoir hose up to the base of the
bend in the radiator pipe.
0. Point the end of the clip rearward.
P. Install the grommet on the coolant reservoir drain
hose to the hole in the coolant reservoir cover.
Q. Place the lock of the hose clamp within the area
shown in the illustration, placing as close to the center
as possible.
R. 90°
S. Point the tip of the clamp rearward.

2-52
 CABLE ROUTING

Canister (top view and left side view) (for California only)

[ID
t
r-------
f---... _---.c:::::: -: ::::::--.
2
C
---- ---.:::::----:---- ~,"'=:---
I -. .......__ - - - ---:----
.
, ,
~
~--~
-:::--...
;;;_:: :::--... _ --.--------=--- ~
~
~ 5::t::~--
~---::-...._
---
·-....---- ---.....::,
'

~ ~ --...:
- /.~~ \
8

fill
(J) '
---------
I -@

[E]
I E

-{Q]

8
[I] ,._

11

f---@

•
[8J

2-53
 CABLE ROUTING

1. Frame
2. Clamp
3. Canister
4. Canister holder
5. Canister breather hose
6. Fuel tank drain hose
7. Fuel tank breather hose
8. Canister purge hose
9 . Fuel tank
10. Rear shock absorber assembly
11. Canister bracket
A. Front side of the vehicle
B. Right side of the vehicle
C. Face the white paint mark on the hose upward.
D. Point the end of the clip downward
E. Install the canister with its stamped mark facing
upward.
F. The tip of the clip and the yellow paint mark on the
hose should face backward. Position the hose so that
its paint mark is visible from the rear of the vehicle.
(Within +45°)
G. Insert the hose up to the section where the fuel tank
pipe increases in diameter.
H. Atmosphere
I. To throttle body
J. Place the clamp on the straight portion of the fuel
tank breather hose.

2-54
 CABLE ROUTING

2-55
 PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE .. ......... .......... ........ ......... .......... ......... ......... .......... 3-1
INTRODUCTION .... ......... ......... .......... ........ ......... ......... ......... .......... ......... . 3-1
PERIODIC MAINTENANCE CHARTS ...... ......... .......... ......... ......... .......... . 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 PLUGS ........ ......... ......... ......... ......... ........ ......... 3-5
ADJUSTING THE VALVE CLEARANCE ... .......... .......... ......... .......... ........ 3-5
CHECKING THE ENGINE IDLING SPEED ........ ......... .......... ......... ......... . 3-8
SYNCHRONIZING THE THROTTLE BODIES ....... ......... ......... ........ ......... 3-9
CHECKING THE THROTTLE BODY JOINTS ..... .......... .......... .......... ..... 3-1 O
CHECKING THE CANISTER (for California only) .......... .......... .......... ..... 3-11
CHECKING THE AIR INDUCTION SYSTEM ....... ......... .......... ......... ....... 3-11
CHECKING THE CYLINDER HEAD BREATHER HOSE ...... .......... ....... 3-11
REPLACING THE AIR FILTER ELEMENT .. .......... ........ .......... ......... ...... 3-11
ADJUSTING THE CLUTCH LEVER FREE PLAY .. ......... .......... ......... ..... 3-12
CHECKING THE BRAKE OPERATION ........ ......... ........ .......... ......... ...... 3-13
CHECKING THE BRAKE FLUID LEVEL ....... ......... ......... ......... ......... ...... 3-13
ADJUSTING THE FRONT DISC BRAKE ... ......... ......... .......... ......... ........ 3-13
CHECKING THE FRONT BRAKE PADS ...... ......... ......... .......... ......... ..... 3-14
ADJUSTING THE REAR DISC BRAKE ....... .......... ........ .......... .......... ..... 3-14
CHECKING THE REAR BRAKE PADS ......... ......... ......... ......... .......... .... 3-15
CHECKING THE FRONT BRAKE HOSES .. ......... ......... ........... ......... ..... 3-15
CHECKING THE REAR BRAKE HOSE ........ ......... ......... .......... ......... ..... 3-15
BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS) ........... ......... ..... 3-15
CHECKING THE WHEELS ....... .......... .......... ......... ......... .......... ......... ..... 3-16
CHECKING THE TIRES .. ......... .......... ........ ......... .......... ......... .......... ....... 3-16
CHECKING THE WHEEL BEARINGS ........ ......... .......... ......... ......... ....... 3-18
CHECKING THE SWINGARM OPERATION ....... ......... .......... ......... ....... 3-18
LUBRICATING THE SWINGARM PIVOT .... ........ .......... ......... .......... ...... 3-18
DRIVE CHAIN SLACK ...... ......... .......... ......... .......... ........ .......... ......... ...... 3-18
LUBRICATING THE DRIVE CHAIN ... .......... ........ .......... ......... .......... ...... 3-19
CHECKING AND ADJUSTING THE STEERING HEAD .......... .......... ..... 3-19
LUBRICATING THE STEERING HEAD ........ ......... ........ .......... ......... ...... 3-20
CHECKING THE CHASSIS FASTENERS ........... ......... .......... .......... ...... 3-20
LUBRICATING THE BRAKE LEVER .. ......... ......... ......... .......... ......... ...... 3-20
LUBRICATING THE CLUTCH LEVER ......... ......... ......... .......... ......... ...... 3-20
LUBRICATING THE PEDAL ...... ......... .......... ......... ......... ......... .......... ..... 3-20
CHECKING THE SIDESTAND ........... ........ .......... ......... .......... ......... ....... 3-20
LUBRICATING THE SIDESTAND ........ ......... .......... ........ .......... ......... ..... 3-20
CHECKING THE CENTERSTAND ..... ......... .......... ........ .......... .......... ..... 3-21
LUBRICATING THE CENTERSTAND ......... ........ .......... ......... .......... ...... 3-21
CHECKING THE SIDESTAND SWITCH ...... .......... ........ .......... .......... ..... 3-21
CHECKING THE FRONT FORK ......... ......... .......... ......... ......... .......... ..... 3-21
ADJUSTING THE FRONT FORK LEGS ....... .......... ........ ......... .......... ..... 3-21
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ..... ......... ..... 3-23
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
(MTT9K/MTT9KC) .......... .......... .......... ......... .......... ......... ......... .......... ..... 3-23
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
(MTT9GTK/MTT9GTKC) .......... ......... .......... ........ ......... .......... ......... ....... 3-24
CHECKING THE CONNECTING ARM AND RELAY ARM ..... ......... ....... 3-25
CHECKING THE ENGINE OIL LEVEL ......... ......... .......... ......... ......... ...... 3-25
CHANGING THE ENGINE OIL .......... ........ .......... ......... ......... .......... ....... 3-25
MEASURING THE ENGINE OIL PRESSURE ....... ......... .......... ......... ..... 3-26
CH EC Kl NG THE COOLANT LEVEL ... ......... ......... ......... ......... .......... ...... 3-27
CHECKING THE COOLING SYSTEM ....... .......... ......... .......... .......... ...... 3-28
CHANGING THE COOLANT ...... ......... ......... .......... ........ .......... ......... ...... 3-28
CHECKING THE FRONT BRAKE LIGHT SWITCH ........ ......... ......... ...... 3-30
ADJUSTING THE REAR BRAKE LIGHT SWITCH ......... ......... ......... ...... 3-30
CHECKING AND LUBRICATING THE CABLES ... ......... ......... .......... ..... 3-30
CHECKING THE THROTTLE GRIP .... ......... .......... ........ .......... .......... ..... 3-30
CHECKING AND CHARGING THE BATTERY .... .......... .......... .......... ..... 3-31
CHECKING THE FUSES ......... .......... .......... ........ .......... ......... .......... ...... 3-31
ADJUSTING THE HEADLIGHT BEAMS ....... ......... ......... ........... ......... .... 3-31
 PERIODIC MAINTENANCE

EAS20022

PERIODIC MAINTENANCE
EAS30022

INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed , these preventive maintenance procedures will ensure more reliable vehicle operation , a lon-
ger service life and reduce the need for costly overhaul work. This information applies to vehicles al-
ready in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EAS32702

PERIODIC MAINTENANCE CHARTS

TIP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
• From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi
(13000 km) or 12 months.
• Items marked with an asterisk require special tools, data and technical skills, have a Yamaha dealer
perform the service.

EAS30614

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

INITIAL ODOMETER READINGS

4000 mi 8000 mi 12000 mi 16000 mi 20000 mi

No. ITEM ROUTINE 600 mi
(13000 (19000 (25000 (31000
(1000 km) (7000 km)
km) km) km) km)
or or
or or or or
1 month 6 months
12 months 18 months 24 months 30 months

• Check fuel hoses for cracks or

1 • Fuel line damage. ✓ ✓ ✓ ✓ ✓
• Replace if necessary.
• Check condition.
✓ ✓ ✓
2 • Spark plugs • Adjust gap and clean.
• Replace. ✓ ✓
• Check and adjust valve clear-
3 • Valve clearance Every 26600 mi (42000 km)
ance when engine is cold.
• Check breather hose for
Crankcase
4 • cracks or damage. ✓ ✓ ✓ ✓ ✓
breather system • Replace if necessary.
5 • Fuel injection • Adjust synchronization. ✓ ✓ ✓ ✓ ✓ ✓
Evaporative emis-
• Check control system for
sion control sys-
6 • damage. ✓ ✓
tern (for California • Replace if necessary.
only)
• Check the air cut-off valve,
reed valve, and hose for dam-
Air Induction sys-
7 • age. ✓ ✓
tern
• Replace any damaged parts if
necessary.

EAS30615

GENERAL MAINTENANCE AND LUBRICATION CHART

INITIAL ODOMETER READINGS

8000 mi 12000 mi 16000 mi 20000 mi

No. ITEM ROUTINE 600 mi 4000 mi
(13000 (19000 (25000 (31000
(1000 km) (7000 km)
km) km) km) km)
or or
or or or or
1 month 6 months
12 months 18 months 24 months 30 months

• Perform dynamic inspection

Diagnostic sys-
1 • using Yamaha diagnostic tool. ✓ ✓ ✓ ✓ ✓ ✓
tern check • Check the fault codes.
2 • Air filter element • Replace. Every 24000 mi (37000 km)

3-1
 PERIODIC MAINTENANCE

INITIAL ODOMETER READINGS

8000 mi 12000 mi 16000 mi 20000 mi

No. ITEM ROUTINE 600 mi 4000 mi (13000 (19000 (25000 (31000
(1000 km) (7000 km)
or or km) km) km) km)
or or or or
1 month 6 months 12 months 18 months 24 months 30 months

• Check operation.
3 • Clutch • Adjust or replace cable. ✓ ✓ ✓ ✓ ✓ ✓

• Check ofteration, flu id level,

and for f uid leakage.
4 • Front brake • Replace brake pads if neces- ✓ ✓ ✓ ✓ ✓ ✓
sary.
• Check operation, flu id level,
and for fluid leakage.
5 • Rear brake ✓ ✓ ✓ ✓ ✓ ✓
• Replace brake pads if neces-
sary.
• Check for cracks or damage.
• Check for correct routing and ✓ ✓ ✓ ✓ ✓
6 • Brake hoses clamping.
• Replace. Every 4 years
7 • Brake fluid • Change. Every 2 years
• Check runout and tor dam-
8 • Wheels age. ✓ ✓ ✓ ✓ ✓
• Replace if necessary.
• Check tread depth and for
damage.
9 • Tires • Replace if necessary. ✓ ✓ ✓ ✓ ✓
• Check air pressure.
• Correct if necessary.
• Check bearings tor smooth
10 • Wheel bearings operation. ✓ ✓ ✓ ✓ ✓
• Replace if necessary.
• Check operation and tor ex- ✓ ✓ ✓
cessive play. ✓ ✓
Swingarm pivot
11 •
bearings • Moderately repack with lithi- Every 32000 mi (50000 km)
um-soap-based grease.
• Check chain slack, alignment
and condition. Every 500 mi (800 km) and after washing the motorcycle,
12 Drive chain • Adjust and lubricate chain
with a special 0 -ring chain lu- rid ing in the rain or rid ing in wet areas
bricant thoroughly.
• Check bearing assemblies for
looseness. ✓ ✓ ✓ ✓ ✓ ✓
13 • Steering bearings
• Moderately repack with lithi- Every 12000 mi (19000 km)
um-soap-based grease.
• Check all chassis fitting and
14 • Chassis fasteners fasteners. ✓ ✓ ✓ ✓ ✓
• Correct if necessary.
Brake lever pivot
15 • Apply silicone grease lightly. ✓ ✓ ✓ ✓ ✓
shaft
Brake pedal pivot • Apply lithium-soap-based
16 ✓ ✓ ✓ ✓ ✓
shaft grease lightly.
Clutch lever pivot • Apply lithium-soap-based
17 ✓ ✓ ✓ ✓ ✓
shaft grease lightly.
Shift pedal pivot • Apply lithium-soap-based
18 ✓ ✓ ✓ ✓ ✓
shaft grease lightly.
• Check operation.
19 Centerstand and • Apply lithium-soap-based ✓ ✓ ✓ ✓ ✓
sidestand pivots
grease lightly.
• Check operation and replace
20 • Sidestand switch if necessary. ✓ ✓ ✓ ✓ ✓ ✓

• Check operation and tor oil

21 • Front fork leakage. ✓ ✓ ✓ ✓ ✓
• Replace if necessary.
Shock absorber • Check operation and tor oil
22 • leakage. ✓ ✓ ✓ ✓ ✓
assembly • Replace if necessary.

3-2
 PERIODIC MAINTENANCE

INITIAL ODOMETER READINGS

8000 mi 12000 mi 16000 mi 20000 mi

No. ITEM ROUTINE 600 mi 4000 mi (13000 (19000 (25000 (31000
(1000 km) (7000 km)
or or km) km) km) km)
or or or or
1 month 6 months 12 months 18 months 24 months 30 months

Rear suspension • Check operation.

23 • link pivots • Correct if necessary. -J -J
• Change (warm engine before
24 Engine oil -J -J -J -J ✓ ✓
draining).
Engine oil filter
25 • Replace. ✓ -J ✓
cartridge
• Check hoses for cracks or
damage. ✓ -J -J ✓ ✓
26 • Cooling system • Replace if necessary.
• Change coolant. -J
Front and rear
27 • • Check operation. ✓ ✓ -J -J ✓ ✓
brake switches
• Apply Yamaha cable lubricant
28 • Control cables or other suitable cable lubri- ✓ ✓ -J -J ✓ ✓
cant thoroughly.
• Check operation.
• Check throttle grip free play,
29 • Throttle grip and adjust if necessary. ✓ -J -J -J -J
• Lubricate cable and grip
housing.
• Check operation.
30 • Lights, siinals ✓ ✓ -J -J ✓ ✓
and switc es • Adjust headlight beam.

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Air filter
• This model uses a disposable oil-coated paper element. This element cannot be cleaned with com-
pressed air, doing so will only damage it.
• Replace the air filter more frequently if you often ride in the rain or dusty conditions.
• Hydraulic brake service
• Regularly check the brake fluid levels. Replenish as necessary.
• 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 or sooner if cracked or damaged.

3-3
 PERIODIC MAINTENANCE

EAS32024 EAS30619

CHECKING THE VEHICLE USING THE CHECKING THE FUEL LINE

YAMAHA DIAGNOSTIC TOOL The following procedure applies to all of the fuel,
Use the Yamaha diagnostic tool and check the drain and breather hoses.
vehicle according to the following procedure. 1. Remove:
1. Remove: • Fuel tank front cover/Front side panel/Front
• Rider seat/Passenger seat side cowling
Refer to "GENERAL CHASSIS (1 )" on page Refer to "GENERAL CHASSIS (2)" on page
4-1 . 4-6.
2. Remove the protective cap "1", and then con- • Passenger seat/Rider seat
nect the Yamaha diagnostic tool to the cou- Refer to "GENERAL CHASSIS (1)" on page
pler. 4-1 .
• Fuel tank cover
Yamaha diagnostic tool USB (US) Refer to "GENERAL CHASSIS (3)" on page
90890-03257 4-13.
Yamaha diagnostic tool (A/1) • Fuel tank
90890-03262
Refer to "FUEL TANK" on page 7-1 .
2. Check:
• Fuel hose "1"
• Fuel tank breather hose "2"
, • Fuel tank drain hose "3"
.
••
•• •'•
0
Cracks/damage ➔ Replace.
/
0 :' . 1 Loose connection ➔ Connect properly.
ECA14940

NOTICE
- - - - - - - - - - - - -
\ Make sure the fuel tank breather hose is rout-
ed correctly.
3. Check: TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• Fault codes Before removing the fuel hoses, place a few
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ rags in the area under where it w ill be removed.
Use the "Diagnosis of malfunction" function of
the Yamaha diagnostic tool to check the fault
codes. For information about using the Yamaha
diagnostic tool, refer to the operation manual
0
that is included with the tool. 0

Fault code number is disp l ayed ➔ Check and

repair the probable cause of the malfunction.
Refer to "TROUBLESHOOTING DETAILS
(FAULT CODE)" on page 8-51 .
4. Perform :
• Dynamic inspection 3. Install:
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ • Fuel tank
Refer to "FUEL TANK" on page 7-1 .
Use the "Dynamic inspection" function of the
Yamaha diagnostic tool version 3.0 and after to • Fuel tank cover
Refer to "GENERAL CHASSIS (3)" on page
perform the dynamic inspection. For information
4-13.
about using the Yamaha diagnostic tool, refer to
the operation manual that is included with the • Rider seat/Passenger seat
Refer to "GENERAL CHASSIS (1 )" on page
tool.
4-1 .
5. Install:
• Rider seat/Passenger seat
Refer to "GENERAL CHASSIS (1)" on page
4-1 .

3-4
 PERIODIC MAINTENANCE

• Front side cowling/ Front side panel/Fuel tank 6. Measure:

front cover • Spark plug gap "a"
Refer to "GENERAL CHASSIS (2)" on page (with a wire thickness gauge)
4-6. Out of specification ➔ Regap.
EAS30620
Spark plug gap
CHECKING THE SPARK PLUGS 0.8-0.9 mm (0.031-0.035 in)
The following procedure applies to all of the
spark plugs.
1. Remove:
• Fuel tank front cover/Front side panel/Front '
side cowling '
'
Refer to "GENERAL CHASSIS (2)" on page •'
4-6. '
.- \
I
• Passenger seat/Rider seat
1
♦
Refer to "GENERAL CHASSIS (1)" on page
4-1 . 1 2
• Fuel tank cover
Refer to "GENERAL CHASSIS (3)" on page
4-13. 7. Install:
• Fuel tank • Spark plugs
Refer to "FUEL TANK" on page 7-1 . • Ignition coils
• Air filter case
Spark plug
Refer to "GENERAL CHASSIS (3)" on page 13 N-m (1.3 kgf-m, 9.6 lb-ft)
4-13.
• Air cut-off valve TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Refer to "A IR INDUCTION SYSTEM" on
Before install ing the spark plug, clean the spark
page 7-21 .
plug and gasket surface.
2. Remove:
• Ignition coils 8. Install:
• Spark plugs • A ir cut-off valve
ECA13320
Refer to "A IR INDUCTION SYSTEM" on
NOTICE
------------- page 7-21 .
Before removing the spark plugs, blow away • A ir filter case
any dirt accumulated in the spark plug wells Refer to "GENERAL CHASSIS (3)" on page
with compressed air to prevent it from falling 4-13.
into the cylinders. • Fuel tank
3. Check: Refer to "FUEL TANK" on page 7-1 .
• Spark plug type • Fuel tank cover
I ncorrect ➔ Change.
Refer to "GENERAL CHASSIS (3)" on page
4-13.
Manufacturer/model • Rider seat/Passenger seat
NGK/CPR9EA9 Refer to "GENERAL CHASSIS (1 )" on page
4-1 .
4. Check: • Front side cowling/Front side panel/Fuel tank
• Electrode "1" front cover
Damage/wear ➔ Replace the spark plug . Refer to "GENERAL CHASSIS (2)" on page
• Insulator "2" 4-6.
Abnormal color ➔ Replace the spark plug .
EAS30622
Normal color is medium-to-light tan .
ADJUSTING THE VALVE CLEARANCE
5. C lean :
The following procedure applies to all of the
• Spark plug
valves.
(with a spark plug cleaner or wire brush)

3-5
 PERIODIC MAINTENANCE

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ a. Turn the crankshaft counterclockwise.

Valve clearance adjustment should be made on b. When piston #1 is at TDC on the compres-
a cold engine, at room temperature. sion stroke, align the TDC mark "a" on the
generator rotor with the generator rotor
1. Remove: cover mark "b".
• Fuel tank front cover/Front side panel/Front
side cowling b
Refer to "GENERAL CHASSIS (2)" on page
4-6. a
• Passenger seat/Rider seat
Refer to "GENERAL CHASSIS (1 )" on page
4-1.
• Fuel tank cover
Refer to "GENERAL CHASSIS (3)" on page
4-13.
• Fuel tank TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Refer to "FUEL TANK" on page 7-1 .
TDC on the compression stroke can be found
• Air fi lter case
when the camshaft lobes are turned away from
Refer to "GENERAL CHASSIS (3)" on page
each other.
4-13.
• Air cut-off valve c. Measure the valve clearance with a thick-
Refer to "AIR INDUCTION SYSTEM" on ness gauge "1".
page 7-21.
• Radiator
Refer to "RADIATOR" on page 6-3.
fb Thickness gauge
90890-03268
Feeler gauge set
2. Remove:
YU-26900-9
• Ignition coils
• Spark plugs
• Cylinder head cover
• Cylinder head cover gasket
Refer to "CAMSHAFTS" on page 5-15.
3. Remove:
• Timing mark accessing bolt "1"
• Crankshaft end cover "2"
,_____1
0 /

0 ~ 1 a>--
~~ a ~ \©5 TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• If the valve clearance is incorrect, record the
measured reading .
• Measure the valve clearance in the following
sequence.
c\
4. Measure:
Valve clearance measuring sequence
• Valve clearance
Cylinder #1 ➔ #2 ➔ #3
Out of specification ➔ Adjust.

Valve clearance (cold)

Intake
0.11-0.20 mm (0.0043-0.0079 in)
Exhaust
0.26-0.30 mm (0.0102-0.0118 in)

3-6
 PERIODIC MAINTENANCE

#1 #2 #3
A. Front
Valve lapper (014)
d. To measure the valve clearances of the 90890-04101
other cylinders, starting with cylinder # 1 at Valve lapping tool (14mm)
TDC, turn the crankshaft counterclock- YM-A8998
wise as specified in the following table.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
B 0° 240° 480° 720° • Cover the timing chain opening with a rag to
'-----> I1--- I --1-----11 prevent the valve pad from falling into the
crankcase.
• Make a note of the position of each valve lifter
#1 D "1" and valve pad "2" so that they can be in-
C #2 D stalled in the correct place.

#3 D

B. Degrees that the crankshaft is turned

counterclockwise
1 2 3
EX
C. Cylinder
D. Combustion cycle IN
Cylinder #2 240°
Cylinder #3 480° 2 1

5. Remove: b. Calculate the difference between the

• Camshaft specified valve clearance and the mea-
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ sured valve clearance.
• Refer to "CAMSHAFTS" on page 5-15. Example:
• When removing the timing chain and cam- Specified valve clearance= 0.11-0.20
shafts, fasten the timing chain with a wire to re- mm (0.004-0.008 in)
trieve it if it falls into the crankcase. Measured valve clearance= 0.25 mm
(0.01 O in)
6. Adjust: 0.25 mm (0.01 O in)-0.20 mm (0.008 in) =
• Valve clearance 0.05 mm (0.002 in)
a. Remove the valve lifter "1" and the valve c. Check the thickness of the current valve
pad "2" with a valve lapper "3". pad.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
The thickness "a" of each valve pad is marked in
hundredths of mi Iii meters on the side that touch-
es the valve lifter.
Example:
If the valve pad is marked "158", the pad
thickness is 1.58 mm (0.062 in).

3-7
 PERIODIC MAINTENANCE

• The valve lifter must turn smoothly when rotat-

a ed by hand.

d. Calculate the sum of the values obtained

in steps (b) and (c) to determine the re-
quired valve pad thickness and the valve
g. Install the exhaust and intake camshafts,
pad number.
timing chain and camshaft caps.
Example:
1.58 mm (0.062 in) + 0.05 mm (0.002 in)= Camshaft cap bolt
1.63 mm (0.064 in) 10 N-m (1.0 kgf •m, 7.4 lb-ft)
The valve pad number is 163.
e. Round off the valve pad number according TIP _ _ _ _ _ _ _ _ _ _ _ _ __
to the following table, and then select the • Refer to "CAMSHAFTS" on page 5-15.
suitable valve pad. • Lubricate the camshaft lobes and camshaft
Last digit Rounded value journals.
0, 1,2 0 • First, install the exhaust camshaft.
3,4, 5,6 5 • Align the camshafts marks with the camshaft
cap marks.
7, 8, 9 10
• Turn the crankshaft counterclockwise several
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ full turns to seat the parts.
Refer to the following table for the available h. Measure the valve clearance again.
valve pads. 1. If the valve clearance is still out of specifi-
cation, repeat all of the valve clearance
Valve pad range Nos. 150-240 adjustment steps until the specified clear-
1.50-2.40 mm ance is obtained.
Valve pad thickness
(0.0590-0.0944 in) 7. Install:
25 thicknesses in 0.05 • All removed parts
Available valve pads mm (0.002 in) incre- TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
ments
For installation, reverse the removal procedure.
Example:
Valve pad number= 163 EAS310 17

Rounded value = 165 CHECKING THE ENGINE IDLING SPEED

New valve pad number= 165 TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
f. Install the new valve pad "1" and the valve Prior to checking the engine idling speed, the
lifter "2". throttle body synchronization should be adjusted
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ properly, the air filter element should be clean,
• Lubricate the valve pad with molybdenum di- and the engine should have adequate compres-
sulfide oil. sion.
• Lubricate the valve lifter (Top side) with molyb- 1. Start the engine and let it warm up for several
denum disulfide oil. minutes.
• Lubricate the valve lifter (Outer side) with en- 2. Check:
gine oil. • Engine idling speed
• Install the valve lifter and the valve pad in the Out of specification ➔ Go to next step.
correct place.

3-8
 PERIODIC MAINTENANCE

Engine idling speed

1100-1 300 r/ min

3. Check:
• ISC (idle speed control) learning value
"00" or "01 " ➔ Check the intake system .
"02" ➔ Clean the throttle bodies.
Refer to "CHECKING AND CLEAN ING THE
THROTTLE BODIES" on page 7-14.
a. Connect the Yamaha diagnostic tool.
4. Install:
Use the diagnostic code number "67".
• Vacuum gauge "1"
Refer to "SELF-DIAGNOSTIC FUNC-
T ION AND DIAGNOSTIC CODE TABLE" Vacuum gauge
on page 9-1 . 90890-03094
b. Check the ISC (idle speed control) leaning Vacuummate
value. YU-44456
EAS30797

SYNCHRONIZING THE THROTTLE BODIES

TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Before synchronizing the throttle bodies, check
the following items:
• Valve clearance
• Spark plugs
• Air filter element
• Throttle body joints
• Fuel hose
• Exhaust system 5. Install:
• Breather hoses • A ir filter case
Refer to "GENERAL CHASSIS (3)" on page
Checking the throttle body synchronization 4-13.
1. Stand the vehicle on a level surface. • Fuel tank
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ Refer to "FU EL TANK" on page 7-1 .
6. Check:
Place the vehicle on the centerstand.
• Throttle body synchronization
2. Remove: a. Start the engine, warm it up for several
• Fuel tank front cover/Front side panel/Front minutes, and then let it run at the specified
side cowling engine idling speed.
Refer to "G ENERAL CHASSIS (2)" on page
4-6. Engine idling speed
• Passenger seat/Rider seat 1100-1300 r/min
Refer to "G ENERAL CHASSIS (1)" on page
b. Check the vacuum pressure.
4-1.
• Fuel tank cover The difference in vacuum pres-
Refer to "G ENERAL CHASSIS (3)" on page sure between the throttle bodies
4-1 3. should not exceed 1.33 kPa (1 O
• Fuel tank mmHg).
Refer to "FUEL TANK" on page 7-1.
• Air filter case If out of specification ➔ Adjust the throttle
Refer to "G ENERAL CHASSIS (3)" on page body synchronization.
4-1 3.
3. Remove:
• Caps "1"

3-9
 PERIODIC MAINTENANCE

Adjusting the throttle body synchronization 2. Stop the engine and remove the measuring
1. Adjust: equipment.
• Throttle body synchronization 3. Install:
a. Start the engine, warm it up for several • Caps
minutes, and then let it run at the specified 4. Install:
engine idling speed . • A ir filter case
Refer to "GENERAL CHASSIS (3)" on page
Engine idling speed 4-13.
1100-1 300 r/min • Fuel tank
Refer to "FU EL TANK" on page 7-1 .
b. Using the throttle body that has the bypass
• Fuel tank cover
air screw "1" with a white paint mark as the
Refer to "G ENERAL CHASSIS (3)" on page
standard, adjust the other throttle bodies
4-13.
by turning its bypass air screw in or out.
ECA21300 • Rider seat/Passenger seat
NOTICE Refer to "GENERAL CHASSIS (1)" on page
------------- 4-1 .
Do not turn the bypass air screw (white paint
• Front side cowling/Front side panel/Fuel tank
mark) of the throttle body that is the stan-
front cover
dard. Otherwise, the engine may run roughly
Refer to "GENERAL CHASSIS (2)" on page
at idle and the throttle bodies may not oper-
4-6.
ate properly.
5. Adjust:
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ • Throttle grip free play
• Turn the bypass air screw using the carburetor Refer to "CHECKING TH E THROTTLE
angle driver. GRIP" on page 3 -30.
• After each step, rev the engine two or three
times, each time for less than a second, and Throttle grip free play
3.0-5.0 mm (0.12-0.20 in)
check the synchronization again.
• If a bypass air screw was removed, turn the
EAS30798
screw in fully and be sure to synchronize the CHECKING THE THROTTLE BODY JOINTS
throttle bodies. 1. Remove:
• If the throttle body synchronization can not be • Throttle bodies
adjusted using the bypass air screw, clean or Refer to "THROTTLE BODIES" on page 7-5.
replace the throttle bodies. 2. Check:
• The difference in vacuum pressure between • Throttle body joints "1"
the throttle bodies should not exceed 1.33 kPa Cracks/damage ➔ Replace.
(10 mmHg) .

Carburetor angle driver 2

90890-03173

3. Install:
• Throttle bodies
Refer to "THROTTLE BODIES" on page 7-5.

3-10
 PERIODIC MAINTENANCE

EAS30626 ECA14920

CHECKING THE CANISTER (for California NOTICE

only) -------------
Make sure the cylinder head breather hose is
1. Remove: routed correctly.
• Fuel tank front cover/Front side panel/Front
side cowling
Refer to "GENERAL CHASSIS (2)" on page
4-6.
• Passenger seat/Rider seat
Refer to "GENERAL CHASSIS (1)" on page
4-1 .
• Fuel tank cover
Refer to "GENERAL CHASSIS (3)" on page
4-13.
• Fuel tank
Refer to "FUEL TANK" on page 7-1. 3. Install:
2. Check: • Air filter case
• Canister Refer to "GENERAL CHASSIS (3)" on page
• Canister purge hose 4-13.
• Fuel tank breather hose EAS30628

• Canister breather hose REPLACING THE AIR FILTER ELEMENT

Cracks/damage ➔ Replace. 1. Remove:
3. Install: • Fuel tank front cover/Front side panel/Front
• Fuel tank side cowling
Refer to "FUEL TANK" on page 7-1 . Refer to "GENERAL CHASSIS (2)" on page
• Fuel tank cover 4-6.
Refer to "GENERAL CHASSIS (3)" on page • Passenger seat/Rider seat
4-13. Refer to "GENERAL CHASSIS (1 )" on page
• Rider seat/Passenger seat 4-1 .
Refer to "GENERAL CHASSIS (1 )" on page • Fuel tank cover
4-1 . Refer to "GENERAL CHASSIS (3)" on page
• Front side cowling/Front side panel/Fuel tank 4-13.
front cover • Fuel tank
Refer to "GENERAL CHASSIS (2)" on page Refer to "FUEL TANK" on page 7-1 .
4-6. 2. Remove:
EAS30627
• ECU (Engine Control Unit) "1"
CHECKING THE AIR INDUCTION SYSTEM • Air filter case cover "2"
Refer to "CHECKING THE AIR INDUCTION Refer to "GENERAL CHASSIS (3)" on page
SYSTEM" on page 7-25. 4-13.

EAS30623

CHECKING THE CYLINDER HEAD

BREATHER HOSE
1. Remove:
• Air filter case
Refer to "GENERAL CHASSIS (3)" on page
4-13.
2. Check:
• Cylinder head breather hose "1"
Cracks/damage ➔ Replace.
3. Check:
Loose connecti on ➔ Connect properly.
• Air filter element "1"
• Air filter seal
Damage ➔ Replace.

3-11
 PERIODIC MAINTENANCE

TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Clutch lever free play
• Replace the air filter element every 37000 km 10.0-15.0 mm (0.39-0.59 in)
(24000 mi) of operation. (MTT9K, MTT9KC)
• The air filter needs more frequent service if you 5.0-10.0 mm (0.20-0.39 in)
are riding in unusually wet or dusty areas. (MTT9GTK, MTT9GTKC)

4. Install:
2. Adjust:
• Air filter element
• Clutch lever free play
• Air filter case cover
• ECU (Engine Control Unit)
ECA20710
Handlebar side
NOTICE a. Turn the adjusting bolt "1" until the speci-
------------- fied clutch lever free play is obtained.
Never operate the engine without the air filter
element installed. Unfiltered air will cause
rapid wear of engine parts and may damage
the engine. Operating the engine without the
air filter element will also affect throttle body
synchronization, leading to poor engine per-
formance and possible overheating.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
When installing the air filter element into the air
filter case cover, make sure that the sealing sur-
faces are aligned to prevent any air leaks. TIP _ _ _ _ _ _ _ _ _ _ _ _ __
5. Install: If the specified clutch lever free play cannot be
• Fuel tank obtained on the handlebar side of the cable, use
Refer to "FUEL TANK" on page 7-1. the adjusting nut on the engine side.
• Fuel tank cover
Refer to "GENERAL CHASSIS (3)" on page Engine side
4-1 3. a. Loosen the locknut "1".
• Rider seat/Passenger seat b. Turn the adjusting nut "2" until the speci-
Refer to "GENERAL C HASSIS (1)" on page fied clutch lever free play is obtained.
4-1. c. Tighten the locknut "1".
• Front side cowling/Front side panel/Fuel tank
front cover Clutch cable locknut
Refer to "GENERAL C HASSIS (2)" on page 7 N-m (0.7 kgf-m, 5.2 lb-ft)
4-6.
EAS30629

ADJUSTING THE CLUTCH LEVER FREE

PLAY
1. Check:
• Clutch lever free play "a"
O ut of specification ➔ Adjust.

3-12
 PERIODIC MAINTENANCE

ill]

C
~
EAS30801
A. Front brake
CHECKING THE BRAKE OPERATION B. Rear brake
1. Check:
EWA13090
• Brake operation
Brake not working properly ➔ Check the
£ WARNING
brake system. • Use only the designated brake fluid. Other
Refer to "FRONT BRAKE" on page 4-35 and brake fluids may cause the rubber seals to
"REAR BRAKE" on page 4-48. deteriorate, causing leakage and poor
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ brake performance.
• Refill with the same type of brake fluid that
Drive on the dry road, operate the front and rear
is already in the system. Mixing brake fluids
brakes separately and check to see if the brakes
may result in a harmful chemical reaction,
are operating properly.
leading to poor brake performance.
• When refilling, be careful that water does
EAS30632

CHECKING THE BRAKE FLUID LEVEL not enter the brake fluid reservoir. Water
1. Stand the vehicle on a level surface. will significantly lower the boiling point of
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ the brake fluid and could cause vapor lock.
ECA13540
• Place the vehicle on the centerstand.
NOTICE
• Make sure the vehicle is upright. -------------
Brake fluid may damage painted surfaces
2. Check: and plastic parts. Therefore, always clean up
• Brake fluid level any spilt brake fluid immediately.
Below the minimum level mark "a" ➔ Add the
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
specified brake fluid to the proper level.
In order to ensure a correct reading of the brake
Front brake fluid level , make sure the top of the brake fluid
Specified brake fluid reservoir is horizontal.
DOT4
Rear brake EAS30630
Specified brake fluid ADJUSTING THE FRONT DISC BRAKE
DOT4 1. Adjust:
• Brake lever position
(distance "a" from the throttle grip to the brake
lever)
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• While pushing the brake lever forward , turn the
adjusting dial "1" until the brake lever is in the
desired position .
• Be sure to align the setting on the adjusting dial
w ith the arrow mark "2" on the brake lever hold-
er.

3-13
 PERIODIC MAINTENANCE

Position #1
Distance " a" is the largest.
Position #5
Distance " a" is the smallest. 1 1

EAS30631

ADJUSTING THE REAR DISC BRAKE

1. Adjust:
• Brake pedal position
a. Loosen the locknut "1".
EWA17050
b. Turn the adjusting bolt "2" until the speci-
& WARNING fied brake pedal position is obtained.
EWA18830

• After adjusting the brake lever position, & WARNING

make sure the pin on the brake lever holder
is firmly inserted in the hole in the adjusting
dial.
• A soft or spongy feeling in the brake lever
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will consid-
erably reduce brake performance resulting
in loss of control and possibly cause an ac-
After adjusting the brake pedal position,
check that the end of the adjusting bolt " a" is
visible through the hole " b" .
c. Tighten the locknut "1" to specification.
Rear brake master cylinder lock-
nut
18 N-m (1.8 kgf-m, 13 lb-ft)
EWA17030

cident. Therefore, check and if necessary, & WARNING

bleed the brake system. A soft or spongy feeling in the brake pedal
ECA13490 can indicate the presence of air in the brake
NOTICE system. Before the vehicle is operated, the
-------------
A ft er adjusting the brake lever position, air must be removed by bleeding the brake
make sure there is no brake drag. system. Air in the brake system will consid-
erably reduce braking performance.
EAS30633 ECA13510

CHECKING THE FRONT BRAKE PADS NOTICE

The following procedure applies to all of the -------------
After adjusting the brake pedal position,
brake pads. make sure there is no brake drag.
1. Operate the brake.
2. Check:
• Front brake pad
Wear indicators "1" almost touch the brake
disc ➔ Replace the brake pads as a set.
Refer to "FRONT BRAKE" on page 4-35 .
.~,o
- ,--loi--~~~~

3-14
 PERIODIC MAINTENANCE

2. Adjust: 3. Hold the vehicle upright and apply the rear

• Rear brake light switch brake several times.
Refer to "ADJUSTING THE REAR BRAKE 4. Check:
LIGHT SWITCH" on page 3-30. • Brake hose
Brake fluid leakage ➔ Replace the damaged
EAS30634

CHECKINGTHEREARBRAKEPADS hose.
The following procedure applies to all of the Refer to "REAR BRA KE" on page 4-48.
brake pads. EAS30893

1. Operate the brake. BLEEDING THE HYDRAULIC BRAKE

2. Check: SYSTEM (ABS)
EWA14000
• Rear brake pad
Wear indicator grooves "1" almost disap- & WARNING
peared ➔ Replace the brake pads as a set. Always bleed the brake system when the
Refer to "REAR BRAKE" on page 4-48. brake related parts are removed.
-.. ECA18050

B NOTICE
-------------
• Bleed the brake system in the following or-
der.
• 1st step: Front brake calipers
• 2nd step: Rear brake caliper
EWA16530

& WARNING
Bleed the ABS whenever:
• the system is disassembled.
EAS30635
• a brake hose is loosened, disconnected or
CHECKING THE FRONT BRAKE HOSES
replaced.
The following procedure applies to all of the
• the brake fluid level is very low.
brake hoses and brake hose holders.
• brake operation is faulty.
1. Check:
• Brake hose TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Cracks/damage/wear ➔ Replace. • Be careful not to spill any brake fluid or allow
2. Check: the brake master cylinder reservoir or brake
• Brake hose holder fluid reservoir to overflow.
Loose ➔ Tighten the holder bolt. • When bleeding the ABS, make sure that there
3. Hold the vehicle upright and apply the brake is always enough brake fluid before applying
several times. the brake. Ignoring this precaution could allow
4. Check: air to enter the ABS, considerably lengthening
• Brake hose the bleeding procedure.
Brake fluid leakage ➔ Replace the damaged • If bleeding is difficult, it may be necessary to let
hose. the brake fluid settle for a few hours.
Refer to "FRONT BRAKE" on page 4-35. • Repeat the bleeding procedure when the tiny
EAS30636
bubbles in the hose have disappeared.
CHECKINGTHEREARBRAKEHOSE 1. Bleed:
1. Check: • ABS
• Brake hose a. Fill the brake master cylinder reservoir or
Cracks/damage/wear ➔ Replace. brake fluid reservoir to the proper level
2. Check: with the specified brake fluid.
• Brake hose holder b. Install the diaphragm (brake master cylin-
Loose Connection ➔ Tighten the holder bolt. der reservoir or brake fluid reservoir).
c. Connect a clear plastic hose "1" tightly to
the bleed screw "2".

3-15
 PERIODIC MAINTENANCE

Brake caliper bleed screw

5 N•m (0.5 kgf•m, 3. 7 lb•ft)
1
m. Fill the brake master cylinder reservoir or
2
brake fluid reservoir to the proper level
with the specified brake fluid.
Refer to "CHECKING THE BRAKE FLU ID
LEVEL" on page 3-13.
EWA13110

A WARNING
[ID After bleeding the hydraulic brake system,
check the brake operation.

EAS30638

CHECKING THE WHEELS

2
The following procedure applies to both of the
1 wheels.
1. Check:
• Wheel
Damage/out-of-round ➔ Replace.
EWA13260
A. Front
B. Rear
A WARNING
Never attempt to make any repairs to the
d. Place the other end of the hose into a con- wheel.
tainer.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
e. Slowly apply the brake several times.
f. Fully squeeze the brake lever or fully de- After a tire or wheel has been changed or re-
press the brake pedal and hold it in posi- placed , always balance the wheel.
tion.
g. Loosen the bleed screw. EAS30640

TIP _ _ _ _ _ _ _ _ _ _ _ _ __ CHECKING THE TIRES

The following procedure applies to both of the
Loosening the bleed screw will release the pres-
tires.
sure and cause the brake lever to contact the 1. Check:
throttle grip or the brake pedal to fully extend. • Tire pressure
h. Tighten the bleed screw and then release Out of specification ➔ Regulate.
the brake lever or brake pedal.
1. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the brake
fluid in the plastic hose.
J. Check the operation of the hydraulic unit.
Refer to "HYDRAULIC UNIT O PERA-
T ION T ESTS" on page 4-65.
ECA1 7061

NOTICE
-------------
Make sure that the main switch is turned to
EWA1318 1
"OFF" before checking the operation of the
hydraulic unit. A WARNING
• The tire pressure should only be checked
k. After operating the ABS, repeat steps (e)
and regulated when the tire temperature
to (i), and then fill the brake master cylin-
equals the ambient air temperature.
der reservoir or brake fluid reservoir to the
proper level with the specified brake fluid.
I. Tighten the bleed screw to specification.

3-16
 PERIODIC MAINTENANCE

• The tire pressure and the suspension must

be adjusted according to the total weight Wear limit (front)
(including cargo, rider, passenger and ac- 1.0 mm (0.04 in)
cessories) and the anticipated riding Wear limit (rear)
1.0 mm (0.04 in)
speed.
• Operation of an overloaded vehicle could EWA14090

cause tire damage, an accident or an injury. & WARNING

NEVER OVERLOAD THE VEHICLE. After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Tire air pressure (measured on Ltd. for this model. The front and rear tires
cold tires) should always be by the same manufacturer
Up to 90 kg (198 lb) load and of the same design. No guarantee con-
Front cerning handling characteristics can be giv-
225 kPa (2.25 kgf/cm 2 , 33 psi)
en if a tire combination other than one
Rear
approved by Yamaha is used on this vehicle.
250 kPa (2.50 kgf/cm 2 , 36 psi)
90 kg (198 lb) load - maximum
load Front tire
Front Size
250 kPa (2.50 kgf/cm 2 , 36 psi) 120/70ZR17 M/C (SSW)
Rear Manufacturer/model
290 kPa (2.90 kgf/cm 2 , 42 psi) DUNLOP/D222F
Maximum load
180 kg (397 lb) (MTT9K,
MTT9KC) Rear tire
179 kg (395 lb) (MTT9GTK, Size
MTT9GTKC) 180/55ZR17 M/C (73W)
Manufacturer/model
* Total weight of rider, passenger, cargo DUNLOP/D222
and accessories
EWA13210

2. Check: & WARNING

• Tire surfaces New tires have a relatively low grip on the
Damage/wear ➔ Replace the tire. road surface until they have been slightly
EWA13190

& WARNING worn. Therefore, approximately 100 km

should be traveled at normal speed before
It is dangerous to ride with a worn-out tire.
any high-speed riding is done.
When the tire tread reaches the wear limit, re-
place the tire immediately. TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Forti res with a direction of rotation mark "1":
• Install the tire with the mark pointing in the di-
rection of wheel rotation.
• Align the mark "2" with the valve installation
point.
3

1. Tire tread depth

2. Side wall
3. Wear indicator

3-17
 PERIODIC MAINTENANCE

EAS30641
2. Shift the transm ission into the neutral posi-
CHECKING THE WHEEL BEARINGS
tion.
The following procedure applies to all of the
3. Check:
wheel bearings.
• Drive chain slack "a"
1. Check:
Out of specification ➔ Adjust.
• Wheel bearings
Refer to "CHECKING THE FRONT WHEEL"
on page 4-22 and "CHECKING THE REAR
WHEEL" on page 4-30.
EAS30802

CHECKING THE SWINGARM OPERATION

1. Check:
• Swingarm operation
Swingarm not working properly ➔ Check the
sw1ngarm.
Refer to "SWINGARM" on page 4-1 08.
2. Check: Drive chain slack (Maintenance
• Swingarm excessive play stand)
Refer to "SWINGARM" on page 4-1 08. 35.0-45.0 mm (1.38-1. 77 in)

EAS30643 ECA20870

LUBRICATING THE SWINGARM PIVOT NOTICE

1. Lubricate: -------------
1m proper drive chain slack will overload the
• Oil seals engine as well as other vital parts of the mo-
• Collars torcycle and can lead to chain slippage or
breakage. If the drive chain slack is more
Recommended lubricant
I than the specified limit, the chain can dam-
Lithium-soap-based grease
age the frame, swingarm, and other parts. To
Refer to "IN STALLING THE SWINGARM" on prevent this from occurring, keep the drive
page 4-111. chain slack within the specified limits.

EAS31923

DRIVE CHAIN SLACK Adjusting the drive chain slack

1. Loosen:
Checking the drive chain slack • Wheel axle nut "1"
ECA13550

NOTICE
-------------
A drive chain that is too tight will overload
the engine and other vital parts, and one that
is too loose can skip and damage the swing-
arm or cause an accident. Therefore, keep
the drive chain slack within the specified lim-
its.
1. Stand the vehicle on a level surface.
EWA13 120

A WARNING 2. Adjust:
• Drive chain slack
Securely support the vehicle so that there is
a. Loosen both locknuts "1".
no danger of it falling over.
b. Turn both adjusting bolts "2" until the spec-
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ ified drive chain slack is obtained.
Place the vehicle on the centerstand so that the
rear wheel is elevated.

3-18
 PERIODIC MAINTENANCE

EAS30645

CHECKING AND ADJUSTING THE

/.r---\~Jt~~-~~~ STEERING HEAD
2 ~'.'-~0 1. Stand the vehicle on a level surface.
EWA13120

& WARNING
Securely support the vehicle so that there is
no danger of it falling over.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Place the vehicle on a maintenance stand so
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ that the front wheel is elevated.
• To maintain the proper wheel alignment, adjust 2. Check:
both sides evenly. • Steering head
• There should be no clearance between the ad- Grasp the bottom of the front fork legs and
justing block and adjusting bolt. gently rock the front fork.
c. T ighten the wheel axle nut to specification. Blinding/looseness ➔ Adjust the steering
head.
Rear wheel axle nut 3. Remove:
150 N-m (15 kgf-m, 111 lb-ft) • Upper bracket
4. Adjust:
d. T ighten the locknuts to specification . • Steering head
a. Remove the lock washer "1", the upper
Chain puller adjusting bolt lock-
ring nut "2", and the rubber washer "3".
nut
16 N-m (1.6 kgf-m, 12 lb-ft)

EAS30803

LUBRICATING THE DRIVE CHAIN

The drive chain consists of many interacting
parts. If the drive chain is not maintained proper-
ly, it will wear out quickly. Therefore, the drive
chain should be serviced, especially when the
vehicle is used in dusty areas. 3
This vehicle has a drive chain with small rubber
0-rings between each side plate. Steam clean- b. Loosen the lower ring nut "4" and then
ing , high-pressure washing , certain solvents, tighten it to specification with a steering
and the use of a coarse brush can damage nut wrench "5".
these 0-rings. Therefore, use only kerosene to
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
clean the drive chain. W ipe the drive chain dry
and thoroughly lubricate it with engine oil or • Set the torque wrench at a right angle to the
chain lubricant that is suitable for 0-ring chains. steering nut wrench.
Do not use any other lubricants on the drive • Move the steering to the left and right a couple
chain since they may contain solvents that could of times to check that it moves smoothly.
damage the 0-rings.

Recommended lubricant
I Chain lubricant suitable for C-
ring chains

3-19
 PERIODIC MAINTENANCE

EAS30646

Steering nut wrench LUBRICATING THE STEERING HEAD

90890-01403 1. Lubricate:
Exhaust flange nut wrench • Upper bearing
YU-A9472 • Lower bearing
• Bearing race

Lower ring nut (initial tightening Recommended lubricant

torque) l Lithium-soap-based grease
52 N•m (5.2 kgf•m, 38 lb-ft)
EAS31186

c. Loosen the lower ring nut "6" completely, CHECKING THE CHASSIS FASTENERS
then tighten it to specification. Make sure that all nuts, bolts, and screws are
EWA13 140
properly tightened.
A WARNING Refer to "CHASSIS T IGHTENING TORQU ES"
Do not overtighten the lower ring nut. on page 2-14.
EAS30804
Lower ring nut (final tightening LUBRICATING THE BRAKE LEVER
torque) Lubricate the pivoting point and metal-to-metal
18 N•m (1.8 kgf•m, 13 lb-ft)
moving parts of the lever.
d. Check the steering head for looseness or
Recommended lubricant
binding by turning the front fork all the way l
Silicone grease
in both directions. If any binding is felt, re-
move the lower bracket and check the up- EAS30805

per and lower bearings. LUBRICATING THE CLUTCH LEVER

Refer to "STEERING HEAD" on page Lubricate the pivoting point and metal-to-metal
4-96. moving parts of the lever.
e. Install the rubber washer "7".
f. Install the upper ring nut "8". Recommended lubricant
l Lithium-soap-based grease
g. Finger tighten the upper ring nut, then
align the slots of both ring nuts. If neces-
EAS30649
sary, hold the lower ring nut and tighten
LUBRICATING THE PEDAL
the upper ring nut until their slots are
Lubricate the pivoting point and metal-to-metal
aligned. moving parts of the pedal.
h. Install the lock washer "9".
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ Recommended lubricant
l
Make sure the lock washer tabs "a" sit correctly Lithium-soap-based grease
in the ring nut slots "b".
EAS30650

CHECKING THE SIDESTAND

1. Check:
• Sidestand operation
Check that the sidestand moves smoothly.
a ..___ Rough movement ➔ Repair or replace.

6~ ~ ~- - 8 EAS30651

LUBRICATING THE SIDESTAND

7 °~s~~}--::_i::t.L Lubricate the pivoting point, metal-to-metal mov-
ing parts and spring contact point of the side-
stand.
5. Install :
• Upper bracket Recommended lubricant
l
Lithium-soap-based grease
Refer to "HANDLEBAR" on page 4-69.

3-20
 PERIODIC MAINTENANCE

EAS30856 EWA13120

CHECKING THE CENTERSTAND & WARNING

1. Check: Securely support the vehicle so that there is
• Centerstand operation no danger of it falling over.
Check that the centerstand moves smoothly.
Rough movement ➔ Repair or replace.
Spring preload
EAS30857 EWA17040

LUBRICATING THE CENTERSTAND & WARNING

Lubricate the pivoting point and metal-to-metal
moving parts of the centerstand.
Recommended lubricant
I Lithium-soap-based grease
Always adjust both front fork legs evenly.
Uneven adjustment can result in poor han-
dling and loss of stability.
ECA13590

NOTICE
-------------
EAS30652 Never go beyond the maximum or minimum
CHECKING THE SIDESTAND SWITCH adjustment positions.
Refer to "ELECTRICAL COMPONENTS" on
1. Adjust:
page 8- 183.
• Spring preload
EAS30653 a. Turn the adjusting bolt "1" in direction "a"
CHECKING THE FRONT FORK or "b".
1. Stand the vehicle on a level surface.
EWA13 120
Direction "a"
& WARNING Spring preload is increased (suspen-
Securely support the vehicle so that there is sion is harder).
no danger of it falling over. Direction "b"
Spring preload is decreased (suspen-
2. Check:
sion is softer).
• Inner tube
Damage/scratches ➔ Replace.
• Front fork leg [ID
O il leaks between inner tube and outer tube
➔ Replace the oil seal.
3. Hold the vehicle upright and apply the front
brake.
4. Check:
------
)i
b -- a
• Front fork operation
Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Rough movement ➔ Repair.
Refer to "FRONT FORK" on page 4-80.

a ~="=2--
----
)i
b - -
-- {_
a -:::;==2

A. MTT9K/MTT9KC (left side)

B. MTT9K/MTT9KC (right side)
EAS30806 C. MTT9GTK/MTT9GTKC
ADJUSTING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.

3-21
 PERIODIC MAINTENANCE

TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Rebound damping
The spring preload setting is determined by Minimum (soft)
measuring the distance "c" shown in the illustra- 12 click(s) in direction "b"*
tion . The shorter distance "c" is, the higher the (MTT9K/MTT9KC)
spring preload; the longer distance "c" is, the 11 click(s) in direction "b"*
lower the spring preload. (MTT9GTK/MTT9GTKC)
Standard
7 click(s) in direction "b"*
Maximum (hard)
1 click(s) in direction "b"*
C * With the adjusting screw fully turned in
direction "a"

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Although the total number of clicks of a damping
force adjusting mechanism may not exactly
match the above specifications due to small dif-
Spring preload ferences in production , the actual number of
Minimum clicks always represents the entire adjusting
19 mm (0.75 in) range. To obtain a precise adjustment, it would
Standard be advisable to check the number of clicks of
16 mm (0.63 in) each damping force adjusting mechanism and
Maximum to modify the specifications as necessary.
4 mm (0.16 in)

a 1 b
Rebound damping (right side only) I
ECA13590

NOTICE
-------------
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
• Rebound damping
a. T urn the adjusting screw "1" in direction
"a" or "b".
Compression damping (left side only)
Direction "a" (MTT9GTK/MTT9GTKC)
ECA13590
Rebound damping is increased (sus-
NOTICE
pension is harder).
Direction "b"
-------------
Never go beyond the maximum or minimum
Rebound damping is decreased (sus- adjustment positions.
pension is softer).
1. Adjust:
• Compression damping
a. Turn the adjusting screw "1" in direction
"a" or "b".

Direction "a"
Compression damping is increased
(suspension is harder).
Direction "b"
Compression damping is decreased
(suspension is softer).

3-22
 PERIODIC MAINTENANCE

a. Adjust the spring preload with the special

Compression damping wrench "1" and extension bar "2" included
Minimum (soft) in the owner's tool kit.
11 click(s) in direction "b"* b. Turn the adjusting ring "3" in direction "a"
Standard
or "b".
7 click(s) in direction "b"*
c. Align the desired position on the adjusting
Maximum (hard)
1 click(s) in direction "b"* ring with the stopper "4".
* With the adjusting screw fully turned in Direction "a"
direction "a" Spring preload is increased (suspen-
sion is harder).
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Direction "b"
Although the total number of clicks of a damping Spring preload is decreased (suspen-
force adjusting mechanism may not exactly sion is softer).
match the above specifications due to small dif-
ferences in production, the actual number of
clicks always represents the entire adjusting Spring preload
range. To obtain a precise adjustment, it would Adjustment value (Soft)
1
be advisable to check the number of clicks of
Adjustment value (STD)
each damping force adjusting mechanism and
4
to modify the specifications as necessary. Adjustment value (Hard)
7

a 1 b
L

4
EAS30808

CHECKING THE REAR SHOCK ABSORBER

ASSEMBLY Rebound damping
Refer to "CHEC KING THE REAR SHOCK AB- ECA13590

SORBER ASSEMBLY" on page 4-106. NOTICE

-------------
EAS30655
Never go beyond the maximum or minimum
ADJUSTING THE REAR SHOCK ABSORBER adjustment positions.
ASSEMBLY (MTT9K/MTT9KC) 1. Adjust:
EWA13 120
• Rebound damping
AwARNING
a. Turn the adjusting screw "1" in direction
Securely support the vehicle so that there is "a" or "b".
no danger of it falling over.
Direction "a"
Spring preload Rebound damping is increased (sus-
ECA13590 pension is harder).
NOTICE Direction "b"
-------------
Never go beyond the maximum or minimum Rebound damping is decreased (sus-
adjustment positions. pension is softer).

1. Adjust:
• Spring preload

3-23
 PERIODIC MAINTENANCE

Rebound damping Spring preload

Minimum (soft) Adjustment value (Soft)
3 turn(s) in direction "b"* 1
Standard Adjustment value (STD)
1 1/2 turn(s) in direction "b"* 11
Maximum (hard) Adjustment value (Hard)
Adjusting screw fully turned in 24
direction "a"
* With the adjusting screw fully turned in
direction "a"

TIP _ _ _ _ _ _ _ _ _ _ _ _ __
To obtain a precise adjustment, it is advisable to 1
check the actual total number of turns of the b
damping force adjusting mechanism. This ad-
justment range may not exactly match the spec-
ifications listed due to small differences in
production.
Rebound damping
ECA13590

NOTICE
-------------
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
• Rebound damping
a. Turn the adjusting screw "1" in direction
"a" or "b".

EAS31609
Direction "a"
ADJUSTING THE REAR SHOCK ABSORBER Rebound damping is increased (sus-
ASSEMBLY (MTT9GTK/MTT9GTKC) pension is harder).
EWA13 120 Direction "b"
AwARNING Rebound damping is decreased (sus-
Securely support the vehicle so that there is pension is softer).
no danger of it falling over.
Rebound damping
Spring preload Minimum (soft)
ECA13590
18 click(s) in direction "b"*
NOTICE
-------------
Never go beyond the maximum or minimum
Standard
7 click(s) in direction "b"*
adjustment positions. Maximum (hard)
1 click(s) in direction "b"*
1. Adjust:
* With the adjusting screw fully turned in
• Spring preload
direction "a"
a. T urn the adjusting ring "1" in direction "a"
or "b". TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

Direction "a" To obtain a precise adjustment, it is advisable to

Spring preload is increased (suspen- check the actual total number of turns of the
sion is harder). damping force adjusting mechanism . This ad-
Direction "b" justment range may not exactly match the spec-
Spring preload is decreased (suspen- ifications listed due to small differences in
sion is softer). production .

3-24
 PERIODIC MAINTENANCE

0 10 30 50 70 90 110 130 "F

I I
. . . .
..ISAE
. . .
... 1OW-401
.. ..
1 a I SAE 10W-50
. . .
SAE.. 1. 5 W-~O
. ... ..
.
ISAE 20W-40'

. 20\J\/-5()
.' SA.E . .
11 11111 1
-20 -10 o 10 20 30 40 50 ·c

ECA1 336 1
EAS30809

CHECKING THE CONNECTING ARM AND NOTICE

- - - - - - - - - - - - -
RELAY ARM • Engine oil also lubricates the clutch and the
Refer to "CHECKING THE CONNECTING ARM wrong oil types or additives could cause
AND RELAY ARM" on page 4-106. clutch slippage. Therefore, do not add any
chemical additives or use engine oils with a
EAS30656

CHECKING THE ENGINE OIL LEVEL
1. Stand the vehicle on a level surface.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• Place the vehicle on the centerstand.
• Make sure the vehicle is upright.
2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Check:
• Engine oil level
The engine oil level should be between the
minimum level mark "a" and maximum level
mark "b".
Below the minimum level mark ➔ Add the
recommended engine oil to the proper level.
grade of "CD" or higher and do not use oils
labeled "ENERGY CONSERVING II".
• Do not allow foreign materials to enter the
crankcase.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Before checking the engine oil level , wait a few
minutes until the oil has settled.
4. Start the engine, warm it up for several min-
utes, and then turn it off.
5. Check the engine oil level again.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Before checking the engine oil level , wait a few
minutes until the oil has settled.
EAS30657

CHANGING THE ENGINE OIL

1. Start the engine, warm it up for several min-
o @
~ ~-r,__;::.
___ utes, and then turn it off.
~~ ,!.e!~ - -b 2. Place a container under the engine oil drain
~~~a ~~~~-a bolt.
1 L::'.:r,..
:::;:;!: : : ;:::_=-....
1--.--1 3. Remove:
~ • Engine oil filler cap "1"
- -~_,_,__----<J---...::0::::_
'--=i___j,)______ • Engine oil drain bolt "2"
• Gasket "3"

Recommended brand
YAMALUBE
SAE viscosity grades
1OW-40, 1OW-50, 1SW-40, 20W-
40 or 20W-50
Recommended engine oil grade
API service SG type or higher,
JASO standard MA

3-25
 PERIODIC MAINTENANCE

Oil filter cartridge

17 N-m (1.7 kgf-m, 13 lb-ft)

(
6. Install:
• Engine oil drain bolt
2 3
(along with the gasket •~MW)
Engine oil drain bolt
43 N-m (4.3 kgf-m, 32 lb-ft)

4. Drain: 7. Fill:
• Engine oil • Crankcase
(completely from the crankcase) (with the specified amount of the recom-
5. If the oil filter cartridge is also to be replaced, mended engine oil)

~
perform the following procedure. Engine oil quantity
a. Remove the oil filter cartridge "1" with an Quantity (disassembled)
oil filter wrench "2". 3.40 L (3.59 US qt, 2.99 Imp.qt)
Oil change
Oil filter wrench 2.40 L (2.54 US qt, 2.11 Imp.qt)
90890-01426 With oil filter removal
Oil filter wrench 2.70 L (2.85 US qt, 2.38 Imp.qt)
YU-38411
8. Install:
• Engine oil filler cap
(along with the 0 -ring l~f:Mi.1
9. Start the engine, warm it up for several min-
utes, and then turn it off.
10.Check:
• Engine
(for engine oil leaks)
2 1 11.Check:
• Engine oil level
b. Lubricate the 0 -ring "3" of the new oil filter Refer to "C HECKING THE ENGINE OIL
cartridge with a thin coat of engine oil. LEVEL" on page 3-25.
ECA13390
EAS30810
NOTICE
- - - - - - - - - - - - - MEASURING THE ENGINE OIL PRESSURE
Make sure the 0-ring "3" is positioned cor- 1. Check:
rectly in the groove of the oil filter cartridge. • Engine oil level
Below the minimum level mark "a" ➔ Add the
recommended engine oil to the proper level.
3
a \__)
a ~-------
~~',,.,.-i;;.::-
a~ ~-;::::o
-::;:p

~
c. T ighten the new oil filter cartridge to spec- _ _,,,,,,,!._,_J,___--u----.. . .: : :L=-_J_~-
:
ification with an oil filter wrench.

3-26
 PERIODIC MAINTENANCE

2. Start the engine, warm it up for several min-

utes, and then turn it off. Oil pressure
ECA13410 230.0 kPa/5000 r/min (2.30 kgf/
NOTICE cm 2/5000 r/min, 33.4 psi/5000 r/
-------------- min)
When the engine is cold, the engine oil will
have a higher viscosity, causing the engine
Out of specification ➔ Check.
oil pressure to increase. Therefore, be sure
to measure the engine oil pressure after Engine oil pressure Possible causes
warming up the engine. • Faulty oil pump
• Clogged oil filter
3. Remove:
Below specification • Leaking oil passage
• Main gallery bolt "1" • Broken or damaged
EWA12980
oil seal
& WARNING
• Leaking oil passage
The engine, muffler and engine oil are ex-
Above specification • Faulty oil filter
tremely hot. • Oil viscosity too high

6. Install:
• Main gallery bolt

Main gallery bolt

8 N-m (0.8 kgf-m, 5.9 lb-ft)

EAS30811

CHECKING THE COOLANT LEVEL

1. Stand the vehicle on a level surface.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
4. Install: • Place the vehicle on the centerstand.
• Pressure gauge "1" • Make sure the vehicle is upright.
• Oil pressure adapter H "2"
2. Check:
Pressure gauge • Coolant level
90890-03153 The coolant level should be between the
Pressure gauge maximum level mark "a" and minimum level
YU-03153 mark "b".
Oil pressure adapter H Below the minimum level mark ➔ Add the
90890-03139 recommended coolant to the proper level.

j ~W,'
~~a.~~ / "'--9:i~

a
b
ECA21281
5. Measure:
NOTICE
• Oil pressure --------------
(at the following conditions) • Adding water instead of coolant dilutes the
antifreeze concentration of the coolant. If
water is used instead of coolant; check,
and if necessary, correct the antifreeze
concentration of the coolant.

3-27
 PERIODIC MAINTENANCE

• Use only distilled water. However, if dis- • Radiator cap "2"

tilled water is not available, soft water may • Radiator cap stopper "3"
EWA13030
be used.
& WARNING
3. Start the engine, warm it up for several min-
A hot radiator is under pressure. Therefore,
utes, and then turn it off.
do not remove the radiator cap when the en-
4. Check:
gine is hot. Scalding hot fluid and steam may
• Coolant level
be blown out, which could cause serious in-
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
jury. When the engine has cooled, open the
Before checking the coolant level, wait a few radiator cap as follows:
minutes until it settles. Place a thick rag or a towel over the radiator
cap and slowly turn the radiator cap counter-
EAS30812
clockwise toward the detent to allow any re-
CHECKING THE COOLING SYSTEM sidual pressure to escape. When the hissing
1. Check: sound has stopped, press down on the radi-
• Radiator "1" ator cap and turn it counterclockwise to re-
• Radiator inlet hose "2" move.
• Radiator outlet hose "3"
• Oil cooler "4"
• Oil cooler inlet hose "5"
• Oil cooler outlet hose "6"
• Water jacket joint "7"
• Water pump inlet hose "8"
Cracks/damage ➔ Replace.
Refer to "RADIATOR" on page 6-3, "OIL
COOLER" on page 6-7, ''THERMOSTAT' on
page 6-9 and "WATER PUMP" on page 6-11 .

2. Remove:
• Coolant reservoir bolt "1"
• Coolant reservoir cover "2"
• Coolant reservoir "3"
mi c'--~\~)0 • Collars "4"

8
~

7
2 3
5

3. Remove:
6
• Coolant reservoir cap "1"

EAS30813

CHANGING THE COOLANT

1. Remove:
• Front side panel (right)
Refer to "GENERAL CHASSIS (2)" on page
4-6.
• Radiator cap bolt "1"

3-28
 PERIODIC MAINTENANCE

~
Recommended antifreeze
High-quality ethylene glycol anti-
-1 freeze containing corrosion
inhibitors for aluminum engines
Mixing ratio
1:1 (antifreeze: water)
Radiator (including all routes)
1.93 L (2.04 US qt, 1.70 Imp.qt)
Coolant reservoir (up to the maxi-
mum level mark)
4. Drain: 0.25 L (0.26 US qt, 0.22 Imp.qt)
• Coolant
(from the coolant reservoir) Handling notes for coolant
5. Remove: Coolant is potentially harmful and should be
• W ater pump drain bolt "1" handled with special care.
EWA13040
• Copper washer "2"
£ WARNING
• If coolant splashes in your eyes, thorough-
ly wash them with water and consult a doc-
tor.
1 2 • If coolant splashes on your clothes, quickly
wash it away with water and then with soap
\ and water.
@ • If coolant is swallowed, induce vomiting
and get immediate medical attention.
ECA21291

6. Drain: NOTICE
- - - - - - - - - - - - -
• Coolant • Adding water instead of coolant dilutes the
(from the engine and radiator) antifreeze concentration of the coolant. If
7. Install : water is used instead of coolant; check,
• W ater pump drain bolt and if necessary, correct the antifreeze
• Copper washer •~M concentration of the coolant.
• Use only distilled water. However, if dis-
Water pump drain bolt tilled water is not available, soft water may
10 N-m (1.0 kgf-m, 7.4 lb•ft) be used.
• If coolant comes into contact with painted
8. Install : surfaces, immediately wash them with wa-
• Collars ter.
• Coolant reservoir • Do not mix different types of antifreeze.
• Coolant reservoir cover
1a.Install:
• Coolant reservoir bolt
• Radiator cap stopper
Coolant reservoir bolt (MS) • Radiator cap
0.5 N-m (0.05 kgf•m, 0.37 lb-ft) • Radiator cap bolt
Coolant reservoir bolt (M6)
9 N-m (0.9 kgf •m, 6.6 lb-ft) Radiator cap bolt
5 N-m (0.5 kgf-m, 3. 7 lb-ft)
9. Fill:
• Cooling system • Front side panel (right)
(with the specified amount of the recom- Refer to "GENERAL C HASSIS (2)" on page
mended coolant) 4-6.

3-29
 PERIODIC MAINTENANCE

11.Fill:
~
• Coolant reservoir
(with the recommended coolant to the maxi- )\ v
mum level mark "a") ~-+-- 1 0

_; ~b~' - @)
~\!..../1\./~~~Dl/_..=''---::ti~~
Vi i
\ / "'--9:;~
" \.t:l:::::..:-iJ

EAS30660

a CHECKING AND LUBRICATING THE

CABLES
The following procedure applies to all of the in-
12.lnstall: ner and outer cables.
EWA13270
• Coolant reservoir cap
13.Start the engine, warm it up for several min- & WARNING
utes, and then turn it off. Damaged outer cable may cause the cable to
14.Check: corrode and interfere with its movement. Re-
• Coolant level place damaged outer cable and inner cables
Refer to "CHECKING THE COOLANT LEV- as soon as possible.
EL" on page 3-27. 1. Check:
TIP - - - - - - - - - - - - - - - - • Outer cable
Before checking the coolant level, wait a few Damage ➔ Replace.
minutes until the coolant has settled. 2. Check:
• Cable operation
EAS30814 Rough movement ➔ Lubricate.
CHECKING THE FRONT BRAKE LIGHT
SWITCH Recommended lubricant
I Engine oil or a suitable cable lu-
Refer to "ELECTRICAL COMPONENTS" on
page 8-183. bricant

EAS30659 TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
ADJUSTING THE REAR BRAKE LIGHT
Hold the cable end upright and pour a few drops
SWITCH
of lubricant into the cable sheath or use a suit-
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
able lubricating device.
The rear brake light switch is operated by move-
ment of the brake pedal. The rear brake light EAS30815

switch is properly adjusted when the brake light CHECKING THE THROTTLE GRIP
comes on just before the braking effect starts. 1. Check:
• Throttle cables
1. Check:
Damage/deterioration ➔ Replace.
• Rear brake light operation timing
• Throttle cable installation
Incorrect ➔ Adjust.
Incorrect ➔ Reinstall the throttle cables.
2. Adjust:
Refer to "HANDLEBAR" on page 4-69.
• Rear brake light operation timing
2. Check:
a. Hold the main body "1" of the rear brake
• Throttle grip movement
light switch so that it does not rotate and
Rough movement ➔ Lubricate or replace the
turn the adjusting nut "2" until the rear
defective part(s).
brake light comes on at the proper time.
Recommended lubricant
I
Suitable cable lubricant

3-30
 PERIODIC MAINTENANCE

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ EAS30816

CHECKING AND CHARGING THE BATTERY

With the engine stopped, turn the throttle grip Refer to "CHECKING AND CHARGING THE
slowly and release it. Make sure that the throttle BATTERY" on page 8-190.
grip turns smoothly and returns properly when
released. EAS30662

CHECKING THE FUSES

Repeat this check with the handlebar turned all
Refer to "CHECKING THE FUSES" on page
the way to the left and right.
8-189.
3. Check:
EAS30664
• Throttle grip free play "a" ADJUSTING THE HEADLIGHT BEAMS
Out of specification ➔ Adjust. 1. Adjust:
Throttle grip free play • Headlight beam (vertically)
3.0-5.0 mm (0.1 2-0.20 in) a. Turn the adjusting knobs "1".
[A]

G 1
= =
1
\ ~

ffi)
4. Adjust:
• Throttle grip free play 1 1
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Prior to adjusting the throttle grip free play, throt-
tle body synchronization should be adjusted
0
~

~~
properly. 0 II

a. Slide back the rubber cover "1".

b. Loosen the locknut "2".
c. Turn the adjusting nut "3" until the speci-
A. MTT9K/MTT9KC
fied throttle grip free play is obtained. B. MTT9GTK/MTT9GTKC

2. Adjust:
• Headlight beam (horizontally)
a. Turn the adjusting screws "1".

d. Tighten the locknut.

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.

3-31
 CHASSIS

GENERAL CHASSIS (1) ........ ......... .......... ......... ........ .......... ......... ......... ......... 4-1
INSTALLING THE REAR SIDE COVER ....... ......... ........ ......... ......... ......... 4-4
INSTALLING THE SEATS .......... ......... ......... ......... ......... .......... ......... ........ 4-4

GENERAL CHASSIS (2) ........ ......... .......... ......... ........ .......... ......... ......... ......... 4-6
REMOVING THE FUEL TANK FRONT COVER .. ......... ......... ......... ........ 4-10
INSTALLING THE FUEL TANK FRONT COVER ........ ......... .......... ........ 4-10
REMOVING THE FRONT SIDE COWLINGS ...... ......... ......... .......... ....... 4-10
INSTALLING THE FRONT SIDE COWLINGS ....... ......... ......... ......... ...... 4-11
REMOVING THE FRONT COVER ...... .......... ......... ......... ......... .......... ..... 4-11
INSTALLI NG THE FRONT COVER ... .......... ........ .......... .......... ......... ...... 4-11
INSTALLING THE SUPPORT STAY .......... .......... ......... .......... ......... ....... 4-12
ADJUSTING THE WINDSHIELD HEIGHT .... ......... ......... ......... .......... ..... 4-12

GENERAL CHASSIS (3) ........ .......... ......... .......... ......... ......... ......... ......... ...... 4-13
REMOVING THE FUEL TANK COVERS ..... .......... ........ .......... ......... ...... 4-19
INSTALLING THE FUEL TANK COVERS ........... .......... ......... .......... ...... 4-19

FRONT WHEEL ... .......... ......... .......... ......... .......... ......... ......... ......... .......... ..... 4-20
REMOVING THE FRONT WHEEL ...... ......... .......... ........ .......... ......... ...... 4-22
DISASSEMBLING THE FRONT WHEEL ...... ......... ......... .......... ......... ..... 4-22
CHECKING THE FRONT WHEEL ...... .......... ......... ......... ......... .......... ..... 4-22
ASSEMBLING THE FRONT WHEEL ......... .......... ......... .......... .......... ...... 4-23
MAINTENANCE OF THE FRONT WHEEL SENSOR AND
SENSOR ROTOR ........... .......... ......... .......... .......... ........ .......... ......... ..... 4-24
ADJUSTING THE FRONT WHEEL STATIC BALANCE ......... .......... ...... 4-25
INSTALLING THE FRONT WHEEL (DISC BRAKE) ...... ......... .......... ...... 4-25

REAR WHEEL .... .......... ......... .......... ......... .......... ........ .......... ......... .......... ...... 4-27
REMOVING THE REAR WHEEL ........ ......... .......... ........ .......... ......... ...... 4-30
DISASSEMBLING THE REAR WHEEL ....... .......... ......... ......... .......... ..... 4-30
CHECKING THE REAR WHEEL .......... ......... ......... ......... ......... .......... ..... 4-30
CHECKING THE REAR WHEEL DRIVE HUB ........ ........ .......... .......... .... 4-31
CHECKING AND REPLACING THE REAR WHEEL SPROCKET ... ...... 4-31
ASSEMBLING THE REAR WHEEL .... ......... .......... ......... ......... .......... ..... 4-31
MAINTENANCE OF THE REAR WHEEL SENSOR AND
SENSOR ROTOR ........... .......... ......... .......... .......... ........ .......... ......... ..... 4-32
ADJUSTING THE REAR WHEEL STATIC BALANCE .. .......... .......... ...... 4-32
INSTALLING THE REAR WHEEL (DISC BRAKE) ........ ......... .......... ...... 4-32
FRONT BRAKE ... .......... ......... .......... ......... .......... ......... ......... ......... .......... ..... 4-35
INTRODUCTION ..... ......... .......... ......... .......... ......... ......... ......... .......... ..... 4-41
CHECKING THE FRONT BRAKE DISCS ... .......... ......... ........... ......... ..... 4-41
REPLACING THE FRONT BRAKE PADS ... ........ .......... ......... .......... ...... 4-42
REMOVING THE FRONT BRAKE CALI PERS .... .......... ......... .......... ...... 4-43
DISASSEMBLING THE FRONT BRAKE CALIPERS ....... .......... ......... .... 4-43
CHECKING THE FRONT BRAKE CALI PERS ....... .......... ......... ......... ..... 4-44
ASSEMBLING THE FRONT BRAKE CALIPERS ... ......... ......... .......... ..... 4-44
INSTALLING THE FRONT BRAKE CALI PERS ...... ......... .......... ......... .... 4-44
REMOVING THE FRONT BRAKE MASTER CYLINDER ...... .......... ....... 4-46
CHECKING THE FRONT BRAKE MASTER CYLINDER .......... .......... .... 4-46
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ..... ......... ..... 4-46
INSTALLING THE FRONT BRAKE MASTER CYLINDER ....... .......... ..... 4-46

REAR BRAKE .... .......... ......... .......... ......... .......... ........ .......... ......... .......... ...... 4-48
INTRODUCTION ..... ......... .......... ......... .......... ......... ......... ......... .......... ..... 4-54
CHECKING THE REAR BRAKE DISC ......... ......... .......... ......... ......... ...... 4-54
REPLACING THE REAR BRAKE PADS ....... ......... ......... .......... ......... ..... 4-54
REMOVING THE REAR BRAKE CALIPER ......... ......... ......... .......... ....... 4-55
DISASSEMBLING THE REAR BRAKE CALI PER .. ......... ......... ......... ..... 4-56
CH ECKi NG THE REAR BRAKE CALI PER .. ......... ......... ........... ......... ..... 4-56
ASSEMBLING THE REAR BRAKE CALI PER ........ ......... ......... ......... ..... 4-57
INSTALLING THE REAR BRAKE CALI PER .......... ......... ......... ......... ...... 4-57
REMOVING THE REAR BRAKE MASTER CYLINDER ......... .......... ...... 4-58
CHECKING THE REAR BRAKE MASTER CYLINDER .. ......... .......... ..... 4-58
ASSEMBLING THE REAR BRAKE MASTER CYLINDER ....... ......... ...... 4-59
INSTALLING THE REAR BRAKE MASTER CYLINDER .......... ......... ..... 4-59

ABS (ANTI-LOCK BRAKE SYSTEM) .. ..... ......... .......... ........ .......... ......... ...... 4-60
REMOVING THE HYDRAULIC UNIT ASSEMBLY .......... ......... ......... ..... 4-63
CHECKING THE HYDRAULIC UNIT ASSEMBLY .......... ......... ......... ...... 4-63
INSTALLING THE HYDRAULIC UNIT ASSEMBLY ....... .......... ......... ...... 4-63
HYDRAULIC UNIT OPERATION TESTS ..... .......... ......... .......... .......... .... 4-65
CHECKING THE ABS WARNING LIGHT .... ......... .......... .......... .......... .... 4-68

HANDLEBAR ..... .......... ......... .......... ......... .......... ........ .......... ......... .......... ...... 4-69
ADJUSTING THE HANDLEBAR POSITION ......... ......... ......... ......... ....... 4-75
REMOVING THE HANDLEBAR .......... ......... .......... ......... ......... ......... ...... 4-75
CHECKING THE HANDLEBAR ......... .......... ........ .......... ......... .......... ...... 4-76
INSTALLING THE HANDLEBAR ........ ......... .......... ......... ......... .......... ..... 4-76
INSTALLING THE REARVIEW MIRRORS AND HANDGUARDS ... ....... 4-78

FRONT FORK ..... .......... ......... .......... ......... .......... ........ .......... ......... .......... ...... 4-80
REMOVING THE FRONT FORK LEGS ....... .......... ........ .......... ......... ...... 4-87
DISASSEMBLING THE FRONT FORK LEGS ...... ......... ........... ......... ..... 4-87
CHECKING THE FRONT FORK LEGS ........ .......... ........ .......... .......... .... 4-88
ASSEMBLING THE FRONT FORK LEGS ... ........ .......... ......... ......... ....... 4-89
INSTALLING THE FRONT FORK LEGS ... .......... ......... .......... .......... ...... 4-94
STEERING HEAD .......... ......... .......... ......... .......... ......... ......... ......... .......... ..... 4-96
REMOVING THE LOWER BRACKET .......... ........ .......... ......... .......... ...... 4-99
CHECKING THE STEERING HEAD .......... ......... .......... .......... ......... ....... 4-99
INSTALLING THE STEERING HEAD ....... .......... ......... ......... .......... ...... 4-100

REAR SHOCK ABSORBER ASSEMBLY ....... .......... ......... .......... ......... ..... 4-101
HANDLING THE REAR SHOCK ABSORBER ..... ......... .......... ......... ..... 4-105
DISPOSING OF A REAR SHOCK ABSORBER ... ......... ......... ......... ..... 4-105
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY .... ........ ..... 4-105
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY .... ......... .... 4-106
CHECKING THE CONNECTING ARM AND RELAY ARM .... .......... ..... 4-106
INSTALLING THE RELAY ARM ......... ........ .......... ......... ......... .......... ..... 4-106
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY .. ......... .... 4-107

SWINGARM ......... .......... ......... ......... .......... ......... ........ .......... ......... ......... ..... 4-108
REMOVING THE SWINGARM .......... ......... ......... ......... .......... ......... ...... 4-110
CHECKING THE SWINGARM .......... ........ .......... ......... ......... ......... ....... 4-110
INSTALLING THE SWINGARM ......... ........ ......... .......... ......... ......... ...... 4-111

CHAIN DRIVE ..... .......... ......... ......... .......... ........ ......... .......... ......... ......... .... .. 4-112
REMOVING THE DRIVE CHAIN ........ ........ .......... ......... ......... .......... ..... 4-114
CHECKING THE DRIVE CHAIN ........ ........ ......... .......... ......... ......... ...... 4-114
CHECKING THE DRIVE SPROCKET ....... ......... .......... ......... ......... ....... 4-115
CH ECKi NG THE REAR WHEEL SPROCKET ....... ........ .......... ......... .... 4-115
CHECKING THE REAR WHEEL DRIVE HUB ..... .......... ......... ......... ..... 4-115
INSTALLING THE DRIVE CHAIN ...... .......... ........ ......... .......... ......... ..... 4-115
ADJUSTING THE SHIFT PEDAL ........ ......... ........ .......... ......... ......... ..... 4-117
 GENERAL CHASSIS (1)

EAS20026

GENERAL CHASSIS (1)

Removing the seats and battery
.
..:, 2.2 N•m 0.22 k f•m , 1.6 lb·ft ,;-, 25 N•m (2.5 kgf•m, 18 lb·ft) ;,;, 32 N•m (3.2 kgf•m, 24 lb·ft)

- I
'
' ~ /
/,
1) \ ,/.·/

IA;:;_~ -~/
i·

Order Job/Parts to remove Q'ty Remarks

1 Passenger seat 1
2 Cap 1
3 Rider seat 1
4 Rider seat height position adjuster 1
5 Battery band 1
6 Negative battery lead 1 Disconnect.
7 Positive battery lead 1 Disconnect.
8 Battery 1
9 Spacer 1
10 Grab bar (left) 1
11 Grab bar (right) 1

4-1
 GENERAL CHASSIS (1)

Removing the rear side covers

~. 3.5 N•m (0.35 kgf•m, 2.6 lb·ft) ~ 35 N•m 3.5 k f•m, 26 lb·ft
0

t~ 13 N•m (1 .3 kgf•m, 9.6 lb·ft)

·",. 35 N•m 3.5 k f•m , 26 lb·ft

-~z. 35 N•m (3.5 kgf•m, 26 lb·ft)

10
'
··--J

'.,~ 35 N•m (3.5 kgf•m, 26 lb·ft)

$c 7 N•m (0.7 kgf•m, 5.2 lb·ft) $c . 3.5 N•m (0.35 kgf•m, 2.6 lb·ft)

Order Job/Parts to remove Q'ty Remarks

Passenger seat/Rider seat Refer to "GENERAL CHASSIS (1 )" on page

4-1 .
Refer to "GENERAL CHASSIS (1 )" on page
Grab bar 4-1 .
1 Top cover 1
2 Rear side cover (right) 1
3 Stay (right) 1
4 Plate (right) 1
5 Rider seat support (right) 1
6 Rider seat support (left) 1
7 Seat lock bracket 1
8 Seat lock assembly 1
9 Seat lock cable 1 Disconnect.
10 Rear side cover (left) 1
11 Stay (left) 1
12 Plate (left) 1

4-2
 GENERAL CHASSIS (1)

Removing the tail/brake light and mudguard assembly

·~.. 7 N•m 0.7 k f•m , 5.2 lb•ft
2
------------
~ ~/ =
' --- 1

"- ' ~®?" '

~ . t) /
3 4
6
r!li\~
12

~.} ~ki ~A,J'v /,0

\
9
, , _ ~ 7. ,A:\,,,
' =~~ ~= ~~

7
"'

Order Job/Parts to remove Q'ty Remarks

Refer to "GENERAL CHASSIS (1 )" on page
Passenger seat/Rider seat
4-1 .
Refer to "GENERAL CHASSIS (1 )" on page
Grab bar 4-1 .
Refer to "GENERAL CHASSIS (1 )" on page
Rear side cover 4-1 .
1 Tail/brake light coupler 1 Disconnect.
2 Tail/brake light 1
3 Owner's tool ki t band 1
4 Owner's tool ki t 1
5 Rear turn signal light coupler 2 Disconnect.
6 License plate light coupler 1 Disconnect.
7 Mudguard assembly 1
8 Lower tail cover 1
9 Stator coil coupler 1 Disconnect.
10 Rectifier/regulator coupler 1 Disconnect.
11 Rectifier/regulator 1
12 Tail/brake light cover 1

4-3
 GENERAL CHASSIS (1)

EAS31084

INSTALLING THE REAR SIDE COVER

The following procedure applies to both of the
rear side covers.
1. Install:
• Rear side covers b
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• Route the seat lock cable "1" through the hole
"a" in the stay (left) "2" as shown in the illustra-
tion . (left side)
eia~::=~=
~~ ~---=--=--=--=-
2--<~
7
• Insert the projection "b" on the rear side cover b. Insert the projection "c" on the front of the
"3" into the slot "c". rider seat into the seat holder "d".
C

' -
c. Align the projection "e" on the bottom of
the rider seat with the "H" position slot ''f',
and then push the rear of the seat down to
b lock it in place as shown .

EAS30125

INSTALLING THE SEATS

1. Install:
• Rider seat height position adjuster "1"
• Rider seat "2"
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
The rider seat height can be adjusted to one of
two positions to suit the rider's preference.
To install the rider seat in the low position
a. Insert the projection "a" on the rider seat
height position adjuster into the grommet
"b".

To install the rider seat in the high posi-

tion
a. Insert the projection "a" on the rider seat
height position adjuster into the grommet b
"b". -
- •~· -~~~-;;
---..i,~1~~! ~~~-_
-------~~~---:..=-===------ /
_,__
b. Insert the projection "c" on the front of the
rider seat into the seat holder "d".

4-4
 GENERAL CHASSIS (1)

c. A lign the projection "e" on the bottom of

the rider seat with the "L" position slot "f ',
and then push the rear of the seat down to
lock it in place as shown.

2. Install:
• Cap
• Passenger seat "1"
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Insert the parts "a" on the rear of the passenger
seat into the seat holders "b" and then push the
front of the seat down to lock it in place.

a - ,..,,-- ~,,,,,~-;)-""'
~~, . - 10

lOC'.. ) ;1'

4-5
 GENERAL CHASSIS (2)

EAS20155

GENERAL CHASSIS (2)

Removing the fuel tank front cover, front side panels and front side cowlings
~. 4.0 N•m 0.40 k f•m, 3.0 lb.ft r~J4.0 N•m (0.40 kgf•m, 3.0 lb·ft) I~
1 ~ t
it : I t
1
1 ~ 6 ,~ ~
___
,,----... ~~
_-, -------- ~

;-----
k-'-J~;
~~ - -----~
t----,,,-. . ;,z 4.0 N•m (0.40 kgf•m, 3.0 lb•ft)
0 i. ~- r
El
aI

'

s~ ~~.G
... cl
r----

~ /~,?.~
:> . -~ ~ _j
J 6 3
2

Order Job/Parts to remove Q'ty Remarks

1 Fuel tank front cover 1

2 Front side panel (left) 1
3 Turn signal/ position light coupler (left) 1 Disconnect.
4 Front side cowling (left) 1
5 Front side panel (right) 1
6 Turn signal/ position light coupler (right) 1 Disconnect.
7 Front side cowling (right) 1

4-6
 GENERAL CHASSIS (2)

Removing the headlight assembly and meter assembly

-------------------------~
''
10:
, ~, 7 N•m (0. 7 kgf•m, 5.2 lb·ft)

4 1.3N•m 0.13k f•m , 0.951b·ft

.i\ 0.5 N•m (0.05 kgf•m, 0.37 lb·ft)
1-----~~~~~~~~~~~~~~~~~~~~
"\ 7 N•m (0.7 kgf•m, 5.2 lb·ft) ' q-,,.._
9

3
~ (,--,--------------, ~.------------..:..
,;'" 1.3 N•m (0.13 kgf•m, 0.95 lb·ft) $... 2.8 N•m (0.28 kgf•m, 2.1 lb·ft)

Order Job/Parts to remove Q'ty Remarks

Fuel tank front cover/Front side panel/Front side Refer to "GENERAL CHASSIS (2)" on page
cowling 4-6.
1 Windshield 1
2 Front cover 1
3 Inner panel 1
4 Support stay 1
5 Auxiliary light coupler 1 Disconnect.
6 Headlight coupler 1 Disconnect.
7 Headlight assembly 1
8 Meter assembly coupler 1 Disconnect.
9 Meter assembly 1 MTT9K/MTT9KC
10 Meter assembly 1 MTT9GTK/MTT9GTKC
11 Meter assembly cover 1 MTT9GTK/MTT9GTKC
12 Auxiliary DC jack coupler 1 Disconnect.
13 Auxiliary DC jack 1

4-7
 GENERAL CHASSIS (2)

Disassembling the headlight assembly

~- 1.3 N•m 0.13 k f•m, 0.95 lb·ft

M 2 ~,. 1.3 N•m (0.13 kgf•m, 0.95 lb·ft)

- ,, ·~ - ~
lr...\\,,,- ----1'----.><-~--------= ~ ~

~
n '-- t .,,:::::::-,
· ::ii_

./4 ~ \ -S-..._"'- ~
~~QI ~ ~

4
I
I '\:
-1-x-~) ~
~~# JI I.
, ~-~•

./JJI,, ~ - ~ ------- ~~~x ~-

~ '11-1---''/I

..
- _,,-

. . ,,,,....
_>A
,, ,, ,,,, I I
.

~... 1.3 N•m (0.13 kgf•m, 0.95 lb·ft)

/.. 1.3 N•m (0.13 kgf•m, 0.95 lb·ft) 3

~... 1.3 N•m (0.13 kgf•m, 0.95 lb·ft)

Order Job/Parts to remove Q'ty Remarks

1 Headlight top cover (left) 1

2 Headlight top cover (right) 1
3 Headlight side cover (left) 1
4 Headlight side cover (ri ght) 1
5 Center cover 1
6 Front center cover 1

4-8
 GENERAL CHASSIS (2)

Removing the headlight stay

4 2

/_

\ '\i'I,
~ ;I~'<-__,, --->
J

-,-., 33 N•m (3.3 kgf•m, 24 lb·ft)

Order Job/Parts to remove Q'ty Remarks

Fuel tank front cover/Front side panel/Front side Refer to "GENERAL CHASSIS (2)" on page
cowling 4-6.
Refer to "GENERAL CHASSIS (2)" on page
Headlight assembly
4-6.
Refer to "GENERAL CHASSIS (2)" on page
Meter assembly
4-6.
1 Handlebar switch lead (left) 1
2 Handlebar switch lead (right) 1
3 Wire harness 2
4 Headlight stay 1

4-9
 GENERAL CHASSIS (2)

EAS31379

REMOVING THE FUEL TANK FRONT COVER JLJJ

1. Remove:
• Fuel tank front cover "1"
a. Remove the quick fasteners "2" and fuel
tank front cover bolts "3".

JLJJ
~--,) ...d~~~:~TV----:?'.:7;':'.:~~~-;-!f:,x;:,~
~;;:1101---~1-......._
EAS31381
--
REMOVING THE FRONT SIDE COWLINGS

~
The following procedure applies to both of the
3 )~ )'--1 front side cowlings.

~ -- ~
b. Remove the projections "a" on the fuel
1. Remove:
• Fuel tank front cover
• Front side panel
tank front cover "1" from the holes "b" in 2. Remove:
the front side cowling "2".
• Front side cowling "1"
a. Remove the front side cowling bolts "2"
~............-;:®
.YI ~ © and quick fastener "3".
·9

2
EAS31380

INSTALLING THE FUEL TANK FRONT

COVER
1. Install:
• Fuel tank front cover "1"
a. Fit the projections "a" on the fuel tank front
cover "1" from the holes "b" in the front
cowling "2".

~~8~CD~R c□1'1--1 I b. Disengage portion "a", and then remove

="'Y;~r...;9ir:::>,. Aie=:Cf.,·_,.1r-~--=
lt the front side cowling by sliding it in the di-

r,. ~ ¾~ ·
rection shown in the illustration.

b. Install the fuel tank front cover bolts "3"

and quick fasteners "4", and then tighten
the bolts to specification .

Fuel tank front cover bolt

4.0 N-m (0.40 kgf-m, 3.0 lb-ft)

4-10
 GENERAL CHASSIS (2)

(
EAS31382
2. Install:
INSTALLING THE FRONT SIDE COWLINGS • Front side panel
The following procedure applies to both of the • Fuel tank front cover
front side cowlings.
1. Install: EAS31398

• Front side cowling "1" REMOVING THE FRONT COVER

a. Insert the slot "a" into the projection "b", 1. Remove:
and then install the front side cowling as • W indshield
shown in the illustration . 2. Remove:
• Front cover "1"
a. Remove the front cover bolt "2".

b. Install the quick fastener "2" and front side

cowling bolts "3", and then tighten the
bolts to specification .
Front side cowling bolt
4.0 N-m (0.40 kgf-m, 3.0 lb-ft)
y .[ }:2L~~=---~i--
b. Move the front cover "1" to the highest po-
sition, remove the front cover bolt "3", and
then remove the cover.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
For information about adjusting the height of the
front cover, refer to "ADJ USTING THE W IND-
SHIELD HEI GHT' on page 4-12.

,,-,. <=) r'lc----:-..f'::=',

.. ?--..
~ =@<

EAS31399

INSTALLING THE FRONT COVER

1. Install:
• Front cover "1"

4-11
 GENERAL CHASSIS (2)

a. Install the front cover bolts "2". (temporari- a. Insert the projections "a" into the slots "b",
ly tighten) and then install the support stay "1" as
shown in the illustration.

b. Move the front cover "1" to the lowest po-

sition , and then install and tighten the front b. Install the support stay bolts, and then
cover bolt "3" to specification . tighten the bolts to specification.

Front cover bolt Support stay bolt

7 N•m (0.7 kgf•m, 5.2 lb-ft) 9 N•m (0.9 kgf•m, 6.6 lb•ft)

EAS31383

ADJUSTING THE WINDSHIELD HEIGHT

1. Adjust:
• W indshield height position
a. To change the position of the windshield,
lift up the windshield lock lever "1" and
slide the windshield "2" up or down . Re-
lease the lock lever when finished.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Make sure the w indshield and lock lever are
c. Move the front cover "1" to the highest po- properly secured before riding .
sition , and then tighten the front cover
bolts "2".

Front cover bolt

7 N•m (0.7 kgf•m, 5.2 lb-ft)

,.;;,J:-:--r,:;;r;'--1,~-::-~,.-( c::, 'fi.-...,...,,...,,.'\,I"\---_~==';,,

~® ~
1

.,

'./1;
2. Install :
• Windshield
EAS32701

INSTALLING THE SUPPORT STAY

1. Install:
• Support stay "1"

4-12
 GENERAL CHASSIS (3)

EAS20156

GENERAL CHASSIS (3)

Removing the fuel tank covers and fuel tank protector
~. 4.0 N•m 0.40 k f•m , 3.0 lb·ft

"t 4.0 N•m (0.40 kgf•m, 3.0 lb•ft)

Order Job/Parts to remove Q'ty Remarks

Refer to "GENERAL CHASSIS (1 )" on page
Passenger seat/Rider seat
4-1 .
Refer to "GENERAL CHASSIS (1 )" on page
Rider seat height position adjuster 4-1 .
Fuel tank front cover/Front side panel/Front side Refer to "GENERAL CHASSIS (2)" on page
cowling 4-6.
1 Fuel tank cover (left) 1
2 Fuel tank cover (right) 1
3 Fuel tank protector 1

4-13
 GENERAL CHASSIS (3)

Removing the electrical components tray (left) (MTT9K/MTT9KC)

'---

'

/:.,, 7 N•m 0.7 k f•m , 5.2 lb·ft

2

Order Job/Parts to remove Q'ty Remarks

Passenger seat/Rider seat Refer to "GENERAL CHASSIS (1 )" on page

4-1 .
Fuel tank front cover/Front side panel/Front side Refer to "GENERAL CHASSIS (2)" on page
cowling 4-6.

Fuel tank cover Refer to "GENERAL CHASSIS (3)" on page

4-13.
Fuel tank Refer to "FUEL TANK" on page 7-1.
1 Electrical components tray (left) 1
2 Handlebar switch lead (left) 1
3 Wire harness 1
4 Intake air temperature sensor 1

4-14
 GENERAL CHASSIS (3)

Removing the electrical components tray (left) (MTT9GTK/MTT9GTKC)

'--

'
4 7 N•m (0.7 kgf•m, 5.2 lb·ft)
3

Order Job/Parts to remove Q'ty Remarks

Passenger seat/Rider seat Refer to "GENERAL CHASSIS (1 )" on page

4-1 .
Fuel tank front cover/Front side panel/Front side Refer to "GENERAL CHASSIS (2)" on page
cowling 4-6.

Fuel tank cover Refer to "GENERAL CHASSIS (3)" on page

4-13.
Fuel tank Refer to "FUEL TANK" on page 7-1.
1 Electrical components tray (left) 1
2 Handlebar switch lead (left) 1
3 Clutch switch lead 1
4 Wire harness 1
5 Intake air temperature sensor 1

4-15
 GENERAL CHASSIS (3)

Removing the electrical components tray (right) (MTT9K/MTT9KC)

..:, 7 N•m (0. 7 kgf•m, 5.2 lb·ft)

~
~

1- 3
,/ , . . \ ,Y~-
'
{~v!\\,
I

r ~w; ~, ® _/
11 -/,,,,, I 1 -~

~
~~
2

~~ 7 N•m (0. 7 kgf•m, 5.2 lb·ft)

Order Job/Parts to remove Q 'ty Remarks

Passenger seat/Rider seat Refer to "GENERAL CHASSIS (1 )" on page

4-1 .
Fuel tank front cover/Front side panel/Front side Refer to "GENERAL CHASSIS (2)" on page
cowling 4-6.

Fuel tank cover Refer to "GENERAL CHASSIS (3)" on page

4-13.
Fuel tank Refer to "FUEL TANK" on page 7-1 .
1 Electrical components tray (right) 1
2 Handlebar switch lead (right) 1
3 Wire harness 1

4-16
 GENERAL CHASSIS (3)

Removing the electrical components tray (right) (MTT9GTK/MTT9GTKC)

l~. 7 N•m (0. 7 kgf•m, 5.2 lb·ft)

~~
,/ ,. . . \ ,Y/'"">,.-
'
r~v!\\ -
I

llr cw; ~,
'

~ @ _/

~ _,,,-->,,,,, I ~ 1 -~

~~~'~
'' 3
--~ 2

4
,,_ 7 N•m (0.7 kgf•m, 5.2 lb·ft)

Order Job/Parts to remove Q'ty Remarks

Passenger seat/Rider seat Refer to "GENERAL CHASSIS (1 )" on page

4-1 .
Fuel tank front cover/Front side panel/Front side Refer to "GENERAL CHASSIS (2)" on page
cowling 4-6.

Fuel tank cover Refer to "GENERAL CHASSIS (3)" on page

4-13.
Fuel tank Refer to "FUEL TANK" on page 7-1 .
1 Electrical components tray (right) 1
2 Handlebar switch lead (right) 1
3 Front brake light switch lead 1
4 Grip warmer lead 2
5 Wire harness 1

4-17
 GENERAL CHASSIS (3)

Removing the air filter case

2
4

"
~, 7 N•m 0.7 k f•m, 5.2 lb·ft
1

(3) ~
,I

•
1;, 1.6 N•m (0.16 kgf•m, 1.2 lb·ft)

~- 2.8 N•m (0.28 kgf•m, 2.1 lb•ft)

Order Job/Parts to remove Q'ty Remarks

Refer to "GENERAL CHASSIS (1 )" on page

Passenger seat/Rider seat
4-1 .
Fuel tank front cover/Front side panel/Front side Refer to "GENERAL CHASSIS (2)" on page
cowling 4-6.
Refer to "GENERAL CHASSIS (3)" on page
Fuel tank cover
4-13.
Fuel tank Refer to "FUEL TANK" on page 7-1.
1 ECU (Engine Control Unit) 1
2 ECU coupler 2 Disconnect.
3 Air filter case cover 1
4 Air filter element 1
5 Air filter case joint clamp screw 3 Loosen.
6 Air induction system hose 1 Disconnect.
7 Cylinder head breather hose 1 Disconnect.
8 Air filter case 1

4-18
 GENERAL CHASSIS (3)

EAS31384

REMOVING THE FUEL TANK COVERS

The following procedure applies to both of the
fuel tank covers.
1. Remove:
• Fuel tank front cover
• Front side panel
• Front side cowling
2. Remove:
• Passenger seat
• Rider seat
2. Install:
3. Remove:
• Rider seat
• Fuel tank cover "1"
• Passenger seat
a. Remove the fuel tank cover bolt "2"
3. Install:
b. Disengage portion "a", and then remove
• Front side cowling
the fuel tank cover by sliding it in the direc-
• Front side panel
tion shown in the illustration.
• Fuel tank front cover

EAS31385

INSTALLING THE FUEL TANK COVERS

The following procedure applies to both of the
fuel tank covers.
1. Install:
• Fuel tank cover "1"
a. Insert the slot "a" into the projection "b",
and then install the fuel tank cover as
shown in the illustration.

b. Install the fuel tank cover bolt "2", and then

tighten the bolt to specification.

Fuel tank cover bolt

4.0 N-m (0.40 kgf-m, 3.0 lb-ft)

4-19
 FRONT WHEEL

EAS20028

FRONT WHEEL
Removing the front wheel and brake discs

~,. 7 N•m (0.7 kgf•m, 5.2 lb·ft)

8
?-
- ,
n,_ 23 N•m (2.3 kgf•m, 17 lb•ft)
"''- 18 N•m (1 .8 kgf•m, 13 lb·ft)

9
p, ~
~~'11 ~ • < ---------

Ah,-.J!

7
~
~ - 18 N•m (1.8 kgf•m, 13 lb·ft)
9 a~ -
Order Job/Parts to remove Q'ty Remarks

1 Reflector 2
2 Front brake caliper 2
3 Front wheel sensor bracket 1
4 Front wheel sensor 1
5 Wheel axle pinch bolt 1 Loosen.
6 Wheel axle 1
7 Front wheel 1
8 Collar 2
9 Front brake disc 2

4-20
 FRONT WHEEL

Disassembling the front wheel

( I
I

3 mm
2

'
~ , 8 N•m (0.8 kgf•m, 5.9 lb·ft)

Order Job/Parts to remove Q'ty Remarks

1 Front wheel sensor rotor 1

2 Oil seal 2
3 Wheel bearing 2
4 Spacer 1

4-21
 FRONT WHEEL

EAS30145
• If any solvent gets on the wheel sensor ro-
REMOVING THE FRONT WHEEL
ECA21380
tor, wipe it off immediately.
NOTICE 1. Remove:
--------------
Keep magnets (including magnetic pick-up • Oil seals
tools, magnetic screwdrivers, etc.) away • Wheel bearings
from the front wheel sensor "1 " , otherwise a. Clean the surface of the front wheel hub.
the wheel sensor may be damaged, resulting b. Remove the oil seals "1" with a flat-head
in improper performance of the ABS. screwdriver.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
To prevent damaging the wheel, place a rag "2"
.~''
between the screwdriver and the wheel surface.

--
''
~m-'.---:::'"'-'',,....-- 1

- -- -~
-

1. Stand the vehicle on a level surface.

0
EWA13 120

& WARNING I
I
Securely support the vehicle so that there is
no danger of it falling over. c. Remove the wheel bearings "3" with a
general bearing puller.
2. Remove:
• Front brake caliper (left)
• Front brake caliper (right)
• Front wheel sensor
ECA21440

NOTICE
- - - - - - - - - - - - - -
• Do not apply the brake lever when remov-
ing the brake calipers.
• Be sure not to contact the sensor electrode
to any metal part when removing the front
wheel sensor from the sensor housing.
EAS301 47
3. Elevate: CHECKING THE FRONT WHEEL
• Front wheel 1. Check:
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ • W heel axle
Place the vehicle on a maintenance stand so Roll the wheel axle on a flat surface.
that the front wheel is elevated. Bends ➔ Replace.
EWA13460

4. Loosen: & WARNING

• Wheel axle pinch bolt Do not attempt to straighten a bent wheel ax-
5. Remove: le.
• Wheel axle
• Front wheel
EAS30146

DISASSEMBLING THE FRONT WHEEL

ECA21340

NOTICE
- - - - - - - - - - - - - -
• Do not drop the wheel sensor rotor or sub-
ject it to shocks.

4-22
 FRONT WHEEL

EAS30151

ASSEMBLING THE FRONT WHEEL

ECA21340

. . . . . . . .- --- - .- - - - - rv
II 111
NOTICE
- - - -
ject it to shocks.
- - - - - - - - -
• Do not drop the wheel sensor rotor or sub-

lO • If any solvent gets on the wheel sensor ro-

tor, wipe it off immediately.
1. Install:
• Wheel bearings 1;t4W
2. Check: • Oil seals 1;t4W
• Tire a. Install the new wheel bearing (right side).
ECA18110
• Front wheel
NOTICE
Damage/wear ➔ Replace. -------------
Do not contact the wheel bearing inner race
Refer to "CHECKING TH E TIRES" on page
3-16 and "CH ECKING THE WH EELS" on "1" or balls "2". Contact should be made
page 3-1 6. only with the outer race "3".
3. Measure: TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Radial wheel runout "1"
Use a socket "4" that matches the diameter of
• Lateral wheel runout "2"
the wheel bearing outer race.
Over the specified limits ➔ Replace.

Radial wheel runout limit

1.0 mm (0.04 in)
Lateral wheel runout limit
•
0.5 mm (0.02 in)

b. Install the spacer.

c. Install the new wheel bearing (left side).
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Place a suitable washer "1" between the socket
"2" and the bearing so that both the inner race
4. Check: "3" and outer race "4" are pressed at the same
• Wheel bearings time, and then press the bearing until the inner
Front wheel turns roughly or is loose ➔ Re- race makes contact with the spacer "5".
place the wheel bearings.
• Oil seals
Damage/wear ➔ Replace.
•
~==l:::::;::~ - - 1
. 3 -ld::1:H-- 4
I s
d. Install the new oil seals.

4-23
 FRONT WHEEL

2. Install : • Do not drop or shock the wheel sensor or

• Front wheel sensor rotor the wheel sensor rotor.

Wheel sensor rotor bolt 1. Check:

8 N-m (0.8 kgf-m, 5.9 lb-ft) • Front wheel sensor "1"
LOCTITE® Cracks/bends/distortion ➔ Replace.
Iron powder/d ust ➔ Clean.
ECA1 7200

NOTICE 1
- -------------
Rep Iace the wheel sensor rotor bolts with
new ones.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Install the wheel sensor rotor with the stamped
mark "1" facing outward.

3. Measure:
• Wheel sensor rotor runout
O ut of specification ➔ Correct the wheel sen-
sor rotor runout or replace the wheel sensor
rotor.
Refer to "MA INTENANC E OF THE FRONT
W HEEL SENSOR A ND SENSOR ROTOR"
on page 4-24.
2. Check:
• Front wheel sensor rotor "1"
Cracks/damage/scratches ➔ Replace the
front wheel sensor rotor.
Iron powder/dust/solvent ➔ Clean.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• The wheel sensor rotor is installed on the inner
side of the wheel hub.
• When cleaning the wheel sensor rotor, be
careful not to damage the surface of the sensor
rotor.
1

Wheel sensor rotor runout limit

0.25 mm (0.01 in)

EAS30155

MAINTENANCE OF THE FRONT WHEEL

SENSOR AND SENSOR ROTOR
ECA21070
NOTICE
--------------
• Handle the ABS components with care
since they have been accurately adjusted.
Keep them away from dirt and do not sub-
ject them to shocks.
• The front wheel sensor cannot be disas-
sembled. Do not attempt to disassemble it.
If faulty, replace with a new one.
• Keep any type of magnets (including mag-
netic pick-up tools, magnetic screwdrivers,
etc.) away from the front wheel sensor or
front wheel sensor rotor.
3. Measure:
• Wheel sensor rotor runout
Out of specification ➔ Clean the installation
surface of the wheel sensor rotor and correct
the wheel sensor rotor runout, or replace the
wheel sensor rotor.
Wheel sensor rotor runout limit
0.25 mm (0.01 in)
a. Hold the dial gauge at a right angle against
the wheel sensor rotor surface.
b. Measure the wheel sensor rotor runout.

4-24
 FRONT WHEEL

EAS30154

INSTALLING THE FRONT WHEEL (DISC

BRAKE)
1. Install:
• Front brake discs

Front brake disc bolt

18 N•m (1.8 kgf •m, 13 lb-ft)
LOCTITE®
ECA19150

NOTICE
-------------
Rep Iace the brake disc bolts with new ones.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Tighten the brake disc bolts in stages and in a
crisscross pattern .

/
c. If the runout is above specification, re-
move the sensor rotor from the wheel, ro-
tate it by two or three bolt holes, and then
install it.

Wheel sensor rotor bolt

8 N•m (0.8 kgf •m, 5.9 lb-ft) I
LOCTITE® 2. Check:
• Front brake discs
ECA17200
Refer to "CHECKING THE FRONT BRAKE
NOTICE
------------- DISCS" on page 4-41 .
RepIace the wheel sensor rotor bolts with 3. Lubricate:
new ones. • Oil seal lips
d. If the runout is still above specification , re-
place the wheel sensor rotor. Recommended lubricant
I Lithium-soap-based grease
EAS30152

ADJUSTING THE FRONT WHEEL STATIC 4. Install:

BALANCE • Collars
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ • Front wheel
• After replacing the tire, wheel or both , the front • Front wheel axle
wheel static balance should be adjusted. 5. Tighten:
• Adjust the front wheel static balance with the • Front wheel axle
brake disc installed. • Front wheel axle pinch bolt

1. Remove: Front wheel axle

• Balancing weight(s) 65 N•m (6.5 kgf •m, 48 lb-ft)
2. Find: Front wheel axle pinch bolt
• Front wheel's heavy spot 23 N•m (2.3 kgf •m, 17 lb-ft)
3. Adjust:
• Front wheel static balance
4. Check:
• Front wheel static balance

4-25
 FRONT WHEEL

ECA19760
vice and caught foreign materials) . If there is
NOTICE
------------- any defective part, repair or replace the de-
Before tightening the wheel axle, push down fective part.
hard on the handlebars several times and
check if the front fork rebounds smoothly. Distance "a" (between the front
wheel sensor rotor and front
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ wheel sensor)
Check that wheel axle end "a" is flush with front 1.0-1.8 mm (0.04-0.07 in)
folk surface "b" and then tighten the wheel axle
pinch bolt. If end "a" is not flush with surface "b", TIP _ _ _ _ _ _ _ _ _ _ _ _ __
align the ends manually or with a plastic ham- Measure the distance between the front wheel
mer. sensor rotor and front wheel sensor in several
places in one rotation of the front wheel. Do not
..,...,._ I- - - - JI turn the front wheel while the thickness gauge is
'
c;---1 '
installed. This may damage the front wheel sen-
'' '' b sor rotor and the front wheel sensor.

Thickness gauge
0 90890-03268
a Feeler gauge set
YU-26900-9

6. Install: \'
• Front wheel sensor '
• Front wheel sensor bracket

Front wheel sensor bolt

7 N-m (0.7 kgf•m, 5.2 lb-ft)
ECA21020

NOTICE
-------------
Make sure there are no foreign materials in
the front wheel sensor rotor and front wheel
sensor. Foreign materials cause damage to
the front wheel sensor rotor and front wheel
sensor.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
When install ing the front wheel sensor, check 1
the front wheel sensor lead for twists.
7. Measure:
• Distance "a"
(between the wheel sensor rotor "1" and front 8. Install:
wheel sensor "2") • Front brake calipers
O ut of specification ➔ Check the wheel bear-
Front brake caliper bolt
ing for looseness, and the front wheel sensor 35 N-m (3.5 kgf-m, 26 lb-ft)
and sensor rotor installation conditions
(warpage caused by overtorque, wrong in- EWA13500

stallation direction , rotor decentering , LOC- & WARNING

T IT E® on the mounting surface of the rotor, Make sure the brake hose is routed properly.
deformation caused by an impact during ser-

4-26
 REAR WHEEL

EAS20029

REAR WHEEL
Removing the rear wheel

r~l7 N•m (0.7 kgf•m, 5.2 lb·ft) I~ 1

. ,-; 150 N•m (15 kgf•m, 111 lb·ft)
. 2,G 10
/ '~ Q.

/' ' ~
0

9
/ /
\
0
/ '
(
( /
I

~. 16 N•m (1 .6 kgf•m, 12 lb·ft) .,i'.. 16 N•m (1 .6 kgf•m, 12 lb·ft)

Order Job/Parts to remove Q 'ty Remarks

Rear brake caliper Refer to "REAR BRAKE" on page 4-48.

1 Rear wheel sensor 1
2 Locknut 2 Loosen.
3 Adjusting bolt 2 Loosen.
4 Wheel axle nut 1
5 Washer 1
6 Wheel axle 1
7 Adjusting block (left) 1
8 Adjusting block (right) 1
9 Rear wheel 1
10 Brake caliper bracket 1

4-27
 REAR WHEEL

Removing the brake disc and rear wheel sprocket

"',, 30 N•m 3.0 k f•m , 22 lb·ft

~. 80 N•m (8.0 kgf•m, 59 lb·ft)

11 10
9
8

Order Job/Parts to remove Q'ty Remarks

1 Rear brake disc 1

2 Bracket 1
3 Rear wheel sprocket 1
4 Collar 1
5 Collar 1
6 Oil seal 1
7 Bearing 1
8 Rear wheel drive hub 1
9 Collar 1
10 Rear wheel drive hub damper 6
11 Rear wheel 1

4-28
 REAR WHEEL

Disassembling the rear wheel

a
5

¾. 8 N•m (0.8 kgf•m, 5.9 lb·ft)

( I 3

( /
I

Order Job/Parts to remove Q'ty Remarks

1 Rear wheel sensor rotor 1

2 Oil seal 1
3 Wheel bearing 1
4 Spacer 1
5 Wheel bearing 1

4-29
 REAR WHEEL

EAS30156

REMOVING THE REAR WHEEL

ECA21390

NOTICE
--------------
Keep magnets (including magnetic pick-up
tools, magnetic screwdrivers, etc.) away
from the rear wheel sensor "1" , otherwise
the wheel sensor may be damaged, resulting
in improper performance of the ABS.

4. Remove:
• Wheel axle nut "1"
0 0 • Washer
0
0 0 • Wheel axle "2"
00

:o ~',.~~~~ /=-:::::::::~ •
•
Rear wheel
Brake caliper bracket
0 ECA21400
0 0 0 0
0 00 0 Oo
NOTICE
\ - - - - - - - - - - - - - -
Be sure to remove the rear wheel sensor be-
fore removing the brake caliper bracket, oth-
1. Stand the vehicle on a level surface.
EWA13 120 erwise the sensor could be damaged.
A WARNING TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Securely support the vehicle so that there is
Push the rear wheel forward and remove the
no danger of it falling over.
drive chain from the rear wheel sprocket.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Place the vehicle on the centerstand so that the
rear wheel is elevated.
2. Remove:
• Rear brake caliper "1"
• Rear wheel sensor
ECA21040

NOTICE
- - - - - - - - - - - - - -
• Do not depress the brake pedal when re-
moving the brake caliper.
• Be sure not to contact the sensor electrode EAS30158

to any metal part when removing the rear DISASSEMBLING THE REAR WHEEL
ECA21340
wheel sensor from the rear brake caliper
NOTICE
bracket. --------------
• Do not drop the wheel sensor rotor or sub-
ject it to shocks.
• If any solvent gets on the wheel sensor ro-
tor, wipe it off immediately.
1. Remove:
• Oil seal
• Wheel bearings
Refer to "DISASSEM BLING T HE FRONT
W HEEL" on page 4-22.
EAS30159

CHECKING THE REAR WHEEL

3. Loosen:
1. Check:
• Locknuts "1"
• Wheel axle
• Adjusting bolts "2"
• Wheel bearings

4-30
 REAR WHEEL

• Oil seals
Refer to "CHECKING THE FRONT WHEEL"
on page 4-22. 1 a
2. Check:
• Tire
• Rear wheel
Damage/wear ➔ Replace.
Refer to "CHECKING THE TIRES" on page
2
3-16 and "CH ECKING THE WH EELS" on
page 3-16.
3. Measure:
b. Correct
• Radial wheel runout
1. Drive chain roller
• Lateral wheel runout
2. Rear wheel sprocket
Refer to "CH ECKING THE FRONT WHEEL"
on page 4-22. 2. Replace:
EAS30160
• Rear wheel sprocket
CHECKING THE REAR WHEEL DRIVE HUB a. Remove the rear wheel sprocket nuts and
1. Check: the rear wheel sprocket.
• Rear wheel drive hub "1" b. Clean the rear wheel drive hub with a
Cracks/damage ➔ Replace. clean cloth , especially the surfaces that
• Rear wheel drive hub dampers "2" contact the sprocket.
Damage/wear ➔ Replace. c. Install the new rear wheel sprocket.

2 Rear wheel sprocket nut

80 N•m (8.0 kgf •m, 59 lb-ft)

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Tighten the rear wheel sprocket nuts in stages
I ~a~ I and in a crisscross pattern .
I I

1 2 2

EAS30161

CHECKING AND REPLACING THE REAR

WHEEL SPROCKET
1. Check:
• Rear wheel sprocket
More than 1/4 tooth "a" wear ➔ Replace the
drive sprocket, the rear wheel sprocket and
the drive chain as a set.
EAS30163
Bent teeth ➔ Replace the drive sprocket, the
ASSEMBLING THE REAR WHEEL
rear wheel sprocket and the drive chain as a ECA21340

set. NOTICE
-------------
• Do not drop the wheel sensor rotor or sub-
ject it to shocks.
• If any solvent gets on the wheel sensor ro-
tor, wipe it off immediately.
1. Install:
• Wheel bearings •~M
• Oil seal •~M
Refer to "ASSEMBLING THE FRONT
WHEEL" on page 4-23 .

4-31
 REAR WHEEL

EAS30167

MAINTENANCE OF THE REAR WHEEL Rear brake disc bolt

SENSOR AND SENSOR ROTOR 30 N-m (3.0 kgf-m, 22 lb-ft)
ECA21060
LOCTITE®
NOTICE
- - - - - - - - - - - - -
• Handle the ABS components with care ECA19 150

NOTICE
since they have been accurately adjusted. -------------
Keep them away from dirt and do not sub- Rep Iace the brake disc bolts with new ones.
ject them to shocks. TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
• The rear wheel sensor cannot be disassem-
bled. Do not attempt to disassemble it. If Tighten the brake disc bolts in stages and in a
crisscross pattern .
faulty, replace with a new one.
• Keep any type of magnets (including mag-
netic pick-up tools, magnetic screwdrivers, /
etc.) away from the rear wheel sensor or
rear wheel sensor rotor.
• Do not drop or shock the wheel sensor or
the wheel sensor rotor.
1. Check:
• Rear wheel sensor
Refer to "MAINTENANCE OF THE FRONT
WHEEL SENSOR AND SENSOR ROTOR" I
on page 4-24. 2. Check:
2. Check: • Rear brake disc
• Rear wheel sensor rotor Refer to "CHECKING THE REAR BRAKE
Refer to "MAINTENANCE OF THE FRONT DISC" on page 4-54.
WHEEL SENSOR AND SENSOR ROTOR" 3. Lubricate:
on page 4-24. • Oil seal lips
3. Measure:
• Wheel sensor rotor runout Recommended lubricant
l Lithium-soap-based grease
Refer to "MAINTENANCE OF THE FRONT
WHEEL SENSOR AND SENSOR ROTOR"
on page 4-24. 4. Install:
• Collars
EAS30164
• Brake caliper bracket
ADJUSTING THE REAR WHEEL STATIC • Rear wheel
BALANCE • Adjusting blocks
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ • Wheel axle
• After replacing the tire, wheel or both , the rear • Washer
wheel static balance should be adjusted. • Wheel axle nut
• Adjust the rear wheel static balance with the TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
brake disc and rear wheel drive hub installed.
• Do not install the brake caliper.
1. Adjust: • Align the projection "a" in the swingarm with the
• Rear wheel static balance slot "b" of the brake caliper bracket.
Refer to "ADJUSTING THE FRONT WHEEL • Install the adjusting block so that projection "c"
STATIC BALANCE" on page 4-25. faces to the front of the vehicle.

EAS30165

INSTALLING THE REAR WHEEL (DISC

BRAKE)
1. Install:
• Rear brake disc

4-32
 REAR WHEEL

TIP _ _ _ _ _ _ _ _ _ _ _ _ __
When tightening the wheel axle nut, there
should be no clearance "a" between the adjust-
ing block "1" and adjusting bolt "2".

8. Install:
• Rear wheel sensor

Rear wheel sensor bolt

7 N-m (0.7 kgf-m, 5.2 lb-ft)
ECA21080
A. Left side NOTICE
B. Right side --------------
Make sure there are no foreign materials in
5. Install : the rear wheel sensor rotor and rear wheel
• Rear brake caliper sensor. Foreign materials cause damage to
• Rear brake caliper bolts the rear wheel sensor rotor and rear wheel
6. Adjust: sensor.
• Drive chain slack TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Refer to "DRIV E CHAIN SLACK" on page
3-1 8. When installing the rear wheel sensor, check the
rear wheel sensor lead for twists.
Drive chain slack (Maintenance 9. Measure:
stand)
• Distance "a"
35.0-45.0 mm (1.38-1.77 in)
(between the wheel sensor rotor "1" and rear
7. Tighten: wheel sensor "2")
• Wheel axle nut Out of specification ➔ Check the wheel bear-
• Rear brake caliper bolts ing for looseness, and the rear wheel sensor
and sensor rotor installation conditions
Rear wheel axle nut (warpage caused by overtorque, wrong in-
150 N-m (15 kgf-m, 111 lb-ft) stallation direction, rotor decentering, LOC-
Rear brake caliper bolt (front) T IT E® on the mounting surface of the rotor,
27 N-m (2. 7 kgf-m, 20 lb-ft) deformation caused by an impact during ser-
Rear brake caliper bolt (rear) vice and caught foreign materials) . If there is
22 N-m (2.2 kgf-m, 16 lb-ft) any defective part, repair or replace the de-
LOCTITE® fective part.
EWA13500

AwARNING
Distance "a" (between the rear
wheel sensor rotor and rear
Make sure the brake hose is routed properly. wheel sensor)
0.7-1.4 mm (0.03-0.05 in)

4-33
 REAR WHEEL

TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Measure the distance between the rear wheel
sensor rotor and rear wheel sensor in several
places in one rotation of the rear wheel. Do not
turn the rear wheel while the thickness gauge is
installed. This may damage the rear wheel sen-
sor rotor and the rear wheel sensor.

Thickness gauge
90890-03268
Feeler gauge set
YU-26900-9

--' :5:1!!::.. ' . I

-
'
I
I•
I
I• '- _r

--- a
1
~

--1~- - ~
2
"
"I'
1 - --- -
L.---

II I
:I -
l
✓

~
__,,
-=>
- I
( .l
I=
------------------------------· ~ -- --

.,-- --
------------------------------- I=

( °1, I
~
L -7
--
_./

4-34
 FRONT BRAKE

EAS20030

FRONT BRAKE
Removing the front brake pads
I

~," 5 N•m (0.5 kgf•m, 3.7 lb·ft)

,. ~- 35 N•m (3.5 kgf•m, 26 lb•ft)

Order Job/Parts to remove Q 'ty Remarks

The following procedure applies to both of

the front brake calipers.
1 Brake pad clip 2
2 Brake pad pin 1
3 Brake pad spring 1
4 Brake pad 2
5 Reflector 1
6 Front brake caliper 1
7 Bleed screw 1
8 Bleed screw 1 Right brake caliper side.

4-35
 FRONT BRAKE

Removing the front brake master cylinder (MTT9K/MTT9KC)

I.;, 1.0 N•m 0.10 k f•m, 0.73 lb·ft

"'\ 1.5 N•m (0.15 kgf•m, 1.1 lb·ft)

,~ 10 N•m 1.0 k f•m, 7.4 lb·ft

.,,-"- 17 N•m (1. 7 kgf•m, 13 lb•ft)

12
/
~- 23 N•m (2.3 kgf•m, 17 lb·ft) / - ~
/

/' 3 ,

4 >t
,), Q~o ,1 /' '
6

\ '
C ~- 0 \ ~ 8
\~ '
7
1
10 •~M\\
f.j/
2
£!~

-~ - 6 N•m (0.6 kgf•m, 4.4 lb·ft) .;t.. 1.2 N•m (0.12 kgf•m, 0.88 lb·ft)
11

-.i,_ 30 N•m 3.0 k f•m, 22 lb·ft

Order Job/Parts to remove Q'ty Remarks

Refer to "GENERAL CHASSIS (2)" on page
Windshield 4-6.
Drain.
Brake fluid Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)" on page 3-15,
1 Rearview mirror 1
2 Handguard 1
3 Brake master cylinder reservoir cap 1
Brake master cylinder reservoir diaphragm hold-
4 1
er
5 Brake master cylinder reservoir diaphragm 1
6 Brake lever 1
7 Front brake light switch lead connector 2 Disconnect.
8 Front brake light switch 1
9 Brake hose union bolt 1
10 Brake hose gasket 2
11 Brake hose 1
12 Front brake master cylinder holder 1
13 Front brake master cylinder 1

4-36
 FRONT BRAKE

Removing the front brake master cylinder (MTT9GTK/MTT9GTKC)

~;. 1.0N•m 0.10k f•m , 0.731b·ft

,-,--------- --~ 1.5 N•m (0.15 kgf•m, 1.1 lb·ft)

I ............... .•

-.._____ •:.. 10 N•m 1.0 k f•m , 7.4 lb·ft

-----.::::::::: ,
-";_, 17 N•m (1.7 kgf•m, 13 lb·ft)
~
;,;, 23 N•m 2.3 k f•m, 17 Ib·ft ~<::::::::~ :;i

/,/
, I
11

,
)U
, ,<

'~, 1.2 N•m (0.12 kgf•m, 0.88 lb•ft)

..--.,_ 6 N•m (0.6 kgf•m, 4.4 lb·ft)
10

•
,.,, 30 N•m 3.0 k f•m, 22 lb·ft

Order Job/Parts to remove Q'ty Remarks

Refer to "GENERAL CHASSIS (2)" on page
Windshield 4-6.
Drain.
Brake fluid Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)" on page 3-15.
1 Rearview mirror 1
2 Handguard 1
3 Brake master cylinder reservoir cap 1

4 Brake master cylinder reservoir diaphragm hold-

er 1

5 Brake master cylinder reservoir diaphragm 1

6 Brake lever 1
7 Front brake light switch 1
8 Brake hose union bolt 1
9 Brake hose gasket 2
10 Brake hose 1
11 Front brake master cylinder holder 1
12 Front brake master cylinder 1

4-37
 FRONT BRAKE

Disassembling the front brake master cylinder

1 mm

Order Job/Parts to remove Q 'ty Remarks

1 Brake master cylinder ki t 1

2 Brake master cylinder body 1

4-38
 FRONT BRAKE

Removing the front brake calipers

/;. 35 N•m (3.5 kgf•m, 26 lb·ft)

3
6

~ . 30 N•m 3.0 k f•m, 22 lb•ft

Order Job/Parts to remove Q'ty Remarks

The following procedure applies to both of
the front brake calipers.
Drain.
Brake fluid Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)" on page 3-15.
1 Brake hose union bolt 1
2 Brake hose gasket 1
3 Brake hose 2
4 Brake hose gasket 2
5 Reflector 1
6 Front brake caliper 1

4-39
 FRONT BRAKE

Disassembling the front brake calipers

~- 5 N•m (0.5 kgf•m, 3.7 lb·ft)

2 1 mm6
mm
6
5

e
7 6

mm ~ 5 mm
e mm
7
6mm
Order Job/Parts to remove Q'ty Remarks
The following procedure applies to both of
the front brake calipers.
1 Brake pad clip 2
2 Brake pad pin 1
3 Brake pad spring 1
4 Brake pad 2
5 Brake caliper piston 4
6 Brake caliper piston dust seal 4
7 Brake caliper piston seal 4
8 Bleed screw 1
9 Bleed screw 1 Right brake caliper side.

4-40
 FRONT BRAKE

EAS30168
e. Measure the runout 1.5 mm (0.06 in) be-
INTRODUCTION
EWA14 10 1
low the edge of the brake disc.
AwARNING
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-
4. Measure:
sembly.
• Brake disc thickness
• Never use solvents on internal brake com-
Measure the brake disc thickness at a few dif-
ponents.
ferent locations.
• Use only clean or new brake fluid for clean-
Out of specification ➔ Replace.
ing brake components.
• Brake fluid may damage painted surfaces Brake disc thickness limit
and plastic parts. Therefore, always clean 4.0 mm (0.16 in)
up any spilt brake fluid immediately.
• Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get im-
mediate medical attention.

EAS30169

CHECKING THE FRONT BRAKE DISCS

The following procedure applies to both brake
discs.
5. Adjust:
1. Remove:
• Brake disc runout
• Front wheel a. Remove the brake disc.
Refer to "FRONT WHEEL" on page 4-20.
b. Rotate the brake disc by one bolt hole.
2. Check: c. Install the brake disc.
• Front brake disc
Damage/galling ➔ Replace. Front brake disc bolt
3. Measure: 18 N-m (1.8 kgf-m, 13 lb-ft)
• Brake disc runout LOCTITE®
Out of specification ➔ Correct the brake disc
ECA19150
runout or replace the brake disc.
NOTICE
-------------
Brake disc runout limit (as mea- Rep Iace the brake disc bolts with new ones.
sured on wheel)
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
0.1 O mm (0.0039 in)
Tighten the brake disc bolts in stages and in a
a. Place the vehicle on a maintenance stand crisscross pattern .
so that the front wheel is elevated.
b. Before measuring the brake disc runout,
turn the handlebar to the left or right to en-
sure 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.

4-41
 FRONT BRAKE

d. Measure the brake disc runout. 3. Measure:

e. If out of specification, repeat the adjust- • Brake pad lining thickness limit "a"
ment steps until the brake disc runout is Out of specification ➔ Replace the brake
within specification. pads as a set.
f. If the brake disc runout cannot be brought
within specification , replace the brake Brake pad lining thickness limit
disc. 0.5 mm (0.02 in)
6. Install:
• Front wheel
Refer to "FRONT WHEEL" on page 4-20.
EAS30170

REPLACING THE FRONT BRAKE PADS a

The following procedure applies to both brake I II I
calipers. LI I J
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disassem-
ble the brake caliper. 4. Remove:
• Brake caliper bolts
1. Remove:
5. Install:
• Brake pad clips "1"
• Brake pads
• Brake pad pin "2"
• Brake pad spring
• Brake pad spring "3"
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
o~~ Always install new brake pads and new brake
pad spring as a set.
a. Connect a clear plastic hose "1" tightly to
the bleed screw "2". Put the other end of
the hose into an open container.
b. Loosen the bleed screw and push the
2 1 brake caliper pistons into the brake caliper
with your finger.

2. Remove:
• Brake pads "1"

c. Tighten the bleed screw.

4-42
 FRONT BRAKE

EAS30724

Brake caliper bleed screw REMOVING THE FRONT BRAKE CALIPERS

5 N•m (0.5 kgf•m, 3.7 lb-ft)
d. Install the brake pads and brake pad
spnng.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
The arrow mark "a" on the brake pad spring
must point in the direction of disc rotation.
The following procedure applies to both of the
brake calipers.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Before removing the brake caliper, drain the
brake fluid from the entire brake system.
1. Remove:
• Brake hose union bolts "1"
• Brake hose gaskets "2"
• Brake hoses "3"
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Put the end of the brake hose into a container
and pump out the brake fluid carefully.

6. Install: ~~+JA-.\- 1
• Brake pad pin
•
•
Brake pad clips
Front brake caliper I()
,2
Front brake caliper bolt
35 N•m (3.5 kgf•m, 26 lb-ft)
-
\ ' -3
7. Check:
• Brake fluid level
Below the minimum level mark "a" ➔ Add the
specified brake fluid to the proper level.
Refer to "CHECKING THE BRAKE FLU ID
LEVEL" on page 3-13.

EAS30t72

~?~~~;;~~ DISASSEMBLING THE FRONT BRAKE

CALIPERS
The following procedure applies to both of the
brake calipers.
'.:.-:'..--:.~~~~~\t,IV--L-\---:::::,, 1. Remove:

~ a • Brake caliper pistons "1"

• Brake caliper piston dust seals "2"
8. Check: • Brake caliper piston seals "3"
• Brake lever operation
Soft or spongy feeling ➔ Bleed the brake sys-
tem.
Refer to "BLEEDING TH E HYDRAULIC
BRAKE SYSTEM (ABS)" on page 3-15.

4-43
 FRONT BRAKE

1 • Brake caliper cylinders "2"

1
Scratches/wear ➔ Replace the brake caliper
0 0 0 0 assembly.
• Brake caliper body "3"
Cracks/damage ➔ Replace the brake caliper
assembly.
• Brake fluid delivery passages
(brake caliper body)
Obstruction ➔ Blow out with compressed air.
3 3 EWA13611

a. Secure the right side brake caliper pistons & WARNING

with a piece of wood "a".
b. Blow compressed air into the brake hose
joint opening "b" to force out the left side
pistons from the brake caliper.
EWA17060
Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seals
and brake caliper piston seals.

& WARNING 3
• Never try to pry out the brake caliper pis-
tons.
• Do not loosen the bolts "4".

0 0
4

EAS30174

ASSEMBLING THE FRONT BRAKE

CALIPERS
EWA16560
a b
& WARNING
• Before installation, all internal brake com-
c. Remove the brake caliper piston dust ponents should be cleaned and lubricated
seals and brake caliper piston seals. with clean or new brake fluid.
d. Repeat the previous steps to force out the • Never use solvents on internal brake com-
right side pistons from the brake caliper. ponents as they will cause the brake caliper
piston dust seals and brake caliper piston
EAS30173
seals to swell and distort.
CHECKING THE FRONT BRAKE CALIPERS
• Whenever a brake caliper is disassembled,
The following procedure applies to both of the
replace the brake caliper piston dust seals
brake calipers.
and brake caliper piston seals.
Recommended brake component
replacement schedule
Specified brake fluid
Brake pads If necessary DOT4
Piston seals Every two years
EAS30175
Piston dust seals Every two years INSTALLING THE FRONT BRAKE CALIPERS
Brake hoses Every four years The following procedure applies to both of the
Every two years and brake calipers.
Brake fluid whenever the brake is 1. Install:
disassembled • Front brake caliper "1"
(temporarily)
1. Check:
• Brake caliper pistons "1"
• Brake hose gaskets i§M
RusVscratches/wear ➔ Replace the brake • Brake hoses "2"
caliper pistons. • Brake hose union bolts "3"

4-44
 FRONT BRAKE

4. Fill :
Front brake hose union bolt • Brake master cylinder reservoir
30 N•m (3.0 kgf•m, 22 lb-ft) (with the specified amount of the specified
EWA13531
brake fluid)
& WARNING
~
Specified brake fluid
Proper brake hose routing is essential to in- DOT4
sure safe vehicle operation.
EWA13090
ECA21410

NOTICE & WARNING

- - - - - - - - - - - - -
• When installing the brake hose onto the
brake caliper "1 ", make sure the brake pipe
"a" touches the projection "b" on the brake
caliper.
• Install the brake pipe "c" so that it is
aligned with the brake pipe "a".
2 _./_~~
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does

t1i~ ,~,b not enter the brake fluid reservoir. Water

will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
a \O 3 ECA13540

NOTICE
I() -------------
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
5. Bleed :
• Brake system
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)" on page 3-15.
\ a 6. Check:
b • Brake fluid level
Below the minimum level mark "a" ➔ Add the
specified brake fluid to the proper level.
1 Refer to "CHECKING THE BRAKE FLUID
2. Remove: LEVEL" on page 3-13.
• Front brake caliper
3. Install:
• Brake pads
• Brake pad spring
• Brake pad pin
• Brake pad clips
• Front brake caliper

Front brake caliper bolt

35 N•m (3.5 kgf•m, 26 lb-ft)
7. Check:
Refer to "REPLACING THE FRONT BRAKE • Brake lever operation
PADS" on page 4-42. Soft or spongy feel i ng ➔ Bleed the brake sys-
tem .
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)" on page 3-15.

4-45
 FRONT BRAKE

EAS30179

REMOVING THE FRONT BRAKE MASTER

CYLINDER
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Before removing the front brake master cylinder, 2
drain the brake fluid from the entire brake sys-
tem .
1. Remove:
• Handguard
2. Disconnect:
• Brake light switch connectors (MTT9K/ 4. Check:
MTT9KC) • Brake hoses
(from the front brake light switch) Cracks/damage/wear ➔ Replace.
3. Remove: EAS30181

• Brake hose union bolt "1" ASSEMBLING THE FRONT BRAKE MASTER
• Brake hose gaskets "2" CYLINDER
EWA13520
• Brake hose "3"
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ £ WARNING
• Before installation, all internal brake com-
To collect any remaining brake fluid, place a
ponents should be cleaned and lubricated
container under the master cylinder and the end
with clean or new brake fluid.
of the brake hose.
• Never use solvents on internal brake com-
ponents.
1
Specified brake fluid
DOT4

EAS30182

INSTALLING THE FRONT BRAKE MASTER

CYLINDER
1. Install:
• Front brake master cylinder
EAS30725
• Front brake master cylinder holder "1"
CHECKING THE FRONT BRAKE MASTER
CYLINDER Front brake master cylinder hold-
1. Check: er bolt
10 N-m (1.0 kgf-m, 7.4 lb-ft)
• Brake master cylinder
Damage/scratches/wear ➔ Replace. TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Brake fluid delivery passages
(brake master cylinder body) • Install the front brake master cylinder holder
Obstruction ➔ Blow out with compressed air. with the "UP" mark "a" facing up.
2. Check: • Align the end of the front brake master cylinder
• Brake master cylinder kit holder with the punch mark "b" on the handle-
Damage/scratches/wear ➔ Replace. bar.
3. Check: • First, tighten the upper bolt, then the lower bolt.
• Brake master cylinder reservoir "1" • There should be more than 11 mm (0.43 in) for
• Brake master cylinder reservoir diaphragm clearance between the handlebar switch (right)
holder "2" and the front brake master cylinder holder. A l-
Cracks/damage ➔ Replace. so, the punch mark should be seen.
• Brake master cylinder reservoir diaphragm
"3"
Damage/wear ➔ Replace.

4-46
 FRONT BRAKE

EWA13540

& WARNING
-::::::::.Jo • Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
b may result in a harmful chemical reaction,
a leading to poor brake performance.
• When refilling, be careful that water does
2. Install :
not enter the brake master cylinder reser-
• Brake hose gaskets 1§t411 voir. Water will significantly lower the boil-
• Brake hose ing point of the brake fluid and could cause
• Brake hose union bolt vapor lock.
ECA13540
Front brake hose union bolt
NOTICE
30 N-m (3.0 kgf-m, 22 lb-ft) -------------
Brake fluid may damage painted surfaces
EWA13531
and plastic parts. Therefore, always clean up
& WARNING any spilt brake fluid immediately.
Proper brake hose routing is essential to in-
5. Bleed :
sure safe vehicle operation.
• Brake system
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ Refer to "BLEEDING THE HYDRAULIC
• Attach the brake hose so that its angle is 20° to BRAKE SYSTEM (A BS)" on page 3- 15.
30° against the straight line in parallel w ith the 6. Check:
ceiling plane of the master cylinder. • Brake fluid level
• While holding the brake hose, tighten the union Below the minimum level mark "a" ➔ Add the
bolt as shown . specified brake fluid to the proper level.
• Turn the handlebar to the left and right to make Refer to "C HECKING THE BRAKE FLUID
sure the brake hose does not touch other parts LEVEL" on page 3-13.
(e.g., wire harness, cables, leads) . Correct if
necessary.

-9--\~\~~;:i::::~~;~JJJ

::.-:-~-=_--,_~¼:----,.¥,>VJ--l- \---=-.:::-
~ a
7. Check:
• Brake lever operation
Soft or spongy feel i ng ➔ Bleed the brake sys-
3. Install : tem .
• Handguard Refer to "BLEEDING THE HYDRAULIC
Refer to "HANDLEBAR" on page 4-69. BRAKE SYSTEM (A BS)" on page 3 -1 5.
4. Fill :
• Brake master cylinder reservoir
(with the specified amount of the specified
brake fluid)

Specified brake fluid

DOT4

4-47
 REAR BRAKE

EAS20031

REAR BRAKE
Removing the rear brake pads

>;, 5 N•m 0.5 k f•m, 3.7 lb·ft

,~" 27 N•m 2. 7 k f•m, 20 lb·ft

I
,,,- 3

-~'1
!'~ -- ',
'J

8 ,...-~ -....:,::~

7
6

2 1
5
~,. 17 N•m (1. 7 kgf•m, 13 lb•ft)

4 ·~, 2.5 N•m (0.25 kgf•m, 1.8 lb·ft)

5

Order Job/Parts to remove Q 'ty Remarks

1 Screw plug 1
2 Brake pad retaining bolt 1
3 Rear brake caliper 1
4 Brake pad 2
5 Brake pad shim 2
6 Brake pad insulator 2
7 Brake pad spring 1
8 Bleed screw 1

4-48
 REAR BRAKE

Removing the rear brake master cylinder

5 fi)/,

"'·· 110 N•m 11 k f•m, 81 lb·ft

"
-'> . 55 N•m 5.5 k f•m, 41 lb·ft
,~ 23 N•m 2.3 k f•m, 17 lb·ft

Order Job/Parts to remove Q'ty Remarks

Fuel tank front cover/Front side panel/Front side Refer to "GENERAL CHASSIS (2)" on page
cowling 4-6.
Refer to "GENERAL CHASSIS (1 )" on page
Passenger seat/Rider seat
4-1 .
Refer to "GENERAL CHASSIS (3)" on page
Fuel tank cover
4-13.
Fuel tank Refer to "FUEL TANK" on page 7-1 .
Drain.
Brake fluid Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)" on page 3-15.
1 Brake fluid reservoir cap 1
2 Brake fluid reservoir diaphragm holder 1
3 Brake fluid reservoir diaphragm 1
4 Brake fluid reservoir 1
5 Brake fluid reservoir holder 1
6 Brake fluid reservoir hose 1

4-49
 REAR BRAKE

Removing the rear brake master cylinder

10- ""7\l"O~
fi)/,
I
I
------ I\

"'·· 110 N•m 11 k f•m, 81 lb·ft

13

"
-'> . 55 N•m 5.5 k f•m, 41 lb·ft
,~ 23 N•m 2.3 k f•m, 17 lb·ft

Order Job/Parts to remove Q'ty Remarks

7 Brake hose union bolt 1
8 Brake hose gasket 2
9 Brake hose 1
10 Rear brake light switch coupler 1 Disconnect.
11 Footrest assembly (right) 1
12 Brake pedal 1
13 Rear brake master cylinder assembly 1
14 Rear brake light switch 1

4-50
 REAR BRAKE

Disassembling the rear brake master cylinder

5
2
mm
e ~
e
_t----------1,

mm '------\'□

4
3 mm e ~, 18 N•m (1.8 kgf•m, 13 lb·ft)

Order Job/Parts to remove Q'ty Remarks

1 Brake master cylinder yoke 1

2 Brake master cylinder ki t 1
3 Hose joint 1
4 Bushing 1
5 Brake master cylinder body 1

4-51
 REAR BRAKE

Removing the rear brake caliper

'
~ . 30 N•m (3.0 kgf•m, 22 lb·ft)

I 1

~ - 22 N•m (2.2 kgf•m, 16 lb·ft)

~, 27 N•m (2.7 kgf•m, 20 lb•ft)

Order Job/Parts to remove Q 'ty Remarks

Drain.
Brake fluid Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)" on page 3-15.
1 Brake hose union bolt 1
2 Brake hose gasket 2
3 Brake hose 1
4 Rear brake caliper 1

4-52
 REAR BRAKE

Disassembling the rear brake caliper

,;;. 5 N•m (0.5 kgf•m, 3.7 lb·ft)

8
mm 9
mm
6

t. 17N•m 1.7k f•m,131b·ft

1
~•. 2.5 N•m (0.25 kgf•m, 1.8 lb·ft)
4

3
4

Order Job/Parts to remove Q'ty Remarks

1 Screw plug 1
2 Brake pad retaining bolt 1
3 Brake pad 2
4 Brake pad shim 2
5 Brake pad insulator 2
6 Brake pad spring 1
7 Brake caliper piston 1
8 Brake caliper piston dust seal 1
9 Brake caliper piston seal 1
10 Bleed screw 1

4-53
 REAR BRAKE

EAS30183

INTRODUCTION Brake disc thickness limit

EWA14 101
4.5 mm (0.18 in)
AwARNING
Disc brake components rarely require disas- 5. Adjust:
sembly. Therefore, always follow these pre- • Brake disc runout
ventive measures: Refer to "C HECKING THE FRONT BRAKE
• Never disassemble brake components un- DISCS" on page 4-41.
less absolutely necessary.
• If any connection on the hydraulic brake Rear brake disc bolt
system is disconnected, the entire brake 30 N-m (3.0 kgf-m, 22 lb-ft)
system must be disassembled, drained, LOCTITE®
cleaned, properly filled, and bled after reas-
6. Install:
sembly.
• Rear wheel
• Never use solvents on internal brake com-
Refer to "REAR WHEEL" on page 4-27.
ponents.
• Use only clean or new brake fluid for clean- EAS30185

ing brake components. REPLACING THE REAR BRAKE PADS

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

Brake pad lining thickness limit

EAS30184

CHECKING THE REAR BRAKE DISC 1.0 mm (0.04 in)

1. Remove:
• Rear wheel
Refer to "REAR WHEEL" on page 4-27.
2. Check: a
• Rear brake disc
Damage/galling ➔ Replace. II
3. Measure: I I 11 11 11 11 II I

• Brake disc runout

Out of specification ➔ Correct the brake disc
runout or replace the brake disc.
Refer to "CHECKING THE FRONT BRAKE
2. Install:
DISCS" on page 4-41.
• Brake pad insulators
Brake disc runout limit (as mea- • Brake pad shims
sured on wheel) (onto the brake pads)
0.15 mm (0.0059 in) • Brake pad spring
(into the rear brake caliper)
4. Measure: • Brake pads
• Brake disc thickness TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Measure the brake disc thickness at a few dif- Always install new brake pads, brake pad insu-
ferent locations. lators, brake pad shims, and brake pad spring as
O ut of specification ➔ Replace. a set.
Refer to "CHECKING THE FRONT BRAKE
DISCS" on page 4-41.

4-54
 REAR BRAKE

ECA14150
a. Connect a clear plastic hose "1" tightly to
NOTICE
the bleed screw "2". Put the other end of - - - - - - - - - - - - -
the hose into an open container. • Do not allow grease to contact the brake
b. Loosen the bleed screw and push the pads.
brake caliper piston into the brake caliper • Remove any excess grease.
with your finger. 4. Install:
• Rear brake caliper
• Brake pad retaining bolts
• Screw plug

Rear brake caliper bolt (front)

27 N•m (2.7 kgf-m, 20 lb-ft)
Rear brake caliper bolt (rear)
22 N•m (2.2 kgf-m, 16 lb-ft)
LOCTITE®
Rear brake pad retaining bolt
c. T ighten the bleed screw. 17 N•m (1.7 kgf-m, 13 lb-ft)
Rear brake caliper screw plug
Brake caliper bleed screw 2.5 N•m (0.25 kgf•m, 1.8 lb-ft)
5 N•m (0.5 kgf•m, 3.7 lb-ft)
5. Check:
d. Install the brake pad insulators and brake • Brake fluid level
pad shims onto each brake pads. Below the minimum level mark "a" ➔ Add the
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ specified brake fluid to the proper level.
Refer to "C HECKING THE BRAKE FLUID
Apply silicone grease between the brake pad in-
LEVEL" on page 3-13.
sulator and brake pad shim.
ECA14 150

NOTICE
-------------
• Do not allow grease to contact the brake
pads.
• Remove any excess grease.
e. Install the brake pads and brake pad
spnng.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
The longer tangs "a" of the brake pad spring 6. Check:
must point in the direction of the brake caliper • Brake pedal operation
piston. Soft or spongy feeling ➔ Bleed the brake sys-
tem .
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM (A BS)" on page 3-1 5.
EAS30186

REMOVING THE REAR BRAKE CALIPER

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1. Remove:
3. Lubricate: • Brake hose union bolt "1"
• Rear brake caliper bolts • Brake hose gaskets "2"
• Brake hose "3"
Recommended lubricant
I
Silicone grease

4-55
 REAR BRAKE

EAS30188
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
CHECKING THE REAR BRAKE CALIPER
Put the end of the brake hose into a container
Recommended brake component
and pump out the brake fluid carefully.
replacement schedule
Brake pads If necessary
Piston seal Every two years
Piston dust seal Every two years
Brake hoses Every fou r years
Every two years and
Brake fluid whenever the brake is
disassembled

1. Check:
• Brake caliper piston "1"
EAS30187
Rust/scratches/wear ➔ Replace the brake
DISASSEMBLING THE REAR BRAKE
caliper piston.
CALIPER
• Brake caliper cylinder "2"
1. Remove:
Scratches/wear ➔ Replace the brake caliper
• Brake caliper piston "1"
assembly.
• Brake caliper piston dust seal "2"
• Brake caliper body "3"
• Brake caliper piston seal "3"
Cracks/damage ➔ Replace the brake caliper
assembly.
• Brake fluid delivery passages
(brake caliper body)
Obstructi on ➔ Blow out with compressed air.

0
0
0 - 2 EWA13601

& WARNING
Whenever a brake caliper is disassembled,
0 ,,___3 replace the brake caliper piston dust seal
and brake caliper piston seal.
a. Blow compressed air into the brake hose
joint opening "a" to force out the piston
from the brake caliper. 2
EWA13550

& WARNING 0
OA---1
• Cover the brake caliper piston with a rag.
Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
• Never try to pry out the brake caliper pis-
ton.
2. Check:
• Rear brake caliper bracket "1"
Cracks/damage ➔ Replace.
Refer to "REAR WHEEL" on page 4-27.

b. Remove the brake caliper piston dust seal

and brake caliper piston seal.

4-56
 REAR BRAKE

EWA13531

& WARNING
Proper brake hose routing is essential to in-
s ure safe vehicle operation.

0
ECA19080

NOTICE
-------------
When installing the brake hose onto the
0 brake caliper " 1 ", make s ure the brake pipe
" a" passes between the projections " b " on
the brake caliper.
EAS30189

ASSEMBLINGTHEREARBRAKECALIPER
EWA17080

& WARNING
• Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake com-
ponents as they will cause the brake caliper 1
piston dust seal and brake caliper piston b
seal to swell and distort. \
• Whenever a brake caliper is disassembled, 2. Remove:
replace the brake caliper piston dust seal • Rear brake caliper
and brake caliper piston seal. 3. Install:
• Brake pad insulators
Specified brake fluid • Brake pad shims
DOT4 (onto the brake pads)
• Brake pad spring
EAS30190 (into the rear brake caliper)
INSTALLING THE REAR BRAKE CALIPER • Brake pads
1. Install: • Rear brake caliper
• Rear brake caliper "1" Refer to "REPLAC ING TH E REAR BRAKE
(temporarily) PADS" on page 4-54.
• Brake hose gaskets l~r:wJ Rear brake caliper bolt (front)
• Brake hose "2"
27 N-m (2.7 kgf-m, 20 lb-ft)
• Brake hose union bolt "3" Rear brake caliper bolt (rear)
22 N-m (2.2 kgf-m, 16 lb-ft)
Rear brake hose union bolt
LOCTITE®
30 N-m (3.0 kgf-m , 22 lb-ft)
Rear brake pad retaining bolt
17 N-m (1.7 kgf-m, 13 lb-ft)
Rear brake caliper screw plug
2.5 N-m (0.25 kgf-m, 1.8 lb-ft)

4. Fill :
• Brake fluid reservoir
(with the specified amount of the specified
brake fluid)

Specified brake fluid

DOT4

4-57
 REAR BRAKE

EWA13090
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
AwARNING
To collect any remaining brake fluid, place a
• Use only the designated brake fluid. Other container under the master cylinder and the end
brake fluids may cause the rubber seals to
of the brake hose.
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
w ill significantly lower the boiling point of
the brake fluid and could cause vapor lock.
ECA13540 ~
NOTICE _ _ _ _ _ _ _ _ _ _ _ __ EAS30194

Brake fluid may damage painted surfaces CHECKING THE REAR BRAKE MASTER
and plastic parts. Therefore, always clean up CYLINDER
any spilt brake fluid immediately. 1. Check:
• Brake master cylinder
5. Bleed: Damage/scratches/wear ➔ Replace.
• Brake system • Brake fluid delivery passages
Refer to "BLEEDING TH E HYDRAULIC (brake master cylinder body)
BRAKE SYSTEM (ABS)" on page 3-15. Obstruction ➔ Blow out with compressed air.
6. Check: 2. Check:
• Brake fluid level • Brake master cylinder kit
Below the minimum level mark "a" ➔ Add the Damage/scratches/wear ➔ Replace.
specified brake fluid to the proper level. 3. Check:
Refer to "CHECKING THE BRAKE FLU ID • Brake fluid reservoir "1"
LEVEL" on page 3-13. • Brake fluid reservoir diaphragm holder "2"
Cracks/damage ➔ Replace.
• Brake fluid reservoir diaphragm "3"
Damage/wear ➔ Replace.

,r '

7. Check:
• Brake pedal operation
Soft or spongy fee li ng ➔ Bleed the brake sys-
tem. 4. Check:
Refer to "BLEEDING TH E HYDRAULIC • Brake hose
BRAKE SYSTEM (ABS)" on page 3-15. • Brake fluid reservoir hose
EAS30193
Cracks/damage/wear ➔ Replace.
REMOVING THE REAR BRAKE MASTER
CYLINDER
1. Remove:
• Brake hose union bolt "1"
• Brake hose gaskets "2"
• Brake hose "3"

4-58
 REAR BRAKE

EAS30195

~
ASSEMBLING THE REAR BRAKE MASTER Specified brake fluid
CYLINDER DOT4
EWA13520

A WARNING EWA13090

• Before installation, all internal brake com- A WARNING

ponents should be cleaned and lubricated • Use only the designated brake fluid. Other
with clean or new brake fluid. brake fluids may cause the rubber seals to
• Never use solvents on internal brake com- deteriorate, causing leakage and poor
ponents. brake performance.
• Refill with the same type of brake fluid that
Specified brake fluid is already in the system. Mixing brake fluids
DOT4 may result in a harmful chemical reaction,
leading to poor brake performance.
1. Install: • When refilling, be careful that water does
• Brake master cylinder kit 1~f41j not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
EAS30196
the brake fluid and could cause vapor lock.
INSTALLING THE REAR BRAKE MASTER
ECA13540
CYLINDER
NOTICE
1. Install: -------------
Brake fluid may damage painted surfaces
• Brake hose gaskets •~fWI and plastic parts. Therefore, always clean up
• Brake hose
any spilt brake fluid immediately.
• Brake fluid reservoir hose
• Brake hose union bolt 3. Bleed :
• Brake system
Rear brake hose union bolt Refer to "BLEEDING THE HYDRAULIC
30 N-m (3.0 kgf-m, 22 lb-ft) BRAKE SYSTEM (ABS)" on page 3-15.
EWA13531
4. Check:
A WARNING • Brake fluid level
Below the minimum level mark "a" ➔ Add the
Proper brake hose routing is essential to in-
sure safe vehicle operation. specified brake fluid to the proper level.
Refer to "CHECKING THE BRAKE FLUID
ECA14 160
LEVEL" on page 3-13.
NOTICE
-------------
When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe touches the projection "a" as shown.

5. Adjust:
• Brake pedal position
Refer to "ADJUSTING THE REAR DISC
BRAKE" on page 3-14.
2. Fill : 6. Adjust:
• Brake fluid reservoir • Rear brake light operation timing
(with the specified amount of the specified Refer to "ADJUSTING THE REAR BRAKE
brake fluid) LIGHT SWITCH" on page 3-30.

4-59
 ABS (ANTI-LOCK BRAKE SYSTEM)

EAS20032

ABS (ANTI-LOCK BRAKE SYSTEM)

Removing the hydraulic unit assembly
-- - - - - - - - - - ~
~ , 30 N•m (3.0 kgf•m, 22 lb•ft) ~ . 7 N•m (0.7 kgf•m, 5.2 lb•ft)
4
2

,_
iG
,~I i
1 ' . )
'/G;,}/ ,

''
'
3 ---,

, p,
e
'

•
"S. 30 N•m (3.0 kgf•m, 22 lb•ft)
;,;, 7 N•m (0.7 kgf•m, 5.2 lb•ft) i <kl)
I @
<k!)
~ ,- I

"'t. 11 N•m (1 .1 kgf•m, 8.1 lb·ft) ;.;-~ 7 N•m (0.7 kgf•m, 5.2 lb·ft)

Order Job/Parts to remove Q'ty Remarks

Fuel tank front cover/Front side panel/Front side Refer to "GENERAL CHASSIS (2)" on page
cowling 4-6.
Refer to "GENERAL CHASSIS (1 )" on page
Passenger seat/Rider seat
4-1 .
Refer to "GENERAL CHASSIS (3)" on page
Fuel tank cover
4-13.
Fuel tank Refer to "FUEL TANK" on page 7-1.
Drain.
Brake fluid Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)" on page 3-15.
1 Lean angle sensor coupler 1 Disconnect.
2 Fuel tank bracket assembly 1
3 ABS ECU coupler 1 Disconnect.
4 Brake hose union bolt/Gasket 1/2

4-60
 ABS (ANTI-LOCK BRAKE SYSTEM)

Removing the hydraulic unit assembly

-, - - - - - - - - - ~
"~, 30 N•m (3.0 kgf•m, 22 lb•ft) ~ - 7 N•m (0.7 kgf•m, 5.2 lb•ft)

5 ..___, iG
! ~I~ ..__....._ ,~I i
6
/'
11()
,,,
' '7' ) ,
Q O '
v- ~ ""
,
. . _,,.o~j
. 9

, '
'

, '

p,
~
11
' 13
".-.. 30 N•m (3.0 kgf•m, 22 lb•ft)
a

l~, 7 N•m (0. 7 kgf•m, 5.2 lb•ft)

t...lir) i_. . , <kl)
I

~ ,..,,,, ' . I

'"- 11 N•m (1.1 kgf•m, 8.1 lb·ft)

~~
✓o._
---
7 N•m (0. 7 kgf•m, 5.2 lb·ft)

Order Job/Parts to remove Q'ty Remarks

Rear brake hose (hydraulic unit to rear brake Disconnect.
5
caliper) 1
6 Brake hose union bolt/Gasket 1/2
Rear brake hose (rear brake master cylinder to
7 hydraulic unit) 1 Disconnect.

8 Brake hose union bolt/Gasket 1/2

Front brake hose (hydraulic unit to front brake Disconnect.
9 caliper) 1
10 Brake hose union bolt/Gasket 1/2
Front brake hose (front brake master cylinder to Disconnect.
11 hydraulic unit) 1
12 Bracket 1
13 Rear brake hose bracket 1

4-61
 ABS (ANTI-LOCK BRAKE SYSTEM)

Removing the hydraulic unit assembly

-. - - - - - - - ~
"~, 30 N•m (3.0 kgf•m, 22 lb•ft) ~ - 7 N•m (0.7 kgf•m, 5.2 lb•ft)

,_
iG
! ~I~ ..__....._ ,~I i
-
11
,,_ () ' '7' -)
oO
v· - ~

15 14
- ''
'

, '

p,
'
".-.. 30 N•m (3.0 kgf•m, 22 lb•ft)
a @
l~, 7 N•m (0.7 kgf•m, 5.2 lb•ft)

~ , -~ I ~~

'"- 11 N•m (1 .1 kgf•m, 8.1 lb·ft)

~~---
✓o._ 7 N•m (0.7 kgf•m, 5.2 lb·ft)

Order Job/Parts to remove Q'ty Remarks

14 Hydraulic unit bracket 1
15 Hydraulic unit 1

4-62
 ABS (ANTI-LOCK BRAKE SYSTEM)

EAS30197
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
REMOVING THE HYDRAULIC UNIT
ASSEMBLY Do not operate the brake lever and brake pedal
ECA21091 while removing the brake hoses.
NOTICE
- - - - - - - - - - - - - ECA18251

UnIe s s 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 assembly to
EWA13930
catch any spilt brake fluid. Do not allow the
& WARNING brake fluid to contact other parts.
Refill with the same type of brake fluid that is 3. Remove:
already in the system. Mixing fluids may re-
• Hydraulic unit assembly "1"
sult in a harmful chemical reaction, leading TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
to poor braking performance.
• 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
(M 1ox 1.0) into each brake hose union bolt
since they have been accurately adjusted. hole.
Keep them away from dirt and do not sub-
• W hen 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
and plastic parts. Therefore, always clean
a
up any spilt brake fluid immediately.
• Do not allow any brake fluid to contact the
couplers. Brake fluid may damage the cou-
plers and cause bad contacts.
• If the union bolts for the hydraulic unit as- 0
sembly have been removed, be sure to 1
tighten them to the specified torque and
bleed the brake system. EAS30198

CHECKING THE HYDRAULIC UNIT

1. Disconnect:
ASSEMBLY
• A BS ECU coupler "1"
1. Check:
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ • Hydraulic unit assembly
Pull the lock lever "a" of the ABS ECU coupler in C racks/damage ➔ Replace the hydraulic unit
the direction of the arrow shown , and then dis- assembly and the brake pipes that are con-
connect the coupler. nected to the assembly as a set.
EAS30200

INSTALLING THE HYDRAULIC UNIT

ASSEMBLY
1. Install:
• Hydraulic unit assembly
ECA21371

NOTICE
-------------
Do not remove the rubber plugs or bolts
(M 1O x 1.0) installed in the brake hose union
bolt holes before installing the hydraulic unit
2. Remove: assembly.
• Brake hoses

4-63
 ABS (ANTI-LOCK BRAKE SYSTEM)

TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Do not allow any foreign materials to enter the
hydraulic unit assembly or the brake hoses
when installing the hydraulic unit assembly.
2. Remove:
• Rubber plugs or bolts (M1 Ox 1.0)
3. Install : 0
• Front brake hose (front brake master cylinder
to hydraulic unit) "1"
• Front brake hose (hydraulic unit to front brake
caliper) "2" llil
• Rear brake hose (rear brake master cylinder
to hydraulic unit) "3" I I
• Rear brake hose (hydraulic unit to rear brake 00 00
caliper) "4"
• Gaskets r.i1~11111f4"fi11
fj 00 00
• Brake hose union bolts
, I l7 " I
Rear brake hose union bolt
- '?
l._,
-
l
30 N•m (3.0 kgf•m, 22 lb-ft)
A. The ABS ECU coupler is connected correctly.
ECA21121 B. The ABS ECU coupler is not connected.
NOTICE
-------------
1f the brake hose union bolt does not turn
5. Fill :
• Brake master cylinder reservoir
easily, replace the hydraulic unit assembly, • Brake fluid reservoir
brake hoses, and related parts as a set. (with the specified amount of the specified
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ brake fluid)
When installing the brake hose (front brake mas-
Specified brake fluid
ter cylinder to hydraulic unit) , make sure that the DOT4
stopper "a" on the hose contacts the brake hose
(hydraulic unit to front brake caliper) . EWA13090

& WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
4. Connect:
will significantly lower the boiling point of
• ABS ECU coupler "1"
the brake fluid and could cause vapor lock.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
ECA13540
• Connect the ABS ECU coupler, and then push NOTICE
the lock lever "a" of the coupler in the direction -------------
of the arrow shown . Brake fluid may damage painted surfaces
• Make sure that the ABS ECU coupler is con- and plastic parts. Therefore, always clean up
nected in the correct position as shown in illus- any spilt brake fluid immediately.
tration "A".

4-64
 ABS (ANTI-LOCK BRAKE SYSTEM)

6. Bleed: 1. Place the vehicle on the centerstand.

• Brake system 2. Turn the main switch to "OFF".
Refer to "BLEEDING THE HYDRAULIC 3. Remove:
BRAKE SYSTEM (ABS)" on page 3-15. • Passenger seat/Rider seat
7. Check the operation of the hydraulic unit ac- Refer to "GENERAL CHASSIS (1)" on page
cording to the brake lever and the brake ped- 4-1 .
al response. (Refer to "HYDRAULIC UNIT 4. Check:
OPERATION TESTS" on page 4-65.) • Battery voltage
ECA14770
Lower than 12.8 V ➔ Charge or replace the
NOTICE
------------- battery.
A I ways check the operation of the hydraulic
unit according to the brake lever and the Battery voltage
brake pedal response. Higher than 12.8 V

8. Delete the fault codes. (Refer to "[B-3] DE- TIP _ _ _ _ _ _ _ _ _ _ _ _ __

LETING THE FAULT CODES" on page
If the battery voltage is lower than 12.8 V, charge
8-177.)
the battery, and then perform brake line routing
9. Perform a trial run. (Refer to "CHECKING
confirmation.
THE ABS WARNING LIGHT' on page 4-68.)
EAS30930
-
HYDRAULIC UNIT OPERATION TESTS
The reaction-force pulsating action generated in O 0

the brake lever and brake pedal when the ABS

is activated can be tested when the vehicle is
stopped.
The hydraulic unit operation can be tested using
)- -
the following two methods. O 0 @
• Brake line routing confirmation: this test
checks the function of the ABS after the sys-
tem was disassembled, adjusted, or serviced . 5. Removing the protective cap "1", and then
• ABS reaction-force confirmation : this test gen- connect the Yamaha diagnostic tool to the
erates the same reaction-force pulsating action Yamaha diagnostic tool coupler (4P) .
that is generated in the brake lever and brake
Yamaha diagnostic tool USB (US)
pedal when the ABS is activated.
90890-03257
Yamaha diagnostic tool (A/1)
Brake line routing confirmation 90890-03262
EWA13 120

& WARNING
Securely support the vehicle so that there is
no danger of it falling over.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• For the brake line routing confirmation, use the
diagnosis of function of the Yamaha diagnostic
tool.
• Before performing the brake line routing confir-
mation , make sure that no malfunctions have
been detected in the ABS ECU and that the
wheels are not rotating.

4-65
 ABS (ANTI-LOCK BRAKE SYSTEM)

6. Start the Yamaha diagnostic tool and display

the diagnosis of function screen.
7. Select code No. 2, "Brake line routing confir-
mation".
8. Click "Actuator Check" "1", and then operate
the brake lever "2" and brake pedal "3" simul-
taneously.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• The hydraulic unit operates 1 second after the
brake lever and brake pedal are operated si-
2 t
,,
multaneously and continues for approximately TIP _ _ _ _ _ _ _ _ _ _ _ _ __
5 seconds.
"ON" and "O FP' on the tool screen indicate
• The operation of the hydraulic unit can be con-
when the brakes are being applied and released
firmed using the indicator.
respectively.
O n: The hydraulic unit is operating.
ECA17371
Flashing: The conditions for operating the hy-
NOTICE
draulic unit have not been met.
Off: The brake lever and brake pedal are not
-------------
• Check that the pulse is felt in the brake le-
being operated. ver, brake pedal, and again in the brake le-
ver, in this order.
• If the pulse is felt in the brake pedal before
it is felt in the brake lever, check that the
brake hoses and brake pipes are connected
correctly to the hydraulic unit assembly.
• If the pulse is hardly felt in either the brake
lever or brake pedal, check that the brake
Actu"tor
hoses and brake pipes are connected cor-
, c~ rectly to the hydraulic unit assembly.
1 1O.lf the operation of the hydraulic unit is normal ,
delete all of the fault codes.

ABS reaction-force confirmation

EWA13120

& WARNING
Securely support the vehicle so that there is
no danger of it falling over.
=------------:
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
-- r---..... 2 • For the A BS reaction-force confirmation , use
the diagnosis of function of the Yamaha diag-
9. Check: nostic tool. For more information, refer to the
• Hydraulic unit operation operation manual of the Yamaha diagnostic
Click "Actuator Check", a single pulse will be tool .
generated in the brake lever "1", brake pedal • Before performing the ABS reaction-force con-
"2", and again in the brake lever "1", in this or- firmation , make sure that no malfunctions have
der. been detected in the A BS ECU and that the
wheels are not rotating.
1. Place the vehicle on the centerstand.
2. Turn the main switch to "O FF".
3. Remove:
• Passenger seat/Rider seat
Refer to "GENERAL C HASSIS (1)" on page
4-1.

4-66
 ABS (ANTI-LOCK BRAKE SYSTEM)

4. Check: • The operation of the hydraulic unit can be con-

• Battery voltage firmed using the indicator.
Lower than 12.8 V ➔ Charge or replace the On: The hydraulic unit is operating.
battery. Flashing : The conditions for operating the hy-
draulic unit have not been met.
Battery voltage Off: The brake lever and brake pedal are not
Higher than 12.8 V being operated .

TIP _ _ _ _ _ _ _ _ _ _ _ _ __
If the battery voltage is lower than 12.8 V , charge
the battery, and then perform ABS reaction-
force confirmation .

-
l\ctuator
O 0 , C.lleck

O 0

5. Removing the protective cap "1", and then

connect the Yamaha diagnostic tool to the
Yamaha diagnostic tool coupler (4P) . =----
Yamaha diagnostic tool USB (US)
90890-03257
Yamaha diagnostic tool (A/1) 9. A reaction-force pulsating action is generated
90890-03262 in the brake lever "1" and continues for a few
seconds.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
~ / '

,--
...-u:;;-- - - - - - ~ @ • The reaction-force pulsating action consists of
quick pulses.
• Be sure to continue operating the brake lever
0
1 and brake pedal even after the pulsating action
/

has stopped .
(l_8:= • "ON" and "OFP' on the tool screen indicate
when the brakes are being applied and re-
leased respectively.

6. Start the Yamaha diagnostic tool and display

the diagnosis of function screen.
7. Select code No. 1, "ABS reaction-force con-
firmation".
8. Click "Actuator Check" "1", and then operate
the brake lever "2" and brake pedal "3" simul-
taneously.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
l-.--- 1
• The hydraulic unit operates 1 second after the
brake lever and brake pedal are operated si-
multaneously and continues for approximately
5 seconds.

4-67
 ABS (ANTI-LOCK BRAKE SYSTEM)

1a.After the pulsating action has stopped in the
brake lever, it is generated in the brake pedal
"1" and continues for a few seconds.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• The reaction-force pulsating action consists of
quick pulses.
• Be sure to continue operating the brake lever
and brake pedal even after the pulsating action
has stopped .
• "ON" and "OFP' on the tool screen indicate
when the brakes are being applied and re-
leased respectively.
12.Turn the main switch to "O FP'.
13.Remove the Yamaha diagnostic tool from the
Yamaha diagnostic tool coupler, and then in-
stall the protective cap.
14.Turn the main switch to "ON".
15.Set the start/engine stop switch to "o".
16.Check for brake fluid leakage around the hy-
draulic unit.
Brake fluid leakage ➔ Replace the hydraulic
unit, brake pipes, and related parts as a set.
17.lf the operation of the hydraulic unit is normal,
delete all of the fault codes.
EAS30202

CHECKING THE ABS WARNING LIGHT

After all checks and servicing are completed, en-
sure that the ABS warning light goes off by walk-
ing the vehicle at a speed of faster than 7 km/h
(4.4 mi/h) or performing a trial run .

1
I
"
11 .After the pulsating action has stopped in the
brake pedal, it is generated in the brake lever
and continues for a few seconds.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• The reaction-force pulsating action consists of
quick pulses.
• "ON" and "OFP' on the tool screen indicate
when the brakes are being applied and re-
leased respectively.
ECA17371

NOTICE
-------------
• Check that the pulse is felt in the brake le-
ver, brake pedal, and again in the brake le-
ver, in this order.
• If the pulse is felt in the brake pedal before
it is felt in the brake lever, check that the
brake hoses and brake pipes are connected
correctly to the hydraulic unit assembly.
• If the pulse is hardly felt in either the brake
lever or brake pedal, check that the brake
hoses and brake pipes are connected cor-
rectly to the hydraulic unit assembly.

4-68
 HANDLEBAR
EAS20033

HANDLEBAR
Removing the handlebar 1/2 (MTT9K/MTT9KC)

"
,,:, 7 N•m 0.7 k f•m, 5.2 lb•ft
0

1~, 17 N•m (1. 7 kgf•m, 13 lb·ft)

x,. 7 N•m (0.7 kgf•m, 5.2 lb·ft)

3 .#.~~ b1-.hn
/4 t!)
jg

'
_J

N•m (0.40 kgf•m, 3.0 lb·ft)

' ;,"- 23 N•m (2.3 kgf•m, 17 lb·ft)

Order Job/Parts to remove Q'ty Remarks

Refer to "GENERAL CHASSIS (2)" on page
Windshield 4-6.
1 Rearview mirror 2
2 Handguard 2
3 Handguard cover 2
4 Handguard bracket 2

4-69
 HANDLEBAR

Removing the handlebar 2/2 (MTT9K/MTT9KC)

;;;_ 3.8 N•m (0.38 kgf•m, 2.8 lb·ft)
~. 26 N•m (2.6 kgf•m, 19 lb·ft)
6

8 7

~; 11 N•m (1.1 kgf•m, 8.1 lb•ft)

7 I

1
' :ii., 26 N•m (2.6 kgf•m, 19 lb·ft) ;;-"- 1.8 N•m (0.18 kgf•m, 1.3 lb·ft)

Order Job/Parts to remove Q 'ty Remarks

Fuel tank front cover/Front side panel/Front side Refer to "GENERAL CHASSIS (2)" on page
cowling 4-6.
1 Front brake light switch connector 2 Disconnect.
2 Front brake master cylinder holder 1
3 Front brake master cylinder assembly 1
4 Handlebar switch (right) 1
5 Throttle cable housing 2
6 Throttle cable 2 Disconnect.
7 Grip end 2
8 Throttle grip 1
9 Clutch switch coupler 1 Disconnect.
10 Handlebar switch (left) 1
11 Handlebar switch holder 2

4-70
 HANDLEBAR

Removing the handlebar 2/2 (MTT9K/MTT9KC)

;;;_ 3.8 N•m (0.38 kgf•m, 2.8 lb·ft)
~. 26 N•m (2.6 kgf•m, 19 lb·ft)

~; 11 N•m (1.1 kgf•m, 8.1 lb•ft)

17

15

1
' :ii., 26 N•m (2.6 kgf•m, 19 lb·ft) ;;-"- 1.8 N•m (0.18 kgf•m, 1.3 lb·ft)

Order Job/Parts to remove Q'ty Remarks

12 Handlebar grip 1
13 Clutch switch 1
14 Clutch cable 1 Disconnect.
15 Clutch lever holder 1
16 Upper handlebar holder 2
17 Handlebar 1
18 Lower handlebar holder 2

4-71
 HANDLEBAR

Removing the handlebar 1/2 (MTT9GTK/MTT9GTKC)

~, 23 N•m (2.3 kgf•m, 17 lb·ft)
~, 7 N•m (0.7 kgf•m, 5.2 lb•ft)
0

~~, 17 N•m (1. 7 kgf•m, 13 lb·ft)

1
,;.. 17 N•m (1. 7 kgf•m, 13 lb·ft)

x,. 7 N•m (0.7 kgf•m, 5.2 lb·ft)

3 .#.~~ b1-..t--in
t!)
jg

'
~, 4.0 N•m (0.40 kgf•m, 3.0 lb·ft)

.,i,. 23 N•m 2.3 k f•m, 17 lb·ft

Order Job/Parts to remove Q'ty Remarks

Refer to "GENERAL CHASSIS (2)" on page
Windshield 4-6,
1 Rearview mirror 2
2 Handguard 2
3 Handguard cover 2
4 Handguard bracket 2

4-72
 HANDLEBAR

Removing the handlebar 2/2 (MTT9GTK/MTT9GTKC)

.,;, 26 N•m (2.6 kgf•m , 19 lb·ft)
3
1 ,. -~ 0.4 N•m (0.04 kgf•m , 0 .30 lb·ft)
6
C-7&~_::::-
r,.:,J 1.2 N•m (0.12 kgf•m, 0.88 lb•ft) I ~ ._
~~ --- -
- ,--..___
'
'

" I
r- ~~,J-3.-5-N--m- (0-.3-5 -kg- f-.m-, -2.-6 -lb--ft-) ~ 4
'
~
8
9
I,,:J 2 2 N•m (2.2 kgf•m, 16 lb•ft) I~ V ,' \),._--""] 7 I
J:

~r1 '
-
2
,J 5
1 ,•:,, 3.8 N•m (0.38 k f•m, 2.8 lb·ft)

- ~ -~ -~
,,
~~~-~-"'_'.:,~?c~=:-~
:, G
:1;.~
-1!0~N~-m~(~1-~0~kg~f•im~
, 7~.4!1ib·~ft)~
3.5 N•m (0.35 kgf•m, 2.6 lb•ft)

' -!::=}.~~q,,,,,,-'
8

' :ii., 26 N•m (2.6 kgf•m , 19 lb·ft) ;;-"- 1.8 N•m (0.18 kgf•m, 1.3 lb·ft)

Order Job/Parts to remove Q'ty Remarks

Fuel tank front cover/Front side panel/Front side Refer to "GENERAL CHASSIS (2)" on page
cowling 4-6.
Main switch guard Refer to "STEERING HEAD" on page 4-96.
1 Front brake light switch 1
2 Front brake master cylinder holder 1
3 Front brake master cylinder assembly 1
4 Handlebar switch (right) 1
5 Throttle cable housing 2
6 Throttle cable 2 Disconnect.
7 Lead holder 1
8 Grip end 2
9 Throttle grip 1
10 Handlebar switch (left) 1

4-73
 HANDLEBAR

Removing the handlebar 2/2 (MTT9GTK/MTT9GTKC)

.,;, 26 N•m (2.6 kgf•m, 19 lb·ft)
,. -~ 0.4 N•m (0.04 kgf•m, 0.30 lb·ft)

15 ·✓
,•:,, 3.8 N•m (0.38 k f•m, 2.8 lb·ft)

12

' :ii., 26 N•m (2.6 kgf•m, 19 lb·ft) ;;-"- 1.8 N•m (0.18 kgf•m, 1.3 lb·ft)

Order Job/Parts to remove Q'ty Remarks

11 Handlebar switch holder 2

12 Handlebar grip 1
13 Clutch switch 1
14 Clutch cable 1 Disconnect.
15 Clutch lever holder 1
16 Upper handlebar holder 2
17 Handlebar 1
18 Lower handlebar holder 2

4-74
 HANDLEBAR
EAS31396
d. Install the handlebar "2" and upper han-
ADJUSTING THE HANDLEBAR POSITION
dlebar holders "1".
1. Check:
• Handlebar position Upper handlebar holder bolt
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ 22 N-m (2.2 kgf •m, 16 lb-ft)
The handlebar position can be adjusted in two ECA19130
positions to suit the rider's preference. NOTICE
- - - - - - - - - - - - -
• First, tighten the bolts on the front side of
the upper handlebar holder, and then on
the rear side.
• Turn the handlebar all the way to the left
and right. If there is any contact with the
fuel tank, adjust the handlebar position.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Align the punch mark "a" on the handlebar with
the left side upper surface of the lower handle-
2. Remove: bar holder (left) "4".
• Fuel tank front cover
• Front side panel
• Front side cowling
Refer to "G ENERAL CHASSIS (2)" on page
4-6.
3. Adjust:
• Handlebar position
a. Remove the upper handlebar holders "1"
and handlebar "2".

e. Tighten the lower handlebar holder nuts.

Lower handlebar holder nut

40 N-m (4.0 kgf-m, 30 lb-ft)

4. Install:
• Front side cowling
• Front side panel
• Fuel tank front cover
b. Loosen the lower handlebar holder nuts. Refer to "GENERAL CHASSIS (2)" on page
c. Adjust the handlebar position by rotating 4-6.
both of the lower handlebar holders "3" in EAS30203
180°. REMOVING THE HANDLEBAR
1. Stand the vehicle on a level surface.
EWA13120

~ WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:
• Handlebar grip "1"
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Blow compressed air between the handlebar
(left) and the handlebar grip, and gradually push
the grip off the handlebar.

4-75
 HANDLEBAR
EAS30205

INSTALLING THE HANDLEBAR

1. Stand the vehicle on a level surface.
EWA13120

& WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Install:
1 • Lower handlebar holders
(temporarily)
• Handlebar "1"
3. Remove:
• Upper handlebar holders "2"
• Throttle cable housings "1"
• Throttle grip "2" Upper handlebar holder bolt
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ 22 N-m (2.2 kgf-m, 16 lb-ft)
While removing the throttle cable housing, pull ECA19130

back the rubber cover "3". NOTICE

- - - - - - - - - - - - -
• First, tighten the bolts on the front side of
the upper handlebar holder, and then on
the rear side.
• Turn the handlebar all the way to the left
and right. If there is any contact with the
fuel tank, adjust the handlebar position.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Align the punch mark "a" on the handlebar with
the left side upper surface of the lower handle-
bar holder (left) "3".
EAS30204

CHECKING THE HANDLEBAR

1. Check:
• Handlebar
Bends/cracks/damage ➔ Replace.
EWA13690

& WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.

3. Tighten:
• Lower handlebar holder nuts

Lower handlebar holder nut

40 N-m (4.0 kgf-m, 30 lb-ft)

4. Install:
• Clutch lever holder "1"
• Clutch cable

Clutch lever holder pinch bolt

11 N-m (1.1 kgf-m, 8.1 lb-ft)

4-76
 HANDLEBAR

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Align the center of slit on the clutch lever holder
with the punch mark "a" on the handlebar.

1 a
0

d. Fit the grip warmer lead into the slot "a" in

the handlebar switch. (MTT9GTK/
MTT9GTKC)

5. Install:
• Handlebar switch (left) "1"

Handlebar switch screw

1.8 N-m (0.18 kgf-m, 1.3 lb-ft)

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Align the projection "a" on the handlebar switch
(left) with the hole "b" in the handlebar.
7. Install:
• Grip end
b • Throttle grip "1"
• Throttle cables
a • Lead holder (MTT9GTK/MTT9GTKC) "2"
• Throttle cable housings "3"

Grip end
26 N-m (2.6 kgf-m, 19 lb-ft)
0 Throttle cable housing bolt
3.8 N-m (0.38 kgf-m, 2.8 lb-ft)
6. Install:
• Handlebar grip "1" TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Grip end "2" • Place the right grip warmer lead "4" in the lead
holder "2" so that it forms a loop as shown in
Grip end the illustration, and then install the lead and
26 N-m (2.6 kgf-m, 19 lb-ft)
holder in the throttle cable housing. Be sure to
a. Apply a thin coat of rubber adhesive onto fit the grommets "a" of the right grip warmer
the end of the handlebar (left). lead into the slots "b" in the throttle cable hous-
b. Side the handlebar grip over the end of the ing. (MTT9GTK/MTT9GTKC)
handlebar (left) . • Align the projection "c" on the throttle cable
c. Wipe off any excess rubber adhesive with housing with the hole "d" in the handlebar.
a clean rag.
EWA13700

AwARNING
Do not touch the handlebar grip until the rub-
ber adhesive has fully dried.

4-77
 HANDLEBAR

9. Install:
• Front brake master cylinder assembly
b Refer to "INSTALLING THE FRONT BRAKE
MASTER CYLINDER" on page 4-46.
10.Adjust:
• Throttle grip free play
Refer to "CHECKING THE THROTTLE
GRIP" on page 3-30.

2 Throttle grip free play

3.0-5.0 mm (0.12-0.20 in)

11 .Adjust:
• Clutch lever free play
Refer to "ADJUSTING THE CLUTCH LEVER
FREE PLAY" on page 3-12.

Clutch lever free play

10.0-15.0 mm (0.39-0.59 in)
(MTT9K, MTT9KC)
5.0-10.0 mm (0.20-0.39 in)
(MTT9GTK, MTT9GTKC)
8. Install:
• Handlebar switch (right) "1" EAS31386

INSTALLING THE REARVIEW MIRRORS

Handlebar switch screw AND HANDGUARDS
3.5 N-m (0.35 kgf-m, 2.6 lb-ft) 1. Install:
• Handguard (left) "1"
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• Rearview mirror (left) "2"
Align the projection "a" on the handlebar switch a. Install the handguard and rearview mirror.
(right) with the hole "b" in the handlebar. TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Temporarily tighten the handguard bracket bolts
a "3", rearview mirror locknut "4" and handguard
bolt "5".

4
b
/ 5

1
b. Tighten the handguard bracket bolts "3" to
specification.

Handguard bracket bolt

7 N-m (0.7 kgf-m, 5.2 lb-ft)
a LOCTITE®

A. MTT9K/MTT9KC c. Tighten the rearview mirror locknut "4" to

B. MTT9GTK/MTT9GTKC specification.

4-78
 HANDLEBAR

e. Loosen the rearview mirror locknut 1/2 of

Rearview mirror locknut a turn or more, and then tighten the lock-
17 N•m ( 1. 7 kgf•m , 13 lb-ft) nut to specification again.
d. T ighten the handguard bolt "5" to specifi- Rearview mirror locknut
cation. 17 N•m (1.7 kgf•m, 13 lb•ft)

Handguard bolt TIP _ _ _ _ _ _ _ _ _ _ _ _ __

23 N•m (2.3 kgf•m , 17 lb-ft)
e. Loosen the rearview mirror locknut 1/2 of
a turn or more, and then tighten the lock-
nut to specification again.
Make sure that the distance "a" from the hand-
guard bracket "6" to the brake lever pivot bolt "7"
is 4-6 mm (0.16-0.24 in) as shown .

Rearview mirror locknut

17 N•m ( 1. 7 kgf•m , 13 lb-ft) 6

2. Install :
• Handguard (right) "1"
• Rearview mirror (right) "2"
@·~ ~-.; ; ;: :;~
i
a. Install the handguard and rearview m irror. -i=:?"-- --... , --,J:::::,,-J

TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Temporarily tighten the handguard bracket bolts
"3", rearview mirror locknut "4" and handguard
bolt "5".

1 \
b. T ighten the handguard bracket bolts "3" to
specification .

Handguard bracket bolt

7 N•m (0.7 kgf•m, 5.2 lb-ft)
LOCTITE®

c. T ighten the rearview mirror locknut "4" to

specification .

Rearview mirror locknut

17 N•m ( 1. 7 kgf•m , 13 lb-ft)

d. T ighten the handguard bolt "5" to specifi-

cation.

Handguard bolt
23 N•m (2.3 kgf•m , 17 lb-ft)

4-79
 FRONT FORK

EAS20034

FRONT FORK
Removing the front fork legs
.
.<!,, 23 N•m (2.3 kgf•m, 17 lb·ft) 4 26 N•m (2.6 kgf•m, 19 lb·ft) <1s. 23 N•m (2.3 kgf•m, 17 lb·ft)

I 0 \~~---------
. ~

,'
/ . -----------
'

Order Job/Parts to remove Q 'ty Remarks

The following procedure applies to both of

the front fork legs.
Front wheel Refer to "FRONT WHEEL:' on page 4-20.
1 Front fender 1
2 Upper bracket pinch bolt 1 Loosen.
3 Cap bolt 1 Loosen.
4 Lower bracket pinch bolt 2 Loosen.
5 Front fork leg 1

4-80
 FRONT FORK

Disassembling the left front fork leg (MTT9K/MTT9KC)

i?,_ 15 N•m (1 .5 kgf•m, 11 lb·ft)

r.=-'1---- 131111
J
1111 2 -
6- ---ll'
3--@
Q

•
12 mm
L- 11

~ 101111
amm
1mm
0

,IJ
,..;," 23 N•m (2.3 kgf•m, 17 lb·ft)

Order Job/Parts to remove Q'ty Remarks

1 Cap bolt 1
2 0-ring 1
3 Washer 1
4 Spacer 1
5 Fork spring 1
6 Locknut 1
7 Dust seal 1
8 Oil seal clip 1
9 Outer tube 1
10 Oil seal 1
11 Washer 1
12 Outer tube bushing 1
13 Inner tube bushing 1

4-81
 FRONT FORK

Disassembling the left front fork leg (MTT9K/MTT9KC)

,,;, 23 N•m 2.3 k f•m, 17 Ib•ft

i?,_ 15 N•m (1.5 kgf•m, 11 lb·ft)

1--- 17

1--- 16

L-

,..;," 23 N•m (2.3 kgf•m, 17 lb·ft)

Order Job/Parts to remove Q'ty Remarks

14 Damper rod assembly bolt 1

15 Copper washer 1
16 Damper rod assembly 1
17 Inner tube 1

4-82
 FRONT FORK

Disassembling the right front fork leg (MTT9K/MTT9KC)

,.
~-- 23 N•m 2.3 k f•m , 17 lb·ft
;',,. 15 N•m (1.5 kgf•m, 11 lb·ft)

mlJ 2 --<. _
6 - -~
3- @ 0

13 mlJ

L- 12

11 mm

9 mlJ
aim 0

;',, 23 N•m (2.3 kgf•m, 17 lb·ft)

Order Job/Parts to remove Q'ty Remarks

1 Cap bolt 1
2 0-ring 1
3 Washer 1
4 Spacer 1
5 Fork spring 1
6 Locknut 1
7 Damper adjusting rod 1
8 Dust seal 1
9 Oil seal clip 1
10 Outer tube 1
11 Oil seal 1
12 Washer 1
13 Outer tube bushing 1

4-83
 FRONT FORK

Disassembling the right front fork leg (MTT9K/MTT9KC)

,.
~-- 23 N•m 2.3 k f•m , 17 lb·ft
;',,. 15 N•m (1.5 kgf•m, 11 lb·ft) 0 \--- 14
lCf mm
0

i--- 18

17

L-
~
mm 16

0 ---id
15

;',, 23 N•m (2.3 kgf•m, 17 lb·ft)

Order Job/Parts to remove Q'ty Remarks

14 Inner tube bushing 1

15 Damper rod assembly bolt 1
16 Copper washer 1
17 Damper rod assembly 1
18 Inner tube 1

4-84
 FRONT FORK

Disassembling the front fork leg (MTT9GTK/MTT9GTKC)

,.
~-- 23 N•m 2.3 k f•m , 17 lb·ft
;',,. 15 N•m (1.5 kgf•m, 11 lb·ft)

mlJ 2 --<. _
6 - -~
3- @ 0

13 mlJ

L- 12

11 mm

9 mlJ
aim 0

;',, 23 N•m (2.3 kgf•m, 17 lb·ft)

Order Job/Parts to remove Q'ty Remarks

1 Cap bolt 1
2 0-ring 1
3 Washer 1
4 Spacer 1
5 Fork spring 1
6 Locknut 1
7 Damper adjusting rod 1
8 Dust seal 1
9 Oil seal clip 1
10 Outer tube 1
11 Oil seal 1
12 Washer 1
13 Outer tube bushing 1

4-85
 FRONT FORK

Disassembling the front fork leg (MTT9GTK/MTT9GTKC)

,.
~-- 23 N•m 2.3 k f•m , 17 lb·ft
;',,. 15 N•m (1.5 kgf•m, 11 lb·ft) 0 \--- 14
lCf mm
0

i--- 18

17

L-

;',, 23 N•m (2.3 kgf•m, 17 lb·ft)

Order Job/Parts to remove Q'ty Remarks

14 Inner tube bushing 1

15 Damper rod assembly bolt 1
16 Copper washer 1
17 Damper rod assembly 1
18 Inner tube 1

4-86
 FRONT FORK

EAS30206 EAS30207

REMOVING THE FRONT FORK LEGS DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the The following procedure applies to both of the
front fork legs. front fork legs.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ 1. Remove:
• MTT9K/MTT9KC: • Cap bolt "1"
Each front fork leg is equipped with a spring (from the damper rod assembly)
preload adjusting bolt, the right fork leg is • Washer "2"
equipped with a rebound damping force adjust- • Spacer "3"
ing screw. • Locknut "4"
• MTT9GTK/MTT9GTKC: • Fork spring
Each front fork leg is equipped with a spring a. Press down on the spacer with the fork
preload adjusting bolt, the fork leg (right) is spring compressor "5".
equipped with a rebound damping force adjust- b. Install the rod holder "6" between the lock-
ing screw, the fork leg (left) is equipped with a nut "4" and the washer "2".
compression damping force adjusting screw.
Fork spring compressor
• Pay attention not to mistake the right and left. 90890-01441
1. Stand the vehicle on a level surface. Fork spring compressor
EWA13 120 YM-01441
A WARNING Rod holder
Securely support the vehicle so that there is 90890-01434
no danger of it falling over. Damper rod holder double ended
YM-01434
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Place the vehicle on a maintenance stand so TIP _ _ _ _ _ _ _ _ _ _ _ _ __
that the front wheel is elevated. Use the side of the rod holder that is marked "B".
2. Remove:
• Front brake caliper ~ - -1
Refer to "FRONT BRAKE" on page 4-35 .
• Front wheel
Refer to "FRONT WHEEL" on page 4-20.
~ ~ --4
3. Loosen:
~t'LJ-- - 2
• Upper bracket pinch bolt "1"
• Cap bolt "2" 3
• Lower bracket pinch bolts "3"
EWA13640

A WARNING c. Hold the cap bolt and loosen the locknut.

Before loosening the upper and lower brack- d. Remove the cap bolt and washer.
et pinch bolts, support the front fork leg. e. Remove the rod holder and fork spring
compressor.
f. Remove the spacer and locknut.
g. Remove the fork spring.
2. Drain:
• Fork oil
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Stroke the damper rod assembly "1" several
times while draining the fork oil.

4. Remove:
• Front fork leg

4-87
 FRONT FORK

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
While holding the damper rod with the damper
rod holder "1", loosen the damper rod assembly
bolt.

\,,--_., Damper rod holder (027)

90890-01582
Damper rod holder
YM-01582

3. Remove:
• Dust seal "1"
• O il seal clip "2"
(with a flat-head screwdriver)
ECA19100

NOTICE
-------------
Do not scratch the outer tube.
•

1
L - -1
EAS30208

CHECKINGTHEFRONTFORKLEGS
The following procedure applies to both of the
front fork legs.
2 1. Check:
• Inner tube "1"
• Outer tube "2"
4. Remove: Bends/damage/scratches ➔ Replace.
EWA13650
• O uter tube
a. Hold the front fork leg horizontally.
& WARNING
b. Securely clamp the brake caliper bracket Do not attempt to straighten a bent inner
in a vise w ith soft jaws. tube as this may dangerously weaken it.
c. Separate the outer tube from the inner
tube by pulling the outer tube forcefully but 1
carefully.
0 0
ECA19880

NOTICE
-------------
Excessive force will damage the bushings.
Damaged bushings must be replaced.

2
2. Measure:
• Spring free length "a"
Out of specification ➔ Replace.

Fork spring free length

305.3 mm (12.02 in)
Limit
299.1 mm (11.78 in)
5. Remove:
• Damper rod assembly bolt
• Damper rod assembly

4-88
 FRONT FORK

-Outer tube bushing

-Oil seal
-Oil seal clip
- Dust seal
- Copper washer
-0-ring
• Before assembling the front fork leg, make
sure all of the components are clean .
1. Install:
• Damper rod assembly "1"
3. Check: E CA19120

NOTICE
• Damper rod "1" -------------
Damage/wear ➔ Replace. A II ow the damper rod assembly to slide
Obstruction ➔ Blow out all of the oil passag- slowly down the inner tube "2" until it pro-
es with compressed air. trudes from the bottom of the inner tube. Be
ECA19 110
careful not to damage the inner tube.
NOTICE
-------------
• The front fork leg has a very sophisticated
internal construction, which are particular-
ly sensitive to foreign material.
• When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.

1
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
0\ 0
1 ~~~010========/========n11=111111, The left side damper rod assembly has the two
holes of oil path, unlike the right side. (MTT9K/
MTT9KC)

EAS30209
[Al
ASSEMBLINGTHEFRONTFORKLEGS , - - - - - - - ,,~ ,
O,_o_ _ _ _ _ _\~,,~ • __.,
The following procedure applies to both of the
front fork legs.
EWA17090

A WARNING
• Note that the amount of the fork oil is differ-
ent in the left and right front fork legs. Make
sure to fill each of the left and right front
A. Left side
fork legs with the specified amount of the
B. Right side
fork oil.
• If both front fork legs are not filled with the 2. Tighten:
specified amount of the fork oil, it may • Damper rod assembly bolt
cause poor handling and a loss of stability. (along with the copper washer •~M 1
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Front fork damper rod assembly
• When assembling the front fork leg , be sure to bolt
replace the following parts: 23 N-m (2.3 kgf-m, 17 lb-ft)
- Inner tube bushing LOCTITE®

4-89
 FRONT FORK

TIP _ _ _ _ _ _ _ _ _ _ _ _ __
While holding the damper rod assembly with the
damper rod holder "1 ", tighten the damper rod
assembly bolt. mms 4
mll6
Damper rod holder (027)
90890-01582
Damper rod holder
YM-01582

ff

3. Lubricate: 5. Install:
• Inner tube's outer surface • Outer tube
(to the inner tube)
Recommended oil 6. Install:
l
Yamaha Suspension Oil 01 • Outer tube bushing "1"
• Washer "2"
4. Install: (with the fork seal driver "3")
• Dust seal "1" •~M Fork seal driver
iiM
• O il seal clip "2" 90890-01442
• O il seal "3'' i@M Adjustable fork seal driver (36-46
• Washer "4" mm)
• O uter tube bushing "5''i@tWJ YM-01442
• Inner tube bushing "6" •~tWI
ECA19170

NOTICE
-------------
Make sure the numbered side of the oil seal
faces bottom side. 3
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ 2
• Before installing the oil seal , lubricate its lips
1 ..- ,
___ ... ,
with lithium-soap-based grease. , ...::::::",
• Lubricate the outer surface of the inner tube
with fork oil.
• Before installing the oil seal, cover the top of 7. Install:
the front fork leg with a plastic bag to protect • Oil seal "1"
the oil seal during installation. (with the fork seal driver "2")

Fork seal driver

90890-01442
Adjustable fork seal driver (36-46
mm)
YM-01442

4-90
 FRONT FORK

Rod puller
90890-01437
Universal damping rod bleeding
tool set
YM-A8703
2 Rod puller attachment (M1 O long)
90890-01578
Universal damping rod bleeding
tool set
YM-A8703
8. Install:
• Oil seal clip "1"
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Adjust the oil seal clip so that it fits into the outer
tube's groove.

11.Fill:
• Front fork leg
(with the specified amount of the recom-
mended fork oil)

9. Install: Recommended oil

• Dust seal "1" Yamaha Suspension Oil 01
(with the fork seal driver "2") Quantity (left)
444.0 cm 3 (15.01 US oz, 15.66

~
Fork seal driver Imp.oz) (MTT9K, MTT9KC)
90890-01442 439.0 cm 3 (14.84 US oz, 15.48
Adjustable fork seal driver (36-46 Imp.oz) (MTT9GTK, MTT9GTKC)
mm) Quantity (right)
YM-01442 431.0 cm 3 (14.57 US oz, 15.20
Imp.oz) (MTT9K, MTT9KC)
443.0 cm 3 (14.98 US oz, 15.62
Imp.oz) (MTT9GTK, MTT9GTKC)
ECA14230

NOTICE
- - - - - - - - - - - - -
• Be sure to use the recommended fork oil.
Other oils may have an adverse effect on
front fork performance.
• When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
1a.Install:
• Rod puller "1" 12.After filling the front fork leg, slowly stroke the
• Rod puller attachment (M10 long) "2" damper rod "1" up and down (at least ten
(onto the damper rod "3") times) to distribute the fork oil.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Be sure to stroke the damper rod slowly be-
cause the fork oil may spurt out.

4-91
 FRONT FORK

a. Remove the rod puller and rod puller at-

13.Before measuring the fork oil level, wait ten
tachment.
minutes until the oil has settled and the air
b. Install the fork spring .
bubbles have dispersed .
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Install the fork spring with the smaller diameter
Be sure to bleed the front fork leg of any residual
"a" facing up "A".
air.
14.Measure:
---► A
• Front fork leg oil level "a"
(from the top of the outer tube, with the outer
tube fully compressed and without the fork
spring) a
Out of specification ➔ Correct.

Level (left)
174 mm (6.9 in) (MTT9K,
MTT9KC)
175 mm (6.9 in) (MTT9GTK, c. Install the locknut all the way onto the
MTT9GTKC) damper rod assembly.
Level (right) d. Install the rod puller and rod puller attach-
175 mm (6.9 in) ment.
e. Install the spacer.
- f. Install the fork spring compressor.
g. Press down on the spacer with the fork
a spring compressor "1".
h. Pull up the rod puller and install the rod
~~ holder "2" between the locknut "3" and the
.~
spacer "4".
J
"

15.lnstall : (MTT9K/MTT9KC left side)

• Fork spring "1"
• Spacer "2"
• Locknut "3"
• Washer "4"
• Cap bolt "5"
(along with the 0-ring •~Mi

4-92
 FRONT FORK

I. Remove the rod holder and fork spring

Rod puller compressor.
90890-01437 16.lnstall: (MTT9K/MTT9KC right side,
Universal damping rod bleeding MTT9GTK/MTT9GTKC)
tool set
YM-A8703 • Fork spring "1"
Rod puller attachment (M10 long) • Spacer "2"
90890-01578 • Locknut "3"
Universal damping rod bleeding • Damper adjusting rod "4"
tool set • Washer "5"
YM-A8703 • Cap bolt "6"
Fork spring compressor (along with the 0-ring 1§t:WJ1
90890-01441
Fork spring compressor
YM-01441
Rod holder
90890-01434
Damper rod holder double ended
YM-01434

TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Use the side of the rod holder that is marked "B".

a. Remove the rod puller and rod puller at-

tachment.
b. Install the fork spring.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
4 -------4:t'~~ Install the fork spring with the smaller diameter
1- --I-~~~ "a" facing up "A".

--► A
----
1. Remove the rod puller and rod puller at- -- -- --.-
tachment.
a
J. Install the washer and cap bolt, and then
finger tighten the cap bolt.
EWA13670

& WARNING
Always use a new cap bolt 0-ring.
k. Hold the cap bolt "5" and tighten the lock- c. Install the locknut all the way onto the
nut "3" to specification. damper rod assembly.
d. Install the rod puller and rod puller attach-
Front fork cap bolt locknut ment.
15 N-m (1.5 kgf-m, 11 lb-ft) e. Install the spacer.
f. Install the fork spring compressor.
g. Press down on the spacer with the fork
:i--- - - 5 spring compressor "1".
h. Pull up the rod puller and install the rod
holder "2" between the locknut "3" and the
spacer "4".

4-93
 FRONT FORK

Rod puller
90890-01437
Universal damping rod bleeding
tool set
YM-A8703
Rod puller attachment (M10 long)
90890-01578
Universal damping rod bleeding C
tool set
YM-A8703
Fork spring compressor I. Install the damper adjusting rod, washer
90890-01441 and cap bolt, and then finger tighten the
Fork spring compressor cap bolt.
YM-01441 EWA13670

Rod holder £ WARNING

90890-01434
Damper rod holder double ended
YM-01434
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Use the side of the rod holder that is marked "B".
Always use a new cap bolt 0-ring.
m. Hold the cap bolt "5" and tighten the lock-
nut "3" to specification .
Front fork cap bolt locknut
15 N-m (1.5 kgf-m, 11 lb-ft)

~--5

4 -------4:t'~~
1- --I-~~~

1.Remove the rod puller and rod puller at-

tachment. n. Remove the rod holder and fork spring
J. Position the locknut "3" as specified "b". compressor.
17.lnstall:
Distance "b" • Cap bolt
12 mm (0.47 in) (to the outer tube)
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Temporarily tighten the cap bolt.
3 • When to tighten the cap bolt to the specified
b torque is after install ing the front fork leg to the
I vehicle and tightening the lower bracket pinch
bolts.

EAS30210

INSTALLING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
k. Set the cap bolt distance "c" to specifica- 1. Install:
tion. • Front fork leg
Temporarily tighten the upper and lower
Distance "c" bracket pinch bolts.
13 mm (0.51 in)

4-94
 FRONT FORK

TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Make sure the outer tube is flush with the top of
the upper bracket.
2. Tighten:
• Lower bracket pinch bolts "1"

~ Lower bracket pinch bolt

61/~ 23 N•m (2.3 kgf•m, 17 lb-ft)

• Cap bolt "2"

~ Front fork cap bolt

&~ 23 N•m (2.3 kgf•m, 17 lb-ft)

• Upper bracket pinch bolt "3"

~ Upper bracket pinch bolt

61/~ 26 N•m (2.6 kgf•m, 19 lb-ft)
EWA13680

A WARNING
Make sure the brake hoses are routed prop-
erly.

4-95
 STEERING HEAD

EAS20035

STEERING HEAD
Removing the lower bracket
, ~ , 110 N•m (11 kgf•m, 81 lb•ft) ~,,-; ~7- N--m
- 0
- .-
7 -k-f-.m- ,-
5-.2- 1b
- ·-ft~ ,--=---~~~~~----7
2 _____,
~., 7 N•m (0.7 kgf•m, 5.2 lb·ft)

'

, ~ 1st 52 N•m (5.2 kgf•m, 38 lb·ft)

. 2nd 18 N•m 1.8 k f•m 13 lb·ft

FWD 0 0

-4: 7 N•m 0.7 k f•m , 5.2 lb·ft

Order Job/Parts to remove Q'ty Remarks

Fuel tank Refer to "FUEL TANK" on page 7-1.

Air filter case Refer to "GENERAL CHASSIS (3)" on page

4-13.
Refer to "GENERAL CHASSIS (2)" on page
Headlight assembly 4-6.
Refer to "GENERAL CHASSIS (2)" on page
Meter assembly 4-6.
Handlebar Refer to "HANDLEBAR" on page 4-69.
Front fork legs Refer to "FRONT FORK" on page 4-80.
1 Main switch guard 1
2 Protector 1
3 Rivet 1
4 Coupler cover assembly 1
5 Clamp 1

4-96
 STEERING HEAD

Removing the lower bracket

'.+;, 110 N•m (11 kgf•m, 81 lb•ft) ~,,-, ~7- N--m
- 0- .-
7 -k -f-.m- ,-
5-.2- 1b
- ·-ft~ ,----~~~~~----7
~" 7 N•m (0.7 kgf•m, 5.2 lb·ft)
13

'

10 11
, >'; I1-st 52 N•m (5.2 kgf•m, 38 lb·ft)
---+---~-~~-~'----<
. 2nd 18 N•m 1.8 k f•m 13 lb·ft

12
FWD 0 0

4 7 N•m 0.7 k f•m , 5.2 lb·ft

Order Job/Parts to remove Q'ty Remarks

6 Main switch coupler 2 Disconnect.
7 Horn lead connector 2 Disconnect.
8 Horn 1
9 Front brake hose 1
10 Front brake hose bracket 1
11 Horn bracket 1
12 Lower bracket cap 1
13 Steering stem nut 1
14 Upper bracket 1
15 Lock washer 1

4-97
 STEERING HEAD

Removing the lower bracket

'.+;, 11 0 N•m (11 kgf•m, 81 lb•ft) ~,,-, ~7-N--m-0-.7-k-f-.m-
- ,-5.2-
- 1-b·-
ft~ ,----~~~~~----7
~" 7 N•m (0.7 kgf•m, 5.2 lb·ft)

'

~ ---;
~ /,
/ -
~~----
I 1\
I
,~
'J.7f :} '3-1~
'
I
'
I
'«:~o

19
L-~

FWD 0 0

4 7 N•m 0.7 k f•m , 5.2 lb·ft

Order Job/Parts to remove Q 'ty Remarks

16 Upper ring nut 1

17 Rubber washer 1
18 Lower ring nut 1
19 Lower bracket 1
20 Bearing cover 1
21 Lower bearing dust seal 1
22 Upper bearing 1
23 Lower bearing 1

4-98
 STEERING HEAD

EAS30213
• Bearing race "2"
REMOVING THE LOWER BRACKET
Damage/pitting ➔ Replace the bearings and
1. Stand the vehicle on a level surface.
EWA13 120
bearing races as a set.
AwARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:
2- -(e3J r::, 2

• Upper ring nut 1 ~t) &ffi@> 1

•
•
Rubber washer
Lower ring nut "1"
2- ~ e- , 2
• Lower bracket
EWA13730

AwARNING
Securely support the lower bracket so that 3. Replace:
there is no danger of it falling. • Bearing
• Bearing race
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ a. Remove the bearing races from the steer-
• Hold the lower ring nut with steering nut ing head pipe "1" with a long rod "2" and
wrench , and then remove the upper ring nut hammer.
with the ring nut wrench . b. Remove the bearing race "3" from the low-
• Remove the lower ring nut with the steering nut er bracket w ith a floor chisel "4" and ham-
wrench "2". mer.
c. Install a new dust seal and new bearing
Ring nut wrench races.
ECA14270
90890-01268
NOTICE
Spanner wrench -------------
YU-01268 1f the bearing race is not installed properly,
Steering nut wrench the steering head pipe could be damaged.
90890-01403
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Exhaust flange nut wrench
YU-A9472 • Always replace the bearings and bearing races
as a set.
• Whenever the steering head is disassembled,
replace the dust seal.

EAS30214

CHECKING THE STEERING HEAD

1. Wash :
• Bearing
• Bearing race

Recommended cleaning solvent

I
Kerosene

2. Check:
• Bearing "1"

4-99
 STEERING HEAD

TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Temporarily tighten the upper and lower bracket
pinch bolts.
3
5. Tighten:
C - • Steering stem nut

Steering stem nut

110 N•m (11 kgf-m, 81 lb-ft)

4. Check:
• Upper bracket
• Lower bracket
(along with the steering stem)
Bends/cracks/damage ➔ Replace.
EAS30216

INSTALLING THE STEERING HEAD

1. Lubricate:
• Upper bearing
• Lower bearing

Recommended lubricant
I Lithium-soap-based grease

2. Install:
• Lower ring nut "1"
• Rubber washer "2"
• Upper ring nut "3"
• Lock washer "4"
Refer to "CHECKING AND ADJUSTING
THE STEERING HEAD" on page 3-19.

2
1

3. Install:
• Upper bracket
• Steering stem nut
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Temporarily tighten the steering stem nut.
4. Install:
• Front fork legs
Refer to "FRONT FORK'' on page 4-80.

4-100
 REAR SHOCK ABSORBER ASSEMBLV

EAS20036

REAR SHOCK ABSORBER ASSEMBLY

Removing the rear shock absorber assembly (MTT9K/MTT9KC)

~ ·
s~-/
/ ,.~ / /-~ ,.---- ---
__ __________---:-:~_-_-.., _'

~~ .,,,,,,," " - C,./

/I ~~ ~ '>;\;
,,,

# 0-..
~ _,

4 ,, ,,"

, ~ /',/
,/ /
""'., 61 N•m 6.1 k f•m , 45 lb·ft
V~ '\, 44 N•m (4.4 kgf•m, 32 lb·ft)

.,t 44 N•m 4.4 k f•m, 32 lb·ft

~•.. 55 N•m (5.5 kgf•m, 41 lb·ft)

Order Job/Parts to remove Q 'ty Remarks

Fuel tank front cover/Front side panel/Front side Refer to "GENERAL CHASSIS (2)" on page
cowling 4-6.

Passenger seat/Rider seat Refer to "GENERAL CHASSIS (1 )" on page

4-1 .

Fuel tank cover Refer to "GENERAL CHASSIS (3)" on page

4-13.
Fuel tank Refer to "FUEL TANK" on page 7-1 .
Canister (for California only) Refer to "FUEL TANK" on page 7-1 .
Muffler assembly Refer to "ENGINE REMOVAL:' on page 5-9,
1 Connecting arm lower nut/Bolt 1/1
2 Relay arm nut/Collar/Bolt 1/1/1

3 Rear shock absorber assembly upper nut/ 1/1/1

Washer/Bolt
Rear shock absorber assembly lower nut/Wash-
4 er/Bolt 1/2/1

4-101
 REAR SHOCK ABSORBER ASSEMBLV

Removing the rear shock absorber assembly (MTT9K/MTT9KC)

10

~, 44 N•m (4.4 kgf•m, 32 lb·ft)

t,, 61 N•m 6.1 k f•m , 45 lb·ft
"
.,t 44 N•m 4.4 k f•m, 32 lb.ft

..::,_
. 55 N•m (5.5 kgf•m, 41 lb·ft)

Order Job/Parts to remove Q'ty Remarks

5 Rear shock absorber assembly 1

6 Connecting arm upper nut/Bolt 1/1
7 Connecting arm 2
8 Relay arm 1
9 Collar/Oil seal/Bearing 1/2/2
10 Collar/Oil seal/Bearing 2/4/2

4-102
 REAR SHOCK ABSORBER ASSEMBLV

Removing the rear shock absorber assembly (MTT9GTK/MTT9GTKC)

.-.; 8 N•m (0.8 kgf•m, 5.9 lb·ft)

1
3

~ , -_,, -- --
,~
~~
/ / .,----~
;----------:---~-~-----.. ,
,. '-._ / I .. \;\
.. / C,./ .... ,,, """"

, #

~ 1\ /,-'

...
,, ~ -- ,_,__ 4 (J~" ____ ___ ,v
3 ,
~0
,/
/,
/
5
e:.V
~ - 61 N•m (6.1 kgf•m, 45 lb·ft)

I'<. 44 N•m (4.4 kgf•m, 32 lb·ft)

? -i\ 44 N•m (4.4 kgf•m, 32 lb·ft)

.. ~ 55 N•m (5.5 kgf•m, 41 lb•ft)

Order Job/Parts to remove Q'ty Remarks

Fuel tank front cover/Front side panel/Front side Refer to "GENERAL CHASSIS (2)" on page
cowling 4-6.

Passenger seat/Rider seat Refer to "GENERAL CHASSIS (1 )" on page

4-1 .

Fuel tank cover Refer to "GENERAL CHASSIS (3)" on page

4-13.
Fuel tank Refer to "FUEL TANK" on page 7-1 .
Canister (for California only) Refer to "FUEL TANK" on page 7-1 .
Muffler assembly Refer to "ENGINE REMOVAL:' on page 5-9.
1 Connecting arm lower nut/Bolt 1/1
2 Relay arm nut/Collar/Bolt 1/1/1

3 Rear shock absorber assembly upper nut/ 1/1/1

Washer/Bolt
Rear shock absorber assembly lower nut/Wash-
4 er/Bolt 1/2/1

5 Rear shock absorber assembly 1

4-103
 REAR SHOCK ABSORBER ASSEMBLV

Removing the rear shock absorber assembly (MTT9GTK/MTT9GTKC)

.-.; 8 N•m (0.8 kgf•m, 5.9 lb·ft)

10

.1\ 44 N•m (4.4 kgf•m, 32 lb·ft)

~ - 61 N•m (6.1 kgf•m, 45 lb·ft)

I'<. 44 N•m (4.4 kgf•m, 32 lb·ft)

.. ~ 55 N•m (5.5 kgf•m, 41 lb•ft)

Order Job/Parts to remove Q'ty Remarks

6 Connecting arm upper nut/Bolt 1/1

7 Connecting arm 2
8 Relay arm 1
9 Collar/Oil seal/Bearing 1/2/2
10 Collar/Oil seal/Bearing 2/4/2

4-104
 REAR SHOCK ABSORBER ASSEMBLV

EAS30826

HANDLINGTHEREARSHOCKABSORBER 20-25 mm
EWA13740
(0.79-0.98 in)
AwARNING
This rear shock absorber contains highly
compressed nitrogen gas. Before handling
the rear shock absorber, read and make sure
you understand the following information.
The manufacturer cannot be held responsi-
ble for property damage or personal injury
that may result from improper handling of
the rear shock absorber. 10-15 mm
• Do not tamper or attempt to open the rear (0.39-0.59 in)
shock absorber.
• Do not subject the rear shock absorber to
an open flame or any other source of high
heat. High heat can cause an explosion due 0 @)
to excessive gas pressure.
• Do not deform or damage the rear shock
absorber in any way. Rear shock absorber
damage will result in poor damping perfor- A. MTT9K/MTT9KC
mance. B. MTT9GTK/MTT9GTKC

EAS30219
EAS30729

DISPOSING OF A REAR SHOCK ABSORBER REMOVING THE REAR SHOCK ABSORBER

1. Gas pressure must be released before dis-
posing of a rear shock absorber. To release
the gas pressure, drill a 2-3 mm (0.08- 0.12
in) hole through the rear shock absorber as
shown.
EWA13760
AwARNING
Wear eye protection to prevent eye damage
from released gas or metal chips.
ASSEMBLY
1. Stand the vehicle on a level surface.
EWA13120
AwARNING
Securely support the vehicle so that there is
no danger of it falling over.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Place the vehicle on the centerstand so that the
rear wheel is elevated.
2. Remove:
• Connecting arm lower nut "1"
• Connecting arm lower bolt
• Relay arm nut "2"
• Relay arm bolt
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

When removing the bolt, hold the swingarm so

that it does not drop down.

4-105
 REAR SHOCK ABSORBER ASSEMBLV

3. Remove: • Oil seals

• Rear shock absorber assembly upper nut
• Rear shock absorber assembly upper bolt Recommended lubricant
l Lithium-soap-based grease
• Rear shock absorber assembly
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
2. Install:
Remove the rear shock absorber assembly from • Bearings "1"
between the swingarm and frame. (to the relay arm)

EAS30220
• Oil seals "2" •~H
(to the relay arm)
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY
Installed depth "a"
1. Check:
6.0 mm (0.24 in)
• Rear shock absorber rod Installed depth "b"
Bends/damage ➔ Replace the rear shock 7.0 mm (0.28 in)
absorber assembly. Installed depth "c"
• Rear shock absorber assembly 1.5-2.5 mm (0.06-0.1 O in)
Gas leaks/oil leaks ➔ Replace the rear shock Installed depth "d"
absorber assembly. 1.0-2.0 mm (0.04-0.08 in)
• Spring
• Bushings TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Damage/wear ➔ Replace the rear shock ab- • W hen installing the oil seals "2" to the relay
sorber assembly. arm , face the character stamp of the oil seals
• Bolts outside.
Bends/damage/wear ➔ Replace. • When installing the connecting arms "4" to the
relay arm, face the 1 RC mark of the connecting
EAS30221

CHECKING THE CONNECTING ARM AND arms outside.

RELAY ARM
1. Check:
• Connecting arms "1"
• Relay arm "2"
Damage/wear ➔ Replace.

'' ''
2 lj 2

1
mm
[Al
4
d
b
3

2. Check: 1
• Bearings
• O il seals
Damage/pitting ➔ Replace. d -tt-t--i+- d
3. Check: b-+-+-~
• Collars 3. Relay arm
Damage/scratches ➔ Replace. 4. Connecting arm
EAS30222 5. Rear shock absorber assembly
INSTALLING THE RELAY ARM A. Left side
1. Lubricate: B. Right side
• Collars

4-106
 REAR SHOCK ABSORBER ASSEMBLV

EAS30225

INSTALLING THE REAR SHOCK

ABSORBER ASSEMBLY
1. Install:
• Rear shock absorber assembly
• Rear shock absorber assembly upper bolt
• Rear shock absorber assembly upper nut
• Relay arm bolt
• Relay arm nut
• Connecting arm lower bolt
• Connecting arm lower nut
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• Install the rear shock absorber assembly upper
bolt, relay arm bolt and connecting arm lower
bolt from the left.
• When installing the rear shock absorber as-
sembly, lift up the swingarm.
• Install the rear shock absorber assembly with
the rebound damping adjusting screw facing
the left side of the vehicle.
2. Tighten:
• Rear shock absorber assembly upper nut
• Relay arm nut
• Connecting arm lower nut

Rear shock absorber assembly

nut (upper)
44 N•m (4.4 kgf•m, 32 lb-ft)
Relay arm nut
61 N•m (6.1 kgf•m, 45 lb-ft)
Connecting arm lower nut
55 N•m (5.5 kgf•m, 41 lb-ft)

4-107
 SWINGARM

EAS20037

SWINGARM
Removing the swingarm
~ ,, ...._ I ~

• ~ . 9 N•m (0.9 kgf•m, 6.6 lb·ft) ::,_. ;;,:" 110 N•m (11 kgf•m, 81 lb·ft)

-:._ 55 N•m (5.5 kgf•m, 41 lb·ft)

~- 7 N•m (0.7 f•m , 5.2 lb·ft
'< -:I . \~
'
?.! "
' . ~-
1 _,,,y
,1/'1 §?I

4 ~ ~ ~/' ~
, / ' , ~~

' ~ :{)'lt::::::-- ~
- ---1-~ ' ~
•
.
-~~~
,<\-
' ~' ,
()V LJ. ~ "-.

.,....., :✓.:,. 7 N•m 0. 7 k f•m, 5.2 lb·ft

rnt!P©,

O rder Job/Parts to remove Q 'ty Remarks

Rear brake caliper Refer to "REAR BRAKE" on page 4-48.

Rear wheel Refer to "REAR WHEEL:' on page 4-27.
Muffler assembly Refer to "ENGINE REMOVAL:' on page 5-9.
Drive chain Refer to "CHAIN DRIVE" on page 4-112.
1 Connecting arm lower nut 1
2 Connecting arm lower bolt 1
3 Pivot shaft nut 1
4 Pivot shaft 1
5 Washer 1
6 Swingarm 1
7 Drive chain guard 1
8 Drive chain guide 1
9 Rear fender 1

4-108
 SWINGARM

Removing the swingarm

~ ,, ...._ I ~

• ~ , 9 N•m (0.9 kgf•m, 6.6 lb·ft) ::,___. "~- 110 N•m (11 kgf•m, 81 lb·ft)

11

rn!'P'@)

Order Job/Parts to remove Q'ty Remarks

10 Rear fender bracket 1

11 Dust cover 4
12 Collar 3
13 Oil seal 4
14 Bearing 4
15 Washer 1

4-109
 SWINGARM

EAS30226

REMOVING THE SWINGARM

1. Stand the vehicle on a level surface.
EWA13 120

AwARNING
Securely support the vehicle so that there is
no danger of it falling over.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Place the vehicle on the centerstand so that the
rear wheel is elevated.
4. Remove:
2. Remove:
• Drive chain
• Connecting arm lower nut "1" Refer to "REMOVING THE DRIVE CHAIN"
• Connecting arm lower bolt on page 4-114.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Swingarm
When removing the bolt, hold the swingarm so
EAS30227
that it does not drop down. CHECKING THE SWINGARM
1. Check:
• Swingarm
Bends/cracks/damage ➔ Replace.
2. Check:
• Pivot shaft
Roll the pivot shaft on a flat surface.
Bends ➔ Replace.
EWA13no

AwARNING
Do not attempt to straighten a bent pivot
3. Measure: shaft.
• Swingarm side play
• Swingarm vertical movement
a. Measure the tightening torque of the pivot
shaft nut.

Pivot shaft nut

110 N-m (11 kgf-m, 81 lb-ft)

b. Check the swingarm side play "A" by mov-

ing the swingarm from side to side.
If the swingarm has excessive side-to-side
play, check the collars, bearings, and dust 3. Wash :
covers. • Pivot shaft
c. Check the swingarm vertical movement • Dust covers
"B" by moving the swingarm up and down. • Collars
If the swingarm vertical movement is not • Washer
smooth or if there is binding, check the piv-
Recommended cleaning solvent
ot shaft, collars, bearings, and dust cov- I
Kerosene
ers.
4. Check:
• Dust covers "1"
• Oil seals "2"
Damage/wear ➔ Replace.
• Collars "3"
Damage/scratches ➔ Replace.

4-110
 SWINGARM

• Bearings "4"
Damage/pitting ➔ Replace. ---i--1- -- b a
- -H--- C C '
I)
~~~
____.17
a -iu- '
- --- - L_:~ :
riil rl]!~~2i'_~ .: ==~-
iAi : ' -- ' II
ffil
--- -): !10, v

_,_;J

d
e e
(l
'
'
IA] ffil
mm2 ~ --> 2mm
1

A. Left side
B. Right side
EAS30228

INSTALLING THE SWINGARM 3. Install:

1. Lubricate: • Swingarm
• Dust covers • Pivot shaft
• Pivot shaft
Pivot shaft nut
• Oil seals 110 N•m (11 kgf •m, 81 lb-ft)
• Collars
4. Install:
Recommended lubricant
Lithium-soap-based grease • Drive chain
Refer to "INSTALLIN G THE DRIVE C HAIN"
2. Install: on page 4-11 5.
• Bearings "1" • Connecting arm lower bolt
(to the swingarm) • Connecting arm lower nut
• Oil seals "2" iiM Connecting arm lower nut
(to the swingarm) 55 N•m (5.5 kgf•m, 41 lb-ft)
Installed depth "a" • Rear wheel
2.0 mm (0.08 in) Refer to "REAR SHOCK ABSORBER AS-
Installed depth "b" SEM BLY'' on page 4-101 and "REAR
9.0 mm (0.35 in)
WHEEL" on page 4-27.
Installed depth "c"
0.5--1.5 mm (0.02-0.06 in) 5. Adjust:
Installed depth "d" • Drive chain slack
7.0 mm (0.28 in) Refer to "DRIVE CHAIN SLAC K" on page
Installed depth "e" 3-18.
1.5--2.5 mm (0.06-0.1 O in)
Drive chain slack (Maintenance
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ stand)
35.0-45.0 mm (1.38-1. 77 in)
When installing the oil seals to the swingarm ,
face the character stamp of the oil seals outside.

4-111
 CHAIN DRIVE

EAS20038

CHAIN DRIVE
Removing the drive chain (MTT9K/MTT9KC)
. ,,______'

3 /.,. 95 N•m 9.5 k f•m, 70 lb•ft

2
1
4
1
' 4. 8 N•m (0.8 kgf•m, 5.9 lb·ft)

~~-- 10 N•m (1 .0 kgf•m, 7.4 lb·ft)

" 14 N•m (1 .4 kgf•m, 10 lb·ft)

Order Job/Parts to remove Q 'ty Remarks

1 Locknut 2
2 Shift rod 1
3 Shift arm 1
4 Drive sprocket cover 1
5 Drive chain guide 1
6 Drive sprocket nut 1
7 Washer 1
8 Drive sprocket 1
9 Drive chain 1

4-112
 CHAIN DRIVE

Removing the drive chain (MTT9GTK/MTT9GTKC)

1~

r. 95 N·m (9.5 kgf·m, 70 lb·ft)

.4_ 10 N · m (1 .0 kgf · m, 7.4 lb·ft)

r.. 14 N·m (1.4 kgf·m, 10 lb·ft)

Order Job/Parts to remove Q'ty Remarks

Refer to "GENERAL CHASSIS (1 )" on page
Passenger seat/Rider seat
4-1 .
1 Shift switch coupler 1 Disconnect.
2 Locknut 3
3 Shift switch 1
4 Shift rod 1
5 Shift arm 1
6 Shift rod joint 1
7 Drive sprocket cover 1
8 Drive chain guide 1
9 Drive sprocket nut 1
10 Washer 1
11 Drive sprocket 1
12 Drive chain 1

4-113
 CHAIN DRIVE

EAS30229
REMOVING THE DRIVE CHAIN
1. Stand the vehicle on a level surface.
EWA13 120
AwARNING
Securely support the vehicle so that there is
no danger of it falling over.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Place the vehicle on the centerstand so that the
rear wheel is elevated.
2. Straighten the drive sprocket nut rib "a".
b. Calculate the length "a" of the 15-link sec-
tion of the drive chain using the following
formula.
Drive chain 15-link section length "a" =
(length "b" between pin inner sides +
length "c" between pin outer sides)/2
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• When measuring a 15-link section of the drive
chain , make sure that the drive chain is taut.
• Perform this procedure 2-3 times, at a different
location each time.

1 2 3 4 5 6121 3 141516

a (Q) 0 0 0

3. Remove:
• Drive chain
ECA17410

NOTICE 1 2 3 4 5 6 121314 15 16
-------------
Be sure to put on safety goggles when work- I I I I I 1 1 1 1 1 11 1 11 1 111 11 11 11 1 1 11
• II
1ng.
(o 0 J (o o) (o 0 ,ro o) Co 0) I O) OJ
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ '
Cut the drive chain with the drive chain cut & riv- b
et tool.
C

Drive chain cut & rivet tool

2. Check:
90890-01550
Drive chain cut & rivet tool • Drive chain
YM-01550 Stiffness ➔ Clean and lubricate or replace.
• •
• •
EAS30230 • •
• •
CHECKING THE DRIVE CHAIN •
• •
• •
1. Measure: • •
•
• 15-link section "a" of the drive chain • •
•
Out of specification ➔ Replace the drive
chain.
(/) •
•
• ••

~ •
•
15-link length limit
239.3 mm (9.42 in)
(J)
I I
•
•
•
•
3. Clean:
a. Measure the length "b" between the inner
• Drive chain
sides of the pins and the length "c" be-
a. Wipe the drive chain with a clean cloth.
tween the outer sides of the pins on a 15-
b. Put the drive chain in kerosene and re-
link section of the drive chain as shown in
move any remaining dirt.
the illustration.
c. Remove the drive chain from the kerosene
and completely dry it.

4-114
 CHAIN DRIVE

ECA19090

NOTICE
- - - - - - - - - - - - - -
• This vehicle has a drive chain with small
rubber 0-rings "1" between the drive chain
side plates. Never use high-pressure water
or air, steam, gasoline, certain solvents 2 1
(e.g., benzine), or a coarse brush to clean
the drive chain. High-pressure methods
could force dirt or water into the drive
chain's internals, and solvents will deterio-
rate the 0-rings. A coarse brush can also
5. Lubricate:
damage the 0-rings. Therefore, use only
• Drive chain
kerosene to clean the drive chain.
• Do not soak the drive chain in kerosene for Recommended lubricant
more than ten minutes, otherwise the 0- I Chain lubricant suitable for C-
rings can be damaged. ring chains

EAS30231

CHECKING THE DRIVE SPROCKET

1. Check:
• Drive sprocket
More than 1/4 tooth "a" wear ➔ Replace the
drive sprocket, the rear wheel sprocket and
the drive chain as a set.
Bent teeth ➔ Replace the drive sprocket, the
rear wheel sprocket and the drive chain as a
set.

1 a

I....--=====r---'
I I I,_-===/-7-1
2

4. Check: b. Correct
• 0-rings "1" 1. Drive chain roller
Damage ➔ Replace the drive chain. 2. Drive sprocket
• Drive chain rollers "2"
Damage/wear ➔ Replace the drive chain . EAS30232

• Drive chain side plates "3" CHECKING THE REAR WHEEL SPROCKET
Damage/wear/cracks ➔ Replace the drive Refer to "CHECKING AND REPLACING THE
chain. REAR WHEEL SPROCKET' on page 4-31.
EAS30233

CHECKING THE REAR WHEEL DRIVE HUB

Refer to "CHECKING THE REAR WHEEL
DRIVE HUB" on page 4-31 .
EAS30234

INSTALLING THE DRIVE CHAIN

1. Install:
• Drive chain

4-115
 CHAIN DRIVE

ECA17410

NOTICE
- - - - - - - - - - - - -
Be sure to put on safety goggles when work-
•
1ng.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
C
Install the drive chain joint with the drive chain
cut & rivet tool.
/ --
1
Drive chain cut & rivet tool
90890-01550
Drive chain cut & rivet tool 2. Lubricate:
YM-01550 • Drive chain

a. When press fitting the connecting plate Recommended lubricant

I Chain lubricant suitable for 0-
"1", make sure the space "a" between the
end of the connecting pin "2" and the con-
ring chains
necting plate is 1.2- 1.4 mm (0.05-0.06
3. Install:
in) .
• Drive sprocket
• Washer "1"
• Drive sprocket nut "2" i§H
Drive sprocket nut
2 95 N-m (9.5 kgf-m, 70 lb-ft)

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
1 --
L-l=J':'..~-::'.'..~:----
.: .:r~::!=:l: : : a • While applying the rear brake, tighten the drive
t sprocket nut.
• Install washer "1" with the "OUT' mark "a" fac-
b. After riveting, make sure the diameter be- ing out.
tween the edges "b" of the connecting pin • Stake the drive sprocket nut "2" at cutouts "b"
"2" is 5.5-5.8 mm (0.22-0.23 in). in the drive axle.

c. After riveting, make sure the space "c", 4. Install:

which is inside of the connecting link "3"
and inside of the connecting plate "1", is
14.1- 14.3 mm (0.56-0.65 in) .
• Shift arm "1"
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Before installing, make sure to align the mark "a"
of the shift shaft w ith the punch mark "b" of the
shift arm.

Shift arm bolt

14 N-m (1.4 kgf-m, 10 lb-ft)

4-116
 CHAIN DRIVE

7. Adjust:
• Drive chain slack
Refer to "DRIVE CHAIN SLACK" on page
3-18.

Drive chain slack (Maintenance

a stand)
~ 0 ::---:::-~:::: 35.0-45.0 mm (1.38-1. 77 in)

5.
---- ~
-------- LJ ----- 1
Install: (MTT9GTK/MTT9GTKC)
ECA13550

NOTICE
-------------
A drive chain that is too tight will overload
• Shift rod joint "1" the engine and other vital parts, and one that
• Shift switch "2" is too loose can skip and damage the swing-
• Shift rod "3" arm or cause an accident. Therefore, keep
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ the drive chain slack within the specified lim-
Install the shift rod joint and shift switch in the di- its.
rection shown in the illustration.
EAS31729

ADJUSTING THE SHIFT PEDAL

Shift rod joint bolt
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
10 N-m (1.0 kgf-m, 7.4 lb-ft)
LOCTITE® The shift pedal position is determined by the in-
Shift switch locknut stalled shift rod length.
7 N-m (0.7 kgf-m, 5.2 lb-ft)
1. Measure:
• Installed shift rod length "a"
Incorrect ➔ Adjust.

Installed shift rod length

256.9-258.9 mm (10.11-10.19 in)
b =
2 [Al

1 ~

----

' 0
3
~'

a. 23- 25 mm (0.91-0.98 in)

b. 15°- 25°

6. Adjust:
• Installed shift rod length
Refer to "ADJUSTING TH E SHIFT PEDAL" A. MTT9K/MTT9KC
on page 4-11 7. B. MTT9GTK/MTT9GTKC

4-117
 CHAIN DRIVE

2. Adjust:
• Installed shift rod length
a. Loosen both locknuts "1".
b. Turn the shift rod "2" until the specified in-
stalled shift rod length is obtained.

0 0 0

A. MTT9K/MTT9KC
B. MTT9GTK/MTT9GTKC
c. Tighten both locknuts to specification.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Be sure to place the shift rod joints in parallel.
The allowable twist of the shift rod joints is ±5°.

Locknut (MTT9K/MTT9KC)
8 N•m (0.8 kgf •m, 5.9 lb-ft)
Locknut (MTT9GTK/MTT9GTKC)
7 N•m (0.7 kgf•m, 5.2 lb-ft)

d. Make sure the installed shift rod length is

within specification.

4-118
 CHAIN DRIVE

4-119
 ENGINE

LUBRICATION SYSTEM CHART AND DIAGRAMS ........... ......... ......... ......... 5-1
ENGINE OIL LUBRICATION CHART ...... .......... ......... ......... .......... ......... .. 5-1
LUBRICATION DIAGRAMS ...... ......... .......... ........ ......... ......... ......... ......... . 5-2

ENGINE INSPECTION .. ......... ......... .......... ......... ........ .......... ......... ......... ......... 5-7
MEASURE THE COMPRESSION PRESSURE .... ......... .......... ......... ........ 5-7

ENGINE REMOVAL ..... ......... ......... .......... ........ ......... .......... ......... ......... ......... . 5-9
REMOVING THE ENGINE ........ ......... .......... ........ ......... .......... ......... ....... 5-13
INSTALLING THE ENGINE ...... .......... ........ ......... .......... ......... ......... ........ 5-13

CAMSHAFTS .. .... .......... ......... .......... ......... .......... ........ .......... ......... .......... ...... 5-15
REMOVING THE CAMSHAFTS .......... ......... .......... ........ .......... ......... ...... 5-19
CHECKING THE CAMSHAFTS ......... ........ .......... .......... ......... .......... ...... 5-20
CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET .. ....... 5-21
CHECKING THE TIMING CHAIN GUIDES .. .......... ......... .......... .......... .... 5-21
CHECKING THE TIMING CHAIN TENSIONER ...... .......... ......... .......... ... 5-21
INSTALLING THE CAMSHAFTS ........ ......... .......... ........ .......... .......... ..... 5-22

CYLINDER HEAD .......... ......... .......... ......... .......... ......... ......... ......... .......... ..... 5-27
REMOVING THE CYLINDER HEAD .. .......... ........ ......... ......... ......... ........ 5-28
CHECKING THE TIMING CHAIN GUIDE (EXHAUST SIDE) ........... ...... 5-28
CHECKING THE CYLINDER HEAD .......... ......... .......... .......... ......... ....... 5-28
INSTALLING THE CYLINDER HEAD ........ ......... .......... .......... ......... ....... 5-29

VALVES AND VALVE SPRINGS .... .......... ......... .......... ........ .......... ......... ...... 5-30
REMOVING THE VALVES ......... .......... ......... .......... ........ .......... ......... ..... 5-32
CHECKING THE VALVES AND VALVE GUIDES ......... .......... ......... ...... 5-32
CHECKING THE VALVE SEATS ........ ......... .......... ......... .......... .......... .... 5-34
CHECKING THE VALVE SPRINGS .... ......... .......... ........ .......... ......... ...... 5-35
CHECKING THE VALVE LIFTERS .... .......... .......... ........ .......... .......... ..... 5-36
INSTALLING THE VALVES ...... .......... ......... .......... ........ .......... .......... ..... 5-36

GENERATOR AND STARTER CLUTCH ......... .......... ......... .......... .......... ...... 5-38
REMOVING THE GENERATOR ......... ......... ........ .......... ......... ......... ....... 5-41
REMOVING THE STARTER CLUTCH ...... .......... ......... ......... .......... ....... 5-41
CHECKING THE STARTER CLUTCH ....... ......... .......... ......... ......... ........ 5-41
INSTALLING THE STARTER CLUTCH ....... ........ .......... ......... ......... ....... 5-42
INSTALLING THE GENERATOR ....... .......... ........ .......... .......... ......... ...... 5-42

ELECTRIC STARTER .. ......... .......... ......... ........ .......... ......... .......... ......... ....... 5-44
CHECKING THE STARTER MOTOR ........ .......... ......... .......... .......... ...... 5-46
ASSEMBLING THE STARTER MOTOR ...... ........ .......... ......... ......... ....... 5-46
INSTALLING THE STARTER MOTOR ..... ......... ......... .......... ......... ......... 5-47
CLUTCH .... .......... ......... ......... .......... ......... .......... ........ .......... ......... .......... ...... 5-48
REMOVING THE CLUTCH ........ .......... ......... .......... ........ .......... ......... ..... 5-52
CHECKING THE FRICTION PLATES ....... .......... .......... ......... .......... ....... 5-53
CHECKING THE CLUTCH PLATES .......... ......... .......... .......... ......... ....... 5-53
CHECKING THE CLUTCH SPRINGS ........ ......... .......... ......... .......... ....... 5-54
CHECKING THE CLUTCH HOUSING ...... .......... .......... ......... .......... ....... 5-54
CHECKING THE CLUTCH BOSS ....... ......... .......... ........ .......... .......... ..... 5-55
CHECKING THE PRESSURE PLATE ....... ......... .......... .......... ......... ....... 5-55
CHECKING THE PRIMARY DRIVE GEAR .. .......... ......... ......... .......... ..... 5-55
CHECKING THE PRIMARY DRIVEN GEAR ...... .......... .......... .......... ...... 5-55
CHECKING THE PULL LEVER SHAFT AND PULL ROD ...... ......... ....... 5-55
INSTALLING THE CLUTCH ...... .......... ......... .......... ......... ......... .......... ..... 5-56

SHIFT SHAFT ..... .......... ......... .......... ......... .......... ........ .......... ......... .......... ...... 5-59
CHECKING THE SHIFT SHAFT ........ .......... .......... ........ .......... .......... ..... 5-61
CHECKING THE STOPPER LEVER .......... .......... ......... ........... ......... ..... 5-61
INSTALLING THE SHIFT SHAFT ...... .......... .......... ........ .......... ......... ...... 5-61

OILPUMP ... .......... ......... ......... .......... ......... .......... ......... ......... ......... .......... ..... 5-62
CHECKING THE SPROCKET AND CHAIN ......... ......... .......... ......... ....... 5-64
CHECKING THE OIL PUMP ..... ......... .......... ........ .......... ......... .......... ...... 5-64
CHECKING THE RELIEF VALVE ...... .......... .......... ........ .......... .......... ..... 5-64
ASSEMBLING THE OIL PUMP ......... ......... ......... .......... ......... .......... ....... 5-65
INSTALLING THE OIL PUMP ... ......... .......... ........ .......... ......... .......... ...... 5-65

OIL PAN .... .......... ......... ......... .......... ......... .......... ........ .......... ......... .......... ...... 5-66
REMOVING THE OIL PAN .......... .......... ......... .......... ......... ......... ......... .... 5-68
CHECKING THE OIL STRAINER ...... .......... ........ .......... ......... .......... ...... 5-68
INSTALLING THE OIL PAN ...... .......... ......... .......... ........ .......... .......... ..... 5-68

CR.A NKCASE ..... .......... ......... .......... ......... .......... ........ .......... ......... .......... ...... 5-69
DISASSEMBLING THE CRANKCASE ......... ......... ......... .......... ......... ...... 5-70
CHECKING THE CRANKCASE ......... ........ .......... ......... .......... .......... ...... 5-70
ASSEMBLING THE CRANKCASE ..... .......... .......... ........ .......... ......... ...... 5-70

CONNECTING RODS AND PISTONS ...... ......... .......... ........ .......... ......... ...... 5-73
REMOVING THE CONNECTING RODS AND PISTONS ...... .......... ....... 5-74
CHECKING THE CYLINDER AND PISTON ....... ......... .......... ......... ........ 5-74
CHECKING THE PISTON RINGS ....... ......... .......... ........ .......... ......... ...... 5-75
CHECKING THE PISTON PIN .. .......... ......... .......... ........ .......... ......... ...... 5-76
CHECKING THE CONNECTING RODS .... .......... .......... ......... .......... ...... 5-76
INSTALLING THE CONNECTING ROD AND PISTON ........... .......... ..... 5-79

CRANKSHAFT AND BALANCER SHAFT .. .... .......... ......... .......... .......... ...... 5-83
REMOVING THE CRANKSHAFT AND BALANCER SHAFT .. .......... ...... 5-84
CHECKING THE OIL NOZZLES ........ .......... .......... ........ .......... ......... ...... 5-84
CHECKING THE CRANKSHAFT ........ ......... .......... ........ .......... .......... ..... 5-84
CHECKING THE BALANCER SHAFT ....... ......... .......... .......... ......... ....... 5-86
INSTALLING THE CRANKSHAFT ..... .......... .......... ........ .......... .......... ..... 5-88
INSTALLING THE BALANCER ASSEMBLY ......... ......... ......... .......... ...... 5-88
TRANSMISSION .. .......... ......... .......... ......... .......... ......... ......... ......... .......... ..... 5-89
REMOVING THE TRANSMISSION ..... .......... ......... .......... ........ .......... .... 5-93
CHECKING THE SHIFT FORKS ........ .......... ........ .......... .......... ......... ...... 5-93
CHECKING THE SHIFT DRUM ASSEMBLY ........ ......... ......... .......... ...... 5-94
CHECKING THE TRANSMISSION .... .......... ........ .......... .......... ......... ...... 5-94
ASSEMBLING THE MAIN AXLE AND DRIVE AXLE .... .......... ......... ....... 5-94
INSTALLING THE TRANSMISSION ......... .......... .......... ......... .......... ....... 5-95
 LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS20298

LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS32362

ENGINE OIL LUBRICATION CHART

171L.
~

16 1L.
-
I I
- Bi, 15
~

I
l
14 II •
- -
13 13 13
'
1:8:1 V
~ - - ~

1' I -
'
/r ~

~
"0"
""
11
'
1:8:1 - ~ LJ n
,;;--.,
r --;-; I

2 6

1
v~
'- 3
I J '7
4
__. L
5 -
-

10
□□□□□on
7 I
8 I ~
u□ODOL._J- ac
10 (
10 10
I
9
1. Oil strainer 17. Exhaust camshaft
2. Oil pump
3. Relief valve
4. Oil cooler
5. Oil filter cartridge
6. Main gallery
7. Drive axle
8. Main axle
9. Shift fork (upper)
10. Mission shower
11. Crankshaft
12. AC magneto
13. Oil nozzle
14. Balancer shaft
15. Timing chain tensioner
16. Intake camshaft

5-1
 LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS32363

LUBRICATION DIAGRAMS

3
2

1
1. Oil level switch
2. Oil filter cartridge union bolt
3. Oil filter cartridge
4. Crankshaft

5-2
 LUBRICATION SYSTEM CHART AND DIAGRAMS

--Cl
Q-
"
-- I
~
' ' '
'
4

9
--

1. Timing chain tensioner

2. Intake camshaft
3. Exhaust camshaft
4. Balancer shaft
5. Crankshaft
6. Oil cooler
7. Oil strainer
8. Oil drain bolt
9. Oil pump driven sprocket

5-3
 LUBRICATION SYSTEM CHART AND DIAGRAMS

r---.. @
u 0
,,--..._ -- I
0r ' I \.

o;
J
~ 2 1

1. Oil cooler
2. Oil filter cartridge
3. Oil level switch
4. Oil strainer
5. Oil pump
6. Main gallery bolt

5-4
 LUBRICATION SYSTEM CHART AND DIAGRAMS

0 0

0 0 t--110

~ 2

) [ r.J
6
1. Balancer shaft
2. Crankshaft
3. Main axle
4. Shift fork guide bar (shift fork-C side)
5. Drive axle
6. Sub gallery bolt
7. Shift fork

5-5
 LUBRICATION SYSTEM CHART AND DIAGRAMS

'' ''

11
'' ''

11
' '
l.J::::lt---'-l ' '
11

1. Cylinder head
2. Exhaust camshaft
3. Intake camshaft
4. Oil passage to the timing chain tensioner
5. Oil passage to the cylinder head
6. Oil passage to the clutch chamber
7. Oil return passage from the cylinder head
8. Crankshaft
9. Main gallery

5-6
 ENGINE INSPECTION

EAS20041

ENGINE INSPECTION Compression gauge

90890-03081
EAS30249
Engine compression tester
MEASURE THE COMPRESSION PRESSURE YU-33223
The following procedure appl ies to all of the cyl- Compression gauge extension
inders. 122mm
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ 90890-04136
Insufficient compression pressure will result in a Compression gauge extension
loss of performance. 122mm
YM-04136
1. Measure:
• Valve clearance
Out of specification ➔ Adjust.
Refer to "ADJUSTING THE VALVE CLEAR- 0
ANCE" on page 3-5. 1 2
2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Remove:
• Fuel tank front cover/Front side panel/Front
side cowling
Refer to "GENERAL CHASSIS (2)" on page 1/i
4-6. 5. Measure:
• Passenger seat/Rider seat • Compression pressure
Refer to "GENERAL CHASSIS (1)" on page Out of specification ➔ Refer to steps (c) and
4-1. (d) .
• Fuel tank cover
Refer to "GENERAL CHASSIS (3)" on page Compression pressure
4-13. 1331-1713 kPa/680 r/min (13.3-
17 .1 kgf/cm 2/680 r/min, 189.3-
• Fuel tank
243.7 psi/680 r/min)
Refer to "FUEL TANK" on page 7-1 .
• Air filter case a. Set the main switch to "ON".
Refer to "GENERAL CHASSIS (3)" on page
b. With the throttle wide open, crank the en-
4-13.
gine until the reading on the compression
• Air cut-off valve
gauge stabilizes.
Refer to "AIR INDUCTION SYSTEM" on EWA17100

page 7-21. & WARNING

• Ignition coils To prevent sparking the plug, remove all ig-
• Spark plugs nition coil couplers and fuel injector cou-
Refer to "CAMSHAFTS" on page 5-15. plers before cranking the engine.
ECA13340

NOTICE TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
-------------
Before removing the spark plugs, use com- The difference in compression pressure be-
pressed air to blow away any dirt accumulat- tween cylinders should not exceed 100 kPa (1
ed in the spark plug wells to prevent it from kg/cm 2 , 15 psi).
falling into the cylinders.
c. If the compression pressure is above the
4. Install: maximum specification , check the cylinder
• Compression gauge "1" head, valve surfaces and piston crown for
• Extension "2" carbon deposits.
Carbon deposits ➔ Eliminate.
d. If the compression pressure is below the
minimum specification , pour a teaspoonful
of engine oil into the spark plug bore and
measure again .

5-7
 ENGINE INSPECTION

Refer to the following table.

Compression pressure (with oil applied into the
cylinder)
Reading Diagnosis
Piston ring(s) wear or
Higher than without oil
damage ➔ Repair.
Piston, valves, cylinder
Same as without oil head gasket possibly
defective ➔ Repair.

6. Install :
• Spark plugs

Spark plug
13 N•m (1.3 kgf•m, 9.6 lb•ft)

7. Install :
• Ignition coils
Refer to "CAMSHAFTS" on page 5-15.
• Air cut-off valve
Refer to "AIR INDUCTION SYSTEM" on
page 7-21 .
• Air filter case
Refer to "GENERAL CHASSIS (3)" on page
4-13.
• Fuel tank
Refer to "FUEL TANK" on page 7-1.
• Fuel tank cover
Refer to "GENERAL CHASSIS (3)" on page
4-13.
• Rider seat/Passenger seat
Refer to "GENERAL CHASSIS (1 )" on page
4-1 .
• Front side cowling/Front side panel/Fuel tank
front cover
Refer to "GENERAL CHASSIS (2)" on page
4-6.

5-8
 ENGINE REMOVAL

EAS20042

ENGINE REMOVAL
Removing the muffler and exhaust pipe
•t 20 N•m (2.0 kgf•m, 15 lb•ft)

I
,-,; 20 N•m (2.0 kgf•m, 15 lb·ft)

,~ 10 N•m (1 .0 kgf•m, 7 .4 lb·ft)

..;-, 12 N•m (1 .2 kgf•m, 8.9 lb·ft)

' \

mm
6
,

7 ~ I -!l
P.'!11 /--; -- ~ _¥-/_r-....\( «✓, --

.,~ ~ '
~
~ ;;;;
-- (6)

~
;-::,, 10 N•m (1 .0 kgf•m, 7 .4 lb·ft)
"
,:, 48 N•m 4.8 k f•m, 35 lb•ft

Order Job/Parts to remove Q 'ty Remarks

1 Spring 1
2 Centerstand 1

3 0 2 sensor coupler bracket 1

4 0 2 sensor coupler 1 Disconnect.

5 Muffler assembly 1
6 Exhaust gasket 3
7 Muffler protector 1
Remove the 0 2 sensor only when neces-
8 0 2 sensor 1
sary.

5-9
 ENGINE REMOVAL

Disconnecting the leads and hoses

-
,,,.,, 12 N•m 1.2 k f•m , 8.9 lb·ft

-
/ / /
~

/;½=
@

4
~ ---~ (,

0
'4,. 7 N•m 0.7 k f•m , 5.2 lb•ft

Order Job/Parts to remove Q 'ty Remarks

Fuel tank front cover/Front side panel/Front side Refer to "GENERAL CHASSIS (2)" on page
cowling 4-6.
Refer to "GENERAL CHASSIS (1 )" on page
Passenger seat/Rider seat/Rear side cover (left)
4-1 .
Refer to "GENERAL CHASSIS (3)" on page
Fuel tank cover
4-13.
Fuel tank Refer to "FUEL TANK" on page 7-1.
Canister (for California only) Refer to "FUEL TANK" on page 7-1.
Refer to "GENERAL CHASSIS (3)" on page
Air filter case 4-13.
Throttle bodies Refer to 'THROTTLE BODIES" on page 7-5.
Fuel rail Refer to "THROTTLE BODIES" on page 7-5.
Radiator Refer to "RADIATOR" on page 6-3.
Refer to "AIR INDUCTION SYSTEM" on
Air cut-off valve
page 7-21.

5-10
 ENGINE REMOVAL

Disconnecting the leads and hoses

-
,,,.,, 12 N•m 1.2 k f•m , 8.9 lb·ft

- 3 4
/ / /
~

/;½=
@

4 7 6

9
~ --- ~
-,

(,

2
_,__ ____

;:--- - - 1
8
5

0
'4,. 7 N•m 0.7 k f•m , 5.2 lb•ft

Order Job/Parts to remove Q'ty Remarks

Footrest assembly (right) Refer to "REAR BRAKE" on page 4-48.
Drive sprocket Refer to "CHAIN DRIVE" on page 4-11 2.
1 Clutch cable 1 Disconnect.
2 Starter motor lead 1 Disconnect.
3 Negative battery lead 1 Disconnect.
4 Ignition coil coupler 3 Disconnect.
5 Coolant temperature sensor coupler 1 Disconnect.
6 Oil level switch coupler 1 Disconnect.
7 Gear position switch coupler 2 Disconnect.
8 Crankshaft position sensor coupler 1 Disconnect.
9 Stator coil coupler 1 Disconnect.

5-11
 ENGINE REMOVAL

Removing the engine

,:., 7 N•m (0. 7 kgf•m, 5.2 lb·ft) ,.;,_ 45 N•m (4.5 kgf•m, 33 lb•ft)
0
< )
~- 45 N•m (4.5 kgf•m, 33 lb·ft)

/..,. 12 N•m 1.2 k f•m , 8.9 lb·ft

;,;:,_, 7 N•m (0. 7 kgf•m, 5.2 lb·ft)

Order Job/Parts to remove Q 'ty Remarks

1 Engine mounting bolt (right front upper side) 1

2 Centerstand bracket bolt (right) 1
Engine mounting bolt (right front lower side)/En-
3 gine mounting bolt (left front lower side)/Engine 1/1/1
mounting bolt (left front upper side)
4 Centerstand bracket bolt (left) 1
Engine mounting bolt (rear lower side)/Engine 1/1
5
mounting nut (rear lower side)
Engine mounting bolt (rear upper side)/ Engine 1/1
6
mounting nut (rear upper side)
7 Engine 1
8 Engine mounting adjust bolt 3

5-12
 ENGINE REMOVAL

EAS30250

REMOVING THE ENGINE

1. Loosen:
• Engine mounting adjust bolt (front)
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Loosen the engine mounting adjust bolt with the
pivot shaft wrench "1".

Pivot shaft wrench 1

90890-01485 2
Frame mount insert wrench EAS30251
YM-01485 INSTALLING THE ENGINE
1. Install:
• Engine mounting adjust bolt (front) "1"
(temporarily tighten)
• Engine mounting adjust bolt (rear) "2"
(temporarily tighten)
2. Install:
• Engine
3. Install:
• Engine mounting bolt (rear upper side) "3"
• Engine mounting bolt (rear lower side) "4"
4. Install:
2. Loosen:
• Centerstand bracket bolt (left) "5"
• Engine mounting adjust bolt (rear)
(temporarily tighten)
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
5. Install:
Loosen the engine mounting adjust bolts with • Engine mounting bolt (left front upper side)
the pivot shaft wrench "1" and pivot shaft wrench "6"
adapter "2". • Engine mounting bolt (left front lower side) "7"
• Engine mounting bolt (right front lower side)
Pivot shaft wrench "8"
90890-01518 TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Frame spanner socket Temporarily tighten the engine mounting bolts
YM-01518
"6"- "8".
Pivot shaft wrench adapter
90890-01476 6. Tighten:
• Engine mounting adjust bolt (front) "1"
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• Tighten the engine mounting adjust bolt to
specification with the pivot shaft wrench.
1 • Make sure that the flange on the engine
mounting adjust bolt contacts the engine.

Engine mounting adjust bolt

(front)
7 N•m (0.7 kgf•m, 5.2 lb•ft)

Pivot shaft wrench

90890-01485
Frame mount insert wrench
YM-01485

5-13
 ENGINE REMOVAL

7. Tighten:
• Engine mounting adjust bolt (rear) "2" 2 1/,'.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
10 '-..: ~~~-U~ ~ 6
• Tighten the engine mounting adjust bolts to
specification with the pivot shaft wrench and
pivot shaft wrench adapter.
W--r@~~~
. \,·_
~(!) -. - ,. II', ,go
~ "....--1) . . .. / 7

, ~ s-~~ 3
/(.,/1/(....--\-.,J- ~

• Make sure that the flange on the engine

mounting adjust bolt contacts the engine. 12 ~~
- ~~. ~, ,~ f!:t,~ l / f - ~ -

Engine mounting adjust bolt

(rear) 9 ~ '--.._ '
7 N•m (0.7 kgf•m, 5.2 lb-ft)

Pivot shaft wrench

90890-01518
11 ~ ~~~"' .
' ~

Frame spanner socket

YM-01518
Pivot shaft wrench adapter
90890-01476

8. Install:
• Centerstand bracket bolt (right) "9"
(temporarily tighten)
9. Install:
• Engine mounting bolt (right front upper side)
"1O"
1a.Tighten:
• Engine mounting nut (rear lower side) "11"
• Engine mounting nut (rear upper side) "12"

Engine mounting nut (rear lower)

45 N•m (4.5 kgf•m, 33 lb-ft)
Engine mounting nut (rear upper)
45 N•m (4.5 kgf•m, 33 lb-ft)

11.Tighten:
• Engine mounting bolt (right front upper side)
"1O"
• Engine mounting bolt (left front upper side)
"6"
• Engine mounting bolt (left front lower side) "7"
• Engine mounting bolt (right front lower side)
"8"

Engine mounting bolt (front up-

per and front lower)
45 N•m (4.5 kgf•m, 33 lb-ft)

12.Tighten:
• Centerstand bracket bolt (left) "5"
• Centerstand bracket bolt (right) "9"

Centerstand bracket bolt

12 N•m (1.2 kgf•m, 8.9 lb•ft)

5-14
 CAMSHAFTS

EAS20043

CAMSHAFTS
Removing the cylinder head cover

''\ 10 N•m (1.0 kgf•m, 7.4 lb·ft) .1-, 10 N•m (1.0 kgf•m, 7.4 lb·ft)

1 0,~

\\L/
~ t, . .____. .____
--
!=
---
"
,!',,. 13 N•m (1.3 kgf•m, 9.6 lb·ft)

Order Job/Parts to remove Q 'ty Remarks

Fuel tank front cover/Front side panel/Front side Refer to "GENERAL CHASSIS (2)" on page
cowling 4-6.
Refer to "GENERAL CHASSIS (1 )" on page
Passenger seat/Rider seat
4-1 .
Refer to "GENERAL CHASSIS (3)" on page
Fuel tank cover
4-13.
Fuel tank Refer to "FUEL TANK" on page 7-1 .

Air filter case Refer to "GENERAL CHASSIS (3)" on page

4-13.
Radiator Refer to "RADIATOR" on page 6-3.
Refer to "AIR INDUCTION SYSTEM" on
Air cut-off valve
page 7-21 .
1 Ignition coil coupler 3 Disconnect.
2 Ignition coil 3

5-15
 CAMSHAFTS

Removing the cylinder head cover

~, 10 N•m (1.0 kgf•m, 7.4 lb·ft) ~;, 10 N•m (1.0 kgf•m, 7.4 lb·ft)

"~,, 13 N•m (1.3 kgf•m, 9.6 lb·ft)

Order Job/Parts to remove Q 'ty Remarks

3 Spark plug 3
4 Cylinder head cover 1
5 Cylinder head cover gasket 1
6 Timing chain guide (top side) 1

5-16
 CAMSHAFTS

Removing the camshafts

~ - 7 N•m (0.7 kgf•m, 5.2 lb·ft)
"· 10 N•m 1.0 k f•m, 7 .4 lb·ft ''\ 10 N•m (1.0 kgf•m, 7.4 lb·ft)

~,. 10 N•m (1.0 kgf•m, 7.4 lb•ft)

, ,G 4)

~~ 1Q
)
3
4fm1
~
Q
\ .----+.,;=:;-~- ~

'
~~tj) ' I
s I~ r

,1
I
'
~
::- 0

- ""-"'...:~'Ej'
@mm>
1 ,
_j mm .
2
. ·

(8)
'

\_ __ :::::::~~ -
'
~- 12 N•m (1.2 kgf•m, 8.9 lb·ft)

..::,. 10 N•m (1 .0 kgf•m , 7.4 lb•ft)

Order Job/Parts to remove Q 'ty Remarks

Crankshaft end cover/Timing mark accessing Refer to "GENERATOR AND STARTER

bolt CLUTCH" on page 5-38.
1 Timing chain cover 1
2 Timing chain cover gasket 1
3 Timing chain tensioner 1
4 Timing chain tensioner gasket 1
5 Intake camshaft cap 1
6 Exhaust camshaft cap 1
7 Camshaft cap 1
8 Intake camshaft 1
9 Exhaust camshaft 1
10 Intake camshaft sprocket 1
11 Exhaust camshaft sprocket 1

5-17
 CAMSHAFTS

Removing the camshafts

~ . 7 N•m (0.7 kgf•m, 5.2 lb·ft)
"· 10 N•m 1.0 k f•m, 7 .4 lb·ft ''\ 10 N•m (1.0 kgf•m, 7.4 lb·ft)

12 - :
. +~-/
~~ tj) '
s I~ r

,1
I
'
~
::- 0

-
' ' ;"'-"--:::::...::~-
@mm>_j
(8)
'

\_ __ :::::::~~ - ""
'

\ :' :
15
'
~. 12 N•m (1.2 kgf•m, 8.9 lb·ft)
; \ /!I 1/
..::,. 10 N•m (1.0 kgf•m, 7.4 lb•ft) 13 14 Y
Order Job/Parts to remove Q 'ty Remarks

12 Timing chain bolt 1

13 Dowel pin 1
14 Timing chain guide (intake side) 1
15 Timing chain 1

5-18
 CAMSHAFTS

EAS30256
• Intake camshaft cap "2"
REMOVING THE CAMSHAFTS
• Exhaust camshaft cap "3"
1. Remove: ECA13720

• Timing mark accessing bolt "1" NOTICE

• Crankshaft end cover "2" -------------
To prevent damage to the cylinder head,
camshafts or camshaft caps, loosen the
camshaft cap bolts in stages and in a criss-
cross pattern, working from the outside in.

2. Align:
• Mark "a" on the generator rotor
(with the generator rotor cover mark "b")
a. T urn the crankshaft counterclockwise.
b. When piston # 1 is at BT DC125° on the 5. Remove:
compression stroke, align the BTDC125° • Intake camshaft "1"
mark "a" on the generator rotor with the • Exhaust camshaft "2"
generator rotor cover mark "b". TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
To prevent the timing chain from falling into the
BTDC125° on the compression stroke can be crankcase, fasten it with a wire "3".
found when the camshaft lobes are turned away
from each other.

~ •--'\ r-\.\',----'-..JIL-~..l\....•l-------lJ-'---'-LI-___,__'"'--il

3. Remove:
• Timing chain tensioner "1"
• Timing chain tensioner gasket

a
6. Remove:
• Camshaft sprocket "1"
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Use the camshaft wrench "2" and loosen the
camshaft sprocket bolt.
4. Remove:
• Camshaft cap "1"

5-19
 CAMSHAFTS

Camshaft wrench
n
90890-04162 □
Camshaft wrench I I
~

YM-04162 9 - ~ ~

.. .
...._
...._ --
-
_.._
~
.
~

I I

2
1 4. Measure:
• Camshaft-journal-to-camshaft-cap clearance
Out of specification ➔ Measure the camshaft
journal diameter.

Camshaft-journal-to-camshaft-
EAS30257
cap clearance
CHECKING THE CAMSHAFTS 0.028-0.062 mm (0.0011-0.0024
1. Check: in)
• Camshaft lobes Limit
Blue discoloration/pitting/scratches ➔ Re- 0.080 mm (0.0032 in)
place the camshaft.
a. Install the camshaft into the cylinder head
2. Measure:
(without the camshaft caps).
• Camshaft lobe dimensions "a"
b. Position strip of Plastigauge® "1" onto the
O ut of specification ➔ Replace the camshaft.
camshaft journal as shown.
Camshaft lobe dimensions 1
Lobe height (Intake)
36.290-36.390 mm (1.4287-
1.4327 in)
Limit
36.190 mm (1.4248 in)
Lobe height (Exhaust)
35. 720-35.820 mm (1.4063-
1.4102 in)
Limit
35.620 mm (1.4024 in)
c. Install the dowel pins and camshaft caps.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
a • Tighten the camshaft cap bolts in stages and in
a crisscross pattern , working from the inner
r-H@ caps out.
• Do not turn the camshaft when measuring the
camshaft journal-to-camshaft cap clearance
with the Plastigauge®.

Camshaft cap bolt

10 N-m (1.0 kgf-m, 7.4 lb-ft)
3. Measure:
• Camshaft runout d. Remove the camshaft caps and then mea-
O ut of specification ➔ Replace. sure the width of the Plastigauge® "2".

Camshaft runout limit

0.030 mm (0.0012 in)

5-20
 CAMSHAFTS

2
1

• 2
•
•
•
•

5. Measure: a. 1/4 tooth

• Camshaft journal diameter "a" b. Correct
Out of specification ➔ Replace the camshaft. 1. Timing chain
Within specification ➔ Replace the cylinder 2. Camshaft sprocket
head and the camshaft caps as a set.
EAS30265

Camshaft journal diameter CHECKING THE TIMING CHAIN GUIDES

24.459-24.472 mm (0.9630- The following procedure applies to all of the
0.9635 in) camshaft sprockets and tim ing chain guides.
1. Check:
• Timing chain guide (intake side) "1"
a • Timing chain guide (top side) "2"
\\
Damage/wear ➔ Replace the defective
part(s) .

EAS30258

CHECKING THE TIMING CHAIN AND 1

CAMSHAFT SPROCKET
1. Check:
EAS30266
• Timing chain
CHECKING THE TIMING CHAIN TENSIONER
Damage/stiffness ➔ Replace the timing
1. Check:
chain and camshaft and camshaft sprocket
• Timing chain tensioner
as a set.
Cracks/damage/rough movement ➔ Re-
2. Check:
place.
• Camshaft sprocket
a. Lightly press the timing chain tensioner
More than 1/4 tooth wear "a" ➔ Replace the
rod into the timing chain tensioner housing
camshaft sprockets and the timing chain as a
by hand .
set.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
While pressing the timing chain tensioner rod,
wind it counterclockwise with a hexagon wrench
"1" (Parts No.: 1 RC-1 2228-00) until it stops.

5-21
 CAMSHAFTS

~ - - - -~ , ,

a
~-------

b. Make sure that the timing chain tensioner
rod moves in and out of the timing chain
tensioner housing smoothly. If there is
rough movement, replace the timing chain
tensioner.
p n
3. Install:
• Intake camshaft sprocket "1"
• Exhaust camshaft sprocket "2"
Camshaft sprocket bolt
24 N•m (2.4 kgf •m, 18 lb-ft)

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Install the camshaft projection "a" at the posi-
tion shown in the illustration .
• Tighten the camshaft sprocket bolt with the
camshaft wrench "3".

Camshaft wrench
90890-04162
EAS30269 Camshaft wrench
INSTALLING THE CAMSHAFTS YM-04162
1. Remove:
• Timing mark accessing bolt "1"
~~
2
• Crankshaft end cover "2" 1 a
' ' ,,_I,
0 __° 1 tj,..____....__ '' --- -,

'
\ . ......
~~~,\~0.)-:(~~
,

, --
', ~,. ~ /

2. Align: 3
• Mark "a" on the generator rotor
(with the generator rotor cover mark "b")
a. Turn the crankshaft counterclockwise.
b. When piston #1 is at BTDC125°, align the
mark "a" on the generator rotor with the
generator rotor cover mark "b".

4. Install:
• Exhaust camshaft "1"
• Intake camshaft "2"

5-22
 CAMSHAFTS

TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Camshaft cap bolt
• Make sure the punch mark "a" on each cam- 10 N-m (1.0 kgf-m, 7.4 lb-ft)
shaft faces up.
• When installing the camshaft, no need to align TIP _ _ _ _ _ _ _ _ _ _ _ _ __
the mark "b" on the camshaft sprocket.
Tighten the camshaft cap bolts in the tightening
sequence as shown .
ECA17430

NOTICE
-------------
• Lubricate the camshaft cap bolts with the
engine oil.
• The camshaft cap bolts must be tightened
evenly or damage to the cylinder head,
camshaft caps, and camshafts will result.
• Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.

b
5. Install:
• Camshaft cap 7. Tighten:
• Intake camshaft cap • Camshaft cap bolts "1"
• Exhaust camshaft cap
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ Camshaft cap bolt
10 N-m (1.0 kgf-m, 7.4 lb-ft)
• Make sure each camshaft cap is installed in its
original place. Refer to the identification marks
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
as follows:
"IL": Intake left side camshaft cap mark Tighten the camshaft cap bolts in stages and in
"EL": Exhaust left side camshaft cap mark a crisscross pattern , working from the inner caps
• Make sure the arrow mark "a" on each cam- out.
shaft points toward the right side of the engine. ECA17430

NOTICE
- - - - - - - - - - - - -
• Lubricate the camshaft cap bolts with the
engine oil.
• The camshaft cap bolts must be tightened
0 evenly or damage to the cylinder head,
camshaft caps, and camshafts will result.
• Do not turn the crankshaft when installing
0
the camshaft to avoid damage or improper
valve timing.

6. Tighten:
• Camshaft cap bolts

5-23
 CAMSHAFTS

I
8. Check: c. Tighten the timing chain tensioner bolts to
• Camshaft punch mark "a" the specified torque.
Make sure the camshaft punch mark "a" on
the camshaft is aligned with the camshaft cap Timing chain tensioner bolt
alignment mark "b". 10 N•m (1.0 kgf•m, 7.4 lb-ft)
LOCTITE®
a b
------- .. d. Screw the hexagon wrench by hand until
the timing chain tensioner rod touches the
timing chain guide, and then tighten 1/4
turn by tool.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
The tim ing chain tensioner rod is extended by
turning the hexagon wrench clockwise.

9. Install :
• Timing chain tensioner
• Timing chain tensioner gasket •~M
a. While lightly pressing the timing chain ten-
sioner rod by hand, turn the timing chain
tensioner rod fully counterclockwise with a
hexagon wrench "1" (Parts No.: 1RC-
12228-00).
I
e. Remove the hexagon wrench, and check
the timing chain tension .

b. Install the timing chain tensioner gasket

"2" the timing chain tensioner "3" and the
' '
timing chain tensioner bolts "4" on the cyl-
inder block.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Face the section "a" of the gasket inward.
I
f. Install the timing chain tensioner cap bolt
and gasket, and then tighten the timing
chain tensioner cap bolt to the specified
torque.

Timing chain tensioner cap bolt

7 N•m (0.7 kgf•m, 5.2 lb•ft)

5-24
 CAMSHAFTS

1a.Turn:
• Crankshaft
(several turns counterclockwise)
11 .Check:
• Mark "a"
Make sure the mark "a" on the generator rotor
is aligned with the generator rotor cover mark
"b".
• Camshaft punch mark "c"
Make sure the camshaft punch mark "c" on p n
the camshaft is aligned with the camshaft cap 14.lnstall:
alignment mark "d". • Timing chain guide (top side)
Out of alignment ➔ Adjust. • Cylinder head cover gasket "1" •~M
Refer to the installation steps above. • Cylinder head cover
-
b Cylinder head cover bolt
~,'----..._
10 N•m (1.0 kgf•m, 7.4 lb-ft)
a
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• Apply Three Bond No.1541 C® onto the mating
surfaces of the cylinder head cover and cylin-
der head cover gasket.
• After installing the cylinder head cover gasket
p n "1" to the cylinder head cover, cut off the "a"
section .

12.Measure:
• Valve clearance
Out of specification ➔ Adjust.
Refer to "ADJUSTING THE VALVE CLEAR-
ANCE" on page 3-5.
13.lnstall:
• Timing mark accessing bolt "1"

Timing mark accessing bolt

15 N-m (1.5 kgf•m, 11 lb-ft)

• Crankshaft end cover "2"

15.lnstall:
Crankshaft end cover • Spark plugs
10 N-m (1.0 kgf•m, 7.4 lb•ft) • Ignition coils "1"

Spark plug
13 N•m (1.3 kgf •m, 9.6 lb-ft)

5-25
 CAMSHAFTS

TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Install the ignition coils "1" in the direction shown
in the illustration .

5-26
 CYLINDER HEAD

EAS20044

CYLINDER HEAD
Removing the cylinder head
1st
20 N•m 2.0 k f•m 15 lb·ft
...
~ 2nd 30 N•m (3.0 kgf•m, 22 lb·ft)
17 N•m (1 .7 kgf•m, 13 lb·ft)
.:,1;, 10 N•m (1 .0 kgf•m, 7.4 lb•ft) 3rd Specified angle 120'

16 N•m (1.6 kgf•m, 12 lb·ft)

~- 10 N•m (1 .0 kgf•m, 7.4 lb·ft)

,
4 3
2 mm
~ ----
'

'

Order Job/Parts to remove Q'ty Remarks

Engine Refer to "ENGINE REMOVAL.:' on page 5-9.

Intake camshaft Refer to "CAMSHAFTS" on page 5-15.
Exhaust camshaft Refer to "CAMSHAFTS" on page 5-15.
1 Coolant temperature sensor 1
2 Cylinder head 1
3 Cylinder head gasket 1
4 Dowel pin 2
5 Timing chain guide (exhaust side) 1

5-27
 CYLINDER HEAD

EAS30276
2. Check:
REMOVING THE CYLINDER HEAD
• Cylinder head
1. Remove:
Damage/scratches ➔ Replace.
• Intake camshaft
• Cylinder head water jacket
• Exhaust camshaft
Mineral deposits/rust ➔ Eliminate.
Refer to "REMOVING THE CAMSHAFTS"
3. Measure:
on page 5-19.
• Cylinder head warpage
2. Remove:
Out of specification ➔ Resurface the cylinder
• Cylinder head bolt (M6) (x 4)
head.
• Cylinder head bolt (M9) (x 8)
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ Warpage limit
• Loosen the bolts in the proper sequence as 0.1 O mm (0.0039 in)
shown .
• Loosen each bolt 1/2 of a turn at a time. After
all of the bolts are fully loosened, remove them .

a. Place a straightedge "1" and a thickness

gauge "2" across the cylinder head.

EAS30278 Thickness gauge

CHECKING THE TIMING CHAIN GUIDE 90890-03268
(EXHAUST SIDE) Feeler gauge set
1. Check: YU-26900-9
• Timing chain guide (exhaust side)
Damage/wear ➔ Replace.

b. Measure the warpage.

EAS302n c. If the limit is exceeded, resurface the cylin-
CHECKING THE CYLINDER HEAD der head as follows.
1. Eliminate: d. Place a 400-600 grit wet sandpaper on
• Combustion chamber carbon deposits the surface plate and resurface the cylin-
(with a rounded scraper) der head using a figure-eight sanding pat-
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ tern.
Do not use a sharp instrument to avoid damag- TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
ing or scratching : To ensure an even surface, rotate the cylinder
• Spark plug bore threads head several times.
• Valve seats

5-28
 CYLINDER HEAD

EAS30282

INSTALLING THE CYLINDER HEAD

1. Install:
• Timing chain guide (exhaust side) "1"
• Cylinder head gasket "2" 1jt4W
• Dowel pins "3"

4. Install:
• Exhaust camshaft
• Intake camshaft
Refer to "INSTALLING THE CAMSHAFTS"
on page 5-22 .

2. Install:
• Cylinder head
• Cylinder head bolt (M6) (x4)
• Cylinder head bolt (M9) (x 8) r.i1~11t4•$•fj
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• Pass the timing chain through the timing chain
cavity.
• Lubricate the cylinder head bolt (M9) thread
and mating surface with engine oil.
3. Tighten:
• Cylinder head bolts "1"- "8"
• Cylinder head bolts "9"- "12"

Cylinder head bolt " 1 "- "8"

1 st: 20 N•m (2.0 kgf •m, 15 lb•ft)
2nd: 30 N•m (3.0 kgf•m, 22 lb-ft)
*3rd: 17 N•m (1.7 kgf•m, 13 lb•ft)
+120°
Cylinder head bolt "9"- "12"
10 N•m (1.0 kgf•m , 7.4 lb•ft)

* Following the tightening order, loosen the

bolt one by one and then retighten it to the
specific torque and the specific angle.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Tighten the cylinder head bolts "1"-"8" in the
tightening sequence as shown and torque them
in 3 stages.

5-29
 VALVES AND VALVE SPRINGS

EAS20045

VALVES AND VALVE SPRINGS

Removing the valves and valve springs

2 1
4 3
7 5
8 mm
9
6

Order Job/Parts to remove Q'ty Remarks

Cylinder head Refer to "CYLINDER HEAD" on page 5-27.

1 Intake valve lifter 6
2 Intake valve pad 6
3 Intake valve cotter 12
4 Intake valve spring retainer 6
5 Intake valve spring 6
6 Intake valve 6
7 Intake valve stem seal 6
8 Intake valve spring seat 6
9 Intake valve guide 6
10 Exhaust valve lifter 6
11 Exhaust valve pad 6

5-30
 VALVES AND VALVE SPRINGS

Removing the valves and valve springs

14 - ~
mm 1s ~ ,._,---
11 ~

'tJ-_18
15

Order Job/Parts to remove Q'ty Remarks

12 Exhaust valve cotter 12

13 Exhaust valve spring retainer 6
14 Exhaust valve spring 6
15 Exhaust valve 6
16 Exhaust valve stem seal 6
17 Exhaust valve spring seat 6
18 Exhaust valve guide 6

5-31
 VALVES AND VALVE SPRINGS

EAS30283
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
REMOVING THE VALVES
The following procedure appl ies to all of the Remove the valve cotters by compressing the
valves and related components. valve spring with the valve spring compressor
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ "1" and the valve spring compressor attachment
"2".
Before removing the internal parts of the cylinder
head (e.g., valves, valve springs, valve seats) ,
make sure the valves properly seal. Valve spring compressor
90890-0401 9
1. Remove: Valve spring compressor
• Valve lifter "1" YM-0401 9
• Valve pad "2" Valve spring compressor attach-
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ ment (0 23)
90890-04179
Make a note of the position of each valve lifter
Valve spring compressor adapt-
and valve pad so that they can be reinstalled in er (023)
their original place. YM-04179

1 2 3
EX
IN

2 1

2. Check:
• Valve sealing 4. Remove:
Leakage at the valve seat ➔ Check the valve • Valve spring retainer "1"
face, valve seat, and valve seat width. • Valve spring "2"
Refer to "CHECKING THE VALVE SEATS" • Valve "3"
on page 5-34. • 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".

EAS30284

3. Remove: CHECKING THE VALVES AND VALVE

• Valve cotters GUIDES
The following procedure applies to all of the
valves and valve guides.

5-32
 VALVES AND VALVE SPRINGS

1. Measure:
• Valve-stem-to-valve-guide clearance
O ut of specification ➔ Replace the valve
guide.
• Valve-stem-to-valve-guide clearance =
Valve guide inside diameter "a" -
Valve stem diameter "b"

Valve-stem-to-valve-guide clear-
ance (intake)
0.010-0.037 mm (0.0004-0.0015 b. Install the new valve guide with the valve
in) guide installer "2" and valve guide remov-
Limit er "1".
0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clear- Valve guide position
ance (exhaust) 13.3-13.7 mm (0.52-0.54 in)
0.025-0.052 mm (0.0010-0.0020
in)
2
Limit
0.100 mm (0.0039 in)

c
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 TIP _ _ _ _ _ _ _ _ _ _ _ _ __
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
After replacing the valve guide, reface the valve
To ease valve guide removal and installation , seat.
and to maintain the correct fit, heat the cylinder
head to 100 °c (212 °F) in an oven.
a. Remove the valve guide with the valve
guide remover "1".

5-33
 VALVES AND VALVE SPRINGS

2. Check:
Valve guide remover (04.5) • Valve seat
90890-04116 Pitting/wear ➔ Replace the cylinder head.
Valve guide remover (4.5 mm) 3. Measure:
YM-04116
• Valve seat contact width "a"
Valve guide installer (04.5)
90890-04117 Out of specification ➔ Replace the cylinder
Valve guide installer (4.5 mm) head.
YM-04117
Valve guide reamer (04.5) Valve seat contact width (intake)
90890-04118 0.90-1.1 O mm (0.0354-0.0433 in)
Valve guide reamer (4.5 mm) Limit
YM-04118 1.60 mm (0.06 in)
Valve seat contact width (ex-
3. Eliminate: haust)
1.10-1.30 mm (0.0433-0.0512 in)
• Carbon deposits
Limit
(from the valve face and valve seat)
1.80 mm (0.07 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: a
• Valve stem runout
Out of specification ➔ Replace the valve.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• When installing a new valve, always replace
the valve guide. a. Apply blue layout fluid "b" onto the valve
• If the valve is removed or replaced, always re- face.
place the valve stem seal.

Valve stem runout

0.01 O mm (0.0004 in)

b. Install the valve into the cylinder head.

c. Press the valve through the valve guide
and onto the valve seat to make a clear
// impression.
d. Measure the valve seat contact width.
EAS30285
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
CHECKING THE VALVE SEATS Where the valve seat and valve face contacted
The following procedure applies to all of the one another, the blue layout fluid will have been
valves and valve seats. removed.
1. Eliminate:
• Carbon deposits 4. Lap:
(from the valve face and valve seat) • Valve face
• Valve seat

5-34
 VALVES AND VALVE SPRINGS

TIP _ _ _ _ _ _ _ _ _ _ _ _ __
After replacing the cylinder head or replacing the
valve and valve guide, the valve seat and valve
face should be lapped.
a. Apply a coarse lapping compound "a" to
the valve face.
ECA13790 b
NOTICE
-------------
Do not let the lapping compound enter the
gap between the valve stem and the valve h. Install the valve into the cylinder head.
guide. 1. Press the valve through the valve guide
and onto the valve seat to make a clear
. .
1mpress1on.
J. Measure the valve seat contact width "c"
again. If the valve seat contact width is out
of specification , reface and lap the valve
seat.
a

b. Apply molybdenum disulfide oil onto the

valve stem. C
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and
valve seat are evenly polished, then clean
off all of the lapping compound.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ EAS30286

CHECKING THE VALVE SPRINGS

For the best lapping results, lightly tap the valve
The following procedure applies to all of the
seat while rotating the valve back and forth be-
valve springs.
tween your hands.
1. Measure:
• Valve spring free length "a"
Out of specification ➔ Replace the valve
spring.

Free length (intake)

39.31 mm (1.55 in)
Limit
37.34 mm (1.47 in)
Free length (exhaust)
37.78 mm (1.49 in)
Limit
e. Apply a fine lapping compound to the 35.89 mm (1.41 in)
valve face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from
the valve face and valve seat.
g. Apply blue layout fluid "b" onto the valve
face.

5-35
 VALVES AND VALVE SPRINGS

r-.,
I

I , I , I , , 1 , 1 ,1 ,1
I ' I ' I
'/
T r:---
,... ,...
~ r [
~
r r
\ I)
' ...,
I
... ... ... ~;.1a
I--

EAS30287 3. Install:
CHECKING THE VALVE LIFTERS • Valve spring seat "1"
The follow ing procedure applies to all of the • 11
Valve stem seal "2" ~i~"t4"'$ijj
valve lifters. • Valve "3"
1. Check: • Valve spring "4"
• Valve lifter • Valve spring retainer "5"
Damage/scratches ➔ Replace the valve lift- (into the cylinder head)
ers and cylinder head . TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Make sure each valve is installed in its original
place.
• Install the valve springs with the larger pitch "a"
facing up.

----.
I'
EAS30288 I
'
INSTALLING THE VALVES
The following procedure applies to all of the I
'
4
valves and related components.
1. Deburr:
• Valve stem end
(with an oil stone)

0
0
0
0

b. Smaller pitch
2. Lubricate:
4. Install:
• Valve stem "1"
• Valve cotters "1"
• Valve stem seal "2"
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
(with the recommended lubricant)
Install the valve cotters by compressing the
Recommended lubricant valve spring with the valve spring compressor
I
Molybdenum disulfide oil "2" and the valve spring compressor attachment
"3".

5-36
 VALVES AND VALVE SPRINGS

• Valve lifter
Valve spring compressor TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
90890-04019
Valve spring compressor • The valve lifter must move smoothly when ro-
YM-04019 tated with a finger.
Valve spring compressor attach- • Each valve lifter and valve pad must be rein-
ment (023) stalled in its original position.
90890-04179
Valve spring compressor adapt-
er (023)
YM-04179

5. To secure the valve cotters onto the valve

stem, lightly tap the valve tip with a soft-face
hammer.
ECA13800

NOTICE
-------------
Hitting the valve tip with excessive force
could damage the valve.

6. Lubricate:
• Valve pad
(with the recommended lubricant)

Recommended lubricant
Molybdenum disulfide oil

• Valve lifter
(with the recommended lubricant)

Recommended lubricant
Engine oil

7. Install:
• Valve pad

5-37
 GENERATOR AND STARTER CLUTCH

EAS20140

GENERATOR AND STARTER CLUTCH

..:, 32 N•m 3.2 k f•m , 24 lb.ft

"
,.;, 75 N•m 7.5 k f•m, 55 lb•ft

""· 15 N•m 1.5 k f•m, 11 lb·ft

r'\I10 N•m (1.0 kgf•m, 7.4 lb•ft) I ~

t.:,. 12 N•m (1.2 kgf•m, 8.9 lb·ft)

t.:, 12 N•m (1.2 kgf•m, 8.9 lb•ft)

Order Job/Parts to remove Q'ty Remarks

Fuel tank front cover/Front side panel/Front side Refer to "GENERAL CHASSIS (2)" on page
cowling 4-6.
Refer to "GENERAL CHASSIS (1 )" on page
Passenger seat/Rider seat/Rear side cover (left)
4-1 .
Refer to "GENERAL CHASSIS (3)" on page
Fuel tank cover
4-13.
Fuel tank Refer to "FUEL TANK" on page 7-1 .
Water pump Refer to "WATER PUMP" on page 6-11 .
Drain.
Engine oil Refer to "CHANGING THE ENGINE OIL'.' on
page 3-25.
1 Stator coil coupler 1 Disconnect.
2 Crankshaft position sensor coupler 1 Disconnect.
Holder (fuel tank overflow hose and fuel tank
3 1
breather hose)

5-38
 GENERATOR AND STARTER CLUTCH

10

,-:, 32 N•m 3.2 k f•m , 24 lb.ft 8

"
,,;, 75 N•m 7.5 k f•m, 55 lb•ft , . 14 N•m (1.4 kgf•m, 10 lb·ft)

>t 15 N•m 1.5 k f•m , 11 lb·ft

r"t.l 10 N•m (1.0 kgf•m, 7.4 lb•ft) I ~

.<1.:,. 12 N•m (1.2 kgf•m, 8.9 lb·ft)

,<1.:, 12 N•m (1.2 kgf•m, 8.9 lb•ft)

Order Job/Parts to remove Q'ty Remarks

4 Generator cover 1
5 Generator cover gasket 1
6 Dowel pin 2
7 Stator coil lead holder 1
Stator coil assembly (stator coil/crankshaft posi-
8
tion sensor)
1

9 Generator rotor 1
10 Starter clutch 1

5-39
 GENERATOR AND STARTER CLUTCH

~
13

,-:, 32 N•m 3.2 k f•m , 24 lb.ft

"
,,;, 75 N•m 7.5 k f•m, 55 lb•ft , . 14 N•m (1.4 kgf•m, 10 lb·ft)

>t 15 N•m 1.5 k f•m , 11 lb·ft

r"t.l 10 N•m (1.0 kgf•m, 7.4 lb•ft) I ~
15

.<1.:,. 12 N•m (1.2 kgf•m, 8.9 lb·ft)

,<1.:, 12 N•m (1.2 kgf•m, 8.9 lb•ft)

Order Job/Parts to remove Q'ty Remarks

11 Starter clutch gear 1

12 Woodruff key 1
13 Starter clutch idle gear shaft 1
14 Starter clutch idle gear 1
15 Crankshaft end cover 1
16 Timing mark accessing bolt 1
17 Water pump outlet pipe 1

5-40
 GENERATOR AND STARTER CLUTCH

EAS30867

REMOVING THE GENERATOR

1. Remove:
• Generator rotor bolt "1"
• Washer
TIP - - - - - - - - - - - - - - - -+-- 2
While holding the generator rotor "2" with the
sheave holder "3", loosen the generator rotor 0

bolt.

Sheave holder EAS30868

90890-01701 REMOVING THE STARTER CLUTCH

Primary clutch holder 1. Remove:
YS-01880-A • Starter clutch bolts
• Starter clutch
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
While holding the generator rotor "1" with the
sheave holder "2", loosen the starter clutch
bolts.

Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
2. Remove:
• Generator rotor "1" 1
(with the flywheel puller "2")
• Woodruff key
ECA13880

NOTICE
-------------
To protect the end of the crankshaft, place an
appropriate sized socket between the fly-
wheel puller set center bolt and the crank-
shaft.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ EAS30869

• Install the flywheel puller bolts to the threaded CHECKING THE STARTER CLUTCH
holes of the starter clutch. 1. Check:
• Make sure the flywheel puller is centered over • Starter clutch rollers
the generator rotor. Damage/wear ➔ Replace.
2. Check:
• Starter clutch idle gear
Flywheel puller
• Starter clutch gear
90890-01362
Heavy duty puller Burrs/chips/roughness/wear ➔ Replace the
YU-33270-B defective part(s).
3. Check:
• Starter clutch gear contact surfaces
Damage/pitting/wear ➔ Replace the starter
clutch gear.
4. Check:
• Starter clutch operation

5-41
 GENERATOR AND STARTER CLUTCH

a. Install the starter clutch gear "1" onto the

generator rotor "2" and hold the generator 2
rotor.
b. When turning the starter clutch gear clock-
wise "A", the starter clutch and the starter
clutch gear should engage, otherwise the
starter clutch is faulty and must be re-
placed.
c. When turning the starter clutch gear coun-
terclockwise "B", it should turn freely, oth-
erwise the starter clutch is faulty and must EAS30872
be replaced. INSTALLING THE GENERATOR
1. Install:
A • Woodruff key
1
• Generator rotor
• Washer •~H
• Generator rotor bolt

\ B
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• C lean the tapered portion of the crankshaft and
2 the generator rotor hub.
• When installing the generator rotor, make sure
the woodruff key is properly seated in the key-
EAS30871

INSTALLING THE STARTER CLUTCH way of the crankshaft.

1. Install: • Lubricate the washer with engine oil.
• Starter clutch "1" • Lubricate the generator rotor bolt threads and
washer mating surfaces with engine oil.
Starter clutch bolt
2. Tighten:
32 N•m (3.2 kgf•m, 24 lb-ft)
LOCTITE® • Generator rotor bolt "1"

Generator rotor bolt

TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• Install the starter clutch so that the side of the
starter clutch roller assembly with the arrow
mark "a" is toward the generator rotor "2".
• While holding the generator rotor with the
sheave holder "3", tighten the starter clutch
bolts.
75 N•m (7.5 kgf •m, 55 lb-ft)
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
While holding the generator rotor "2" w ith the
sheave holder "3", tighten the generator rotor
bolt.

Sheave holder
Sheave holder 90890-01701
90890-01701 Primary clutch holder
Primary clutch holder YS-01880-A
YS-01880-A

5-42
 GENERATOR AND STARTER CLUTCH

3. Apply:
• Sealant
(onto the stator coil assembly lead grommet)

Yamaha bond No. 1215

90890-85505
(Three bond No.1215® )

4. Install:
• Generator cover gasket 1~f4ij
• Generator cover

Generator cover bolt "1"

12 N-m (1.2 kgf-m, 8.9 lb-ft)
LOCTITE®
Generator cover bolt "2"
12 N-m (1.2 kgf-m, 8.9 lb•ft)

TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Tighten the generator cover bolts in stages and
in a crisscross pattern.

1
5. Connect:
• Stator coil coupler
• Crankshaft position sensor coupler
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
To route the stator coil lead, refer to "CABLE
ROUTIN G" on page 2-15.

5-43
 ELECTRIC STARTER

EAS20052

ELECTRIC STARTER
Removing the starter motor

..:,. 12 N•m (1 .2 kgf•m, 8.9 lb·ft)

$,. 7 N•m (0.7 kgf•m, 5.2 lb•ft)

\ \
Order Job/Parts to remove Q 'ty Remarks

Fuel tank front cover/Front side panel/Front side Refer to "GENERAL CHASSIS (2)" on page
cowling 4-6.
Refer to "GENERAL CHASSIS (1 )" on page
Passenger seat/Rider seat
4-1 .
Refer to "GENERAL CHASSIS (3)" on page
Fuel tank cover
4-13.
Fuel tank Refer to "FUEL TANK" on page 7-1.

Air filter case Refer to "GENERAL CHASSIS (3)" on page

4-13.
Canister (for California only) Refer to "FUEL TANK" on page 7-1.
Throttle bodies Refer to 'THROTTLE BODIES" on page 7-5.
1 Starter motor lead 1 Disconnect.
2 Negative battery lead 1 Disconnect.
3 Starter motor 1

5-44
 ELECTRIC STARTER

Disassembling the starter motor

s •~Mi

5 •~t4❖J

New

,.'l;, 5 N•m (0.5 kgf•m, 3.7 lb·ft)

Order Job/Parts to remove Q'ty Remarks

1 0-ring 1
2 Starter motor front cover 1
3 Starter motor yoke 1
4 Armature assembly 1
5 Gasket 2
6 Brush holder set 1
7 Starter motor rear cover 1

5-45
 ELECTRIC STARTER

EAS30325
4. Measure:
CHECKING THE STARTER MOTOR
• Brush length "a"
1. Check:
Out of specification ➔ Replace the brush
• Commutator
holder set.
D irt ➔ Clean with 600 grit sandpaper.
2. Measure: Brush overall length limit
• Mica undercut "a" 6.5 mm (0.26 in)
O ut of specification ➔ Scrape the mica to the
proper measurement with a hacksaw blade
that has been grounded to fit the commutator.

Mica undercut (depth)

0.70 mm (0.03 in)

TIP _ _ _ _ _ _ _ _ _ _ _ _ __ a
The mica of the commutator must be undercut to
ensure proper operation of the commutator.

I ■ • - ■
5. Measure:
• Brush spring force
Out of specification ➔ Replace the brush
holder set.

Brush spring force

6.03-6.52 N (615-665 gf, 21.71-
23.47 oz) (MTT9K, MTT9KC)
6.02-6.51 N (614-664 gf, 21.69-
23.45 oz) (MTT9GTK,
3. Check: MTT9GTKC)
• A rmature assembly
a. Connect the digital circuit tester to the ar-
mature coil and check the continuity.

Digital circuit tester (CD732)

90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927

b. If there is no continuity, replace the starter

motor.
6. Check:
• Gear teeth
I
Damage/wear ➔ Replace the starter motor.
r'-
, ' 7. Check:
• Bearing
• Oil seal
1 Damage/wear ➔ Replace the starter motor.
I I EAS30326
I I
I
-"
I
ASSEMBLING THE STARTER MOTOR
1. Install:
1. Armature coil resistance • Brush holder set
2. Insulation resistance • Insulator "1"

5-46
 ELECTRIC STARTER

TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Install the insulator as shown in the illustration.

1
~ ~----:::::

a
~::=::::::::::~
'''------' u . . ._____,
2. Install:
• Starter motor rear cover "1"
• Starter motor yoke "2"
• Starter motor front cover "3"
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Align the match marks "a" on the starter motor
yoke with the match marks "b" on the front and
rear cover.

b a b

1 2 3
EAS30327

INSTALLING THE STARTER MOTOR

1. Install:
• Starter motor "1"
• Negative battery lead "2"
• Starter motor bolts "3"
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Install the negative battery lead as shown in the
illustration.

Starter motor bolt

12 N•m (1.2 kgf•m, 8.9 lb•ft)

2. Connect:
• Starter motor lead

5-47
 CLUTCH

EAS20055

CLUTCH
Removing the clutch cover
·''. 12 N•m (1 .2 kgf•m, 8.9 lb•ft) ,'<,, 7 N•m (0.7 kgf•m, 5.2 lb·ft)

---1 '
(~ 1

.,;;~
r
~~/
7
2
,_. . .~ \ 6

x~
6

/ fi(t)
~ ,1.,.--.,._ 4

~ -(_G)_ -11!:
~J_J1!_!2:..!:N!:!•m~(1~
.2~kil;9f!:!;•m!.!!,~8.==.9~1b~·f!l.Jt) I
«, 1.5 N•m (0.15 kgf•m, 1.1 lb·ft)
.;,. 12 N•m (1 .2 kgf•m, 8.9 lb·ft)

Order Job/Parts to remove Q'ty Remarks

Drain.
Engine oil Refer to "CHANGING THE ENGINE OIL'.' on
page 3-25.
1 Clutch cable 1 Disconnect
2 Cover 1

3 0 2 sensor coupler bracket 1

4 Clutch cover 1
5 Clutch cover gasket 1
6 Dowel pin 2
7 Oil filler cap 1

5-48
 CLUTCH

Removing the pull lever shaft

;,r, 10 N•m 1.0 k f•m, 7.4 lb·ft

4.. 10 N•m 1.0 k f•m , 7.4 lb·ft

2 - --l a

10
9

4
3mz!1
Order Job/Parts to remove Q'ty Remarks

Clutch cover damper plate Install the clutch cover damper plate with its
1 1 folded-up side facing upward.
2 Clutch cover damper 1
3 Circlip 1
4 Pull lever 1
5 Pull lever spring 1
6 Circlip 1
7 Pull lever shaft 1
8 Oil seal 1
9 Bearing 1
10 Bearing 1

5-49
 CLUTCH

Removing the clutch

;,-::,_. 125 N•m (12.5 kgf•m, 92 lb·ft)

'
a 12 11

( /'~
~ (@ ~ '•@"@
a O \&(ore
El~ li: 111

Ill
Ill
7

-
- /
~ -/ -
-B
Gl
- 9
,

4
2
~- 10 N•m (1.0 kgf•m, 7.4 lb·ft)
3 1

Order Job/Parts to remove Q 'ty Remarks

Oil pump driven sprocket Refer to "OIL PUMP" on page 5-62.
1 Pressure plate 1 1
2 Clutch spring 3
3 Absorber 3
4 Pressure plate 2 1
5 Pull rod 1
6 Bearing 1
7 Friction plate 1 3 Inside diameter: 126 mm (4.96 in)
8 Clutch plate 1 1 Inside diameter: 116 mm (4.57 in)
9 Clutch plate 2 7 Inside diameter: 105 mm (4.13 in)
10 Friction plate 2 6 Inside diameter: 119 mm (4.69 in)
11 Clutch damper spring 1
12 Clutch damper spring seat 1

5-50
 CLUTCH

Remo ·
,---v•ng the clutch

;,-::,, 125 N•m (12. 5 kgf•m, 92 lb·ft)

20
19

17
16
mm
13

'

-~ ~~ 0

. ~ //
~. -- -
Cil A
~ '

~. 10 N•m ( 1.0 kgf•m, 7.4 lb·ft)

Order Job/Parts t Q 'ty Remarks

Clutch boss nut o remove
13 1
14 Conical spring washer 1
15 Washer 1
16 Clutch boss 1
17 Thrust plate 1
18 Clutch housing 1
19 Oil pump drive chain 1
20 Bearing 1
21 Spacer 1
22 Thrust plate 1
23 Thrust plate 1

5-51
 CLUTCH

EAS30346
4. Remove:
REMOVING THE CLUTCH
• Friction plates 1 "1"
1. Remove:
• Cover "1"
• C lutch cover "2"
• Gasket
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Loosen each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern.
After all of the bolts are fully loosened, remove
them .

5. Remove:
• Clutch plate 1 "1"
• Clutch plates 2
• Friction plates 2
• Clutch damper spring
• Clutch damper spring seat
V

2. Remove:
• O il pump driven sprocket "1"
Refer to "OIL PUMP" on page 5-62.

6. Straighten the clutch boss nut rib "a".

1/

0. ~ L}J/['f t::; ~,...._;Y- a s;::----JL-✓•.

~o~
~=------~-~-~_t_~Jof'[~O 1 u
@
I
3. Remove:
• C lutch spring bolts "1"
• Pressure plate 1 "2"
• C lutch springs
• Pressure plate 2 "3"
• Pull rod "4" 7. Loosen:
• Clutch boss nut "1"
V
4 TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
While holding the clutch boss "2" with the univer-

® ~\1 sal clutch holder "3", loosen the clutch boss nut.

Universal clutch holder

90890-04086
Universal clutch holder
3 --------\) "' ~ YM-91042
()(j ~~2

5-52
 CLUTCH

Im

8. Remove: A. Friction plate 1

• C lutch boss nut B. Friction plate 2
• Conical spring washer
• Washer EAS30349

• Clutch boss CHECKING THE CLUTCH PLATES

• Thrust plate The following procedure applies to all of the
• Clutch housing clutch plates.
• O il pump drive chain 1. Check:
• Clutch plate 1 , 2
EAS30348
Damage ➔ Replace the clutch plates as a
CHECKING THE FRICTION PLATES set.
The following procedure applies to all of the fric- 2. Measure:
tion plates. • Clutch plate 1 , 2 thickness
1. Check: (with a surface plate and thickness gauge "1")
• Friction plate 1, 2 Out of specification ➔ Replace the clutch
Damage/wear ➔ Replace the friction plates plates as a set.
as a set.
2. Measure: Thickness gauge
• Friction plate 1, 2 thickness 90890-03268
O ut of specification ➔ Replace the friction Feeler gauge set
plates as a set. YU-26900-9
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Measure the friction plate at four places. Clutch plate 1 thickness
2.20-2.40 mm (0.087-0.094 in)
Friction plate 1 thickness Warpage limit
2.92-3.08 mm (0.115-0.121 in) 0.1 O mm (0.004 in)
Wear limit Clutch plate 2 thickness
2.82 mm (0.111 in) 1.90-2.1 O mm (0.075-0.083 in)
Friction plate 2 thickness Warpage limit
2.92-3.08 mm (0.115-0.121 in) 0.1 O mm (0.004 in)
Wear limit
2.82 mm (0.111 in) TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
The clutch plate thickness specification listed
above is for the plates with the standard thick-
ness only. If a clutch plate with one of the other
, .......
two plate thicknesses is installed, use 1.50- 1.70
mm (0.059-0.067 in) or 2.20-2.40 mm (0.086-
0.094 in) for the specification according to the
plate.

5-53
 CLUTCH

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
When adjusting the clutch assembly width [by
replacing the clutch plate(s)], be sure to replace
the clutch plate "1" fast.
After replacing the clutch plate "1", if specifica-
tions cannot be met, replace the clutch plate "2".

·- , (

i~
\
, '7 I
1 ''' ''' '''

3. Measure:
"' I
L,,
~., '' '
'l _ • • •''
-
''
''
I
..,.)-..
1--
• Assembly width "a" of the friction plates and ,
clutch plates "'
Out of specification ➔ Adjust. i,
'
~

~
~
'""
n
Assembly width ~
'
42.7-43.5 mm (1.68-1.71 in) 2 1
EAS30351
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
CHECKING THE CLUTCH SPRINGS
• Perform the thickness measurement without The following procedure applies to all of the
applying the oil. clutch springs.
• This step should be performed only if the fric- 1. Check:
tion plates and clutch plates were replaced . • Clutch spring
• To measure the total width of the friction plates Damage ➔ Replace the clutch springs as a
and clutch plates, combine 9 friction plates and set.
8 clutch plates as shown. 2. Measure:
• Clutch spring free length "a"
Out of specification ➔ Replace the clutch
springs as a set.

Clutch spring free length

45.23 mm (1. 78 in)
Limit
42.97 mm (1.69 in)

' I
D
a. Assembly width adjusted by clutch plate I_.
"1" and "2".
b. Select the clutch plate from the following
table. '-"
Clutch plate "1"
' \r
II

4B 1-16324-00 1.6 mm (0.063 in)

a 7,
5VY-16325-00 2.0 mm (0.079 in) STD
4B 1-16325-00 2.3 mm (0.091 in) EAS30352

CHECKING THE CLUTCH HOUSING

Clutch plate "2" 1. Check:
• Clutch housing dogs
4B 1-16324-00 1.6 mm (0.063 in)
Damage/pitting/wear ➔ Deburr the clutch
5VY-16325-00 2.0 mm (0.079 in) STD housing dogs or replace the clutch housing.
4B 1-16325-00 2.3 mm (0.091 in)

5-54
 CLUTCH

EAS30354
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
CHECKING THE PRESSURE PLATE
Pitting on the clutch housing dogs will cause er- 1. Check:
ratic clutch operation . • Pressure plate 1 "1"
• Pressure plate 2 "2"
Cracks/damage ➔ Replace.
• Bearing "3"
Damage/wear ➔ Replace.

1 2 3

2. Check:
• Oil pump drive sprocket "1"
Cracks/damage/wear ➔ Replace.

1 EAS30356

CHECKING THE PRIMARY DRIVE GEAR

1. Check:
• Primary drive gear
Damage/wear ➔ Replace the crankshaft and
clutch housing as a set.
Excessive noise during operation ➔ Replace
the crankshaft and clutch housing as a set.
EAS30357

CHECKING THE PRIMARY DRIVEN GEAR

3. Check:
1. Check:
• Bearing
• Primary driven gear "1"
Damage/wear ➔ Replace the bearing and
Damage/wear ➔ Replace the clutch housing
clutch housing.
and crankshaft as a set.
EAS30353 Excessive noise during operation ➔ Replace
CHECKING THE CLUTCH BOSS the clutch housing and crankshaft as a set.
1. Check:
• C lutch boss splines
Damage/pitti ng/wear ➔ Replace the clutch
boss.
Q ----- 1
g
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ g
Pitting on the clutch boss splines will cause er-
ratic clutch operation .

EAS30358

CHECKING THE PULL LEVER SHAFT AND

PULL ROD
1. Check:
• Pull lever shaft pinion gear teeth "1"
• Pull rod teeth "2"
Damage/wear ➔ Replace the pull rod and
pull lever shaft as a set.

5-55
 CLUTCH

Universal clutch holder

90890-04086
Universal clutch holder
YM-91042

2. Check:
• Pull rod bearing
Damage/wear ➔ Replace.

EAS30363

INSTALLING THE CLUTCH

1. Install:
• O il pump drive chain "1"
• Clutch housing "2"
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Install the oil pump drive chain onto the oil pump
drive sprocket "a".

-u _; /
()/ ,
C'

3. Install:
• Clutch damper spring seat
0 • Clutch damper spring
• Friction plates 1
• Clutch plates 2
a
• Friction plates 2
• Clutch plate 1
2. Install:
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Thrust plate
• C lutch boss "1" • First, install a friction plate and then alternate
• Washer between a clutch plate and a friction plate.
• Conical spring washer "2" • Install the last friction plate "1" offset from the
other friction plates "2", making sure to align a
• C lutch boss nut "3" 1;f4¼j projection on the friction plate with the punch
Clutch boss nut mark "a" on the clutch housing .
125 N•m (12.5 kgf •m, 92 lb-ft)
LOCTITE®

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Install the conical spring washer on the main
axle with the "OUT' mark "a" facing away from
the vehicle.
• While holding the clutch boss "1" with the uni-
versal clutch holder "4", tighten the clutch boss
nut.
• Stake the clutch boss nut at cutouts "b" in the 4. Install:
main axle. • Pull rod

5-56
 CLUTCH

• Pressure plate 2 TIP _ _ _ _ _ _ _ _ _ _ _ _ __

• C lutch springs • Apply engine oil onto the bearing.
• Pressure plate 1 • Tighten the clutch cover bolts in stages and in
• C lutch spring bolts "1" a crisscross pattern .
Clutch spring bolt 6. Install:
10 N•m (1.0 kgf•m, 7.4 lb•ft) • Pull lever
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• O il pump driven sprocket "2"
• Install the pull lever with the "O" mark facing to-
Oil pump driven sprocket bolt ward lower side.
15 N•m (1.5 kgf•m, 11 lb-ft) • When installing the pull lever, push the pull le-
LOCTITE® ver and check that the punch mark "a" on the
pull lever aligns with the mark "b" on the clutch
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ cover. Make sure that the pull rod teeth and
• Tighten the clutch spring bolts in stages and in pull lever shaft pinion gear are engaged .
a crisscross pattern.
• Apply lithium-soap-based grease onto the pull I
rod.
• Position the pull rod so that the teeth "a" face
towards the hole "b". Then , install the clutch
cover.
I

I
\..

7. Connect:
• Clutch cable "1"
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• For the clutch cable "1", turn the nut "2" in fully
and then adjust the length "a" by using the nut
"3" so that the cable length is 47.1- 54.8 mm
5. Install: (1 .85- 2.16 in).
• Dowel pins • Measure the length while keeping the measur-
ing surface "b" parallel.
• C lutch cover gasket •~tMJ • After installing the clutch cable, bend the pro-
• C lutch cover
jection "c" on the pull lever.
• Cover

Clutch cover bolt

12 N•m (1.2 kgf•m, 8.9 lb•ft)

5-57
 CLUTCH

b
1

8. Adjust:
• C lutch lever free play
Refer to "ADJUSTING THE CLUTCH LEVER
FREE PLAY" on page 3-12.

Clutch lever free play

10.0-15.0 mm (0.39-0.59 in)
(MTT9K, MTT9KC)
5.0-10.0 mm (0.20-0.39 in)
(MTT9GTK, MTT9GTKC)

5-58
 SHIFT SHAFT

EAS20057

SHIFT SHAFT
Removing the s hift s haft and stopper lever

4
5
6
7
9

Order Job/Parts to remove Q'ty Remarks

Clutch assembly Refer to "CLUTCH" on page 5-48.

Shift arm Refer to "CHAIN DRIVE" on page 4-112.
1 Circlip 1
2 Washer 1
3 Shift shaft 1
4 Washer 1
5 Circlip 1
6 Washer 1
7 Stopper lever 1
8 Stopper lever spring 1
9 Collar 1

5-59
 SHIFT SHAFT

Removing the shift shaft and stopper lever

r;,::.J 22 N•m (2.2 kgf•m , 16 lb·ft) I

-
G) 10

Order Job/Parts to remove Q 'ty Remarks

10 Shift shaft spring 1

11 Shift shaft spring stopper 1
12 Oil seal 1
13 Bearing 1

5-60
 SHIFT SHAFT

EAS303n
• Mesh the stopper lever with the shift drum seg-
CHECKING THE SHIFT SHAFT
ment assembly.
1. Check:
• Shift shaft "1"
Bends/damage/wear ➔ Replace.
• Shift shaft spring "2"
• Collar
Damage/wear ➔ Replace.

2 0
0

2. Install:
• Bearing
• Oil seal ~i~"M"¼•fJ

EAS30378

CHECKING THE STOPPER LEVER

• Washer "1"
• Circlip "2" •~M
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
1. Check: • Lubricate the oil seal lips with lithium-soap-
• Stopper lever "1" based grease.
Bends/damage ➔ Replace. • Lubricate the outer periphery of the oil seal with
Roller turns roughly ➔ Replace the stopper the silicone fluid.
lever.

l o

EAS30381

INSTALLING THE SHIFT SHAFT

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

Shift shaft spring stopper

22 N•m (2.2 kgf•m, 16 lb-ft)
LOCTITE®

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Hook the end of the shift shaft spring "3" onto
the shift shaft spring stopper "1".
• Hook the ends of the stopper lever spring "2"
onto the stopper lever "4" and the crankcase
boss "5".

5-61
 OIL PUMP

EAS20054

OIL PUMP
Removing the oil pump

~. 10 N•m (1.0 kgf•m, 7.4 lb·ft)

' ~I 1
L_ ___ ,,,,_.

~=.J \ --;!-1- --a

~l 2 •~--ff
.4.. 10 N•m 1.0 k f•m , 7.4 lb·ft ' ;,;" 15 N•m (1.5 kgf•m, 11 lb•ft)

Order Job/Parts to remove Q 'ty Remarks

Clutch cover Refer to "CLUTCH" on page 5-48.
1 Oil pump driven sprocket 1
2 Oil pump assembly 1

5-62
 OIL PUMP

Disassembling the oil pump

..:, 3.8 N•m (0.38 kgf•m, 2.8 lb·ft)

3
mlJ6---o
1--0
I
4 8 -----'

10

~ "--- , ~ I
'"'~ /,j,?~
"----, -Y": / _
'
'
-- I

10 .,

Order Job/Parts to remove Q'ty Remarks

1 Oil pump cover 1

2 Oil pump shaft 1
3 Pin 1
4 Oil pump inner rotor 1
5 Oil pump outer rotor 1
Hold down the washer when removing the
6 Circlip 1
circlip.
7 Washer 1
8 Spring 1
9 Relief valve 1
10 Dowel pin 2

5-63
 OIL PUMP

EAS30336

CHECKING THE SPROCKET AND CHAIN Inner-rotor-to-outer-rotor-tip

1. Check: clearance
• Oil pump drive sprocket 0.000-0.120 mm (0.0000-0.0047
Refer to "CHECKING THE CLUTCH HOUS- in)
ING" on page 5-54. Limit
2. Check: 0.20 mm (0.0079 in)
• Oil pump drive chain "1" Outer-rotor-to-oil-pump-housing
Damage/stiffness ➔ Replace the oil pump clearance
drive chain and oil pump drive sprocket
0.09-0.1 9 mm (0.0035-0.0075 in)
Limit
(clutch housing) as a set.
0.21 mm (0.0083 in)

EAS30337

CHECKING THE OIL PUMP 1. Inner rotor

1. Check: 2. Outer rotor
• Oil pump driven sprocket "1"
• O il pump housing "2" 3. Check:
Cracks/damage/wear ➔ Replace the defec- • Oil pump operation
tive part(s) . Rough movement ➔ Repeat steps (1) and
(2) or replace the defective part(s) .

2. Measure:
• Inner-rotor-to-outer-rotor-tip clearance "a" EAS30338

• Outer-rotor-to-oil-pump-housing clearance CHECKING THE RELIEF VALVE

"b" 1. Check:
Out of specification ➔ Replace the defective • Relief valve "1"
part(s). • Spring "2"
Damage/wear ➔ Replace the oil pump as-
sembly.

5-64
 OIL PUMP

Oil pump bolt

10 N-m (1.0 kgf-m, 7.4 lb-ft)

1 • Oil pump driven sprocket "3"

Oil pump driven sprocket bolt

2 15 N-m (1.5 kgf-m, 11 lb-ft)
0 LOCTITE®
0 ECA20940

NOTICE
EAS30342 -------------
ASSEMBLING THE OIL PUMP After installing the oil pump drive chain and
1. Lubricate: driven sprocket, make sure the oil pump
• Inner rotor turns smoothly.
• O uter rotor TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
• O il pump shaft
(with the recommended lubricant) • 1RC mark of the oil pump driven sprocket is in-
stalled at oil pump side.
Recommended lubricant • Install the oil pump drive chain onto the oil
I Engine oil pump driven sprocket.

2. Install:
• O uter rotor "1"
• Inner rotor "2"
• Pin "3"
• O il pump cover "4"
• O il pump cover screw

Oil pump cover screw

3.8 N-m (0.38 kgf-m, 2.8 lb-ft)

TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Align the pin "3" in the oil pump shaft with the
groove in the inner rotor "2".

3. Check:
• O il pump operation
Refer to "CHECKING THE OIL PUMP" on
page 5-64.
EAS30343

INSTALLING THE OIL PUMP

1. Install:
• O il pump "1"
• O il pump bolts "2"

5-65
 OIL PAN

EAS201n

OIL PAN
Removing the oil pan

4 43 N•m 4.3 k f•m , 32 lb·ft

0 -

~<> (13)

.>t, 10 N•m 1.0 k f•m, 7.4 lb·ft

Order Job/Parts to remove Q'ty Remarks

Fuel tank front cover/Front side panel/Front side Refer to "GENERAL CHASSIS (2)" on page
cowling 4-6.

Passenger seat/Rider seat Refer to "GENERAL CHASSIS (1 )" on page

4-1 .

Fuel tank cover Refer to "GENERAL CHASSIS (1 )" on page

4-1 .
Fuel tank Refer to "FUEL TANK" on page 7-1 .
Muffler assembly Refer to "ENGINE REMOVAL.:' on page 5-9.
Drain.
Engine oil Refer to "CHANGING THE ENGINE OIL:' on
page 3-25.
1 Oil level switch coupler 1 Disconnect.
2 Oil level switch lead holder 1
3 Oil level switch 1

5-66
 OIL PAN

Removing the oil pan

-~ 43 N•m 4.3 k f•m , 32 lb·ft

<> -
~., (13) 7

,-t, 10 N•m 1.0 k f•m, 7.4 lb·ft

Order Job/Parts to remove Q'ty Remarks

4 0 2 sensor lead holder 1

5 Oil pan 1
6 Oil pan gasket 1
7 Oil strainer 1

5-67
 OIL PAN

EAS31068

REMOVING THE OIL PAN Engine oil drain bolt

1. Remove: 43 N-m (4.3 kgf-m, 32 lb-ft)
• Oil level switch "1"
EWA12820
• Oil pan "2"
• Oil pan gasket £ WARNING
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ Always use new copper washers.
Loosen each bolt 1/4 of a turn at a time, in stag- TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
es and in a crisscross pattern. After all of the • Tighten the oil pan bolts in stages and in a
bolts are fully loosened, remove them. crisscross pattern .
• Lubricate the oil level switch 0-ring with lithi-
um-soap-based grease.

EAS31069
1
CHECKING THE OIL STRAINER
1. Check:
• Oil strainer "1"
Damage ➔ Replace.
Contam i nants ➔ Clean with solvent.

EAS31070

INSTALLING THE OIL PAN

1. Install:
• Oil pan gasket ilf4Yi
• Oil pan "1"

Oil pan bolt

10 N-m (1.0 kgf-m, 7.4 lb•ft)

• Oil level switch "2"

Oil level switch bolt

10 N-m (1.0 kgf-m, 7.4 lb-ft)

• Engine oil drain bolt "3"

5-68
 CRANKCASE
EAS20059

CRANKCASE
Separating the crankcase
$,.. 24 N•m (2.4 kgf•m, 18 lb·ft) 1st 25 N•m 2.5 k f•m, 18 lb·ft
~'- 10 N•m (1.0 kgf•m, 7 .4 lb·ft) ~. 2nd 18 N•m (1.8 kgf•m, 13 lb·ft)
3rd Specified angle 60°
1st
25 N•m 2.5 k f•m, 18 lb·ft
(6) ""· 10 N•m (1.0 kgf•m, 7.4 lb·ft)
·"·· 2nd 15 N•m (1.5 kgf•m, 11 lb·ft)
3rd Specified angle 60' /
,.,, 24 N•m 2.4 k f•m, 18 lb·ft ...._,.,.
.,..
l E

(2 -
E

v·
-~ -
6-i 6

Gl ~- 17 N•m (1 .7 kgf•m, 13 lb·ft)

~- 70 N•m (7.0 kgf•m, 52 lb·ft)

t;, 12 N•m (1 .2 kgf•m, 8.9 lb·ft)

,-;, 4.0 N•m (0.40 kgf•m, 3.0 lb·ft)

Order Job/Parts to remove Q 'ty Remarks

Engine Refer to "ENGINE REMOVAL:' on page 5-9.

Cylinder head Refer to "CYLINDER HEAD" on page 5-27.
Water pump Refer to "WATER PUMP" on page 6-11 .
Refer to "GENERATOR AND STARTER
Starter clutch CLUTCH" on page 5-38.
Refer to "ELECTRIC STARTER" on page
Starter motor 5-44.
Clutch housing Refer to "CLUTCH" on page 5-48.
Oil strainer Refer to "OIL PAN" on page 5-66.
1 Oil filter cartridge 1
2 Oil filter cartridge union bolt 1
3 Gear position switch 1
4 Clutch cable holder 1
5 Lower crankcase 1
6 Dowel pin 3

5-69
 CRANKCASE
EAS30389 EAS30390

DISASSEMBLING THE CRANKCASE CHECKING THE CRANKCASE

1. Place the engine upside down. 1. Thoroughly wash the crankcase halves in a
2. Remove: mild solvent.
• Crankcase bolt (x30) 2. Thoroughly clean all the gasket surfaces and
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ crankcase mating surfaces.
• Loosen each bolt 1/4 of a turn at a time, in stag- 3. Check:
es and in a crisscross pattern. After all of the • Crankcase
bolts are fully loosened, remove them. Cracks/damage ➔ Replace.
• Loosen the bolts in the proper sequence as • Oil delivery passages
shown. Obstructi on ➔ Blow out with compressed air.
• The numbers embossed on the crankcase in- EAS30397

dicate the crankcase tightening sequence. ASSEMBLING THE CRANKCASE

1. Lubricate:
• Crankshaft journal bearing inner surface
(with the recommended lubricant)

Recommended lubricant
I
Engine oil

2. Apply:
• Sealant
(onto the crankcase mating surfaces)

Yamaha bond No. 1215

90890-85505
(Three bond No.1215® )

TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Do not allow any sealant to come into contact
with the oil gallery or crankshaft journal bear-
ings, or balancer shaft journal bearings.

3. Remove:
• Lower crankcase
/n\
ECA13900 j
,
NOTICE ~~ .,,o,
--------------
Tap on one side of the crankcase with a soft-
r
"' I , ~ (

face hammer. Tap only on reinforced por- 'o (\ / "'"'

tions of the crankcase, not on the crankcase
I -
0 0 0 a 1
mating surfaces. Work slowly and carefully
r
and make sure the crankcase halves sepa- 0 0 0 0
rate evenly. '--'

b l 'I
~

l:l '
4. Remove:
(
-~ - 0
~

...__,
D

• Dowel pins
' l.. - r
~
I

5. Remove:
'-' li ]h
• Crankshaft journal lower bearing 0 I
a ~ ~
0
• Balancer shaft journal bearing
(from the lower crankcase)
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Identify the position of each part very carefully so
that it can be reinstalled in its original place. 3. Install:
• Dowel pins

5-70
 CRANKCASE

4. Set the shift drum assembly and transmission

gears in the neutral position.
5. Install:
• Lower crankcase "1"
(onto the upper crankcase "2")
ECA13980

NOTICE
- - - - - - - - - - - - -
Before tightening the crankcase bolts, make
sure the transmission gears shift correctly
when the shift drum assembly is turned by
hand.

7. Tighten:
• Crankcase bolts "1"-"8"
6. Install:
• Crankcase bolt (x30) Crankcase bolts "1 "-"6"
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ 1st: 25 N-m (2.5 kgf •m, 18 lb-ft)
• Lubricate the bolts "1 "-"8" thread, mating sur- *2nd: 15 N-m (1.5 kgf •m, 11 lb-ft)
faces and washers with engine oil. 3rd: +60°
• Lubricate the bolts "9"-"12" thread , mating sur- Crankcase bolts "7"-"8"
faces and 0-rings with engine oil.
1st: 25 N-m (2.5 kgf •m, 18 lb-ft)
*2nd: 18 N-m (1.8 kgf •m, 13 lb-ft)
• Lubricate the bolts "13"-"30" thread and mat-
3rd: +60°
ing surfaces with engine oil.
• MS x 100 mm (3.94 in) bolts with washers: * Following the tightening order, loosen the
bolt one by one and then retighten it to the
"7" , "8" .~
_!t=WI
• MS x 85 mm (3.35 in) bolts with washers: "1 "- specific torque.
EWA16610

"6" •~tMI & WARNING

• MS x 78 mm (3.07 in) bolts with new 0-rings:
"9"-"12"
• MS x 60 mm (2.36 in) bolts: "13", "14"
• M6 x 85 mm (3.35 in) bolt: "18"
• M6 x 65 mm (2.56 in) bolts: "15", "16"
• M6 x 65 mm (2.56 in) bolt: "26"
• M6 x 50 mm (1.97 in) bolts: "17", "19"-"21 ",
"23"-"25" "27"-"30"
' bolt to the specified angle.
• M6 x 40 mm (1.57 in) bolt: "22"
If the bolt is tightened more than the speci-
fied angle, do not loosen the bolt and then re-
tighten it. Instead, replace the bolt with a new
one and perform the procedure again.
ECA20890
NOTICE
-------------
Do not use a torque wrench to tighten the
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Tighten the bolts in the tightening sequence cast
on the crankcase.

5-71
 CRANKCASE

0 0

8. Tighten:
• Crankcase bolts "9"-"30"

Crankcase bolts "9"- "14"

24 N•m (2.4 kgf•m, 18 lb-ft)
Crankcase bolts "15"- "30"
10 N•m (1.0 kgf•m, 7.4 lb•ft)

TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Tighten the bolts in the tightening sequence cast
on the crankcase.

5-72
 CONNECTING RODS AND PISTONS

EAS20132

CONNECTING RODS AND PISTONS

Removing the connecting rods and pistons

, .,, 1-1_s_t _ 2o
_ N_
•m__,_
(2_.0_k_,g'-f._m--'-,_15
_ 1b_·ft_,_)---1
¼ 2nd Specified angle 175-185°

Q 1

10

9
8
-
Gl
Order Job/Parts to remove Q 'ty Remarks
Lower crankcase Refer to "CRANKCASE" on page 5-69.
1 Connecting rod cap 3
2 Big end lower bearing 3
3 Piston pin clip 6
4 Piston pin 3
5 Piston 3
6 Connecting rod 3
7 Big end upper bearing 3
8 Top ring 3
9 2nd ring 3
10 Oil ring 3

5-73
 CONNECTING RODS AND PISTONS

EAS30745

REMOVING THE CONNECTING RODS AND

PISTONS
The following procedure applies to all of the con-
necting rods and pistons.
1. Remove:
• Connecting rod cap "1"
• Connecting rod
• Big end bearings
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• Identify the position of each big end bearing so
that it can be reinstalled in its original place.
• After removing the connecting rods and con-
-------x 3 2
necting rod caps, care should be taken not to
damage the mating surfaces of the connecting
rods and connecting rod caps.
""
4

3. Remove:
• Top ring
• 2nd ring
• Oil ring
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
2. Remove: When removing a piston ring , open the end gap
with your fingers and lift the other side of the ring
• Piston pin clips "1"
over the piston crown .
• Piston pin "2"
• Piston "3"
ECA13810

NOTICE
-------------
Do not use a hammer to drive the piston pin
out. 0
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• For reference during installation, put identifica-
tion marks on the piston crown .
• Before removing the piston pin, deburr the pis-
ton pin clip groove and the piston pin bore ar-
EAS30747
ea. If both areas are deburred and the piston
CHECKING THE CYLINDER AND PISTON
pin is still difficult to remove, remove it with the
1. Check:
piston pin puller set "4".
• Piston wall
• Cylinder wall
Piston pin puller set Vertical scratches ➔ Replace the cylinder,
90890-01304 and replace the piston and piston rings as a
Piston pin puller
set.
YU-01304
2. Measure:
• Piston-to-cylinder clearance
a. Measure cylinder bore "C" with the cylin-
der bore gauge.

5-74
 CONNECTING RODS AND PISTONS

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Piston-to-cylinder clearance
Measure cylinder bore "C" by taking side-to-side
0.010-0.035 mm (0.0004-0.0014
and front-to-back measurements of the cylinder. in)

Bore f . If out of specification , replace the cylinder,

78.000-78.01 Omm (3.0709- and replace the piston and piston rings as
3.0713 in) a set.
Wear limit
EAS30748
78.060 mm (3.0732 in)
CHECKING THE PISTON RINGS
1. Measure:
• Piston ring side c learance
Out of specification ➔ Replace the piston
and piston rings as a set.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Before measuring the piston ring side clearance,
eliminate any carbon deposits from the piston
ring grooves and piston rings.
- - - - --
- - D4
Piston ring
Top ring
Ring side clearance
0.030-0.065 mm (0.0012-
b. If out of specification , replace the cylinder,
0.0026 in)
and replace the piston and piston rings as
Side clearance limit
a set. 0.115 mm (0.0045 in)
c. Measure piston skirt diameter "P" w ith the 2nd ring
micrometer. Ring side clearance
0.020-0.055 mm (0.0008-
Piston 0.0022 in)
Diameter Side clearance limit
77.975-77.990 mm (3.0699- 0.115 mm (0.0045 in)
3.0705 in)

2. Install:
a. 12.0 mm (0.47 in) from the bottom edge of the • Piston ring
piston
(into the cylinder)
d. If out of specification, replace the piston TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
and piston rings as a set. Use the piston crown to level the piston ring near
e. Calculate the piston-to-cylinder c learance bottom of cylinder "a", where cylinder wear is
with the following formula. lowest.
Piston-to-cylinder clearance = Cylinder bore "C" -
Piston skirt diameter "P"

5-75
 CONNECTING RODS AND PISTONS

3. Measure:
• Piston ring end gap
O ut of specification ➔ Replace the piston
nng.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ /

The oil ring expander spacer's end gap cannot

0
be measured. If the oil ring rail's gap is exces-
sive, replace all three piston rings.

Top ring
End gap limit 3. Measure:
0.50 mm (0.0197 in) • Piston pin bore inside diameter "b"
2nd ring Out of specification ➔ Replace the piston.
End gap limit
0.80 mm (0.0315 in) Piston pin bore inside diameter
17.002-17.013 mm (0.6694-
0.6698 in)
Limit
17.043 mm (0.6710 in)

- I
b. Upper of cylinder

EAS30749

CHECKING THE PISTON PIN

The following procedure applies to all of the pis-
ton pins. 4. Calculate:
1. Check: • Piston-pin-to-piston-pin-bore clearance
• Piston pin Out of specification ➔ Replace the piston pin
Blue discoloration/grooves ➔ Replace the and piston as a set.
piston pin and then check the lubrication sys- Piston-pin-to-piston-pin-bore clearance = Piston
tem. pin bore inside diameter "b" - Piston pin outside
2. Measure: diameter "a"
• Piston pin outside diameter "a"
O ut of specification ➔ Replace the piston pin. Piston-pin-to-piston-pin-bore
clearance
Piston pin outside diameter 0.007-0.023 mm (0.0003-0.0009
16.990-16.995 mm (0.6689- in)
0.6691 in)
Limit EAS30750
16.970 mm (0.6681 in) CHECKING THE CONNECTING RODS
1. Measure:
• Crankshaft-pin-to-big-end-bearing clearance
Out of specification ➔ Replace the big end
bearings.

Oil clearance
0.027-0.051 mm (0.0011-0.0020
in)

5-76
 CONNECTING RODS AND PISTONS

The following procedure applies to all of the TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

connecting rods. • Clean the connecting rod bolts and lubricate
ECA13930

NOTICE
the bolt threads and seats with molybdenum
------------- disulfide oil.
Do not interchange the big end bearings and
• Make sure that the projection "a" on the con-
connecting rods. To obtain the correct necting rod cap faces the same direction as the
crankshaft-pin-to-big-end-bearing clear-
"Y" mark "b" on the connecting rod.
ance and prevent engine damage, the big
• After installing the big end bearing , assemble
end bearings must be installed in their origi-
the connecting rod and connecting rod cap
nal positions.
without installing them onto the crankshaft.
a. Clean the big end bearings, crankshaft
pins, and the inside of the connecting rods
halves.
b. Install the big end upper bearing into the
connecting rod and the big end lower
bearing into the connecting rod cap.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Align the projections "a" on the big end bearings
a
with the notches "b" in the connecting rod and
connecting rod cap.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
b a Install by carrying out the following procedures in
order to assemble in the most suitable condition.
e. Tighten the connecting rod bolt while
checking that the sections shown "a" and
"b" are flush with each other by touching
the surface.

Connecting rod bolt

c. Put a piece of Plastigauge® "1" on the
crankshaft pin.
30 N-m (3.0 kgf-m, 22 lb-ft)
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
To install the big end bearing , care should be
taken not to install it at an angle and the position
should not be out of alignment.

d. Assemble the connecting rod halves.

ECA18390

NOTICE _ _ _ _ _ _ _ _ _ _ _ __
Tighten the connecting rod bolts using the
plastic-region tightening angle method. Al- a. Side machined face
ways install new bolts. b. Thrusting faces

5-77
 CONNECTING RODS AND PISTONS

f. Loosen the connecting rod bolt, remove

the connecting rod and connecting rod
cap and install these parts to the crank-
shaft with the big end bearing kept in the
current condition .
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• Do not move the connecting rod or crankshaft
until the clearance measurement has been
completed .
1ao·
• Make sure that the projection "a" on the con- EWA16610
necting rod cap faces the same direction as the £ WARNING
"Y" mark "b" on the connecting rod.
If the bolt is tightened more than the speci-
• Make sure the "Y" marks "b" on the connecting
fied angle, do not loosen the bolt and then re-
rods face towards the left side of the crank-
tighten it. Instead, replace the bolt with a new
shaft.
one and perform the procedure again.
ECA20890

NOTICE
-------------
Do not use a torque wrench to tighten the
bolt to the specified angle.
J. After the installation, check that the sec-
tion shown "a" is flush w ith each other by
touching the surface.
a

g. T ighten the connecting rod bolts w ith a

torque wrench.

Connecting rod bolt (1 st)

20 N•m (2.0 kgf•m, 15 lb-ft)

h. Put a mark "1" on the corner of the con- a \

necting rod bolt "2" and the connecting rod
cap "3". k. Remove the connecting rod and big end
bearings.
I. Measure the compressed Plastigauge®
------- 2 width on the crankshaft pin. If the crank-
shaft-pin-to-big-end-bearing clearance is
out of specification , select replacement
big end bearings.
1--- 3

i. T ighten the connecting rod bolts further to

reach the specified angle 175°-185°.

Connecting rod bolt (final)

Specified angle 175°-185°

2. Select:
• Big end bearings (P 1- P3 )

5-78
 CONNECTING RODS AND PISTONS

TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• The numbers "A" stamped into the crankshaft
web and the numbers "1" on the connecting
rods are used to determine the replacement
big end bearings sizes.
(
• "P/'-"P3" refer to the bearings shown in the
crankshaft illustration.
For example, if the connecting rod "P/' and
the crankshaft web "P1" numbers are 5 and 2 1
respectively, then the bearing size for "P / ' is: EAS30751

INSTALLING THE CONNECTING ROD AND

"P1" (connecting rod) - "Pl' (crankshaft) = 5 - 2 =
3 (brown)
PISTON
The following procedure applies to all of the con-
necting rods and pistons.
Bearing color code 1. Install:
Code 1 • Big end bearings
Blue • Connecting rod cap
Code2 (onto the connecting rod)
Black
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Code3
Brown • Be sure to reinstall each big end bearing in its
Code4 original place.
Green • Align the projections "a" on the big end bear-
ings with the notches "b" in the connecting rods
and connecting rod caps.
• Make sure that the projection "c" on the con-
- - = = necting rod cap faces the same direction as the

-
Jp3\ -
- -
"Y" mark "d" on the connecting rod .

- 1- t P20
P1
0-:
.;,
-
-- b a
- =
-

2. Tighten:
• Connecting rod bolts 1~t4W

5-79
 CONNECTING RODS AND PISTONS

ECA18390
• Top ring "5"
NOTICE
------------- (into the piston)
Tighten the connecting rod bolts using the TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
plastic-region tightening angle method. Al-
Be sure to install the piston rings so that the
ways install new bolts. manufacturer's marks or numbers "a" face up.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Install by carrying out the following procedures in
order to assemble in the most suitable condition .
a. Replace the connecting rod bolts w ith new
ones.
b. Clean the connecting rod bolts and lubri-
cate the bolt threads and seats with mo-
lybdenum disulfide oil.
c. After installing the big end bearing, as-
semble the connecting rod and connecting
rod cap w ithout install ing them onto the 4. Install:
crankshaft. • Piston "1"
d. T ighten the connecting rod bolt while (onto the respective connecting rod "2")
checking that the sections shown "a" and • Piston pin "3"
"b" are flush with each other by touching
the surface.
• Piston pin clips "4" •~M
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Connecting rod bolt • Apply engine oil onto the piston pin.
30 N-m (3.0 kgf-m , 22 lb-ft) • Make sure that the "Y" mark "a" on the connect-
ing rod faces left when the punch mark "b" on
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ the piston is pointing up as shown .
To install the big end bearing , care should be • Install the piston pin clips, so that the clip ends
taken not to install it at an angle and the position are 3 mm (0.12 in) "c" or more from the cutout
should not be out of alignment. in the piston.
• Reinstall each piston into its original cylinder.

a b

b 1

2 3 - -F.&
,,/45
m1J4-\J
a. Side machined face
b. Thrusting faces
e. Loosen the connecting rod bolt, remove
the connecting rod and connecting rod
cap and install these parts to the crank-
shaft with the big end bearing kept in the
current condition .
3. Install : 4
• Oil ring expander "1"
• Lower oil ring rail "2"
• Upper oil ring rail "3"
5. Lubricate:
• 2nd ring "4"
• Piston

5-80
 CONNECTING RODS AND PISTONS

• Piston rings ·o '

• Cylinder .---------,~O
(with the recommended lubricant) 2 b
a 1
Recommended lubricant
I
Engine oil 0

6. Offset:
• Piston ring end gaps
~-3-~t ~ Q ~ --=::., , ~:
IA] 3 --:::::::::::- 1
go• 9. Install:
b,e • Connecting rod caps
• Connecting rod bolts
' TIP _ _ _ _ _ _ _ _ _ _ _ _ __
,:-----t- go·
• Make sure the "Y" marks "a" on the connecting
/ rods face towards the left side of the crank-
shaft.
ad
~ 45• ' • Make sure that the projection "b" on the con-
necting rod cap faces the same direction as the
a. Top ring
"Y" mark "a" on the connecting rod .
b. 2nd ring
• Apply Molybdenum disulfide oil to the bolt
c. Upper oil ring rail
threads and seats.
d. Oil ring expander
e. Lower oil ring rail
A. Exhaust side

7. Lubricate:
• Crankshaft pins
• Connecting rod big end bearing inner surface
(with the recommended lubricant)
b
Recommended lubricant
I
Engine oil

8. Install : 1a.T ighten :

• Piston assemblies "1" • Connecting rod bolts "1"
(into the cylinder "2" and onto the crankshaft
pin)

Piston installing tool

90890-04161
Piston installing tool
YM-04161

ECA21490

NOTICE
-------------
1f the projection "a" of the piston installing
tool damages, you cannot use it. Please han-
dle with care. TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Tighten the connecting rod bolts using the fol-
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
lowing procedure.
Fit the projection "a" of the piston installing tool
"3" and blunt-edged part "b" of the cylinder, fix a. Tighten the connecting rod bolts with a
the position of the piston installing tool, and then torque wrench .
push the piston up to the cylinder.

5-81
 CONNECTING RODS AND PISTONS

Connecting rod bolt (1 st)

20 N•m (2.0 kgf•m, 15 lb-ft)

b. Put a mark "1" on the corner of the con-

necting rod bolt "2" and the connecting rod
cap "3".

------- 2 a \

1--- 3

c. T ighten the connecting rod bolts further to

reach the specified angle 175°-185°.

Connecting rod bolt (final)

Specified angle 175°-185°

1ao·
EWA16610

~ WARNING
If the bolt is tightened more than the speci-
fied angle, do not loosen the bolt and then re-
tighten it. Instead, replace the bolt with a new
one and perform the procedure again.
ECA20890

NOTICE
-------------
Do not use a torque wrench to tighten the
bolt to the specified angle.
d. After the installation, check that the sec-
tion shown "a" is flush with each other by
touching the surface.
EWA17120

~ WARNING
If the connecting rod and cap are not flush
with each other, remove the connecting rod
bolts and big end bearing and restart from
step (1 ). In this case, make sure to replace
the connecting rod bolts.

5-82
 CRANKSHAFT AND BALANCER SHAFT

EAS20178

CRANKSHAFT AND BALANCER SHAFT

Removing the crankshaft and balancer shaft

~ 2
I 1

Order Job/Parts to remove Q'ty Remarks

Lower crankcase Refer to "CRANKCASE" on page 5-69.
Refer to "REMOVING THE CONNECTING
Connecting rod RODS AND PISTONS" on page 5-74.
1 Balancer shaft 1
2 Balancer shaft journal lower bearing 2
3 Balancer shaft journal upper bearing 2
4 Crankshaft 1
5 Crankshaft journal lower bearing 4
6 Crankshaft journal upper bearing 4
7 Oil nozzle 3

5-83
 CRANKSHAFT AND BALANCER SHAFT

EAS31171

REMOVING THE CRANKSHAFT AND

BALANCER SHAFT
1. Remove:
• Balancer shaft "1"
• Balancer shaft journal bearing
• Crankshaft assembly "2"
• Crankshaft journal bearings
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Identify the position of each balancer shaft jour-
nal bearings and crankshaft journal bearings so
that it can be reinstalled in its original place. 2. Check:
• Crankshaft journal surfaces
• Crankshaft pin surfaces
• Bearing surfaces
Scratches/wear ➔ Replace the crankshaft.
3. Measure:
• Crankshaft-journal-to-crankshaft-journal-
bearing clearance
Out of specification ➔ Replace the crank-
shaft journal bearings.

Journal oil clearance

EAS31174 0.014-0.038 mm (0.0006-0.0015
CHECKING THE OIL NOZZLES in)
The following procedure applies to all of the oil
ECA13920
nozzles.
NOTICE
1. Check: -------------
Do not interchange the crankshaft journal
• O il nozzle "1"
Damage/wear ➔ Replace the oil nozzle. bearings. To obtain the correct crankshaft-
• O il passage journal-to-crankshaft-journal-bearing clear-
Obstruction ➔ Blow out with compressed air. ance and prevent engine damage, the crank-
shaft journal bearings must be installed in
their original positions.
a. Clean the crankshaft journal bearings,
crankshaft journals, and bearing portions
of the crankcase.
b. Place the upper crankcase upside down
C> on a bench .
c. Install the crankshaft journal upper bear-
ings "1" and the crankshaft into the upper
crankcase.
EAS31075
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
CHECKING THE CRANKSHAFT Align the projections "a" on the crankshaft jour-
1. Measure: nal upper bearings with the notches "b" in the up-
• Crankshaft runout per crankcase.
Out of specification ➔ Replace the crank-
shaft.

Runout limit
0.030 mm (0.0012 in)

5-84
 CRANKSHAFT AND BALANCER SHAFT

h. Measure the compressed Plastigauge®

width "a" on each crankshaft journal.
If the crankshaft-journal-to-crankshaft-
journal-bearing clearance is out of specifi-
cation, select replacement crankshaft
journal bearings.
( /;

d. Put a piece of Plastigauge® "1" on each

,..___,,.if, a•i ~ ~
crankshaft journal.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Do not put the Plastigauge® over the oil hole in
the crankshaft journal.
Q

4. Select:
• Crankshaft journal bearings (J 1-J 4 )
1
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• The numbers "A" stamped into the crankshaft
web and the numbers "B" stamped into the
lower crankcase are used to determine the re-
placement crankshaft journal bearing sizes.
• "J/'-"J4" refer to the bearings shown in the
a (( crankshaft and lower crankcase illustration.
e. Install the crankshaft journal lower bear- For example, if the crankcase "J 1" and crank-
ings "1" into the lower crankcase and as-
shaft web "J/' numbers are 7 and 2 respec-
semble the crankcase halves.
tively, then the bearing size for "J 1" is:
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
"J 1" (crankcase) - "J 1" (crankshaft web) -1 = 7 - 2 -
• Align the projections "a" of the crankshaft jour-
nal lower bearings with the notches "b" in the 1 = 4 (green)
lower crankcase.
• Do not move the crankshaft until the clearance Bearing color code
measurement has been completed. CodeO
White
Code 1
Blue
Code2
Black
Code3
Brown
Code4
Green

f. Tighten the bolts to specification in the

tightening sequence cast on the crank-
case.
Refer to "CRANKCASE" on page 5-69.
g. Remove the lower crankcase and the
crankshaft journal lower bearings.

5-85
 CRANKSHAFT AND BALANCER SHAFT

• Bearing surfaces
Scratches/wear ➔ Replace the balancer
- - = ~ shaft.

J \ - 3. Measure:

J1 - 1J 2~
~

- • Balancer shaft journal-to-balancer shaft bear-

Ja - J4
-~ t 0 t = - - ~
ing clearance
Out of specification ➔ Replace the balancer
- - shaft journal bearings.

Balancer shaft journal to balanc-

er shaft bearing clearance
0.024-0.048 mm (0.0009-0.0019
in)
ECA18400

NOTICE
- - - - - - - - - - - - -
Do not interchange the balancer shaft jour-
nal bearings. To obtain the correct balancer
shaft-journal-to-balancer shaft-journal-bear-
ing clearance and prevent engine damage,
the balancer shaft journal bearings must be
installed in their original positions.
a. Clean the balancer shaft journal bearings,
balancer shaft journals, and bearing por-
tions of the crankcase.
\ 0
b. Place the upper crankcase upside down
\ ~ /dl-.::7
on a bench.
( ~I,:,:.• c. Install the balancer shaft journal upper
~ _rgµ, _____,,,~.;;:& bearings "1" and the balancer shaft into
the upper crankcase.
ffil J 1 J 2 J 3 J 4
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
EAS31076
Align the projections "a" on the balancer shaft
CHECKING THE BALANCER SHAFT
1. Measure: journal upper bearings with the notches "b" in the
upper crankcase.
• Balancer shaft runout
Out of specification ➔ Replace the balancer
shaft.

Balancer shaft runout limit 1

0.030 mm (0.0012 in) a

b~ _L./:_)_,..~~':::-\{)r----
\.

d. Put a piece of Plastigauge® "1" on each

balancer shaft journal.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Do not put the Plastigauge® over the oil hole in
the balancer shaft journal.
2. Check:
• Balancer shaft journal surfaces

5-86
 CRANKSHAFT AND BALANCER SHAFT

4. Select:
• Balancer shaft journal bearing (J 1-J 2 )
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• The numbers "A" stamped into the balancer
shaft web and the numbers "B" stamped into
the lower crankcase are used to determine the
replacement balancer shaft journal bearing siz-
es.
• "J 1"-"J2 " refer to the bearings shown in the bal-
e. Install the balancer shaft journal lower ancer shaft and lower crankcase illustration.
bearings "1" into the lower crankcase and For example, if the crankcase "J 1" and bal-
assemble the crankcase halves. ancer shaft web "J / ' numbers are 5 and 2 re-
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
spectively, then the bearing size for "J/' is:
• Align the projections "a" of the balancer shaft
"J 1" (crankcase) - "J/' (balancer shaft web) =
journal lower bearings with the notches "b" in
5 - 2 = 3 (brown)
the crankcase.
• Do not move the balancer shaft until the clear-
ance measurement has been completed. Bearing color code
Code 1
Blue
Code2
Black
Code3
Brown
Code4
Green
Codes
Yellow

f. T ighten the bolts to specification in the

tightening sequence cast on the crank-
case. Refer to "CRANKCASE" on page
5-69. -....".. J1 e-
~

~
g. Remove the lower crankcase and the bal-
- ~
-J2
ancer shaft journal lower bearings. t;;; ~E
h. Measure the compressed Plastigauge®
width "a" on each balancer shaft journal. If
the balancer shaft-journal-to-balancer
shaft-journal-bearing clearance is out of
specification, select replacement balancer
shaft journal bearings.
II '

a "- --
:!:I I!! E -
--
~
F
-
~
-
;;; ~
0

'

5-87
 CRANKSHAFT AND BALANCER SHAFT

)\
(~ Q ~

0-,, QO

[al J 1 J 2
EAS310n
2. Install:
INSTALLING THE CRANKSHAFT • Balancer shaft
1. Install: TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Crankshaft journal upper bearings Install by aligning the crankshaft match mark "a"
(into the upper crankcase) and the balancer shaft match mark "b".
• Crankshaft journal lower bearings
(into the lower crankcase)
• Crankshaft
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• Align the projections "a" on the crankshaft jour-
nal bearings "1" with the notches "b" in the
crankcase.
• Be sure to install each crankshaft journal bear-
ings in its original place.

EAS31172

INSTALLING THE BALANCER ASSEMBLY

1. Install:
• Balancer shaft journal upper bearings
(into the upper crankcase)
• Balancer shaft journal lower bearings
(into the lower crankcase)
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Align the projections "a" on the balancer shaft
journal bearings "1" with the notches "b" in the
crankcases.
• Be sure to install each balancer shaft journal
bearing in its original place.

5-88
 TRANSMISSION

EAS20062

TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks

11 1

'-
()

-<:, 10 N•m 1.0 k f•m, 7.4 lb.ft

5\
G
,
~> i::; <>,
'
I E
/
~ .__,.,,m.- - ~~~- s
9 1(;]
B
.4'<t. 10 N•m (1 .0 kgf•m, 7 .4 lb·ft)

Order Job/Parts to remove Q'ty Remarks

Lower crankcase Refer to "CRANKCASE" on page 5-69.
1 Drive axle assembly 1
2 Oil seal 1
3 Bearing 1
4 Washer 1
5 Shift drum retainer 2
6 Shift fork guide bar 2
7 Shift fork-L 1
8 Shift fork- R 1
9 Shift drum assembly 1
10 Shift fork-C 1
11 Main axle assembly 1
12 Bearing 1

5-89
 TRANSMISSION

Disassembling the main axle assembly

14
10
11
12
15

91 ~~ ,
1

~~ 3
2

4
91 5
6
, mm1
01 \
8

[;)1 C} 91

Order Job/Parts to remove Q'ty Remarks

1 2nd pinion gear 1

2 Toothed lock washer 1
3 Toothed lock washer retainer 1
4 6th pinion gear 1
5 Collar 1
6 Washer 1
7 Circlip 1
8 3rd pinion gear 1
9 Circlip 1
10 Washer 1
11 5th pinion gear 1
12 Collar 1
13 Bearing housing 1
14 Bearing 1
15 Main axle 1

5-90
 TRANSMISSION

Disassembling the drive axle assembly

mm
6
7
8

2
1

12
, 11

Order Job/Parts to remove Q'ty Remarks

1 Bearing 1
2 Washer 1
3 1st wheel gear 1
4 Collar 1
5 5th wheel gear 1
6 Circlip 1
7 Washer 1
8 3rd wheel gear 1
9 Collar 1
10 Toothed lock washer 1
11 Toothed lock washer retainer 1
12 4th wheel gear 1
13 Collar 1

5-91
 TRANSMISSION

Disassembling the drive axle assembly

20
19
0 ,~ 18
16 mm
17

21

24 23 mm

Order Job/Parts to remove Q'ty Remarks

14 Washer 1
15 Circlip 1
16 6th wheel gear 1
17 Circlip 1
18 Washer 1
19 Collar 1
20 2nd wheel gear 1
21 Collar 1
22 Bearing 1
23 Circlip 1
24 Drive axle 1

5-92
 TRANSMISSION

EAS30430 EAS30431

REMOVING THE TRANSMISSION CHECKING THE SHIFT FORKS

1. Remove: The following procedure applies to all of the shift
• Drive axle assembly "1" forks.
• Shift drum retainers "2" 1. Check:
• Shift fork guide bars • Shift fork cam follower "1"
• Shift fork-L • Shift fork pawl "2"
• Shift fork-R Bends/damage/scori ng/wear ➔ Replace the
• Shift drum assembly shift fork.
• Shift fork-C

2
Q)

2
II 2. Check:
2. Remove: • Shift fork guide bar
• Bearing housing "1" Roll the shift fork guide bar on a flat surface.
• Main axle assembly "2" Bends ➔ Replace.
EWA12840
a. Insert two bolts "3" of the proper size, as
shown in the illustration, into the main axle £ WARNING
assembly bearing housing . Do not attempt to straighten a bent shift fork
guide bar.

3
319-010
b. T ighten the bolts until they contact the
crankcase surface. 3. Check:
c. Continue tightening the bolts until the main • Shift fork movement
axle assembly comes free from the upper (along the shift fork guide bar)
crankcase. Rough movement ➔ Replace the shift forks
3. Remove: and shift fork guide bar as a set.
• Bearing "1"

319-011

4. Check:
• Shift fork guide bar
(for the shift fork-C) oil passage.

5-93
 TRANSMISSION

C logging/damage ➔ Replace the shift fork

guide bar (for the shift fork-C).
EAS30432
1
CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:
• Shift drum groove
Damage/scratches/wear ➔ Replace the shift
drum assembly.
• Shift drum segment "1"
Damage/wear ➔ Replace the shift drum as-
sembly. 3. Check:
• Shift drum bearing "2" • Transmission gears
Damage/pitting ➔ Replace the shift drum as- Blue discoloration/pitting/wear ➔ Replace
sembly. the defective gear(s).
• Transmission gear dogs
Cracks/damage/rounded edges ➔ Replace
the defective gear(s).

EAS30433

CHECKING THE TRANSMISSION

1. Measure:
• Main axle runout 4. Check:
(with a centering device and dial gauge "1") • Transmission gear engagement
Out of specification ➔ Replace the main axle. (each pinion gear to its respective wheel
gear)
Main axle runout limit Incorrect ➔ Reassemble the transmission
0.08 mm (0.0032 in) axle assemblies.
5. Check:
• Transmission gear movement
Rough movement ➔ Replace the defective
1 part(s) .
6. Check:
• Circlips
Bends/damage/looseness ➔ Replace.
EAS30435

ASSEMBLING THE MAIN AXLE AND DRIVE

AXLE
1. Install:
2. Measure:
• Toothed washer "1"
• Drive axle runout
(with a centering device and dial gauge "1") • Circlip "2" •~t4ii
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Out of specification ➔ Replace the drive axle.
• Be sure the circlip sharp-edged corner "a" is
Drive axle runout limit positioned opposite side to the toothed washer
0.08 mm (0.0032 in) and gear.
• Align the opening between the ends "b" of the
circlip with a groove "c" in the axle.

5-94
 TRANSMISSION

• Install the circlip so that a spline "d" is in the

center of the gap between the circlip ends "e"
as shown.

2 1
v 1

a [ID C
1
b
~ b 1"--l 2
-b

A. Main axle
C B. Drive axle

EAS30438

[ID INSTALLING THE TRANSMISSION

e 1. Install:
• Bearing "1"
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Face the seal side of bearing to the outside.

d
A. Main axle
B. Drive axle

2. Install :
• Toothed lock washer retainer "1"
• Toothed lock washer "2"
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ 2. Install:
• With the toothed lock washer retainer in the • Main axle assembly "1"
groove "a" in the axle, align the projection on • Bearing housing "2"
the retainer with an axle spline, and then install
the toothed lock washer. Main axle bearing housing bolt
12 N•m (1.2 kgf •m, 8.9 lb-ft)
• Be sure to align the projection on the toothed LOCTITE®
lock washer that is between the alignment
marks "b" with the alignment mark "c" on the re-
tainer.

5-95
 TRANSMISSION

3. Install:
• Shift fork-C "1"
• Shift drum assembly "2"
• Shift fork guide bar "3"
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• The embossed marks on the shift forks should
face towards the right side of the engine and be
in the following sequence: "R", "C", "L".
• Carefully position the shift forks so that they
are installed correctly into the transmission
gears.
• Install shift fork-C into the groove "a" in the 3rd 6. Main axle assembly
and 4th pinion gear on the main axle.
4. Install:
• Install the shift fork guide bar "3" in the crank-
• Shift fork-R "1"
case with the plug "4" facing in the direction
• Shift fork-L "2"
shown in the illustration.
• Shift fork guide bar
• Shift drum retainers "3"
'-.......:::(o'---::'.O
• Bearing
• Oil seal i 11
11:ii@l'l!f4"'¾

• Circlip "4" i@M

• Drive axle assembly "5"

Shift drum retainer bolt

10 N•m (1.0 kgf•m, 7.4 lb-ft)
LOCTITE®

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Install shift fork-R into the groove "a" in the 5th
wheel gear and shift fork-L into the groove "b"
in the 6th wheel gear on the drive axle.
• Install the shift drum retainer with its "OUT'
mark "c" facing outward.
• Touch the protrusion "d" on the shift fork guide
bar to the side of the shift drum retainer.
• Make sure that the drive axle bearing circlip "4"
is inserted into the grooves "e" in the upper
crankcase.

5-96
 TRANSMISSION

6)

5. Check:
• Transmission
Rough movement ➔ Repair.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Oil each gear, shaft, and bearing thoroughly.

5-97
 COOLING SYSTEM

COOLING SYSTEM DIAGRAMS .... .......... ......... ........ .......... ......... ......... ......... 6-1

RADIATOR .......... .......... ......... ......... .......... ......... ........ .......... ......... ......... ......... 6-3
CHECKING THE RADIATOR .... ......... ........ .......... ......... ......... .......... ......... 6-5
INSTALLING THE RADIATOR .......... ........ .......... ......... ......... ......... ......... .. 6-5

OIL COOLER .. .... .......... ......... ......... .......... ........ ......... .......... ......... ......... ......... . 6-7
CHECKING THE OIL COOLER ........ ........ ......... ......... .......... ......... ......... .. 6-8
INSTALLING THE OIL COOLER ....... .......... ........ ......... .......... ......... ......... 6-8

TH ER MOSTAT ... .......... ......... ......... .......... ........ ......... .......... ......... ......... ......... . 6-9
CHECKING THE THERMOSTAT ....... .......... .......... ........ .......... ......... ...... 6-10
INSTALLING THE THERMOSTAT ASSEMBLY .. ......... .......... ......... ....... 6-10

WATER PUMP .... .......... ......... .......... ......... .......... ........ .......... ......... .......... ...... 6-11
DISASSEMBLING THE WATER PUMP ....... .......... ......... ......... .......... ..... 6-13
CHECKING THE WATER PUMP ........ ......... .......... ......... ......... .......... ..... 6-13
ASSEMBLING THE WATER PUMP ... .......... ........ ......... .......... ......... ....... 6-13
 COOLING SYSTEM DIAGRAMS

EAS20299

COOLING SYSTEM DIAGRAMS

1. Water pump
2. Thermostat
3. Radiator

6-1
 COOLING SYSTEM DIAGRAMS

1 2 3

''
'
'

91== !Fl\J\LIL 4

---=-~ ~~= l.OW

-□
6 5
1. Water jacket
2. Thermostat
3. Radiator
4. Water pump
5. Oil cooler
6. Coolant reservoir

6-2
 RADIATOR

EAS20063

RADIATOR
Removing the radiator
-;-.:,_ 7 N•m (0.7 kgf•m, 5.2 lb·ft)
/\,
,/- \
6 ~
~
' 10
....,__ ,.•·"•;t,
~·''
0,
/
'\
'

,/,~ ~
--v __ , ,~\ \\>\ ' '

(S) \~~ \
~~~------
:._),,__"'K_ ------------ \ ~

2
.
t; 5 N•m (0.5 k f•m, 3. 7 lb•ft)

"\ 0.5 N•m (0.05 kgf•m, 0.37 lb·ft)

-~ 9 N•m (0.9 kgf•m, 6.6 lb•ft) 4 10 N•m (1.0 kgf•m, 7.4 lb·ft)

Order Job/Parts to remove Q 'ty Remarks

Fuel tank front cover/Front side panel/ Front side Refer to "GENERAL CHASSIS (2)" on page
cowling 4-6,
Drain.
Coolant Refer to "CHANGING THE COOLANT' on
page 3-28.
1 Coolant reservoir hose 1 Disconnect
2 Coolant reservoir cover 1
3 Coolant reservoir 1
4 Coolant reservoir cap 1
5 Radiator cap 1
6 Radiator fan motor coupler 1 Disconnect
7 Radiator hose (cylinder head to rad iator) 1 Disconnect
8 Radiator inlet hose 1 Disconnect
9 Radiator outlet hose 1 Disconnect

6-3
 RADIATOR

Removing the radiator

"

.;t.~ 0.5 N•m (0.05 kgf•m, 0.37 lb·ft)

" ~; 10 N•m (1.0 kgf•m, 7 .4 lb·ft)
~. 9 N•m (0.9 kgf•m, 6.6 lb•ft)

Order Job/Parts to remove Q 'ty Remarks

10 Radiator 1
11 Radiator fan cover 1
12 Radiator fan 1
13 Radiator stay 1

6-4
 RADIATOR

EAS30439

CHECKING THE RADIATOR

1. Check:
• Radiator fins
Obstruction ➔ Clean.
Apply compressed air to the rear of the radia-
tor.
Damage ➔ Repair or replace.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Straighten any flattened fins with a thin , flat-head
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.
- ~ / Malfunction ➔ Check and repair.
-
Refer to "COOLING SYSTEM" on page 8-39.
-
-
- - EAS30440

INSTALLING THE RADIATOR

• 1. Fill :
2. Check: • Cooling system
• Radiator hoses (with the specified amount of the recom-
• Radiator pipes mended coolant)
Cracks/damage ➔ Replace. Refer to "CHANGING THE COOLANT" on
3. Measure: page 3-28.
• Radiator cap valve opening pressure 2. Check:
Below the specified pressure ➔ Replace the • Cooling system
radiator cap. Leaks ➔ Repair or replace any faulty part.
a. Attach the radiator cap tester "1" and radi-
Radiator cap valve opening pres- ator cap tester adapter "2" to the radiator.
sure
93.3-122.7 kPa (0.93-1.23 kgf/
cm 2 , 13.5-17.8 psi) fb Radiator cap tester
90890-01325
Mityvac cooling system tester kit
a. Install the radiator cap tester "1" and radi- YU-24460-A
ator cap tester adapter "2" to the radiator Radiator cap tester adapter
cap "3". 90890-01352
Pressure tester adapter
fb Radiator cap tester
90890-01325
Mityvac cooling system tester kit
YU-33984

YU-24460-A
Radiator cap tester adapter
90890-01352
Pressure tester adapter
YU-33984

2
0
b. Apply 122.7 kPa (1.23 kgf/cm 2 , 17.8 psi) of
pressure.

6-5
 RADIATOR

c. Measure the indicated pressure with the

gauge.
3. Measure:
• Radiator cap opening pressure
Below the specified pressure ➔ Replace the
radiator cap.
Refer to "CHECKING THE RADIATOR" on
page 6-5.

6-6
 OIL COOLER

EAS20064

OIL COOLER
Removing the oil cooler

.ii.. 10 N•m (1 .0 kgf•m, 7.4 lb·ft)

~ 1'3
3

4 ~
p, -- ~ 10 N•m (1.0 kgf•m, 7.4 lb·ft)

Order Job/Parts to remove Q'ty Remarks

Coolant reservoir Refer to "RADIATOR" on page 6-3.

Muffler assembly Refer to "ENGINE REMOVAL:' on page 5-9.
Drain.
Coolant Refer to "CHANGING THE COOLANT' on
page 3-28.
Drain.
Engine oil Refer to "CHANGING THE ENGINE OIL:' on
page 3-25.
1 Radiator inlet hose 1
2 Oil cooler inlet hose 1
3 Oil cooler outlet hose 1
4 Oil cooler 1
5 Water jacket joint 1

6-7
 OIL COOLER

EAS30441
5. Measure:
CHECKING THE OIL COOLER
• Radiator cap valve opening pressure
1. Check:
Below the specified pressure ➔ Replace the
• Oil cooler
radiator cap.
Cracks/damage ➔ Replace.
Refer to "CHECKING THE RADIATOR" on
2. Check:
page 6-5.
• Oil cooler inlet hose
• Oil cooler outlet hose
Cracks/damage/wear ➔ Replace.

EAS30442

INSTALLING THE OIL COOLER

1. Clean :
• Mating surfaces of the oil cooler and the
crankcase
(with a cloth dampened with lacquer thinner)
2. Install:
• 0 -ring 1§t411
• Oil cooler
• Oil cooler bolt 3 "1"

Oil cooler bolt

10 N•m (1.0 kgf•m, 7.4 lb•ft)

TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• Before install ing the oil cooler, apply lithium-
soap-based grease to the 0-ring.
• Make sure the 0 -ring is positioned properly.

-
n
)L )
1 (\
J_

3. Fill :
• Cooling system
(with the specified amount of the recom-
mended coolant)
Refer to "CHANG ING THE COOLANT" on
page 3-28.
• Crankcase
(with the specified amount of the recom-
mended engine oil)
Refer to "CHANGING THE ENGINE OIL" on
page 3-25.
4. Check:
• Cooling system
Leaks ➔ Repair or replace any faulty part.
Refer to "INSTALLING TH E RAD IATOR" on
page 6-5.

6-8
 THERMOSTAT

EAS20065

THERMOSTAT
Removing the thermostat assembly

.0
y -----
' - - - - - r - -- -- \ · u-@/ ) "\__,'<---{(D

'
2

~ ~ c, ~ . _ j ~
'
\_ _ _ _ 2:
- -.=i ~
~Q;;~i_ ( :: 0 /

3 - -1

-1 ,\ - ~ - ¥19/) ~ V
~-i-------___,-~\ ~I)~
.c:· l-- ~ , -~- ~
---10~(- -~ ~
-'
0
4

Order Job/Parts to remove Q'ty Remarks

Muffler assembly Refer to "ENGINE REMOVAL.:' on page 5-9.

Drain.
Coolant Refer to "CHANGING THE COOLANT' on
page 3-28.
1 Radiator outlet hose 1
2 Water pump inlet hose 1
3 Oil cooler outlet hose 1 Disconnect.
4 Thermostat assembly 1

6-9
 THERMOSTAT

EAS30443

CHECKING THE THERMOSTAT

1. Check:
• Thermostat assembly "1"
Cracks/damage ➔ Replace.

EAS30445

INSTALLING THE THERMOSTAT

ASSEMBLY
1. Install:
• Thermostat assembly
2. Fill :
• Cooling system
(with the specified amount of the recom-
mended coolant)
Refer to "CHANG ING THE COOLANT' on
page 3-28.
3. Check:
• Cooling system
Leaks ➔ Repair or replace any faulty part.
Refer to "INSTALLING THE RAD IATOR" on
page 6-5.
4. Measure:
• Radiator cap opening pressure
Below the specified pressure ➔ Replace the
radiator cap.
Refer to "CHECKING THE RADIATOR" on
page 6-5.

6-10
 WATER PUMP

EAS20066

WATER PUMP
Removing the water pump

''
..I'-"' '- ff
@:)
'"
'
11 ' " '"
1

-,.;, 12 N•m (1.2 kgf•m, 8.9 lb·ft)

Order Job/Parts to remove Q 'ty Remarks

Drain.
Coolant Refer to "CHANGING THE COOLANT' on
page 3-28.
1 Water pump inlet hose 1 Disconnect.
2 Water pump assembly 1

6-11
 WATER PUMP

Disassembling the water pump

s mm
9 mm10

mm8

4 7 mm 2

~~:;?
-v
''
' ', '
' ' -

.,~ 10 N•m (1 .0 kgf•m, 7.4 lb·ft)

Order Job/Parts to remove Q 'ty Remarks

1 Water pump housing cover 1

2 0-ring 1
3 Circlip 1
4 Water pump driven gear 1
5 Pin 1
6 Washer 1
7 Impeller shaft 1
8 Mechanical seal 1
9 Bearing 1
10 Oil seal 1

6-12
 WATER PUMP

EAS30446 EAS30447

DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP

1. Remove: 1. Check:
• Mechanical seal (housing side) "1" • Water pump housing cover "1"
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ • Impeller shaft "2"
Remove the mechanical seal (housing side) Cracks/damage/wear ➔ Replace.
from the inside of the water pump housing "2". • Water pump housing "3"
Cracks/damage/wear ➔ Replace the water
pump assembly.

3
2
1

1 2

2. Remove:
• Bearing "1" 2. Check:
• Oil seal "2" • Bearing
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ Rough movement ➔ Replace.
Remove the oil seal and bearing from the out- 3. Check:
side of the water pump housing "3". • Water pump inlet hose
Cracks/damage/wear ➔ Replace.
EAS30448

ASSEMBLING THE WATER PUMP

1. Install:
•~f:iJ
• Oil seal "1''
• Bearing "2" •~f:iJ
(into the water pump housing "3")

Installed depth "a"

0.5-1.0 mm (0.02-0.04 in)
3. Remove:
• Mechanical seal (impeller side) "1" TIP _ _ _ _ _ _ _ _ _ _ _ _ __
(from the impeller, with a thin , flat-head Install the oil seal with a socket that matches its
screwdriver) outside diameter.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Do not scratch the impeller shaft.

mm2--m...,.,.,

2. Install:
• Mechanical seal (housing side) "1'' •~f:iJ

6-13
 WATER PUMP

ECA20330

NOTICE
- - - - - - - - - - - - -
Never lubricate the mechanical seal (hous-
ing side) surface with oil or grease.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Use the special tools and a press to press the
mechanical seal (housing side) straight in until it
touches the water pump housing.

Mechanical seal installer 4. Measure:

90890-04078 • Impeller shaft tilt
Water pump seal installer Out of specification ➔ Repeat steps (3) and
YM-33221-A (4) .
Middle driven shaft bearing driv- ECA20340

er NOTICE
90890-04058 -------------
Make sure the mechanical seal (impeller
Middle drive bearing installer 40
&50mm side) is flush with the impeller.
YM-04058
Impeller shaft tilt limit
0.15 mm (0.006 in)
A
♦
-;--- 4

2. Water pump housing

3. Mechanical seal installer 1. Straightedge
4. Middle driven shaft bearing driver 2. Impeller
A. Push down

3. Install:
• Mechanical seal (impeller side) "1'' i~f:iJ
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• Before installing the mechanical seal (impeller
side) , apply tap water or coolant onto its outer
surface.
• If the top of the mechanical seal is dirty, clean
it.

6-14
 WATER PUMP

6-15
 FUEL SYSTEM

FUEL TANK ......... .......... ......... ......... .......... ......... ........ .......... ......... ......... ......... 7-1
REMOVING THE FUEL TANK ........... ........ ......... ......... ......... ......... .......... . 7-3
REMOVING THE FUEL PUMP ......... ......... ......... ......... .......... ......... ......... . 7-3
CHECKING THE FUEL PUMP BODY ...... ......... .......... ......... ......... .......... .. 7-3
CHECKING THE FUEL PUMP OPERATION ..... ......... ......... .......... ......... .. 7-3
INSTALLING THE FUEL PUMP ........ ........ .......... ......... ......... ......... ......... .. 7-4
INSTALLING THE FUEL TANK ......... ......... ......... ......... .......... ......... ......... . 7-4

THROTTLE BODIES .... ......... ......... .......... ........ ......... .......... ......... ......... ......... . 7-5
CHECKING THE INJECTORS (BEFORE REMOVING) ......... .......... ...... 7-14
REMOVING THE FUEL HOSE (FUEL RAIL SIDE) ..... .......... .......... ....... 7-14
REMOVING THE INJECTORS .......... ........ ......... .......... ......... ......... ........ 7-14
CHECKING THE INJECTORS .......... ......... .......... ......... .......... ......... ....... 7-14
CHECKING AND CLEANING THE THROTTLE BODIES ...... .......... ....... 7-14
REPLACING THE THROTTLE BODIES ...... .......... ........ .......... ......... ...... 7-16
INSTALLING THE INJECTORS ........ ......... ......... .......... .......... ......... ....... 7-16
CHECKING THE INJECTOR PRESSURE ... ........ .......... .......... .......... ..... 7-17
CHECKING THE FUEL PRESSURE ......... .......... ......... .......... .......... ...... 7-17
INSTALLING THE FUEL HOSE (FUEL RAIL SIDE) ..... .......... ......... ....... 7-18
ADJUSTING THE THROTTLE POSITION SENSOR .... .......... ......... ....... 7-18
ADJUSTING THE ACCELERATOR POSITION SENSOR ..... .......... ....... 7-19

AIR INDUCTION SYSTEM .... ......... .......... ........ .......... ......... .......... ......... ....... 7-21
CHECKING THE AIR INDUCTION SYSTEM ........ ......... .......... ......... ...... 7-25
INSTALLING THE AIR INDUCTION SYSTEM ........ ......... ......... ......... ..... 7-25
 FUEL TANK

EAS20067

FUEL TANK
Removing the fuel tank
~. 7 N•m (0.7 kgf•m, 5.2 lb·ft)

(4)

~., 7 N•m (0. 7 kgf•m, 5.2 lb·ft)

.-.,, 4.0 N•m (0.40 kgf•m, 3.0 lb·ft)

Order Job/Parts to remove Q 'ty Remarks

Refer to "GENERAL CHASSIS (1 )" on page
Passenger seat/Rider seat
4-1 .
Fuel tank front cover/Front side panel/Front side Refer to "GENERAL CHASSIS (2)" on page
cowling 4-6.
Refer to "GENERAL CHASSIS (3)" on page
Fuel tank cover
4-13.
1 Fuel hose connector 1 Disconnect.
2 Fuel pump coupler 1 Disconnect.
3 Fuel tank breather hose 1 Disconnect.
4 Fuel tank drain hose 1 Disconnect.
5 Fuel tank 1
6 Fuel pump bracket 1
7 Fuel pump 1
8 Fuel pump gasket 1

7-1
 FUEL TANK

Removing the canister (for California only)

1
2
,

5
~✓-,/, / 3 7
'

I / I :\ I

, ~ - ,._.,, \I~ \\ -
(" ® \J~

~,~,,.,~ - ;~,-,,,I_,, __,,,-=-,-,..__~-";:

~

~
~~ 7 N•m (0.7 kgf•m, 5.2 lb·ft)

Order Job/Parts to remove Q'ty Remarks

Refer to "GENERAL CHASSIS (1 )" on page
Passenger seat/Rider seat
4-1 .
Fuel tank front cover/Front side panel/Front side Refer to "GENERAL CHASSIS (2)" on page
cowling 4-6,
Refer to "GENERAL CHASSIS (3)" on page
Fuel tank cover
4-13,
Fuel tank Refer to "FUEL TANK" on page 7-1 .
1 Canister purge hose (hose joint to canister) 1
2 Fuel tank breather hose (fuel tank to canister) 1
3 Canister holder 1
4 Canister 1
5 Canister breather hose 1
6 Canister bracket 1 MTT9K/MTT9KC
7 Canister bracket 1 MTT9GTK/MTT9GTKC

7-2
 FUEL TANK

EAS30450

REMOVING THE FUEL TANK

1. Extract the fuel in the fuel tank through the 1
fuel tank cap with a pump.
2. Remove:
• Passenger seat/Rider seat
Refer to "GENERAL CHASSIS (1 )" on page
4-1.
• Fuel tank front cover/Front side panel/Front
side cowling
Refer to "GENERAL CHASSIS (2)" on page
4-6.
• Fuel tank cover a
Refer to "GENERAL CHASSIS (3)" on page
4-13.
3. Disconnect: /
• Fuel hose (fuel tank side)
• Fuel pump coupler
• Fuel tank drain hose
• Fuel tank breather hose
EWA17320

AwARNING 4. Remove:
Cover fuel hose connections with a cloth • Fuel tank
when disconnecting them. Residual pres- TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
sure in the fuel lines could cause fuel to Do not set the fuel tank down so that the instal-
spurt out when removing the hose. lation surface of the fuel pump is directly under
ECA17490 the tank. Be sure to lean the fuel tank in an up-
NOTICE right position .
-------------
Be sure to disconnect the fuel hose by hand.
Do not forcefully disconnect the hose with EAS30451

tools. REMOVING THE FUEL PUMP

1. Remove:
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ • Fuel pump
ECA14721
• While pushing the ends "a" of the fuel hose
NOTICE
connector cover "1" in direction "b", slide the - - - - - - - - - - - - -
fuel hose connector cover in direction "c", and • Do not drop the fuel pump or give it a
then remove the hose from the fuel pump. strong shock.
• Before removing the hose, place a few rags in • Do not touch the base section of the fuel
the area under where it will be removed. sender.
• It is prohibited to wear the cotton work gloves
or equivalent coverings. EAS30454

CHECKING THE FUEL PUMP BODY

1. Check:
• Fuel pump body
Obstruction ➔ Clean.
Cracks/damage ➔ Replace fuel pump as-
sembly.
EAS30455

CHECKING THE FUEL PUMP OPERATION

1. Check:
• Fuel pump operation
Refer to "CHECKING THE FUEL PRES-
SURE" on page 7-17.

7-3
 FUEL TANK

EAS30456

INSTALLING THE FUEL PUMP

1. Install:
• Fuel pump gasket 1§t4W 1
• Fuel pump
• Fuel pump bracket
• Fuel pump bolts

Fuel pump bolt

4.0 N-m (0.40 kgf-m, 3.0 lb-ft)

TIP _ _ _ _ _ _ _ _ _ _ _ _ __ 2. Connect:
• Do not damage the installation surfaces of the • Fuel tank breather hose
fuel tank when installing the fuel pump. • Fuel tank drain hose
• Always use a new fuel pump gasket. • Fuel pump coupler
• Install the fuel pump gasket so that the lip side
turns to the inside of the fuel tank.
• Install the fuel pump as shown in the illustra-
tion.
• Align the projection "a" on the fuel pump with
the slot in the fuel pump bracket.
• Tighten the fuel pump bolts in the proper tight-
ening sequence as shown.

A. Forward

EAS30457

INSTALLING THE FUEL TANK

1. Connect:
• Fuel hose (fuel tank side)
ECA1 7SOO

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 onto the fuel pump secure-
ly, and slide the fuel hose connector cover "1"
in the direction shown in the illustration.
• It is prohibited to wear the cotton work gloves
or equivalent coverings.

7-4
 THROTTLE BODIES

EAS20070

THROTTLE BODIES
Removing the throttle bodies
~ 4.5 N•m 0.45 k f•m, 3.3 lb·ft) ,,,~ - -- - - - - - - -
, ,,,,,,,,,,,, \
,,, \ '
\
- ,.-"('I~~~ \
\

, ,,, ,,, -'

~- 3.0 N•m 0.30 k f•m , 2.2 lb·ft

- ,

Order Job/Parts to remove Q 'ty Remarks

Refer to "GENERAL CHASSIS (1 )" on page
Passenger seat/Rider seat
4-1 .
Fuel tank front cover/Front side panel/Front side Refer to "GENERAL CHASSIS (2)" on page
cowling 4-6.
Refer to "GENERAL CHASSIS (3)" on page
Fuel tank cover
4-13.
Fuel tank Refer to "FUEL TANK" on page 7-1.

Air filter case Refer to "GENERAL CHASSIS (3)" on page

4-13.
1 Fuel hose 1
2 Intake air pressure sensor 1 coupler 1 Disconnect.
3 Intake air pressure sensor 2 coupler 1 Disconnect.
4 Accelerator position sensor coupler 1 Disconnect.
5 Throttle servo motor coupler 1 Disconnect.

7-5
 THROTTLE BODIES

Removing the throttle bodies

4. 4.5 N•m 0.45 k f•m, 3.3 lb·ft ,,~ - - - - - - - - - ~
,,,,~ - - --- - --- ....
',,,,--/ \ 12~ //,,,,------ \\
-
/

-~ \

\
'

\
,,,,,,,.,,,,,,,,
\
\
\
\
\
\
\
'\ lI
_,,,,,,.,'
',
\
,.-,---..
\
\
\
11 '- \
'
,

0 4.,__
3.0 N•m 0.30 k f•m , 2.2 lb·ft

N
~~
~-
lr .
i
_.,.,./
/ · 13
I
-.L-~:f---__:., _ _,__,,_-'-----'-'
,

I~.~ ·
"~,t;;cj7'
1
,
10
6
(~ ,
,
~ 1.--... J,,--y, " \\\'\ ,
7. '

~ I/ -

sp % ~ -~ Q);
, '

9
~v~3/7-,

Order Job/Parts to remove Q'ty Remarks

6 Throttle position sensor coupler 1 Disconnect

7 Grip cancel switch coupler 1 Disconnect
8 Throttle cable (accelerator cable) 1 Disconnect (Black)
9 Throttle cable (decelerator cable) 1 Disconnect
10 Throttle body joint clamp screw 6 Loosen.
11 Throttle body assembly 1 MTT9K/MTT9KC
12 Throttle body assembly 1 MTT9GTK/MTT9GTKC
13 Throttle body joint 3

7-6
 THROTTLE BODIES

Removing the throttle bodies (for California only)

~. 4.5 N•m 0.45 k f•m, 3.3 lb·ft) ,,~ - - - - - - - - - ~
',,,, ,,,, ~ \
/ \ '
- \
\
\

_,,,,,,.,'

4. 3.0 N•m 0.30 k f•m , 2.2 lb·ft

- ,

Order Job/Parts to remove Q 'ty Remarks

Refer to "GENERAL CHASSIS (1 )" on page
Passenger seat/Rider seat
4-1 .
Fuel tank front cover/Front side panel/Front side Refer to "GENERAL CHASSIS (2)" on page
cowling 4-6.
Refer to "GENERAL CHASSIS (3)" on page
Fuel tank cover
4-13.
Fuel tank/Canister Refer to "FUEL TANK" on page 7-1 .

Air filter case Refer to "GENERAL CHASSIS (3)" on page

4-13.
1 Fuel hose 1
2 Intake air pressure sensor 1 coupler 1 Disconnect
3 Intake air pressure sensor 2 coupler 1 Disconnect
4 Accelerator position sensor coupler 1 Disconnect
5 Throttle servo motor coupler 1 Disconnect

7-7
 THROTTLE BODIES

Removing the throttle bodies (for California only)

~. 4.5 N•m 0.45 k f•m, 3.3 lb·ft) ,,~ - - - - - - - - - ~
,,,,~ - - - --- --- ....
',,,, ,,,, ~ \ 12 ~ ,, ,,,,,,,,,,,, \\
/ \ '
- \ ,,,,,,,.,,,,,,,, \
\ \ \
\ \
\ \
'\ lI
_,,,,,,.,'
',
\
.---.-
\
\
\
11 '- \
'
,

0 4. 3.0 N•m 0.30 k f•m , 2.2 lb·ft

N
~~
~-
lr .
i
_.,.,./
/ · 13
I
-.L-~:f---__:., "---->-->L-'-----'-'
,

I~.~ ·
"~,t;;cj7'
1
,
10
6
(~ ,
,
~ 1.--... J,,--y, " \\\'\ ,
7. '

~ I/ -

sp % ~ -~ Q);
, '

9
~v~3/7-,

Order Job/Parts to remove Q'ty Remarks

6 Throttle position sensor coupler 1 Disconnect

7 Grip cancel switch coupler 1 Disconnect
8 Throttle cable (accelerator cable) 1 Disconnect (Black)
9 Throttle cable (decelerator cable) 1 Disconnect
10 Throttle body joint clamp screw 6 Loosen.
11 Throttle body assembly 1 MTT9K/MTT9KC
12 Throttle body assembly 1 MTT9GTK/MTT9GTKC
13 Throttle body joint 3

7-8
 THROTTLE BODIES

Removing the sensors (MTT9K/MTT9KC)

"
;.;, 3.5 N•m 0.35 k f•m, 2.6 lb·ft

,.,, 3.5 N•m 0.35 k f•m, 2.6 lb·ft 6

4
5

Cs

Order Job/Parts to remove Q'ty Remarks

1 Negative pressure hose 6
2 Hose joint 2
3 Intake air pressure sensor 2 1
4 Intake air pressure sensor 1 1
5 Throttle position sensor 1
6 Accelerator position sensor 1

7-9
 THROTTLE BODIES

Removing the sensors (MTT9GTK/MTT9GTKC)

~. 3.5 N•m (0.35 kgf•m, 2.6 lb·ft)

, ~. 3.5 N•m (0.35 kgf•m, 2.6 lb•ft)

4
5

3
7
a-

Cs
-1.. 0.28 N•m (0.028 kgf•m, 0.207 lb·ft)

2
---....}

Order Job/Parts to remove Q 'ty Remarks

1 Negative pressure hose 6

2 Hose joint 2
3 Intake air pressure sensor 2 1
4 Intake air pressure sensor 1 1
5 Throttle position sensor 1
6 Accelerator position sensor 1
7 Grip cancel switch 1

7-10
 THROTTLE BODIES

Removing the sensors (for California only) (MTT9K/MTT9KC)

"
~, 3.5 N•m 0.35 k f•m , 2.6 lb·ft
3
I
"
,-.,. 3.5 N•m 0.35 k f•m, 2.6 lb·ft 8
3

7 6 _ ~G ) ( <J
,/·-------_ _ ___,,,/ cfo
I

3
'

__,r-,_-_J r-----
-r--·
- - ~~~~-:<.., :P
(f»
-r-~-- "' .-4~~
5 ' ---- 7 r<d 'J</"J

e.::~I~

Cs
6)'()

2 ----.i

Order Job/Parts to remove Q'ty Remarks

1 Negative pressure hose 6
2 Hose joint 2
3 Canister purge hose 4
4 Hose joint 2
5 Intake air pressure sensor 2 1
6 Intake air pressure sensor 1 1
7 Throttle position sensor 1
8 Accelerator position sensor 1

7-11
 THROTTLE BODIES

Removing the sensors (for California only) (MTT9GTK/MTT9GTKC)

~. 3.5 N•m (0.35 kgf•m, 2.6 lb·ft)

3
I
, ~. 3.5 N•m (0.35 kgf•m, 2.6 lb•ft)
3

7
cfo
I

__,r-,_-_J r-----
-r---·
- - ~~~~-:<.,#'
(f»
-r-~-- "' ~~~
5 , ------- 7 r<d 'J</"J

~~..C::~ ----::

Cs
6)'()
-1.. 0.28 N•m (0.028 kgf•m, 0.207 lb·ft)

2
----..i

Order Job/Parts to remove Q 'ty Remarks

1 Negative pressure hose 6

2 Hose joint 2
3 Canister purge hose 4
4 Hose joint 2
5 Intake air pressure sensor 2 1
6 Intake air pressure sensor 1 1
7 Throttle position sensor 1
8 Accelerator position sensor 1
9 Grip cancel switch 1

7-12
 THROTTLE BODIES

Removing the injectors

;;;,, 5 N•m 0.5 k f•m , 3.7 lb·ft
1

~ ' 2
~ ~
l 0 '° '~
Oil~~- ---,,/"' -,
·~ ~ ~ '
~~-,-
- -

-~-

i . 12 N•m (1 .2 kgf•m, 8.9 lb·ft)

Order Job/Parts to remove Q'ty Remarks

Throttle bodies/Throttle body joint Refer to 'THROTTLE BODIES" on page 7-5.
1 Fuel rail 1
2 Injector 3
3 Injector coupler 2 Disconnect.
4 Injector lead 1
5 Injector lead coupler 1 Disconnect.
6 Wire harness 1
7 Adapter 1

7-13
 THROTTLE BODIES

EAS30475
• Be careful when disconnecting the fuel
CHECKING THE INJECTORS (BEFORE
hose. Any remaining pressure in the fuel
REMOVING)
hose may cause the fuel to spray out. Place
1. Check:
a container or rag under the hose to catch
• Injectors
any fuel that spills. Always clean up any
Use the diagnostic code numbers "36"-"38".
spilt fuel immediately.
Refer to "SELF-DIAGNOSTIC FUNCTION
• Turn the main switch to "OFF" and discon-
AND DIAGNOSTIC CODE TABLE" on page
nect the negative battery lead from the bat-
9 -1.
tery terminal before removing the injectors.
EAS31158
1. Remove:
REMOVING THE FUEL HOSE (FUEL RAIL
• Throttle bodies
SIDE)
• Fuel rail "1"
1. Remove:
a. Remove the fuel rail bolts "2" as shown.
• Fuel tank
Refer to "REMOVING THE FU EL TANK" on
page 7-3.
2. Remove:
• Fuel hose (fuel rail side)
ECA17490

NOTICE
-------------
Be sure to disconnect the fuel hose by hand.
Do not forcefully disconnect the hose with
tools.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
EAS304n

• To remove the fuel hose from the fuel rail joint, CHECKING THE INJECTORS
slide the fuel hose connector cover "1" on the 1. Check:
end of the hose in the direction of the arrow • Injectors
shown , press the two buttons "2" on the sides Obstruction ➔ Replace and check the fuel
of the connector, and then remove the hose. pump/fuel supply system.
• Before removing the hose, place a few rags in Depos it ➔ Replace.
the area under where it will be removed. Damage ➔ Replace.
• It is prohibited to wear the cotton work gloves 2. Check:
or equivalent coverings. • Injector resistance
Refer to "CHECKING THE FUEL INJEC-
TORS" on page 8-203.
EAS30769

CHECKING AND CLEANING THE THROTTLE

BODIES
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Clean the throttle bodies only if they cannot be
synchronized using the bypass air screws. Be-
fore cleaning the throttle bodies, check the fol-
lowing items:
EAS30476 • Valve clearance
REMOVING THE INJECTORS • Spark plugs
EWA17330
• Air fi lter element
A WARNING • Throttle body joints
• Check the injectors in a well-ventilated area • Fuel hose
free of combustible materials. Make sure • Exhaust system
that there is no smoking or use of electric • Cylinder head breather hose
tools in the vicinity of the injectors.

7-14
 THROTTLE BODIES

EWA1 7340

& WARNING
If the throttle bodies are subjected to strong
shocks or dropped during cleaning, replace 0
them as a set.
1. Check:
• Throttle bodies
Cracks/damage ➔ Replace the throttle bod-
ies as a set. a a - ..c...:::~~a
2. Clean:
• Throttle bodies c. Hold the throttle valves in the open posi-
ECA21540 tion.
NOTICE EWA 15940

--------------
• Observe the following precautions; other- & WARNING
wise, the throttle bodies may not operate When cleaning the throttle bodies, be careful
properly. not to injure yourself on the throttle valves or
• Do not subject the throttle bodies to exces- other components of the throttle bodies.
sive force. ECA20380

• Clean the throttle bodies in the recom- NOTICE

mended cleaning solvent.
- - - - - - - - - - - - - -
• Do not open the throttle valves by supply-
• Do not use any caustic carburetor cleaning ing electrical power to the throttle bodies.
solution. • Do not use tools to open the throttle valves
• Do not apply cleaning solvent directly to or to keep them in the open position.
any plastic parts, sensors, or seals. • Do not open the throttle valves quickly.
• Be careful not to remove the white paint
mark that identifies the standard throttle
body.
• Do not turn the bypass air screws "a"; oth-
erwise, the throttle body synchronization
will be affected.

Recommended cleaning solvent

l
Yamaha Oil & Brake Cleaner

d. Apply the recommended cleaning solvent

to the throttle valves and the inside of the
throttle bodies to remove any carbon de-
posits.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• Do not allow any cleaning solvent to enter the
opening for the injectors.
• Do not apply any cleaning solvent to the por-
a tions of the throttle valve shafts between the
a. Place the throttle bodies on a flat surface throttle bodies.
with the air filter case side facing up. e. Remove the carbon deposits from the in-
b. Install the caps (895- 14 169-00) onto the side of each throttle body in a downward
hose fittings "a". direction, from the air filter case side of the
throttle body to the engine side.

7-15

ECA17590
NOTICE
- - - - - - - - - - - - - AND DIAGNOSTIC CODE TABLE" on page
• Do not use a tool, such as a wire brush, to
remove the carbon deposits; otherwise, the
inside of the throttle bodies may be dam-
aged.
• Do not allow carbon deposits or other for-
eign materials to enter any of the passages
in each throttle body or in the space be-
tween the throttle valve shaft and the throt-
tle body.
f. After removing the carbon deposits, clean
the inside of the throttle bodies with the
recommended cleaning solvent, and then
dry the throttle bodies using compressed
arr.
g. Make sure that there are no carbon de-
posits or other foreign materials in any of
the passages "a" in each throttle body or in
the space "b" between the throttle valve
shaft and the throttle body.
a
3. Install the throttle bodies.
4. Reset:
• ISC (idle speed control) learning values
Use the diagnostic code number "67".
Refer to "SELF-DIAGNOSTIC FUNCTION
AND DIAGNOSTIC CODE TABLE" on page
9-1.
5. Adjust:
• Throttle bodies synchronizing
Out of specification ➔ Replace the throttle
bodies.
Refer to "SYNCHRON IZ ING TH E THROT-
TLE BODIES" on page 3-9.
EAS31160
REPLACING THE THROTTLE BODIES
1. Remove the throttle bodies from the vehicle.
2. Install a new throttle bodies to the vehicle.
3. Reset:
• ISC (idle speed control) learning values
Use the diagnostic code number "67".
7-16
THROTTLE BODIES
Refer to "SELF-DIAGNOSTIC FUNCTION
9-1 .
4. Adjust:
• Throttle bodies synchronizing
Refer to "SYNCHRON IZING THE THROT-
TLE BODIES" on page 3-9.
5. Place the vehicle on the centerstand so that
the rear wheel is elevated.
6. Check:
• Engine idling speed
Start the engine, warm it up, and then mea-
sure the engine idling speed.
Engine idling speed
1100-1300 r/min
EAS30480
INSTALLING THE INJECTORS
ECA21550
NOTICE
- - - - - - - - - - - - -
• Always use new 0-rings.
• When installing the injectors, do not allow
any foreign material to enter or adhere to
the injectors, fuel rails, or 0-rings.
• Be careful not to twist or pinch the 0-rings
when installing the injectors.
• When installing the injector, install it at the
same position as the removed cylinder.
• If an injector is subject to strong shocks or
excessive force, replace it.
• If installing the original fuel rail and bolts,
remove the white paint marks using a
cleaning solvent. Otherwise, paint chips on
the bolt seats could prevent the bolts from
being tightened to the specified torque.
1. Install a new seal onto the end of each injec-
tor.
2. Install the injectors to the fuel rail, making
sure to install them in the correct direction.
3. Install the injector assemblies to the adapter.
Fuel rail bolt
5 N-m (0.5 kgf-m, 3. 7 lb-ft)
4. Check the injector pressure after the injectors
are installed.
Refer to "CHECKING THE INJ ECTOR
PRESSURE" on page 7-17.
 THROTTLE BODIES

EAS30481
Pressure drops ➔ Check the pressure
CHECKING THE INJECTOR PRESSURE
gauge and adapter.
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Check the seals and 0-rings and then re-
• After installing the injectors, perform the follow- install.
ing steps to check the injector pressure. Out of specification ➔ Replace the fuel in-
• Do not allow any foreign materials to enter the jectors.
fuel lines.
EAS30482

1. Check: CHECKING THE FUEL PRESSURE

• Injector pressure 1. Remove:
a. Connect the fuel injector pressure adapter • Passenger seat/Rider seat
"1" to the fuel rail joint "2", and then con- Refer to "GENERAL CHASSIS (1 )" on page
nect an air compressor "3" to the adapter. 4-1 .
b. Connect the pressure gauge "4" to the fuel • Fuel tank front cover/Front side panel/Front
injector pressure adapter "1". side cowling
Refer to "GENERAL CHASSIS (2)" on page
Pressure gauge 4-6.
90890-03153 • Fuel tank cover
Pressure gauge Refer to "GENERAL CHASSIS (3)" on page
YU-03153
4-13.
Fuel injector pressure adapter
90890-03210 2. Check:
Fuel injector pressure adapter • Fuel pressure
YU-03210 a. Remove the fuel tank bolts and hold up the
fuel tank.
b. Disconnect the fuel hose "1" from the fuel
4 pump.
0 Refer to "FUEL TANK" on page 7-1.
EWA17320

& WARNING
1 Cover fuel hose connections with a cloth
when disconnecting them. Residual pres-
sure in the fuel lines could cause fuel to
spurt out when removing the hose.
3 ECA17490

NOTICE
c. Close the valve on the fuel injector pres- -------------
Be sure to disconnect the fuel hose by hand.
sure adapter.
d. Apply air pressure with the air compres- Do not forcefully disconnect the hose with
sor.
tools.
e. Open the valve on the fuel injector pres-
sure adapter until the specified air pres-
sure is reached.
0
Specified air pressure 0
490 kPa (5.0 kgf/cm 2 , 71.1 psi)
ECA1 7600

NOTICE
-------------
Never exceed the specified air pressure or
damage could occur.
c. Connect the pressure gauge "2" and fuel
f. Close the valve on the fuel injector pres- pressure adapter "3" to the fuel hose.
sure adapter.
g. Check that the specified air pressure is
held at least one minute.

7-17
 THROTTLE BODIES

TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Pressure gauge
90890-03153 • Install the fuel hose securely onto the fuel rail
Pressure gauge joint until a distinct "click" is heard.
YU-03153 • To install the fuel hose onto the fuel rail joint,
Fuel pressure adapter slide the fuel hose connector cover "1" on the
90890-03176 end of the hose in the direction of the arrow
Fuel pressure adapter shown .
YM-03176 • It is prohibited to wear the cotton work gloves
or equivalent coverings.

/ -
\, - I
I

- '

1/
d. Start the engine.
EAS30485
e. Measure the fuel line pressure. ADJUSTING THE THROTTLE POSITION
Faulty ➔ Replace the fuel pump. SENSOR
ECA17540

Fuel line pressure (at idle) NOTICE

300--390 kPa (3.0-3.9 kgf/cm 2 , -------------
• Handle the throttle position sensor with
43.5-56.6 psi)
special care.
3. Install: • Never subject the throttle position sensor
• Fuel tank to strong shocks. If the throttle position
Refer to "FUEL TANK" on page 7-1. sensor is dropped, replace it.
• Fuel tank cover 1. Check:
Refer to "GENERAL CHASSIS (3)" on page • Throttle position sensor
4-13. Refer to "CHECKING THE THROTTLE PO-
• Front side cowling/ Front side panel/Fuel tank SITION SENSOR" on page 8-199.
front cover 2. Adjust:
Refer to "GENERAL CHASSIS (2)" on page • Throttle position sensor angle
4-6. TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• Rider seat/Passenger seat Before adjusting the throttle position sensor, the
Refer to "GENERAL CHASSIS (1 )" on page throttle bodies must be removed.
4-1.
a. Temporary tighten the throttle position
EAS31159
sensor screws.
INSTALLING THE FUEL HOSE (FUEL RAIL
b. Check that the throttle valves are fully
SIDE)
closed.
1. Connect:
c. Connect the throttle position sensor to the
• Fuel hose (fuel rail side)
ECA17500 wire harness.
NOTICE d. Remove the protective cap "1", and then
------------- connect the Yamaha diagnostic tool to
When installing the fuel hose, make sure that
it is securely connected, and that the fuel coupler.
hose connector cover on the fuel hose is in
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
the correct position, otherwise the fuel hose For information about using the Yamaha diag-
will not be properly installed. nostic tool, refer to the operation manual that is
included with the tool.

7-18
 THROTTLE BODIES

b. Check that the throttle valves are fully

© closed.
c. Connect the accelerator position sensor to
'' '
' 0 the wire harness.
'' ''
'' '' d. Connect the throttle cables to the throttle
/
0
'' 1 bodies.
____' '.,'
' ' e. Remove the protective cap "1 ", and then
:.•:~ j
0 © connect the Yamaha diagnostic tool to
\
coupler.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
e. Diagnostic code number "01" is selected. For information about using the Yamaha diag-
f. Adjust the position of the throttle position nostic tool , refer to the operation manual that is
sensor angle so that 11-21 can appear in included with the tool.
the Yamaha diagnostic tool screen.
g. After adjusting the throttle position sensor
angle, tighten the throttle position sensor
screws "2".

Throttle position sensor screw

3.5 N-m (0.35 kgf-m, 2.6 lb-ft)

f. Diagnostic code number "14" is selected.

g. Turn the throttle grip to the fully closed po-
sition.
h. Adjust the position of the accelerator posi-
2 tion sensor angle so that 12-22 can ap-
pear in the Yamaha diagnostic tool
screen.
EAS30486 1. After adjusting the accelerator position
ADJUSTING THE ACCELERATOR POSITION sensor angle, tighten the accelerator posi-
SENSOR tion sensor bolts "2".
EWA15960

~ WARNING
Accelerator position sensor bolt
• Handle the accelerator position sensor with 3.5 N-m (0.35 kgf-m, 2.6 lb-ft)
special care.
• Never subject the accelerator position sen-
sor to strong shocks. If the accelerator po-
sition sensor is dropped, replace it.
1. Check:
• Accelerator position sensor
Refer to "CHECKING THE ACCELERATOR
POSITION SENSOR" on page 8-200.
2. Adjust:
• Accelerator position sensor angle
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
J. Turn the throttle grip to the fully open posi-
Before adjusting the accelerator position sensor, tion.
the throttle bodies must be removed. k. Check the Yamaha diagnostic tool screen
a. Temporary tighten the accelerator position value. If the Yamaha diagnostic tool
sensor bolts. screen value is not 97- 107, adjust the ac-
celerator position sensor angle.

7-19
 THROTTLE BODIES

I. Select the diagnostic code number "15".

m. Turn the throttle grip to the fully closed po-
sition.
n. Check the Yamaha diagnostic tool screen
value. If the Yamaha diagnostic tool
screen value is not 10-24, adjust the ac-
celerator position sensor angle.
o. Turn the throttle grip to the fully open posi-
tion.
p. Check the Yamaha diagnostic tool screen
value. If the Yamaha diagnostic tool
screen value is not 95-109, adjust the ac-
celerator position sensor angle.
q. Repeat steps (f) to (p) until the Yamaha di-
agnostic tool screen values are within the
specified ranges.
r. If the Yamaha diagnostic tool screen val-
ues are not within the specified ranges af-
ter repeating steps (f) to (p) several times,
replace the accelerator position sensor.

7-20
 AIR INDUCTION SYSTEM

EAS20071

AIR INDUCTION SYSTEM

-..._______

3---L( -
~-.!
•
•
'•
.\; ·:\\V -
\
\.
\'\;l·\
:~
·, ,, ": '-l- \

••
••

••
,, 2

~-
3

,r---(;:-;~:-~~~-
4 , -idl-, '
: \'> __,-- - ' -. -- ~2
--
4

7-21
 AIR INDUCTION SYSTEM

1. Air filter case

2. Air induction system hose (air filter case to air
cut-off valve)
3. Air cut-off valve
4. Air induction system hose (air cut-off valve to
reed valve cover)

7-22
 AIR INDUCTION SYSTEM

Removing the air cut-off valve assembly and reed valves

'
~ - 10 N•m (1.0 kgf•m, 7.4 lb•ft)

a \
,

/ 1
3
I - .,,. - - -·
..::
-<;...-1_0_N
_•_m_(_1_.0_k_g_f•-m-,-7-.4- 1-b·-ft-.
)
' •

\ '
~ ~ ..._~ 2

~,,,-,---:'-
----, '

"(:
-
- - -- --
/4 /
~-=all=~ \..._o
/
n

Order Job/Parts to remove Q'ty Remarks

Refer to "GENERAL CHASSIS (1 )" on page
Passenger seat/Rider seat
4-1 .
Fuel tank front cover/Front side panel/ Front side Refer to "GENERAL CHASSIS (2)" on page
cowling 4-6.
Refer to "GENERAL CHASSIS (3)" on page
Fuel tank cover
4-13.
Fuel tank Refer to "FUEL TANK" on page 7-1 .

Air filter case Refer to "GENERAL CHASSIS (3)" on page

4-13.
Radiator Refer to "RADIATOR" on page 6-3.
1 Air cut-off valve coupler 1 Disconnect.
Air induction system hose (air cut-off valve to
2 reed valve cover) 1

Air induction system hose (air cut-off valve to

3 reed valve cover) 1

7-23
 AIR INDUCTION SYSTEM

Removing the air cut-off valve assembly and reed valves

'
~ . 10 N•m (1.0 kgf•m, 7.4 lb•ft)

a \
4
,

/ I ----·
.,,. ..::
-<;...-1_0_N
_•_m_(_1_.0_k_g_f•-m-,-7-.4- 1-b·-ft-.
)
' •
~~
\ '

~,,,-,---:
----, ' ~
"(:
-
<.>
/4 /
~-=all=~ \..._o
0 /
7 n
- - -- - ~

' 8
9
,

Order Job/Parts to remove Q'ty Remarks

Air induction system hose (air filter case to air
4 1
cut-off valve)
5 Air cut-off valve 1
6 Air cut-off valve holder 1
7 Reed valve cover 1
8 Reed valve assembly 1 1
9 Reed valve plate 1
10 Reed valve cover 1
11 Reed valve assembly 2 1
12 Reed valve plate 2

7-24
 AIR INDUCTION SYSTEM

EAS30488
• Reed valve stopper
CHECKING THE AIR INDUCTION SYSTEM
• Reed valve seat
Cracks/damage ➔ Replace the reed valve
Air injection
assembly.
The air induction system burns unburned ex-
3. Measure:
haust gases by injecting fresh air (secondary air)
• Reed valve bending limit "a"
into the exhaust port, reducing the emission of
Out of specification ➔ Replace the reed
hydrocarbons. When there is negative pressure
valve assembly.
at the exhaust port, the reed valve opens, allow-
ing secondary air to flow into the exhaust port. Reed valve bending limit
The required temperature for burning the un- 0.4 mm (0.02 in)
burned exhaust gases is approximately 600 to
700 °c (1112 to 1292 °F) .

Air cut-off valve

The air cut-off valve is controlled by the signals
from the ECU in accordance with the combus-
tion conditions. Ordinarily, the air cut-off valve
opens to allow the air to flow during idle and
closes to cut-off the flow when the vehicle is be-
ing driven. However, if the coolant temperature
is below the specified value, the air cut-off valve
remains open and allows the air to flow into the
4. Check:
exhaust pipe until the temperature becomes
higher than the specified value. • A ir cut-off valve
Cracks/damage ➔ Replace.
5. Check
• A ir induction system solenoid
Refer to "CHECKING THE A IR INDUCTION
SYSTEM SOLENOID" on page 8-201 .
[Al
- EAS30489

INSTALLING THE AIR INDUCTION SYSTEM

1. Install:
[ru ) - - \
[ru • Reed valve plate "1"
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Align the projection "a" on the cylinder head
cover w ith the notch "b" in the reed valve plate
"1".
I • Align the projection "c" on the cylinder head
cover with the hole "d" in the reed valve plate
[Al , . '•
• "1".
t:=-= ~~ •
•
...
•

[ru [ru b

A. From the air filter case

B. To the cylinder head
1. Check:
• Hoses
Loose connections ➔ Connect properly.
Cracks/damage ➔ Replace.
2. Check:
• Reed valve

7-25
 AIR INDUCTION SYSTEM

0 d

2. Install :
• Reed valve assembly 1
• Reed valve assembly 2
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
• Install the reed valve assembly 1 so that the
open side turns to the exhaust side of the en-
gine.
• Install the reed valve assembly 2 so that the
open side turns to the intake side of the engine.

-
[ru

-
A. Reed valve assembly 1
B. Reed valve assembly 2
C. Exhaust side
3. Install :
• Reed valve cover

Reed valve cover bolt

10 N•m (1.0 kgf•m, 7.4 lb•ft)
LOCTITE®

7-26
 AIR INDUCTION SYSTEM

7-27
 ELECTRICAL SYSTEM

IGNITION SYSTEM ....... ......... ......... .......... ......... ........ .......... ......... ......... ......... 8-1
CIRCUIT DIAGRAM (MTT9K/MTT9KC) ....... ........ ......... .......... ......... ......... 8-1
CIRCUIT DIAGRAM (MTT9GTK/MTT9GTKC) ..... ......... .......... ......... ......... 8-3
ENGINE STOPPING DUE TO SI DESTAND OPERATION ... ......... .......... . 8-5
TROUBLESHOOTING ... ......... .......... ........ ......... .......... ......... ......... .......... . 8-6

ELECTRIC STARTING SYSTEM .... .......... ......... ........ .......... ......... ......... ......... 8-9
CIRCUIT DIAGRAM (MTT9K/MTT9KC) ....... ........ ......... .......... ......... ......... 8-9
CIRCUIT DIAGRAM (MTT9GTK/MTT9GTKC) ..... ......... .......... ......... ....... 8-11
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION .......... ......... ..... 8-13
TROUBLESHOOTING ... .......... ......... ......... ......... .......... ......... .......... ....... 8-15

CHARGING SYSTEM ... ......... .......... ......... .......... ........ .......... ......... ......... ....... 8-17
CIRCUIT DIAGRAM (MTT9K/MTT9KC) ....... .......... ........ .......... ......... ...... 8-17
CIRCUIT DIAGRAM (MTT9GTK/MTT9GTKC) ....... ........ .......... ......... ...... 8-18
TROUBLESHOOTING ... .......... ......... ......... ......... .......... ......... .......... ....... 8-19

LIGHTING SYSTEM ..... ......... .......... ......... .......... ........ .......... ......... ......... ....... 8-21
CIRCUIT DIAGRAM (MTT9K/MTT9KC) ....... .......... ........ .......... ......... ...... 8-21
CIRCUIT DIAGRAM (MTT9GTK/MTT9GTKC) ....... ........ .......... ......... ...... 8-23
TROUBLESHOOTING ... .......... ......... ......... ......... .......... ......... .......... ....... 8-25

SIGNALING SYSTEM .. ......... .......... ......... .......... ........ ......... .......... ......... ....... 8-27
CIRCUIT DIAGRAM (MTT9K/MTT9KC) ....... .......... ........ .......... ......... ...... 8-27
CIRCUIT DIAGRAM (MTT9GTK/MTT9GTKC) ....... ........ .......... ......... ...... 8-29
TROUBLESHOOTING ... .......... ......... ......... ......... .......... ......... .......... ....... 8-31

COOLING SYSTEM .. ..... ......... .......... ......... .......... ......... ......... ......... ......... ...... 8-39
CIRCUIT DIAGRAM (MTT9K/MTT9KC) ....... .......... ........ .......... ......... ...... 8-39
CIRCUIT DIAGRAM (MTT9GTK/MTT9GTKC) ....... ........ .......... ......... ...... 8-41
TROUBLESHOOTING ... .......... ......... ......... ......... .......... ......... .......... ....... 8-43

FUEL INJECTION SYSTEM .. ......... .......... ........ .......... ......... .......... ......... ....... 8-45
CIRCUIT DIAGRAM (MTT9K/MTT9KC) ....... .......... ........ .......... ......... ...... 8-45
CIRCUIT DIAGRAM (MTT9GTK/MTT9GTKC) ....... ........ .......... ......... ...... 8-47
ECU SELF-DIAGNOSTIC FUNCTION ....... .......... ......... .......... ......... ....... 8-49
TROUBLESHOOT! NG METHOD ........ ......... .......... ......... ......... .......... ..... 8-49
YAMAHA DIAGNOSTIC TOOL ......... ......... ......... .......... ......... .......... ....... 8-50
TROUBLESHOOTING DETAILS (FAULT CODE) ....... .......... .......... ....... 8-51
CRUISE CONTROL SYSTEM (MTT9GTK/MTT9GTKC) .... ......... .......... ..... 8-121
CIRCUIT DIAGRAM .......... .......... ......... .......... ......... .......... ........ .......... .. 8-121
CRUISE CONTROL Cl RCU IT OPERATION ........ ......... .......... ......... ..... 8-123
BASIC INSTRUCTIONS FOR TROUBLESHOOT! NG ... ......... ......... ..... 8-124
BASIC PROCESS FOR TROUBLESHOOTING ... ......... .......... ......... .... 8-125
[A] CHECKING THE CRUISE CONTROL SYSTEM INDICATOR
LIGHT ........... ......... .......... ......... .......... ......... .......... ........ .......... ......... .... 8-126
[B-1] DIAGNOSIS USING THE FAULT CODES .. ......... .......... ......... ..... 8-126
[B-2] DIAGNOSIS USING THE MALFUNCTION HISTORY CODES .... 8-135
[B-3] MALFUNCTION HISTORY IS NOT DISPLAYED .. .......... ......... .... 8-135
[C-1] DELETING THE FAULT CODES ..... .......... ......... .......... ......... ...... 8-136
[C-2] FINAL CHECK ......... .......... ......... .......... ......... ........ .......... ......... .... 8-136

FUEL PUMP SYSTEM .. ......... ......... .......... ........ ......... .......... ......... ......... ...... 8-139
CIRCUIT DIAGRAM (MTT9K/MTT9KC) ....... ........ ......... .......... ......... ..... 8-139
CIRCUIT DIAGRAM (MTT9GTK/MTT9GTKC) ..... ......... .......... ......... ..... 8-141
TROUBLESHOOTING ... ......... .......... ........ ......... .......... ......... ......... ....... 8-143

ABS (ANTI-LOCK BRAKE SYSTEM) .. ..... ......... .......... ........ .......... ......... .... 8-145
CIRCUIT DIAGRAM (MTT9K/MTT9KC) ....... .......... ........ .......... ......... .... 8-145
CIRCUIT DIAGRAM (MTT9GTK/MTT9GTKC) ....... ........ .......... ......... .... 8-147
ABS COMPONENTS CHART .. .......... ........ .......... ......... .......... ......... ..... 8-149
ABS COUPLER LOCATION CHART (MTT9K/MTT9KC) ........ ......... ..... 8-150
ABS COUPLER LOCATION CHART (MTT9GTK/MTT9GTKC) ........ .... 8-151
MAINTENANCE OF THE ABS ECU .......... .......... ......... .......... ......... ..... 8-152
ABS TROUBLESHOOTING OUTLINE ....... ......... .......... ......... .......... ..... 8-1 52
BASIC INSTRUCTIONS FOR TROUBLESHOOT! NG ... ......... ......... ..... 8-153
BASIC PROCESS FOR TROUBLESHOOTING ... ......... .......... ......... .... 8-154
[A] CHECKING THE ABS WARNING LIGHT ...... .......... ......... ......... ...... 8-155
[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON ..... ...... 8-155
[A-2] THE ABS WARNING LIGHT AND OTHER INDICATOR
LIGHTS FAIL TOCOMEON ... ......... ......... .......... ......... .......... .......... .... 8-155
[A-3] THE ABS WARNING LIGHT COMES ON ..... ......... .......... ......... ... 8-155
[A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE .......... ......... ... 8-156
[A-5] ABS ECU AND FI ECU FAIL TO COMMUNICATE ........ ......... ..... 8-156
[B-1] MALFUNCTION ARE CURRENTLY DETECTED .. ......... ......... .... 8-156
[B-2] DIAGNOSIS USING THE FAULT CODES .. ......... .......... ......... ..... 8-156
[B-3] DELETING THE FAULT CODES ...... .......... ......... .......... ......... ...... 8-177
[C-1] FINAL CHECK ......... ......... .......... ......... .......... ........ .......... ......... .... 8-177

GRIP WARMER SYSTEM (MTT9GTK/MTT9GTKC) ........... ......... .......... .... 8-179

CIRCUIT DIAGRAM .......... .......... ......... ......... .......... ........ .......... ......... ... 8-179
TROUBLESHOOT! NG ... .......... ......... ......... ......... .......... ......... .......... ..... 8-181
ELECTRICAL COMPONENTS ........ .......... ......... .......... ........ .......... ......... .... 8-183
CHECKING THE SWITCHES .. ......... ......... ......... .......... ......... .......... ..... 8-187
CHECKING THE FUSES ......... ......... ......... ......... .......... ......... .......... ..... 8-189
REPLACING THE ECU (Engine Control Un it) ..... .......... ......... .......... .... 8-189
CHECKING AND CHARGING THE BATTERY .... ......... .......... ......... ..... 8-190
CHECKING THE RELAYS ........ ......... .......... ........ .......... ......... .......... .... 8-190
CH ECKi NG THE TURN SIGNAUHAZARD RELAY ...... ......... ......... ...... 8-191
CHECKING THE RELAY UNIT (DIODE) ..... ........ .......... ......... .......... .... 8-192
CHECKING THE IGNITION COILS .... ........ .......... ......... .......... ......... ..... 8-193
CHECKING THE IGNITION SPARK GAP .... .......... ......... ......... ......... .... 8-194
CH ECKi NG THE CRANKSHAFT POSITION SENSOR .......... ......... ..... 8-194
CHECKING THE LEAN ANGLE SENSOR ... ........ .......... .......... ......... .... 8-195
CH ECKi NG THE STARTER MOTOR OPERATION ..... .......... ......... ..... 8-195
CHECKING THE STATOR COIL ........ .......... ......... ........ .......... ......... .... 8-196
CHECKING THE RECTIFIER/REGULATOR ...... ......... .......... ......... ...... 8-196
CHECKING THE ENGINE OIL LEVEL SWITCH .. ......... ......... ......... ..... 8-196
CHECKING THE FUEL SENDER ...... .......... ........ .......... ......... .......... .... 8-197
CHECKING THE FUEL METER ........ ........ .......... ......... .......... ......... ...... 8-197
CHECKING THE OIL LEVEL WARNING LIGHT .. ......... .......... ......... .... 8-198
CHECKING THE RADIATOR FAN MOTOR ....... ......... .......... .......... ..... 8-198
CHECKING THE COOLANT TEMPERATURE SENSOR ...... .......... ..... 8-198
CH ECKi NG THE THROTTLE POSITION SENSOR ..... ......... .......... ..... 8-199
CHECKING THE ACCELERATOR POSITION SENSOR ...... .......... ..... 8-200
CHECKING THE THROTTLE SERVO MOTOR .. .......... .......... ......... .... 8-200
CHECKING THE AIR INDUCTION SYSTEM SOLENOID ...... ......... ..... 8-201
CHECKING THE INTAKE AIR PRESSURE SENSOR .. ......... ......... ..... 8-201
CHECKING THE INTAKE AIR TEMPERATURE SENSOR .... ......... ..... 8-202
CHECKING THE GEAR POSITION SWITCH ..... ......... .......... ......... ...... 8-202
CHECKING THE FUEL INJECTORS ......... ......... .......... ......... .......... ..... 8-203
CHECKING THE GRIP WARMERS (MTT9GTK/MTT9GTKC) ......... .... 8-203
CHECKING THE WHEEL SWITCH (MTT9GTK/MTT9GTKC) ......... ..... 8-204
 IGNITION SYSTEM

EAS20072

IGNITION SYSTEM
EAS30490

CIRCUIT DIAGRAM (MTT9K/MTT9KC)

I.
•

ft_ti
4•
'
:' ~
~ :
'
'

m
..~t:- ' ,·rJ ·r·u·---
:..~ . ____ _:
~ i

'~- -..«:"
1e 1100
'-- ------'

8-1
 IGNITION SYSTEM

3. Main switch
4. Main fuse
11. Ignition fuse
15.Battery
16. Engine ground
17.Fuel injection system fuse
22.Joint coupler
23. Handlebar switch (right)
26.Start/engine stop switch
28. Relay unit
31.Sidestand switch
34. ECU (Engine Control Unit)
35. Ignition coil #1
36. Ignition coil #2
37.lgnition coil #3
38.Spark plug
46.Crankshaft position sensor
51.Lean angle sensor
71.Gear position switch
A. Wire harness
B. Negative battery sub-wire harness

8-2
 IGNITION SYSTEM

EAS31335

CIRCUIT DIAGRAM (MTT9GTK/MTT9GTKC)

Iffl!
•ir.f•
• ,a,
' ""'.
•,.1.$11
- -'

.~-,
- r,;·
-•
H<>

----

--· ~
Pi
4 •

8-3
 IGNITION SYSTEM

3. Main switch
4. Main fuse
11. Ignition fuse
16.Battery
17.Engine ground
18. Fuel injection system fuse
21.Joint coupler
26. Handlebar switch (right)
28.Start/engine stop switch
30.Relay unit
33.Sidestand switch
36. ECU (Engine Control Unit)
37.lgnition coil #1
38. Ignition coil #2
39. Ignition coil #3
40.Spark plug
48.Crankshaft position sensor
53.Lean angle sensor
76.Gear position switch
A. Wire harness
B. Negative battery sub-wire harness

8-4
 IGNITION SYSTEM

EAS30491

ENGINE STOPPING DUE TO SIDESTAND OPERATION

When the engine is running and the transmission is in gear, the engine will stop if the sidestand is
moved down. This is because the electric current from the ignition coils does not flow to the ECU when
both the gear position switch (neutral circuit) and sidestand switch are set to "OFF", thereby preventing
the spark plugs from producing a spark. However, the engine continues to run under the following con-
ditions:
• The transm ission is in gear (the neutral circuit of the gear position switch is open) and the sidestand
is up (the sidestand switch circuit is closed).
• The transmission is in neutral (the neutral circuit of the gear position switch is closed) and the side-
stand is down (the sidestand switch circuit is open).

12 2
I I
0 ©
--
-- 1

!
3

4
1111

10 5

8
6
11 9

1. Battery
2. Main fuse
3. Main switch
4. Ignition fuse
5. Start/engine stop switch
6. Ignition coil
7. Spark plug
8. ECU (Engine Control Unit)
9. Sidestand switch
10. Relay unit (diode)
11. Gear position switch (neutral circuit)
12. Battery negative lead

8-5
 IGNITION SYSTEM

EAS30492

TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark) .
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Before troubleshooting, remove the following part(s):
1. Fuel tank front cover/Front side panel/Front side cowling
2. Passenger seat/Rider seat
3. Fuel tank cover
4. Fuel tank
5. Air fi lter case

1. Check the fuses. NG ➔

(Main, ignition and fuel injection
system) Replace the fuse(s) .
Refer to "CHECKING THE FUS-
ES" on page 8-189.

OKt

2. Check the battery.

Refer to "CHECKING AND • Clean the battery term inals.
CHARG ING THE BATTERY" on • Recharge or replace the battery.
page 8-190 .

OKt

3. Check the spark plugs.

Refer to "CHECKING THE SPARK Re-gap or replace the spark plug(s).
PLUGS" on page 3-5.

OKt

4. Check the ignition spark gap. OK ➔

Refer to "CHECKING THE IGNI- Ignition system is OK.
T ION SPARK GAP" on page 8-194.

NGt

5. Check the ignition coils.

Refer to "CHECKING THE IGNI- Replace the ign ition coil(s) .
T ION COILS" on page 8-193.

OKt

6. Check the crankshaft position sen-

sor.
Refer to "CHECKING THE CRANK- Replace the crankshaft position sensor.
SHAFT POSIT ION SENSOR" on
page 8-194.

OKt

7. Check the main switch .

Refer to "CHECKING THE Replace the main switch .
SWITCHES" on page 8-187 .

OKt

8-6
 IGNITION SYSTEM

8. Check the start/engine stop switch . NG ➔

Refer to "CHECKING THE Replace the handlebar switch (right).
SWITCHES" on page 8-187.

OKJ,,

9. Check the gear position switch.

Refer to "CHECKING THE GEAR
Replace the gear position switch .
POSIT ION SWITCH" on page
8-202 .

OKJ,,

1a .Check the sidestand switch .

Refer to "CHECKING THE Replace the sidestand switch.
SWITCHES" on page 8-187 .

OKJ,,

11 .Check the relay unit (diode) .

Refer to "CHECKING THE RELAY Replace the relay unit.
UNIT (DIODE)" on page 8-192.

OKJ,,

12.Check the lean angle sensor.

Refer to "CHECKING THE LEAN Replace the lean ang le sensor.
ANGLE SENSOR" on page 8-195.

OKJ,,

13.Check the entire ignition system's

w1nng .
Refer to "C IRCU IT DIAGRAM
Properly connect or replace the ignition
(MTT9K/MTT9KC)" on page 8-1 , or
system's wiring .
refer to "C IRCU IT DIAGRAM
(MTT9GTK/MTT9GTKC)" on page
8-3.

OKJ,,

Replace the ECU.

Refer to "REPLACING THE ECU (En-
gine Control Unit)" on page 8-189.

8-7
 IGNITION SYSTEM

8-8
 ELECTRIC STARTING SYSTEM

EAS20073

ELECTRIC STARTING SYSTEM

EAS30493

CIRCUIT DIAGRAM (MTT9K/MTT9KC)

'
:' ~
~ :
'
'

m
..~t:- ' ,·rJ ·r·u·---
:..~ . ____ _:
~ i

'~- -..«:"
1e 11!
'-- ------'

8-9
 ELECTRIC STARTING SYSTEM

3. Main switch
4. Main fuse
11. Ignition fuse
15.Battery
16. Engine ground
18. Starter relay
19.Starter motor
22.Joint coupler
23. Handlebar switch (right)
26.Start/engine stop switch
28. Relay unit
29.Starting circuit cut-off relay
31.Sidestand switch
71.Gear position switch
76. Handlebar switch (left)
83.Clutch switch
A. Wire harness
B. Negative battery sub-wire harness

8-10
 ELECTRIC STARTING SYSTEM

EAS3 1336

CIRCUIT DIAGRAM (MTT9GTK/MTT9GTKC)

ii•
; -~:
' '
' ®'
--,_- - - - - - - - - - - - - - - 1 - - - - - ~
S- St •.__
;;
i,- - - -..1
If,,-!➔••-----+-------------'

~ ' '
.~11~1~111
'

aii ~
~ Eil

8-11
 ELECTRIC STARTING SYSTEM

3. Main switch
4. Main fuse
11. Ignition fuse
16.Battery
17.Engine ground
19.Starter relay
20.Starter motor
21.Joint coupler
23.Clutch switch
26. Handlebar switch (right)
28.Start/engine stop switch
30.Relay unit
31.Starting circuit cut-off relay
33.Sidestand switch
76.Gear position switch
A. Wire harness
B. Negative battery sub-wire harness

8-12
 ELECTRIC STARTING SYSTEM

EAS30494

STARTING CIRCUIT CUT-OFF SYSTEM OPERATION

If the main switch is turned to "ON" and the"(?)" side of the start/engine stop switch is pushed, the starter
motor can only operate if at least one of the following conditions is met:
• The transmission is in neutral (the neutral circuit of the gear position switch is closed) .
• The clutch lever is pulled to the handlebar (the clutch switch is closed) and the sidestand is up (the
sidestand switch is closed).
The starting circuit cut-off relay prevents the starter motor from operating when neither of these condi-
tions has been met. In this instance, the starting circuit cut-off relay is open so current cannot reach the
starter motor. When at least one of the above conditions has been met the starting circuit cut-off relay
is closed and the engine can be started by pushing the "(?)" side of the start/engine stop switch.
13
/ ~

,
M
--
-- '
(

12

e (±)
1

--
',.
2
('

64
~

, ~11 ~,
('

I ~ ~

5
r

~
A

\..

~ a 5

7
1
~,
~ I •~
,~
. -' • ~

8,
. l
9 10 ' ~

1 1
8-13
 ELECTRIC STARTING SYSTEM

a. WHEN THE TRANSMISSION IS IN NEUTRAL

b. WHEN THE SIDESTAND IS UP AND THE
CLUTCH LEVER IS PULLED TO THE
HANDLEBAR

1 . Battery
2. Main fuse
3. Main switch
4. Ignition fuse
5. Start/engine stop switch
6. Starting circuit cut-off relay
7. Diode
8. Clutch switch
9. Sidestand switch
10. Gear position switch (neutral circuit)
11. Diode
12. Starter relay
13. Starter motor

8-14
 ELECTRIC STARTING SYSTEM

EAS30495

TROUBLESHOOTING
The starter motor fails to turn.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Before troubleshooting, remove the following part(s):
1. Fuel tank front cover/Front side panel/Front side cowling
2. Passenger seat/Rider seat
3. Fuel tank cover
4. Fuel tank
5. Air filter case
6. Throttle bodies

1. Check the fuses. NG ➔

(Main and ignition)
Replace the fuse(s) .
Refer to "CHECKING THE FUS-
ES" on page 8-189.

OKt

2. Check the battery.

Refer to "CHECKING AND • Clean the battery terminals.
CHARG ING THE BATTERY" on • Recharge or replace the battery.
page 8-190.

OKt

3. Check the starter motor operation. OK ➔

Starter motor is OK. Perform the electric
Refer to "CHECKING THE START-
starting system troubleshooting , starting
ER MOTOR OPERATION" on page
with step 5.
8-195.

NGt

4. Check the starter motor.

Refer to "CHECKING THE START- Repair or replace the starter motor.
ER MOTOR" on page 5-46.

OKt

5. Check the relay unit (starting circuit

cut-off relay).
Replace the relay unit.
Refer to "CHECKING THE RE-
LAYS" on page 8-190.

OKt

6. Check the relay unit (diode).

Refer to "CHECKING THE RELAY Replace the relay unit.
UNIT (DIODE)" on page 8-192.

OKt

7. Check the starter relay.

Refer to "CHECKING THE RE- Replace the starter relay.
LAYS" on page 8-190.

OKt

8-15
 ELECTRIC STARTING SYSTEM

8. Check the main switch . NG ➔

Refer to "CHECKING THE Replace the main switch .
SWITCHES" on page 8-187.

OKJ,,

9. Check the gear position switch.

Refer to "CHECKING THE GEAR
Replace the gear position switch .
POSIT ION SWITCH" on page
8-202 .

OKJ,,

1a .Check the sidestand switch .

Refer to "CHECKING THE Replace the sidestand switch.
SWITCHES" on page 8-187 .

OKJ,,

11 .Check the clutch switch .

Refer to "CHECKING THE Replace the clutch switch .
SWITCHES" on page 8-187 .

OKJ,,

12.Check the starVengine stop switch .

Refer to "CHECKING THE Replace the handlebar switch (right).
SWITCHES" on page 8-187.

OKJ,,

13.Check the entire starting system's

w1nng .
Refer to "C IRCU IT DIAGRAM
Properly connect or replace the starting
(MTT9K/MTT9KC)" on page 8-9, or
system's wiring .
refer to "C IRCU IT DIAGRAM
(MTT9GTK/MTT9GTKC)" on page
8-11 .

OKJ,,

The starting system circu it is OK.

8-16
 CHARGING SYSTEM

EAS20074

CHARGING SYSTEM
EAS30496

CIRCUIT DIAGRAM (MTT9K/MTT9KC)

w
...~1: '
li
l
;
.
'' .
.,.: . ... Iiit?J:~·
~ -.
' f.;!

1. AC magneto
2. Rectifier/regulator
4. Main fuse
15.Battery
16. Engine ground
A. Wire harness
B. Negative battery sub-wire harness

8-17
 CHARGING SYSTEM

EAS31337

CIRCUIT DIAGRAM (MTT9GTK/MTT9GTKC)

:!:.El~l:1
l
ij ••
-- ---,
'' @Jt=o,=---,
'
: - (i):ij)g . __ __,
---- ,_
1. AC magneto
2. Rectifier/regulator
4. Main fuse
16.Battery
17.Engine ground
A. Wire harness
B. Negative battery sub-wire harness

8-18
 CHARGING SYSTEM

EAS30497

TROUBLESHOOTING
The battery is not being charged.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Before troubleshooting, remove the following part(s):
1. Passenger seat/Rider seat
2. Rear side cover (left)/Lower tail cover

1. Check the fuse. NG ➔

(Main)
Replace the fuse.
Refer to "CHECKING THE FUS-
ES" on page 8-189.

OKt

2. Check the battery.

Refer to "CHECKING AND • Clean the battery terminals.
CHARG ING THE BATTERY" on • Recharge or replace the battery.
page 8-190.

OKt

3. Check the stator coil.

Refer to "CHECKING THE STATOR Replace the stator coil assembly.
COi i.'.' on page 8-196.

OKt

4. Check the rectifier/regulator.

Refer to "CHECKING THE RECTI-
Replace the rectifier/regulator.
FIER/REGULATOR" on page
8-196.

OKt

5. Check the entire charging system's

w1nng .
Refer to "CIRCU IT DIAGRAM
Properly connect or replace the charging
(MTT9K/MTT9KC)" on page 8-17,
system's wiring.
or refer to "CIRCU IT DIAGRAM
(MTT9GTK/MTT9GTKC)" on page
8-18.

OKt

The charging system circuit is OK.

8-19
 CHARGING SYSTEM

8-20
 LIGHTING SYSTEM

EAS20075

LIGHTING SYSTEM
EAS30498

CIRCUIT DIAGRAM (MTT9K/MTT9KC)

!I· . .
, :
····· . . . • ····· : . ®. .
. . . . : . . • . • . . . . . . . .• : • . . . . . . : . : . . .. 1 I
: ..
l l l l : ........
·-·
, ... · ·... -,
= ················'
'

71=~
.:r
• ' , l I

~
I
:- - --------- ----------------- 1t !
'
'
'
'
'
'
----> - '

~-- ,·~tl~·
~---,;~.. ~~t·~·:
®':®-
.. ''
• .--1~...s..;
.
.'

··1·r ·r·f ·····

:. ·~······:
J
''-- ----- _,

8-21
 LIGHTING SYSTEM

3. Main switch
4. Main fuse
8. Backup fuse
11. Ignition fuse
13. Signaling system fuse
15.Battery
16. Engine ground
17.Fuel injection system fuse
22.Joint coupler
33. ECU (Engine Control Unit)
58.Meter assembly
60.Meter light
65. High beam indicator light
69.Multi-function meter
75. Handlebar switch (left)
76. Dimmer/pass switch
85. Front turn signal/position light (right)
86. Front turn signal/position light (left)
87.Headlight control unit
88. Headlight (high beam)
89. Headlight (low beam)
90.Auxiliary light (right)
91.Auxiliary light (left)
92. License plate light
93. Tail/brake light
98. Headlight fuse
A. Wire harness
B. Negative battery sub-wire harness

8-22
 LIGHTING SYSTEM

EAS31338

CIRCUIT DIAGRAM (MTT9GTK/MTT9GTKC)

I : - - - - - I I =--•.-..- Ii Ii Ii ii f t -, : :,,..

©;
fu&
.
1
• - - - - F-
- -=-
- ;- - -:..:-:..:-'l'F-=i
- :..: - -=---=- -:;-:..:-:..;-c.:--t"''r"'r"~i't '
- :..:
-
'
'
'

,- - - - - - - - - -
'

r+-- +•t~®~@}!
•
' '' i-
® : i
-
r

'
f,''1-...J~ ,-
'

. -
IBm"-" .
· • ·41· -. ..
~ -~~{
l ~ ,~ -· :@-----~~

aii ~
~ Eil

8-23
 LIGHTING SYSTEM

3. Main switch
4. Main fuse
8. Backup fuse
11. Ignition fuse
13. Signaling system fuse
16.Battery
17.Engine ground
18. Fuel injection system fuse
21.Joint coupler
35. ECU (Engine Control Unit)
60.Meter assembly
64.Multi-function meter
71 . Meter light
73. High beam indicator light
79. Handlebar switch (left)
80. Dimmer/pass switch
91. Front turn signal/position light (right)
92. Front turn signal/position light (left)
93. Headlight control unit
94. Headlight (high beam)
95. Headlight (low beam)
96.Auxiliary light (right)
97 .Auxiliary light (left)
98. License plate light
99.Tail/brake light
106. Headlight fuse
A. Wire harness
B. Negative battery sub-wire harness

8-24
 LIGHTING SYSTEM

EAS30499

TROUBLESHOOTING
Any of the following fail to light: headlight, high beam indicator light, tail/brake light, auxiliary light, li-
cense plate light or meter light.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Before troubleshooting, remove the following part(s):
1. Fuel tank front cover/Front side panel/Front side cowling
2. Passenger seat/Rider seat
3. Fuel tank cover
4. Fuel tank
5. Rear side cover
6. Headlight assembly

1. Check the bulb and bulb socket NG ➔

cond it ion.
Refer to "CHECKING THE BULB Replace the bulb and bulb socket.
AND BULB SOCKETS" in "BASIC
INFORMATION" (separate volume).

OKJ,,

2. Check the fuses.

(Main, backup, headlight, ign ition,
fuel injection system and signaling
Replace the fuse(s) .
system)
Refer to "CHECKING THE FUS-
ES" on page 8-189.

OKJ,,

3. Check the battery.

Refer to "CHECKING AND • Clean the battery term inals.
CHARG ING THE BATTERY" on • Recharge or replace the battery.
page 8-190 .

OKJ,,

4. Check the main switch .

Refer to "CHECKING THE Replace the main switch .
SWITCHES" on page 8-187 .

OKJ,,

5. Check the dimmer/pass switch.

The dimmer/pass switch is faulty. Replace
Refer to "CHECKING THE
the handlebar switch (left).
SWITCHES" on page 8-187 .

OKJ,,

8-25
 LIGHTING SYSTEM

6. C~~ck the entire lighting system's NG ➔

w1nng.
Refer to "CIRCU IT DIAGRAM
Properly connect or replace the lighting
(MTT9K/MTT9KC)" on page 8-21 ,
system's wiring.
or refer to "CIRCU IT DIAGRAM
(MTT9GTK/MTT9GTKC)" on page
8-23.

OK.J,
Replace the ECU, meter assembly,
head light assembly, front turn signal/
position light or tail/brake light.
Refer to "REPLACING THE ECU (En-
gine Control Unit)" on page 8-189.

8-26
 SIGNALING SYSTEM

EAS20076

SIGNALING SYSTEM
EAS30500

CIRCUIT DIAGRAM (MTT9K/MTT9KC)

. .
- ---- - •- • '

-
•t- ····· · 1
L_Jl_./U!_ _:_:_~..:..:_-~== +' ..- --1-__.,
• il=l--1
~ - +,=
'
' ''i6:!
)l •, ,' i ..;·1
f;'!,m I 1~ 1 1 I "'
~ I 1 ~ _1 , SJf: I

. i~
r>~ ; ! •-f°.. - _,
: ~ -; I I .,
I - - j I OI I

- ~
; ~ :
@:_ - - - - - - - _:

8-27
 SIGNALING SYSTEM

3. Main switch
4. Main fuse
5. ABS motor fuse
6. ABS solenoid fuse
8. Backup fuse
11. Ignition fuse
12.ABS control unit fuse
13. Signaling system fuse
15.Battery
16. Engine ground
17.Fuel injection system fuse
21. Rear brake light switch
22.Joint coupler
23. Handlebar switch (right)
24. Front brake light switch
25. Hazard switch
28. Relay unit
33. ECU (Engine Control Unit)
47.Coolant temperature sensor
55. Rear wheel sensor
56.ABS ECU (electronic control unit)
58.Meter assembly
59.Neutral indicator light
61.Tachometer
62.0il level warning light
66.Turn signal indicator light (left)
67.Turn signal indicator light (right)
69.Multi-function meter
70.Gear position switch
71.0il level switch
73. Fuel sender
74.Turn signal/hazard relay
75. Handlebar switch (left)
77.Turn signal switch
78. Horn switch
79.Horn
83. Rear turn signal light (right)
84. Rear turn signal light (left)
85. Front turn signal/position light (right)
86. Front turn signal/position light (left)
93. Tail/brake light
95. Parking lighting fuse
A. Wire harness
B. Negative battery sub-wire harness
D. Sub-wire harness (coolant temperature
sensor)

8-28
 SIGNALING SYSTEM

EAS31339

CIRCUIT DIAGRAM (MTT9GTK/MTT9GTKC)

:· -@r'®'-i'-" ·=-::
· ..:..:
·
~
"'-1'f-=1 · ·c:.c
"1..:..: · ·=-r
'
· -~;_f®~i""r"'i't:
· -=-r 1:
' '
~ ® ~ , : ••
. '
,---1: - - - -'-~- 1,. -- -~w-- ~ ,_ -. :
I
@ J I
L
., M •l'.>l_i - ..
.

<;)I : @ it-ll)i ~ ---'

' ---------

-
'-U!c-t-t•,- - - - - - - - - - - - - - - - - - -
H<1

,- - - - - - - - - ~

·r:11=J·
I' @1 I'
'
'
'' 111
' '
f.' ., ~

-fli !.
'
'
- •
•
'
'
'
I<-

B'I 11

~ - -,.~ ,:l]~l~I: ,

3+··---~,
.,
"- ---- ~
L~.-
~ _@_ - ; -- ---+--+---+-------,1-------------:_:_~--------_
__._- - - - - - ~
4 ~.- -- - 1-<- -1-- - - - - - - - - - - - - - - - - - - - - - - - - ~

~fl :t!J
~~,!a
\-t::=~
:t] -
;11~6
·_
-
;;"
· --;-=:::=:-=-=-=--=:·
! : r:·w
=-----~'
· j
-_- .j.._
±----±---' '
, - · ....:
· ~- ~- - ·=·
~
-__J
- ~
- - - - - -•
'-- -.. f<: . . • i- - -- s.Yt-
:@ ~ :
'
'
'------
'
·' I
8-29
 SIGNALING SYSTEM

3. Main switch
4. Main fuse
5. ABS motor fuse
6. ABS solenoid fuse
8. Backup fuse
11. Ignition fuse
12.ABS control unit fuse
13. Signaling system fuse
14. Brake light fuse
16.Battery
17.Engine ground
18. Fuel injection system fuse
21.Joint coupler
24. Front brake light switch
25. Rear brake light switch
29.Brake light relay
30. Relay unit
34.Shift switch
35. ECU (Engine Control Unit)
49.Coolant temperature sensor
57.Rear wheel sensor
58.ABS ECU (electronic control unit)
60.Meter assembly
61. Engine oil and coolant warning light
62. Neutral indicator light
63. Shift timing indicator light
64.Multi-function meter
67.Turn signal indicator light (left)
68.Turn signal indicator light (right)
7 4. Oil level switch
75.Gear position switch
77.Fuel sender
78.Turn signal/hazard relay
79. Handlebar switch (left)
81.Turn signal switch
82. Horn switch
83.Horn
88. Hazard switch
89. Rear turn signal light (right)
90. Rear turn signal light (left)
91. Front turn signal/position light (right)
92. Front turn signal/position light (left)
99.Tail/brake light
103. Parking lighting fuse
A. Wire harness
B. Negative battery sub-wire harness
D. Sub-wire harness (coolant temperature
sensor)

8-30
 SIGNALING SYSTEM

EAS30501

TROUBLESHOOTING
• Any of the following fail to light: turn signal light, brake light or an indicator light.
• The horn fails to sound.
• The fuel meter fails to come on.
• The coolant temperature display fails to operate.
• The speedometer fails to operate.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Before troubleshooting, remove the following part(s):
1. Fuel tank front cover/Front side panel/Front side cowling
2. Passenger seat/Rider seat
3. Fuel tank cover
4. Fuel tank
5. Air filter case
6. Headlight assembly

1. Check the fuses. NG ➔

(Main, ignition , signaling system ,
backup, ABS motor, ABS solenoid ,
ABS control unit, fuel injection sys-
Replace the fuse(s) .
tem , brake light (MTT9GTK/
MTT9GTKC), and parking lighting)
Refer to "CHECKING THE FUS-
ES" on page 8-189.

OKt

2. Check the battery.

Refer to "CHECKING AND • Clean the battery terminals.
CHARG ING THE BATTERY" on • Recharge or replace the battery.
page 8-190.

OKt

3. Check the main switch .

Refer to "CHECKING THE Replace the main switch.
SWITCHES" on page 8-187.

OKt

4. Check the entire signaling sys-

tem's wiring.
Refer to "CIRCU IT DIAGRAM
Properly connect or replace the signaling
(MTT9K/MTT9KC)" on page 8-27,
system's wiring.
or refer to "CIRCU IT DIAGRAM
(MTT9GTK/MTT9GTKC)" on page
8-29.

OKt

Check the condition of each of the sig-

naling system circuits. Refer to
"Checking the signaling system" on
page 8-32.

8-31
 SIGNALING SYSTEM

Checking the signaling system

The horn fails to sound.

1. Check the horn switch . NG ➔

Refer to "CHECKING THE Replace the handlebar switch (left) .
SWITCHES" on page 8-187.

OK.J,
2. Check the entire signaling sys-
tem's wiring.
Refer to "CIRCU IT DIAGRAM
Properly connect or replace the signaling
(MTT9K/MTT9KC)" on page 8-27,
system's wiring.
or refer to "CIRCU IT DIAGRAM
(MTT9GTK/MTT9GTKC)" on page
8-29.

OK.J,
Replace the horn.

The tail/brake light fails to come on.

1. Check the front brake light switch.

Refer to "CHECKING THE Replace the front brake light switch .
SWITCHES" on page 8-187.

OK.J,
2. Check the rear brake light switch.
Refer to "CHECKING TH E Replace the rear brake light switch.
SWITCHES" on page 8-187.

OK.J,
3. Check the brake light relay.
(MTT9GTK/MTT9GTKC)
Replace the brake light relay.
Refer to "CHECKING TH E RE-
LAYS" on page 8-190.

OK.J,
4. Check the entire signaling sys-
tem's wiring.
Refer to "CIRCU IT DIAGRAM
Properly connect or replace the signaling
(MTT9K/MTT9KC)" on page 8-27,
system's wiring.
or refer to "CIRCU IT DIAGRAM
(MTT9GTK/MTT9GTKC)" on page
8-29.

OK.J,
Replace the tail/brake light.

8-32
 SIGNALING SYSTEM

The turn siqnal liqht, turn siqnal indicator liqht or both fail to blink.

1. Check the turn signal light bulb and NG ➔

socket.
Replace the turn signal light bulb(s) , sock-
Refer to "CHECKING THE BULB
et(s) or both .
AND BULB SOCKET" in "BASIC
INFORMATION" (separate volume).

OKt

2. Check the turn signal switch . NG ➔

Refer to "CHECKING THE Replace the handlebar switch (left) .
SWITCHES" on page 8-187 .

OKt

3. Check the hazard switch . Replace the handlebar switch (right)

Refer to "CHECKING THE (MTT9K/MTT9KC) . Replace the handlebar
SWITCHES" on page 8-187 . switch (left) (MTT9GTK/MTT9GTKC).

OKt

4. Check the turn signal/hazard relay.

Refer to "CHECKING THE TURN
Replace the turn signal/hazard relay.
SIGNAL/HAZARD RELAY" on page
8-191 .

OKt

5. Check the entire signaling sys-

tem's wiring .
Refer to "CIRCU IT DIAGRAM
Properly connect or replace the signaling
(MTT9K/MTT9KC)" on page 8-27,
system's wiring.
or refer to "CIRCU IT DIAGRAM
(MTT9GTK/MTT9GTKC)" on page
8-29.

OKt

Replace the meter assembly.

The neutral indicator light fails to come on.

1. Check the gear position switch.

Refer to "CHECKING THE GEAR
Replace the gear position switch .
POSIT ION SWITCH" on page
8-202 .

OKt

2. Check the relay unit (d iode) .

Refer to "CHECKING THE RELAY Replace the relay unit.
UNIT (DIODE)" on page 8-192.

OKt

8-33
 SIGNALING SYSTEM

3. Check the entire signaling sys- NG ➔

tem's wiring .
Refer to "C IRCU IT DIAGRAM
Properly connect or replace the signaling
(MTT9K/MTT9KC)" on page 8-27,
system's wiring .
or refer to "C IRCU IT DIAGRAM
(MTT9GTK/MTT9GTKC)" on page
8-29.

OK.J,
Replace the meter assembly.

The oil level warning light fails to come on. (MTT9K/MTT9KC)

1. Check the oil level switch . NG ➔

Refer to "CHECKING THE Replace the oil level switch.
SWITCHES" on page 8-187 .

OK.J,
2. Check the entire signaling sys-
tem's wiring . Properly connect or replace the signaling
Refer to "C IRCU IT DIAGRAM system's wiring .
(MTT9K/MTT9KC)" on page 8-27.

OK.J,
Replace the meter assembly.

The oil level warning icon and engine oil and coolant warning light both come on . (MTT9GTK/
MTT9GTKC)

1. Check the oil level switch .

Refer to "CHECKING THE Replace the oil level switch.
SWITCHES" on page 8-187 .

OK.J,
2. Check the entire signaling sys-
tem's wiring .
Properly connect or replace the signaling
Refer to "C IRCU IT DIAGRAM
system's wiring .
(MTT9GTK/MTT9GTKC)" on page
8-29.

OK.J,
Replace the meter assembly.

QSS (Quick Shift System) does not 01,2erate. (MTT9GTK/MTT9GTKC)

1. Check that the engine trouble light

Repair the faulty parts.
does not come on .

OK.J,

8-34
 SIGNALING SYSTEM

2. Check that the ass

is working un- NG ➔ Check the QSS operating conditions ex-
der normal QSS operating condi- plained in the owner's manual and operate
tions. the QSS accordingly.

OKJ,,

3. Make sure that the QSS is effective.

Activate the QSS. (Set the QSS to a set-
(Check whether the "OS" icon is
ting other than "OFF".)
displayed at the top of the meter.)

OKJ,,

4. Check that the sh ift switch coupler

Connect the shift switch coupler.
is connected .

OKJ,,

5. Check the shift switch .

Refer to "DIAGNOSTIC CODE:
SENSOR OPERATION TABLE" on Replace the sh ift switch .
page 9-11 and "CHECKING THE
SWITCHES" on page 8-187 .

OKJ,,

6. Check the gear position switch.

Refer to "DIAGNOSTIC CODE:
SENSOR OPERATION TABLE" on Replace the gear position switch .
page 9-11 and "CHECKING THE
SWITCHES" on page 8-187 .

OKJ,,

7. Check the entire signaling sys-

tem's wiring .
Properly connect or repair the signaling
Refer to "C IRCU IT DIAGRAM
system's wiring .
(MTT9GTK/MTT9GTKC)" on page
8-29.

OKJ,,

Replace the ECU.

Refer to "REPLACING THE ECU (En-
gine Control Unit)" on page 8-189.

The fuel meter. fuel level warning light. or both fail to come on .

1. Check the fuel sender. NG ➔

Refer to "CHECKING THE FUEL Replace the fuel pump assembly.
SENDER" on page 8-197.

OKJ,,

8-35
 SIGNALING SYSTEM

2. Check the entire signaling sys- NG ➔

tem's wiring .
Refer to "C IRCU IT DIAGRAM
Properly connect or replace the signaling
(MTT9K/MTT9KC)" on page 8-27,
system's wiring .
or refer to "C IRCU IT DIAGRAM
(MTT9GTK/MTT9GTKC)" on page
8-29.

OK.J,

Replace the ECU or meter assembly.

Refer to "REPLACING THE ECU (En-
gine Control Unit)" on page 8-189.

The coolant temperature disgla~ fails to ogerate. (MTT9K/MTT9KC)

1. Check the coolant temperature sen- NG ➔

sor.
Refer to "CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR"
on page 8-198.

OK.J,

2. Check the entire signaling system

w1nng . Properly connect or replace the wiring har-
Refer to "C IRCU IT DIAGRAM ness.
(MTT9K/MTT9KC)" on page 8-27.

OK.J,

Replace the ECU or meter assembly.

The coolant temperature warning icon and engine oil and coolant warning light both come on .
(MTT9GTK/MTT9GTKC)

1. Check the coolant temperature sen-

sor.
Refer to "CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR"
on page 8-198.

OK.J,

2. Check the entire signaling system

w1nng .
Properly connect or replace the wiring har-
Refer to "C IRCU IT DIAGRAM
ness.
(MTT9GTK/MTT9GTKC)" on page
8-29.

OK.J,

Replace the ECU or meter assembly.

8-36
 SIGNALING SYSTEM

The speedometer fails to operate.

1. Check the rear wheel sensor. NG ➔

Refer to "MAINTENANCE OF THE
Replace the rear wheel sensor.
REAR WHEEL SENSOR AND
SENSOR ROTOR" on page 4-32.

OKt
2. Check the entire wheel sensor wir-
Properly connect or replace the wheel sen-
ing.
sor w1nng.
Refer to TIP.

OKt
Replace the hydraulic unit assembly,
ECU, meter assembly.
Refer to "REPLACING THE ECU (En-
gine Control Unit)" on page 8-189.

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Replace the wire harness if there is an open or short circuit.
• Between rear wheel sensor coupler and ABS ECU coupler.
(white-white)
(black-black)
• Between ABS ECU coupler and ECU coupler.
(white/green-white/green)
(white/yellow-white/yellow)
• Between ECU coupler and meter assembly.
(light green/blue-light green/blue)
(light green/white-light green/white)

8-37
 SIGNALING SYSTEM

8-38
 COOLING SYSTEM

EAS200n

COOLING SYSTEM
EAS30502

CIRCUIT DIAGRAM (MTT9K/MTT9KC)

~.
~ ~ffl
'

-
'--~
~ -.
;.~e,....- + - - - - - - - - + - - - - - - - - - - - - - - - - 1 - - - - - - '

''-- ----- _,

8-39
 COOLING SYSTEM

3. Main switch
4. Main fuse
9. Radiator fan motor fuse
11. Ignition fuse
15.Battery
16. Engine ground
17.Fuel injection system fuse
20. Radiator fan motor relay
22.Joint coupler
33. ECU (Engine Control Unit)
47.Coolant temperature sensor
94. Radiator fan motor
A. Wire harness
B. Negative battery sub-wire harness
D. Sub-wire harness (coolant temperature
sensor)

8-40
 COOLING SYSTEM

EAS3 1340

CIRCUIT DIAGRAM (MTT9GTK/MTT9GTKC)

~--Pr bll .:•:s~·:·

.,
"- ---- ~
'f·•··~,
: .®.. :L ~---- - + - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - < f - - ~

aii ~
~ Eil

8-41
 COOLING SYSTEM

3. Main switch
4. Main fuse
9. Radiator fan motor fuse
11. Ignition fuse
16.Battery
17.Engine ground
18. Fuel injection system fuse
21.Joint coupler
35. ECU (Engine Control Unit)
49.Coolant temperature sensor
100. Radiator fan motor relay
101. Radiator fan motor
A. Wire harness
B. Negative battery sub-wire harness
D. Sub-wire harness (coolant temperature
sensor)

8-42
 COOLING SYSTEM

EAS30503

TROUBLESHOOTING
The radiator fan motor fails to turn.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Before troubleshooting, remove the following part(s):
1. Fuel tank front cover/Front side panel/Front side cowling
2. Passenger seat/Rider seat
3. Fuel tank cover
4. Fuel tank
5. Air filter case
6. Canister (for California only)
7. Throttle bodies

1. Check the fuses. NG ➔

(Main, ignition , fuel injection system
and radiator fan motor) Replace the fuse(s) .
Refer to "CHECKING THE FUS-
ES" on page 8-189.

OKJ,,

2. Check the battery.

Refer to "CHECKING AND • Clean the battery terminals.
CHARG ING THE BATTERY" on • Recharge or replace the battery.
page 8-190.

OKJ,,

3. Check the main switch .

Refer to "CHECKING THE Replace the main switch.
SWITCHES" on page 8-187.

OKJ,,

4. Check the radiator fan motor.

Refer to "CHECKING THE RADIA- Replace the radiator fan motor.
TOR FAN MOTOR" on page 8-198.

OKJ,,

5. Check the radiator fan motor relay.

Refer to "CHECKING THE RE- Replace the radiator fan motor relay.
LAYS" on page 8-190.

OKJ,,

6. Check the coolant temperature sen-

sor.
Refer to "CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR"
on page 8-198.

OKJ,,

8-43
 COOLING SYSTEM

7. C~~ck the entire cooling system's NG ➔

w1nng.
Refer to "CIRCU IT DIAGRAM
Properly connect or replace the cooling
(MTT9K/MTT9KC)" on page 8-39,
system's wiring.
or refer to "CIRCU IT DIAGRAM
(MTT9GTK/MTT9GTKC)" on page
8-41 .

OK.J,
Replace the ECU.
Refer to "REPLACING THE ECU (En-
gine Control Unit)" on page 8-189.

8-44
 FUEL INJECTION SYSTEM

EAS20078

FUEL INJECTION SYSTEM

EAS30504

CIRCUIT DIAGRAM (MTT9K/MTT9KC)

. ..
®'. ....... .

. ...,.._,'
··· - '
'

. - - - - - I -~ ~ • • • ~ GH ' '
\(SM . !--..-........ ~

'@
~ >---~ --~

~--· -l½~--+-++--
~a.. --+-++----------------+-------------------------- -- --------------~'
~~~~1f7~ -•i:• -
'···<4

8-45
 FUEL INJECTION SYSTEM

3. Main switch B. Negative battery sub-wire harness

4. Main fuse C. Sub-wire harness (injector #2)
5. ABS motor fuse D. Sub-wire harness (coolant temperature
6. ABS solenoid fuse sensor)
7. Electronic throttle valve fuse
8. Backup fuse
11. Ignition fuse
12.ABS control unit fuse
15.Battery
16. Engine ground
17.Fuel injection system fuse
18. Starter relay
20. Radiator fan motor relay
22.Joint coupler
23. Handlebar switch (right)
26.Start/engine stop switch
27.Drive mode switch
28. Relay unit
29.Starting circuit cut-off relay
30. Fuel pump relay
31.Sidestand switch
33. ECU (Engine Control Unit)
34. Ignition coil #1
35. Ignition coil #2
36. Ignition coil #3
37.Spark plug
38. Injector #1
39. Injector #2
40. Injector #3
43.Air induction system solenoid
44.02 sensor
45.Crankshaft position sensor
46. Intake air temperature sensor
47.Coolant temperature sensor
48. Intake air pressure sensor 1
49. Intake air pressure sensor 2
50.Lean angle sensor
51.Throttle servo motor
52.Accelerator position sensor
53.Throttle position sensor
54. Front wheel sensor
55. Rear wheel sensor
56.ABS ECU (electronic control unit)
57. Yamaha diagnostic tool coupler
58.Meter assembly
63. Engine trouble warning light
69.Multi-function meter
70.Gear position switch
72.Fuel pump
75. Handlebar switch (left)
82.Clutch switch
87. Headlight control unit
A. Wire harness

8-46
 FUEL INJECTION SYSTEM

EAS3 1341

CIRCUIT DIAGRAM (MTT9GTK/MTT9GTKC)

• -
-
• ••
.
.. I' .. -
••'
' ••
• ,-- ---------
''
• ''
'' ••
- '
''
g!______ ',
.b .. __
'
I
,---1' ----"---
® • '
L.j
- ..
.

----'
' '
ii• ~-+-+---~
• ~
I
-,
;-~-·
I
I A\ I
s- st ___
;-
· I'
.: .,
I.
-
·.""'=-+---+--1-1-+-------------+------~
II - i,- - - - - t --,
'Ufc-t-t••- - - - - + - + - - + + + - - - - - - - - - - - - - '
~ -t ti+-b==l=l:i!~•L...i!:::l
,-- .J I@
:•:=;--
!i - -•l
' =:::--+-H+.;;::-+1-
, , - 1§11!1 ,& i;l:::!:===:::l-'
~ !ml 'O'

- j
. ' ""'
'&
I: '
'
' L;--, '
~ I '
....

- - -,~ ,--------'

8-47
 FUEL INJECTION SYSTEM

3. Main switch A. Wire harness

4. Main fuse B. Negative battery sub-wire harness
5. ABS motor fuse C. Sub-wire harness (injector #2)
6. ABS solenoid fuse D. Sub-wire harness (coolant temperature
7. Electronic throttle valve fuse sensor)
8. Backup fuse
11. Ignition fuse
12.ABS control unit fuse
16.Battery
17.Engine ground
18. Fuel injection system fuse
19.Starter relay
21.Joint coupler
23.Clutch switch
26. Handlebar switch (right)
28.Start/engine stop switch
30. Relay unit
31.Starting circuit cut-off relay
32. Fuel pump relay
33.Sidestand switch
34.Shift switch
35. ECU (Engine Control Unit)
36. Ignition coil #1
37.lgnition coil #2
38. Ignition coil #3
39.Spark plug
40. Injector #1
41. Injector #2
42. Injector #3
43.Grip warmer (left)
44.Grip warmer (right)
45.Air induction system solenoid
46.02 sensor
47.Crankshaft position sensor
48. Intake air temperature sensor
49.Coolant temperature sensor
50. Intake air pressure sensor 1
51.lntake air pressure sensor 2
52. Lean angle sensor
53.Throttle servo motor
54.Accelerator position sensor
55.Throttle position sensor
56. Front wheel sensor
57.Rear wheel sensor
58.ABS ECU (electronic control unit)
59. Yamaha diagnostic tool coupler
60.Meter assembly
64.Multi-function meter
66. Engine trouble warning light
75.Gear position switch
76.Fuel pump
93. Headlight control unit
100. Radiator fan motor relay

8-48
 FUEL INJECTION SYSTEM

EAS30505

ECU SELF-DIAGNOSTIC FUNCTION

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

Checking the engine trouble warning light

The engine trouble warning light comes on for around 2 seconds after the main switch has been set to
"ON". If the warning light does not come on, the warning light (LED) may be defective.

ECU detects an abnormal signal from a sensor

If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi-
nates the engine trouble warning light and provides the engine with alternate operating instructions that
are appropriate for the type of malfunction .
When an abnormal signal is received from a sensor, the ECU processes the specified values that are
programmed for each sensor in order to provide the engine with alternate operating instructions that
enable the engine to continue operating or stop operating, depending on the conditions.
EAS30506

TROUBLESHOOTING METHOD

The engine operation is not normal and the engine trouble warning light comes on.
1. Check:
• Fault code number
a. Check the fault code numbers that have a condition of "Malfunction" using the Yamaha diagnostic
tool.
b. Identify the faulty system with the fault code number.
c. Identify the probable cause of the malfunction.
2. Check and repair the probable cause of the malfunction.
Fault code No. No fault code No.
Check and repair. Refer to "TROUBLESHOOTING Check and repair.
DETAILS (FAULT CODE)" on page 8-51.
Monitor the operation of the sensors and actuators in
the diagnostic mode. Refer to "TROUBLESHOOT-
ING DETAILS (FAULT CODE)" on page 8-51 and
"SELF-DIAGNOSTIC FUNCTION AND DIAGNOS-
TIC CODE TABLE" on page 9-1.

3. Perform the reinstatement action for the fuel injection system.

Refer to "Confirmation of service completion" in the appropriate table in "TROUBLESHOOTING DE-
TAILS (FAULT CODE)" on page 8-51 .
TIP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
• If another fault code number is displayed , repeat steps (1) to (3) until no fault code number is dis-
played .
• Turning the main switch to "OFP' will not erase the malfunction history.

8-49
 FUEL INJECTION SYSTEM

The engine operation is not normal, but the engine trouble warning light does not come on.
1. Check the operation of the following sensors and actuators in the diagnostic mode. Refer to "DIAG-
NOSTIC CODE: ACTUATOR OPERATION TABLE" on page 9-14 and "DIAGNOSTIC CODE: SEN-
SOR OPERATION TABLE" on page 9-11.
01: Throttle position sensor signal 1
(throttle angle)
13: Throttle position sensor signal 2
(throttle angle)
14: Accelerator position sensor signal 1
(throttle angle)
15: Accelerator position sensor signal 2
(throttle angle)
30: Cylinder-#1 ignition coil
31: Cylinder-#2 ignition coil
32: Cylinder-#3 ignition coil
36: Injector #1
37: Injector #2
38: Injector #3
48: Air induction system solenoid

If a malfunction is detected in the sensors or actuators, repair or replace all faulty parts.
If no malfunction is detected in the sensors and actuators, check and repair the inner parts of the
engine.
EAS3095 1

YAMAHA DIAGNOSTIC TOOL

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

Yamaha diagnostic tool USB (US)

90890-03257
Yamaha diagnostic tool (A/1)
90890-03262

TIP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
A generic scan tool can also be used to identify malfunctions.

OBD/ GST Leadwire kit

90890-03249

Connecting the Yamaha diagnostic tool

Remove the protective cap "1", and then connect the Yamaha diagnostic tool to the coupler.

J\..·. '
''
1
p (
0 ,: ,'I
"'
<
l~
-<-i
•
•
--'' ,f>•' -
0 @ @

8-50
 FUEL INJECTION SYSTEM

EAS31791

TROUBLESHOOTING DETAILS (FAULT CODE)

This section describes the measures per fault code number displayed on the Yamaha diagnostic tool.
Check and service the items or components that are the probable cause of the malfunction following
the order given.
After the check and service of the malfunctioning part have been completed, delete the fault codes dis-
played on the Yamaha diagnostic tool according to the reinstatement method.
Fault code No.:
Fault code number displayed on the Yamaha diagnostic tool when the engine failed to work normally.
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. Refer to "SELF-DIAGNOS-
TIC FUNCTION AND DIAGNOSTIC CODE TABLE" on page 9-1 .

Parts connected to the ECU

The following parts are connected to the ECU .
When checking for a power short circuit, the couplers must be disconnected from all of the following
parts beforehand.
• Crankshaft position sensor • Lean angle sensor
• Fuel injector #1 • ABS ECU (electronic control unit)
• Fuel injector #2 • Rectifier/regulator
• Fuel injector #3 • Starter relay
• Ignition coil #1 • Air induction system solenoid
• Ignition coil #2 • Throttle servo motor
• Ignition coil #3 • Grip warmer (OPTION (MTT9K/MTT9KC))
• Throttle position sensor • Grip warmer (MTT9GTK/MTT9GTKC)
• Accelerator position sensor • Relay unit
• Intake air pressure sensor 1 • Headlight assembly
• Intake air pressure sensor 2 • Radiator fan motor relay
• Coolant temperature sensor • Meter assembly
• Intake air temperature sensor • Shift switch (OPTION (MTT9K/MTT9KC))
• 0 2 sensor • Shift switch (MTT9GTK/MTT9GTKC)

Fault code No. P0030

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• If fault code numbers "P0030" and "P0112" are both indicated, take the actions specified for fault code
number "P0112" first.
• If fault code numbers "P0030" and "P0113" are both indicated, take the actions specified for fault code
number "P0113" first.
• If fault code numbers "P0030" and "P0122" are both indicated, take the actions specified for fault code
number "P0122" first.
• If fault code numbers "P0030" and "P0123" are both indicated, take the actions specified for fault code
number "P0123" first.
• If fault code numbers "P0030" and "P0222" are both indicated, take the actions specified for fault code
number "P0222" first.
• If fault code numbers "P0030" and "P0223" are both indicated, take the actions specified for fault code
number "P0223" first.
• If fault code numbers "P0030" and "P2135" are both indicated, take the actions specified for fault code
number "P2135" first.

8-51
 FUEL INJECTION SYSTEM

Fault code No. P0030

Item 0 2 sensor heater: defective heater controller detected.

Able to start engine

Fail-safe system
Able to drive vehicle
Diagnostic code No. -
Tool display -
Procedure -
Probable cause of malfunc- Confirmation of service corn-
Item Maintenance job
tion and check pletion
1 Connection of 0 2 sensor cou- Improperly connected ➔ Con- Turn the main switch to "ON",
pier. nect the coupler securely or re- and then check the condition of
Check the locking condition of place the wire harness. the fault code using the mal-
the coupler. function mode of the Yamaha di-
Disconnect the coupler and agnostic tool.
check the pins (bent or broken Condition is "Recover" ➔ Go to
terminals and locking condition item 6 and finish the service.
of the pins). Condition is "Malfunction" ➔
Start the engine, and then
check the condition of the fault
code.
Condition is "Recover" ➔ Go to
item 6 and finish the service.
Condition is "Malfunction" ➔ Go
to item 2.
TIP
For this check, also set the start/
engine stop switch to "ON".

2 Connection of wire harness
ECU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 6 and finish the service.
Condition is "Malfunction" ➔
Start the engine, and then
check the condition of the fault
code.
Condition is "Recover" ➔ Go to
item 6 and finish the service.
Condition is "Malfunction" ➔ Go
to item 3.
TIP
For this check, also set the start/
engine stop switch to "ON".

8-52
 FUEL INJECTION SYSTEM

Fau lt code No. P0030

Item 0 2 sensor heater: defective heater controller detected.

3 Wire harness continuity.
Open or short circuit ➔ Properly
connect or replace the wire har-
ness.
Between 0 2 sensor coupler and
ECU coupler.
pink/black- pink/black
Between 0 2 sensor coupler and
ignition fuse.
red/white- red/white
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 6 and finish the service.
Condition is "Malfunction" ➔
Start the engine, and then
check the condition of the fault
code.
Condition is "Recover" ➔ Go to
item 6 and finish the service.
Condition is "Malfunction" ➔ Go
to item 4.
TIP _ _ _ _ _ _ _ __
For this check, also set the start/
engine stop switch to "ON".

4 Defective 0 2 sensor heater.
Replace the 0 2 sensor.
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 6 and finish the service.
Condition is "Malfunction" ➔
Start the engine, and then
check the condition of the fault
code.
Condition is "Recover" ➔ Go to
item 6 and finish the service.
Condition is "Malfunction" ➔ Go
to item 5.
TIP _ _ _ _ _ _ _ _ __
For this check, also set the start/
engine stop switch to "ON".

5 Malfunction in ECU. Replace the ECU. Service is finished.

6 Delete the fault code and check
that the engine trouble warning
light goes off.
Refer to "REPLACING TH E
ECU (Engine Control Unit)" on
page 8-189.
Confirm that the fault code has
a condition of "Recover" using
the Yamaha diagnostic tool, and
then delete the fault code.

Fault code No. P0107, P0108

Fault code No. P0107, P0108

[P0107] Intake air pressure sensor 1: ground short circuit detected.

Item [P0108] Intake air pressure sensor 1: open or power short circuit de-
tected.
Able to start engine
Fail-safe system
Able to drive vehicle

8-53
 FUEL INJECTION SYSTEM

Fault code No. P0107,P0108

[P0107] Intake air pressure sensor 1: ground short circuit detected.

Item (P0108] Intake air pressure sensor 1: open or power short circuit de-
tected.
Diagnostic code No. 03
Tool display Displays the intake air pressure.
Operate the throttle while pushing the "0>" side of the start/engine stop
Procedure
switch. (If the display value changes, the performance is OK.)
Probable cause of malfunc-
Item
tion and check
1 Connection of intake air pres-
sure sensor 1 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).
2 Connection of ECU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
3 Wire harness continuity.
3-1
1
Maintenance job
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
Open or short circuit ➔ Replace
the wire harness.
2
l
3 l
5V
-r-
Confirmation of service corn-
pletion
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 2.
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 3.
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 4.
-
5V
I-

'- i p 4 p
<>

f -
/

Bll. 5 Bll.
1-

1. Intake air pressure sensor 1

2. ECU
3. Sensor input lead
4. Sensor output lead
5. Sensor ground lead
3-2 Disconnect the ECU coupler from the ECU.
Disconnect the intake air pressure sensor 1 coupler from the intake air pressure sensor 1.

8-54
 FUEL INJECTION SYSTEM

Fault code No. P0107, P0108

[P0107] Intake air pressure sensor 1: ground short circuit detected.

Item (P0108] Intake air pressure sensor 1: open or power short circuit de-
tected.
3-3 [For P0107] Ground short circuit
Between intake air pressure sensor 1 coupler and ground: pink- ground
If there is continuity, replace the wire harness.

ia SSS ssss SSS SSS

--
--

3-4 [For P0108] Open circuit

Between intake air pressure sensor 1 coupler and ECU coupler: blue-blue
If there is no continuity, replace the wire harness.
[Al [ID

' I I I I
' '
v ;l'/1~ B G/B X r/R Y/G Y/Rw.i A ·w
~
1,...
B G/8 X dR 'M V/R
BI p L I\\ 0/G V/8 B lJ8 P/8 X. X V x X ~1~,~~\ \\ ~JG '!!!. B l./8 P/B 1' }', V X
0 G/Y lfY R/8 /', I L 8M /Ix y ~ A
~

" 0 GM lJ/ RIB llM

Q Q

A. MTT9K/MTT9KC
B. MTT9GTK/MTT9GTKC
3-5 [For P0 108] Open circuit
Between intake air pressure sensor 1 coupler and ECU coupler: pin k-pink
If there is no continuity, replace the wire harness.
[Al [ID

VIAi R/L 1>--. A

~

G WW IGN/ Lr Y/R I R/LIGN X

-
Gy w w IGIWI LgA.
BI p L I\\'
BIR LIW X )< B Br/W l nAN
B
1
~ \ \ ' I V B/R LIW G/B G B B 81" ..
B/L 8/W WIG I> P/W p L p L L I)
L " " BIL 8/W W/L Y/B P/W
BILi BIL IBIY X Iv,LI WI\' •,v/G IGvJG VIG BIL I8/L IB/Y G/Y Y/L lwf/ ~1/G bvld
Y/G

Q Q

A. MTT9K/MTT9KC
B. MTT9GTK/MTT9GTKC

8-55
 FUEL INJECTION SYSTEM

Fault code No. P0107,P0108

[P0107] Intake air pressure sensor 1: ground short circuit detected.

Item (P0108] Intake air pressure sensor 1: open or power short circuit de-
tected.
3-6 [For P0108] Open circuit
Between intake air pressure sensor 1 coupler and ECU coupler: black/blue-black/blue
If there is no continuity, replace the wire harness.
IA] [ru
= =
Y/R R/L X IX Gy w w GNi! LgA. lvJR RILIGN IX Gy w I w IGMIILgA.
iffBI p L 111\ \, BIR LMI X IX B 8 Br/W LgNI @~@ \\,'" B/R LMI W/LG/B Y/BG 8
P/W p L L IXI
B Br"'A "
B/L 8/W WIG IX P/W p L L " " Bll. 8/W
Bit 8/L 8/Y IXI Y/L WN WIG Gy/GI VIG I8/L :J1L I BN GN Y/L lwNlw1Gbytdv1G

Q Q

A. MTT9K/MTT9KC
B. MTT9GTK/MTT9GTKC
3-7 Disconnect the couplers from the parts that are connected to the ECU.
Refer to "Parts connected to the ECU" on page 8-51.
3-8 [For P0107/P0108] Short circuit
Between intake air pressure sensor 1 output terminal (pink) "a" of ECU coupler and any other ECU
coupler terminal "b" .
If there is continuity, replace the wire harness.
IA] [ru
a a
,----------
'
. :. .- -----.J ---·'
,- ---------.:..:;- -----f ---.
:' Y/R R,I. IGIYI) VI VI 1/.lllilLaA :'
1
Y/RAA.I ~ X IGil YI I w /.GIIY lg>I. :
' . '
',\ \ \ \ \ \ \ \ \
I
ll/ll U\V )< X B B ~rJ// ~
&\.SN/WIG)( PHI p l l
Bit. &t l m1x 1v11.lwr wG & ~ '
:
:
\\ \\\\\\\\
BIR I.}// Goll G B B 'j(/\
811. B/W WA. YIB PNI p' L ~!
: 811. 811. IBIY IG/Y YA. ~vr '1/GhwGI Y/G :
b/ ··t·········· ........ b/··t··········· ........
1

' ' ' '

:......... Q :.........<m-
A. MTT9K/MTT9KC
B. MTT9GTK/MTT9GTKC
4 Installed condition of intake air Check for looseness or pinch- Turn the main switch to "ON",
pressure sensor 1. 1ng. and then check the condition of
Improperly installed sensor ➔ the fault code using the mal-
Reinstall or replace the sensor. function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 5.

8-56
 FUEL INJECTION SYSTEM

Fau lt code No. P0107, P0108

[P0107] Intake air pressure sensor 1: ground short circuit detected.

Item (P0108] Intake air pressure sensor 1: open or power short circuit de-
tected.
5 Defective intake air pressure
sensor 1.
6 Malfunction in ECU.
7 Delete the fault code and check
that the engine trouble warning
light goes off.
Execute the diagnostic mode. Crank the engine, and then
(Code No. 03) check the condition of the fault
When engine is stopped: code using the malfunction
Atmospheric pressure at the mode of the Yamaha diagnostic
current altitude and weather tool.
conditions is indicated. Condition is "Recover" ➔ Go to
At sea level: Approx. 101 kPa item 7 and finish the service.
(757.6 mmHg, 29.8 inHg) Condition is "Malfunction" ➔ Go
1000 m (3300 ft) above sea lev- to item 6.
el: Approx. 90 kPa (675.1
mmHg, 26.6 in Hg)
2000 m (6700 ft) above sea lev-
el: Approx. 80 kPa (600.0
mmHg, 23.6 in Hg)
3000 m (9800 ft) above sea lev-
el: Approx. 70 kPa (525.0
mmHg, 20.7 in Hg)
When engine is cranking: Make
sure that the indication value
changes.
The value does not change
when engine is cranking. ➔
Check the intake air pressure
sensor 1.
Refer to "CHECKING THE IN-
TAKE AIR PRESSURE SEN-
SOR" on page 8-201.
Replace if defective.
Replace the ECU. Service is finished.
Refer to "REPLACING TH E
ECU (Engine Control Unit)" on
page 8-189.
Confirm that the fault code has
a condition of "Recover" using
the Yamaha diagnostic tool, and
then delete the fault code.

Fault code No. P0112, P0113

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Perform this procedure when the engine is cold.

Fault code No. P011 2, P0113

[P0112] Intake air temperature sensor: ground short circuit detected.

Item (P0113] Intake air temperature sensor: open or power short circuit
detected.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 05
When engine is cold: Display temperature closer to air temperature.
Tool display
When engine is hot: Air temperature + approx. 20 °C (68 °F)

8-57
 FUEL INJECTION SYSTEM

Fault code No. P0112,P0113

(P0112] Intake air temperature sensor: ground short circuit detected.

Item [P0113] Intake air temperature sensor: open or power short circuit
detected.
Compare the actually measured air temperature with the tool display val-
Procedure
ue.
Probable cause of malfunc-
Item
tion and check
1 Connection of intake air tern-
perature 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).
2 Connection of ECU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
3 Wire harness continuity.
3-1
Maintenance job
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
Open or short circuit ➔ Replace
the wire harness.
2
sv
~ I-
Confirmation of service corn-
pletion
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 2.
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 3.
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 4.

1 •>
\ 3 •~
I "
\ ,fl Br/W Br/W -

B/l B/L
4 1

1. Intake air temperature sensor

2. ECU
3. Sensor output lead
4. Sensor ground lead
3-2 Disconnect the ECU coupler from the ECU.
Disconnect the intake air temperature sensor coupler from the intake air temperature sensor.

8-58
 FUEL INJECTION SYSTEM

Fault code No. P0112,P0113

(P0112] Intake air temperature sensor: ground short circuit detected.

Item [P0113] Intake air temperature sensor: open or power short circuit
detected.
3-3 [For P011 2] Ground short circuit
Between intake air temperature sensor coupler and ground: brown/white-ground
If there is continuity, replace the wire harness.

~ \ \\\\\\\\\\ %

--
--

3-4 [For P0113] Open circuit

Between intake air temperature sensor coupler and ECU coupler: brown/white-brown/white
If there is no continuity, replace the wire harness.
[Al [ID
~

=
Y/R R/LIX IX G wl w GN/ Le l Y/R RILIGNIX Gy wI w GIWI LgA.
BIR LMI X >< B 8 Br/W l.gNI ~ IVIB/R LMI G/8 G 8 B Br" ..
~
...,, •. \\\
8/L 8/W WIG >< P/W p L L ll<Ml !»' ', "" s1t. 8/W W/L Y/8 P/W p L I)
8/L BILI BIY IX lviLI WN lw1G GvlG Y/G 8/L 8/L IBNIGN Y/LlwNIW/G 3v/dYJG

,n1
-
Q

A. MTT9K/MTT9KC
B. MTT9GTK/MTT9GTKC
3-5 [For P011 3] Open circuit
Between intake air temperature sensor coupler and ECU coupler: black/blue-black/blue
If there is no continuity, replace the wire harness.
[Al [ID
~

Y/R R/LIA.IA G wl w GN/ Lr

-
Y/R R/LIGNI X Gy wI w GIWI LgA.
BIR LMI X )< B 8 Br/W l nAN ~ IVIB/R LMI G/8 G 8 B 81.."
ifu'M,.i ,.'!J )J \ \
~
" .,. \\\
8/L 8/W WIG I> P/W p L L
8/[ 8/LI 8/Y IX IY/LI WN IWIG IGv/G VIG
'
"" BIL 8/W W/L Y/8 P/W p L L I)
8/l i:lA. IBN IGN Y/LlwNlw1Gbv/dv1G

-@- -@-
A. MTT9K/MTT9KC
B. MTT9GTK/MTT9GTKC
3-6 Disconnect the couplers from the parts that are connected to the ECU.
Refer to "Parts connected to the ECU" on page 8-51 .

8-59
 FUEL INJECTION SYSTEM

Fault code No. P0112,P0113

(P0112] Intake air temperature sensor: ground short circuit detected.

Item [P0113] Intake air temperature sensor: open or power short circuit
detected.
3-7 [For P0112/P0113] Short circuit
Between intake air temperature sensor output terminal (brown/white) "a" of ECU coupler and any
other ECU coupler terminal "b".
If there is continuity, replace the wire harness.
[§]
a a
.- -------- -..:..,- ------ -/ -, :- - - - - - - - - -..:.=,- - - - --_-_i -:
: YIRI M I ~ IAIG• ' w I w I ~ ~ l /:
: v1R IR11. IG1YI IG lwI w ~ :
B B B<11/ \\ ' B.IR lNi Gill G B B li,/,VW/1\)1 :
811. B/W WI.. YIB PNI p T♦TI :
',\ .\ \ \ \ \ \ \ \ lllll UW - , :
'\ \ \ \ \ \ \ \

t_____________ ·-----
I &\.SN/WIG) PN/ p . l :
•• BA. I B/1. I B/Y IGIYI YI.. ~VIYIW/G w/GIY/G ••
b/ - -t-------------..... -
• lllll &t I l!/Y IX IY/1.IWIY IW/G G-·"llY/G •
•"""-'"-'-"-'-"-'J..!.'.!:J.::::.:..C:!!el""'"'-""'
u '
b/ • __ •

:_ ---------- Q :_ ----------- Q

A. MTT9K/MTT9KC
B. MTT9GTK/MTT9GTKC
4 Installed condition of intake air Check for looseness or pinch- Turn the main switch to "ON",
temperature sensor. 1ng. and then check the condition of
Improperly installed sensor ➔ the fault code using the mal-
Reinstall or replace the sensor. function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 5.
5 Defective intake air tempera- Execute the diagnostic mode. Turn the main switch to "ON",
ture sensor. (Code No. 05) and then check the condition of
When engine is cold: the fault code using the mal-
Displayed temperature is close function mode of the Yamaha di-
to the ambient temperature. agnostic tool.
The displayed temperature is Condition is "Recover" ➔ Go to
not close to the ambient tern- item 7 and finish the service.
perature. ➔ Check the intake air Condition is "Malfunction" ➔ Go
temperature sensor. to item 6.
Refer to "CHECKING THE IN-
TAKE AIR TEMPERATURE
SENSOR" on page 8-202.
Replace if defective.
6 Malfunction in ECU. Replace the ECU. Service is finished.
Refer to "REPLACING THE
ECU (Engine Control Unit)" on
page 8-189.
7 Delete the fault code and check Confirm that the fault code has
that the engine trouble warning a condition of "Recover" using
light goes off. the Yamaha diagnostic tool, and
then delete the fault code.

Fault code No. P0117, P0118

TIP--------------------------------
Perform this procedure when the engine is cold.

8-60
 FUEL INJECTION SYSTEM

Fault code No. P0117,P0118

(P0117] Coolant temperature sensor: ground short circuit detected.

Item [P0118] Coolant temperature sensor: open or power short circuit de-
tected.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 06
When engine is cold: Displays temperature closer to air temperature.
Tool display
When engine is hot: Displays current coolant temperature.
Compare the actually measured coolant temperature with the tool display
Procedure
value.
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Connection of coolant tempera- Improperly connected ➔ Con- Turn the main switch to "ON",
ture sensor coupler. nect the coupler securely or re- and then check the condition of
Check the locking condition of place the wire harness. the fault code using the mal-
the coupler. function mode of the Yamaha di-
Disconnect the coupler and agnostic tool.
check the pins (bent or broken Condition is "Recover" ➔ Go to
terminals and locking condition item 7 and finish the service.
of the pins). Condition is "Malfunction" ➔ Go
to item 2.
2 Connection of ECU coupler. Improperly connected ➔ Con- Turn the main switch to "ON",
Check the locking condition of nect the coupler securely or re- and then check the condition of
the coupler. place the wire harness. the fault code using the mal-
Disconnect the coupler and function mode of the Yamaha di-
check the pins (bent or broken agnostic tool.
terminals and locking condition Condition is "Recover" ➔ Go to
of the pins). item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 3.
3 Wire harness and/or sub-wire Open or short circuit ➔ Replace Turn the main switch to "ON",
harness continuity. the wire harness and/or sub- and then check the condition of
wire harness. the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 4.

8-61
 FUEL INJECTION SYSTEM

Fau lt code No. P0117, P0118

(P0117] Coolant temperature sensor: ground short circuit detected.

Item [P0118] Coolant temperature sensor: open or power short circuit de-
tected.
3-1
2
_,_
5V

1 5
,,,,,.,,, .....--.-.., 3 3
\'-11...:1....)V
lf J GIVV - - GM!/ - GNI --GNJ - + - - - -•-►

' - - - - I - 8/l - - 8/l - 8/l _._ B/L - ~

4 4 i
1. Coolant temperature sensor
2. ECU
3. Sensor output lead
4. Sensor ground lead
5. Sub-wire harness
3-2 Disconnect the ECU coupler from the ECU.
Disconnect the coolant temperature sensor coupler from the coolant temperature sensor.
3-3 (For P0117] Ground short circuit
Between wire harness coupler (ECU side) and ground: green/white-ground
Between sub-wire harness coupler (coolant temperature sensor side) and ground: green/white-
ground
If there is continuity, replace the wire harness and/or sub-wire harness.

[ID

@ sssssssssss%
Q Q
-- --

A. Wire harness coupler (ECU side)

B. Sub-wire harness coupler (coolant temperature sensor side)

8-62
 FUEL INJECTION SYSTEM

Fau lt code No. P0117, P0118

(P0117] Coolant temperature sensor: ground short circuit detected.

Item [P0118] Coolant temperature sensor: open or power short circuit de-
tected.
3-4 [For P0118] Open circuit
Between wire harness coupler (ECU side) and ECU coupler: green/white- green/white
Between sub-wire harness coupler (coolant temperature sensor side) and coolant temperature sen-
sor coupler: green/white- green/white
If there is no continuity, replace the wire harness and/or sub-wire harness.

Y/R RA. G/Y

~-----<Q - - - - ~

A. Wire harness coupler (ECU side) (MTT9K/MTT9KC)

B. Wire harness coupler (ECU side) (MTT9GTK/MTT9GTKC)
C. Sub-wire harness coupler (coolant temperature sensor side)
3-5 [For P0118] Open circuit
Between wire harness coupler (ECU side) and ECU coupler: black/blue- black/blue
Between sub-wire harness coupler (coolant temperature sensor side) and coolant temperature sen-
sor coupler: black/blue-black/blue
If there is no continuity, replace the wire harness and/or sub-wire harness.
[Al [ID [g

Y/R RA. G/Y

Bit 8/W W/G

Bit B/L B/Y

A. Wire harness coupler (ECU side) (MTT9K/MTT9KC)

B. Wire harness coupler (ECU side) (MTT9GTK/MTT9GTKC)
C. Sub-wire harness coupler (coolant temperature sensor side)
3-6 Disconnect the couplers from the parts that are connected to the ECU.
Refer to "Parts connected to the ECU" on page 8-51.

8-63
 FUEL INJECTION SYSTEM

Fau lt code No. P0117, P0118

(P0117] Coolant temperature sensor: ground short circuit detected.

Item [P0118] Coolant temperature sensor: open or power short circuit de-
tected.
3-7 [For P0117/P0118] Short circuit
Between wire harness (ECU side) output terminal (green/white) "a" of ECU coupler and any other
ECU coupler terminal "b".
Between sub-wire harness (coolant temperature sensor side) output terminal (green/white) "c" and
output terminal (black/blue) "d".
If there is continuity, replace the wire harness and/or sub-wire harness.
[ID [g]
a a
:· --------· . :.: -------l: :· ---------~------·i·:
RA. '"'"
• VIRI Gy•I IV I YI IG111lu,t ' : V/RIRIL IG/Y I >( G Iw I w IG/1'/IL :
' ' ,\ \ \ \ \ \ \ \ \ ' BIR 1/tV G/B G B B Br/:. ~·• ;
'\\ \ \ \ \ \ \ \ \ 8/RUII x 8 8 s,p-, •I.MY :
I BILBIWWJG><.PNIP t l: BA. B/W V//L YIB Pt.v P L l ,

b/ - ·t-----------------.
:1011.1 B11. I B1i , x v~lv/N IVI/G IG'/GI Y/G : : BILIMIBIY IG/Y
b/ -·t··------------ ----
'
Yll lwNlw/Gb !Glv/G :
'

,
' ,_ ------------ Q
·- ----------- Q

A. Wire harness coupler (ECU side) (MTT9K/MTT9KC)

B. Wire harness coupler (ECU side) (MTT9GTK/MTT9GTKC)
C. Sub-wire harness coupler (coolant temperature sensor side)
4 Installed condition of coolant Check for looseness or pinch- Turn the main switch to "ON",
temperature sensor. 1ng. and then check the condition of
Improperly installed sensor ➔ the fault code using the mal-
Reinstall or replace the sensor. function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 5.
5 Defective coolant temperature Execute the diagnostic mode. Turn the main switch to "ON",
sensor. (Code No. 06) and then check the condition of
When engine is cold: the fault code using the mal-
Displayed temperature is close function mode of the Yamaha di-
to the ambient temperature. agnostic tool.
The displayed temperature is Condition is "Recover" ➔ Go to
not close to the ambient tem- item 7 and finish the service.
perature ➔ Check the coolant Condition is "Malfunction" ➔ Go
temperature sensor. to item 6.
Refer to "CHECKING THE
COOLANT TEMPERATURE
SENSOR" on page 8-198.
Replace if defective.
6 Malfunction in ECU. Replace the ECU. Service is finished.
Refer to "REPLACING TH E
ECU (Engine Control Unit)" on
page 8-189.
7 Delete the fault code and check Confirm that the fault code has
that the engine trouble warning a condition of "Recover" using
light goes off. the Yamaha diagnostic tool, and
then delete the fault code.

8-64
 FUEL INJECTION SYSTEM

Fault code No. P0122, P0123, P0222, P0223, P2135

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
If a fault code other than No. P2135 (P0122/P0123/P0222/P0223) is detected, perform troubleshooting
first.

Fault code No. P0122,P0123,P0222, P0223,P2135

[P0122] Throttle position sensor: ground short circuit detected.

[P0123] Throttle position sensor: open or power short circuit detect-
ed.
Item [P0222] Throttle position sensor: ground short circuit detected.
[P0223] Throttle position sensor: open or power short circuit detect-
ed.
[P2135] Throttle position sensor: output voltage deviation error.
Able/Unable to start engine
Fail-safe system
Able/Unable to drive vehicle
Diagnostic code No. 01, 13
Throttle position sensor signal 1
Tool display • 11-21 (fully closed position)
01 • 96-106 (fully open position)
• Check with throttle valves fully closed.
Procedure
• Check with throttle valves fully open.
Throttle position sensor signal 2
Tool display • 9-23 (fully closed position)
13 • 94-108 (fully open position)
• Check with throttle valves fully closed.
Procedure
• Check with throttle valves fully open.
Probable cause of malfunc- Confirmation of service corn-
Item Maintenance job
tion and check pletion
1 Connection of throttle position Improperly connected ➔ Con- Turn the main switch to "ON",
sensor coupler. nect the coupler securely or re- and then check the condition of
Check the locking condition of place the wire harness. the fault code using the mal-
the coupler. function mode of the Yamaha di-
Disconnect the coupler and agnostic tool.
check the pins (bent or broken Condition is "Recover" ➔ Go to
terminals and locking condition item 8 and finish the service.
of the pins). Condition is "Malfunction" ➔ Go
to item 2.
2 Connection of ECU coupler. Improperly connected ➔ Con- Turn the main switch to "ON",
Check the locking condition of nect the coupler securely or re- and then check the condition of
the coupler. place the wire harness. the fault code using the mal-
Disconnect the coupler and function mode of the Yamaha di-
check the pins (bent or broken agnostic tool.
terminals and locking condition Condition is "Recover" ➔ Go to
of the pins). item 8 and finish the service.
Condition is "Malfunction" ➔ Go
to item 3.
3 Wire harness continuity. Open or short circuit ➔ Replace Turn the main switch to "ON",
the wire harness. and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 8 and finish the service.
Condition is "Malfunction" ➔ Go
to item 4.

8-65
 FUEL INJECTION SYSTEM

Fault code No. P01 22,P0123, P0222, P0223,P2135

(P0122] Throttle position sensor: ground short circuit detected.

[P0123] Throttle position sensor: open or power short circuit detect-
ed.
Item [P0222] Throttle position sensor: ground short circuit detected.
[P0223] Throttle position sensor: open or power short circuit detect-
ed.
[P2135] Throttle position sensor: output voltage deviation error.
3-1

2
1
l
3 l
sv
~ ~-
SV

- -• .>
.>

•
• ; w 4 w "'l -
AAA
V VY -
•
~
- SV
~

-
--
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•
;:.
A A A
~ • -- B B V VV

-- Bit. 6 B/l
1-

1. Throttle position sensor

2. ECU
3. Sensor input lead
4. Sensor output lead 1
5. Sensor output lead 2
6. Sensor ground lead
3-2 Disconnect the ECU coupler from the ECU.
Disconnect the throttle position sensor coupler from the throttle position sensor.
3-3 [ For P0122] Ground short circuit
[ For P2135] Deviation error
Between throttle position sensor coupler and ground: white-ground
If there is continuity, replace the wire harness.

IC -11
@w IL IB ~1 , , , , , , , , , , , "
~ '

,Q

--

8-66
 FUEL INJECTION SYSTEM

Fault code No. P0122,P0123, P0222, P0223,P2135

(P0122] Throttle position sensor: ground short circuit detected.

[P0123] Throttle position sensor: open or power short circuit detect-
ed.
Item [P0222] Throttle position sensor: ground short circuit detected.
[P0223] Throttle position sensor: open or power short circuit detect-
ed.
[P2135] Throttle position sensor: output voltage deviation error.
3-4 [For P0123] Open circuit
[For P2135] Deviation error
Between throttle position sensor coupler and ECU coupler: white-white
If there is no continuity, replace the wire harness.

IA] [ID
= =
YIRI R/L I X IX Gy w w I GNII LgA. YIRIRILIGNIX Gy w w IGMII LgA.
BIR LMI X >< 8 or/'N l.gNI
B
1\/1
LMI G/8 G 8 B ~1..A "
~ LI B~I \\\
BIL 8/W WIG >< P/W p L L Mw4@1\\' u " ~:
8/W W/L Y/8 P/W p L L IXI
BILi 8.IL I 8/Y IXIY/L WN V1G IGylGI Y/G 8/L I B/1. I BN IGN Y/L lwN \I\ 'G by/d Y/G

Q Q

A. MTT9K/MTT9KC
B. MTT9GTK/MTT9GTKC
3-5 [For P0222] Ground short circuit
[For P2135] Deviation error
Between throttle position sensor coupler and ground: black-ground
If there is continuity, replace the wire harness.

"
~B/LIWILI 8.,JJ1\ \ \ \ \ \ \ \ \ \ \ \~
~

--
--

3-6 [For P0223] Open circuit

[For P2135] Deviation error
Between throttle position sensor coupler and ECU coupler: black-black
If there is no continuity, replace the wire harness.

[Al [ID
~

YIRI R/L 1>-..1,,< G w w IGNII L, YIRIRILIGNIX Gy

- w wIGJWILgA.
~W!:_IaJjl\ \' BIR LMI X )< 8 Br/'N l nJW
BIL 8/W WIG I> P/W '1' L
B
L
@Eil! B]jl\ \ ' ,v1 8/R LMI G/8 G 8
u " 8/l 8/W W/L Y/8 P/W
B BrM
I L L I)
BILi 8/L I 8/Y IX IY/L WN WIG IGvJGI Y/G 8/L I B/1. I 8N IGN Y/L lwN W/Gby~Y/G

Q Q

A. MTT9K/MTT9KC
B. MTT9GTK/MTT9GTKC

8-67
 FUEL INJECTION SYSTEM

Fault code No. P01 22,P0123, P0222, P0223, P2135

(P0122] Throttle position sensor: ground short circuit detected.

[P0123] Throttle position sensor: open or power short circuit detect-
ed.
Item [P0222] Throttle position sensor: ground short circuit detected.
[P0223] Throttle position sensor: open or power short circuit detect-
ed.
[P2135] Throttle position sensor: output voltage deviation error.
3-7 [For P0123/P0223] Open circuit
[For P2135] Deviation error
Between throttle position sensor coupler and ECU coupler: blue-blue
If there is no continuity, replace the wire harness.
IA] [ID
= =
YIRI RILIX IX Gy wI w IGNI LgA. IYIR IRILi GN IX Gy wI w IG/W LgA.
BIR LMI X >< B 8 Br/W l.gNI LMI G/8 G 8 B B 1" A "
1\/1

[ll!JW~I\ \' BIL 8/W WIG >< P/W p L L @Ell® I\ \' u " ~: 8/W W/L Y/8 P/W p L L IXI
BILi B.IL I BIY IX lv1L WN lw1G IGyJG OG IBJLIB/1. IBNIGN Y/LlwNIW/GbyM ~/JG

,Q ,Q

A. MTT9K/MTT9KC
B. MTT9GTK/MTT9GTKC
3-8 [For P0123/P0223] Open circuit
[For P2 135] Deviation error
Between throttle position sensor coupler and ECU coupler: black/blue- black/blue
If there is no continuity, replace the wire harness.
IA] [ID
~
=
YIRI RILIX IX G wl w IGNI Le t IYIR IRILi GN IX Gy wI w IG/W LgA.
BIR LMI X 'x B 8 Br/W l.gNI - ,v B
1
/R LMI G/8 G 8 B Br"
r~~Lls~, ,,, BIL 8/W WIG )< P/W p L L [ ~I\\' u " B/l. 8/W W/L Y/8 P/W p L L I)
BILi 8.IL I 8/Y IX IY/L WN IWIG IGvlG Y/G IBJLIBILI BNIGN Y/LlwNlw1Gby~Y/G

,Q ,Q

A. MTT9K/MTT9KC
B. MTT9GTK/MTT9GTKC
3-9 Disconnect the couplers from the parts that are connected to the ECU.
Refer to "Parts connected to the ECU" on page 8-51.

8-68
 FUEL INJECTION SYSTEM

Fault code No. P01 22,P0123, P0222, P0223, P2135

(P0122] Throttle position sensor: ground short circuit detected.

[P0123] Throttle position sensor: open or power short circuit detect-
ed.
Item [P0222] Throttle position sensor: ground short circuit detected.
[P0223] Throttle position sensor: open or power short circuit detect-
ed.
[P2135] Throttle position sensor: output voltage deviation error.
3-10 [For P0122/P0123] Short circuit
[For P2135] Deviation error
Between throttle position sensor output terminal (white) "a" of ECU coupler and any other ECU cou-
pler terminal "b".
If there is continuity, replace the wire harness.
[ru
a a
:· -------------- --/;._ - -- '" :
: Y/R RA. GN VI VI Gm :
1
B,IRI..M'G/9GBB .~ :

b/ t____________ ·------
__
,
·- ---------

A. MTT9K/MTT9KC
B. MTT9GTK/MTT9GTKC
3-11 [For P0222/P0223] Short circuit
[For P2135] Deviation error
Between throttle position sensor output terminal (black) "a" of ECU coupler and any other ECU cou-
pler terminal "b".
If there is continuity, replace the wire harness.
[Al [ru
a
: ~~·~ ~ ... ~.·v; .,"( ~ .. ·:
' Vi_ '
I B,IRUW~ G B B :
&\.SN I l : ''

·t·................. . ''
1
'' 811. 811.
·= = '-"'-"'= \WYW}G
' M.Me/Y
:.:.1.::::= '
b/ ··t·········· ....... . B/Y G/Y Y/1.
I

b/ .
' '

·-' ------- .. '

,_ ...... -----

A. MTT9K/MTT9KC
B. MTT9GTK/MTT9GTKC
4 Installed condition of throttle po- Check for looseness or pinch- Turn the main switch to "ON",
sition sensor. ing . and then check the condition of
Improperly installed se nso r ➔ the fault code using the mal-
Reinstall or adjust the sensor. function mode of the Yamaha di-
Refer to "ADJUSTING THE agnostic tool.
TH ROTTLE POSITION SEN- Condition is "Recover" ➔ Go to
SOR" on page 7-1 8. item 8 and finish the service.
Condition is "Malfunction" ➔ Go
to item 5.

8-69
 FUEL INJECTION SYSTEM

Fault code No. P0122,P0123, P0222,P0223,P2135

(P0122] Throttle position sensor: ground short circuit detected.

[P0123] Throttle position sensor: open or power short circuit detect-
ed.
Item [P0222] Throttle position sensor: ground short circuit detected.
[P0223] Throttle position sensor: open or power short circuit detect-
ed.
[P2135] Throttle position sensor: output voltage deviation error.
5 Throttle position sensor resis- Measure the throttle position Turn the main switch to "ON",
tance. sensor resistance. and then check the condition of
black/blue-blue the fault code using the mal-
Refer to "CHECKING THE function mode of the Yamaha di-
THROTTLE POSITION SEN- agnostic tool.
SOR" on page 8-199. Condition is "Recover" ➔ Go to
item 8 and finish the service.
Condition is "Malfunction" ➔ Go
to item 6.
6 Defective throttle position sen- Check throttle position sensor Turn the main switch to "ON",
sor. signal 1. and then check the condition of
Execute the diagnostic mode. the fault code using the mal-
(Code No. 01) function mode of the Yamaha di-
When the throttle valves are ful- agnostic tool.
ly closed: Condition is "Recover" ➔ Go to
A value of 11-21 is indicated. item 8 and finish the service.
When throttle valves are fully Condition is "Malfunction" ➔ Go
open: to item 7.
A value of 96-106 is indicated.
Check throttle position sensor
signal 2.
Execute the diagnostic mode.
(Code No. 13)
When the throttle valves are ful-
ly closed:
A value of 9-23 is indicated.
When the throttle valves are ful-
ly open:
A value of 94-108 is indicated.
An indicated value is out of the
specified range ➔ Replace the
throttle position sensor.
7 Malfunction in ECU. Replace the ECU. Service is finished.
Refer to "REPLACING THE
ECU (Engine Control Unit)" on
page 8-189.
8 Delete the fault code and check Confirm that the fault code has
that the engine trouble warning a condition of "Recover" using
light goes off. the Yamaha diagnostic tool, and
then delete the fault code.

Fault code No. P0132

Fault code No. P0132

Item 0 2 sensor: short circuit detected (power short circuit).

Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. -

8-70

Fault code No. P0132
Item 0 2 sensor: short circuit detected (power short circuit).
Tool display -
Procedure -
Probable cause of malfunc-
Item
tion and check
1 Installed condition of 0 2 sensor.
2 Connection of 0 2 sensor cou-
pier.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
3 Connection of wire harness
ECU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
4 Wire harness continuity.
5 Defective 0 2 sensor.
6 Malfunction in ECU.
FUEL INJECTION SYSTEM
Maintenance job
Check for looseness or pinch-
1ng.
Improperly installed sensor ➔
Reinstall or replace the sensor.
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
Open or short circuit ➔ Properly
connect or replace the wire har-
ness.
Between 0 2 sensor coupler and
ECU.
black/blue-black/blue
gray/green-gray/green
Check the 0 2 sensor.
Defective ➔ Replace the 0 2
sensor.
Refer to "ENGINE REMOVAL:'
on page 5-9.
Replace the ECU.
Refer to "REPLACING THE
ECU (Engine Control Unit)" on
page 8-189.
8-71
Confirmation of service corn-
pletion
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 2.
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 3.
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 4.
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 5.
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 6.
 FUEL INJECTION SYSTEM

Fault code No. P0132

Item 0 2 sensor: short circuit detected (power short circuit).

7 Delete the fault code and check Confirm that the fault code has
that the engine trouble warning a condition of "Recover" using
light goes off. the Yamaha diagnostic tool, and
then delete the fault code.

Fault code No. P0201

Fault code No. P0201

Item Fuel injector #1: malfunction in fuel injector #1.

Fail-safe system
Diagnostic code No.
Actuation
Procedure
Probable cause of malfunc-
Item
tion and check
1 Connection of fuel injector #1
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).
2 Defective fuel injector # 1.
3 Connection of ECU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
4 Wire harness continuity.
Able to start engine (depending on the number of faulty cylinders)
Able to drive vehicle (depending on the number of faulty cylinders)
36
Actuates fuel injector #1 five times at one-second intervals.
The check indicator on the Yamaha diagnostic tool screen comes on
each time the fuel injector is actuated.
Disconnect the fuel pump coupler. Check that fuel injector #1 is actuated
five times by listening for the operating sound.
Confirmation of service corn-
Maintenance job
pletion
Improperly connected ➔ Con- Execute the diagnostic mode.
nect the coupler securely or re- (Code No. 36)
place the wire harness. Operating sound ➔ Go to item
6.
No operating sound ➔ Go to
item 2.
Measure the fuel injector resis- Execute the diagnostic mode.
tance. (Code No. 36)
Refer to "CHECKING THE Operating sound ➔ Go to item
FUEL INJECTORS" on page 6.
8-203. No operating sound ➔ Go to
Replace if out of specification. item 3.
Improperly connected ➔ Con- Execute the diagnostic mode.
nect the coupler securely or re- (Code No. 36)
place the wire harness. Operating sound ➔ Go to item
6.
No operating sound ➔ Go to
item 4.
Open or short circuit ➔ Connect Execute the diagnostic mode.
the coupler securely or replace (Code No. 36)
the wire harness. Operating sound ➔ Go to item
Between fuel injector coupler 6.
and ECU coupler. No operating sound ➔ Go to
red/black-red/black item 5.
Between fuel injector coupler
and relay unit coupler.
red/blue-red/blue

8-72
 FUEL INJECTION SYSTEM

Fault code No. P0201

Item Fuel injector #1: malfunction in fuel injector #1.

5 Malfunction in ECU.
6 Delete the fault code and check
that the engine trouble warning
light goes off.
Replace the ECU.
Refer to "REPLACING THE
ECU (Engine Control Unit)" on
page 8-189.
Start the engine and let it idle for
approximately 5 seconds.
Confirm that the fault code has
a condition of "Recover" using
the malfunction mode of the
Yamaha diagnostic tool, and
then delete the fault code.

Fault code No. P0202

Fault code No. P0202

Item Fuel injector #2: malfunction in fuel injector #2.

Able to start engine (depending on the number of faulty cylinders)
Fail-safe system
Able to drive vehicle (depending on the number of faulty cylinders)
Diagnostic code No. 37
Actuates fuel injector #2 five times at one-second intervals.
Actuation The check indicator on the Yamaha diagnostic tool screen comes on
each time the fuel injector is actuated.
Disconnect the fuel pump coupler. Check that fuel injector #2 is actuated
Procedure
five times by listening for the operating sound.
Probable cause of malfunc- Confirmation of service corn-
Item Maintenance job
tion and check pletion
1 Connection of fuel injector #2 Improperly connected ➔ Con- Execute the diagnostic mode.
coupler. nect the coupler securely or re- (Code No. 37)
Check the locking condition of place the wire harness. Operating sound ➔ Go to item
the coupler. 7.
Disconnect the coupler and No operating sound ➔ Go to
check the pins (bent or broken item 2.
terminals and locking condition
of the pins).
2 Defective fuel injector #2. Measure the fuel injector resis- Execute the diagnostic mode.
tance. (Code No. 37)
Refer to "CHECKING THE Operating sound ➔ Go to item
FUEL INJECTORS" on page 7.
8-203. No operating sound ➔ Go to
Replace if out of specification. item 3.
3 Connection of ECU coupler. Improperly connected ➔ Con- Execute the diagnostic mode.
Check the locking condition of nect the coupler securely or re- (Code No. 37)
the coupler. place the wire harness. Operating sound ➔ Go to item
Disconnect the coupler and 7.
check the pins (bent or broken No operating sound ➔ Go to
terminals and locking condition item 4.
of the pins).

8-73
 FUEL INJECTION SYSTEM

Fault code No. P0202

Item Fuel injector #2: malfunction in fuel injector #2.

4 Connection of sub-wire har-
ness 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).
5 Wire harness continuity.
6 Malfunction in ECU.
7 Delete the fault code and check
that the engine trouble warning
light goes off.
Improperly connected ➔ Con- Execute the diagnostic mode.
nect the coupler securely or re- (Code No. 37)
place the sub-wire harness. Operating sound ➔ Go to item
7.
No operating sound ➔ Go to
item 5.
Open or short circuit ➔ Connect Execute the diagnostic mode.
the coupler securely or replace (Code No. 37)
the wire harness. Operating sound ➔ Go to item
Between fuel injector coupler 7.
and sub-wire harness coupler. No operating sound ➔ Go to
green/black-green/black item 6.
red/blue-red/blue
Between sub-wire harness cou-
pier and ECU coupler.
green/black-green/black
Between sub-wire harness cou-
pier and relay unit coupler.
red/blue-red/blue
Replace the ECU.
Refer to "REPLACING THE
ECU (Engine Control Unit)" on
page 8-189.
Start the engine and let it idle for
approximately 5 seconds.
Confirm that the fault code has
a condition of "Recover" using
the malfunction mode of the
Yamaha diagnostic tool, and
then delete the fault code.

Fault code No. P0203

Fault code No. P0203

Item Fuel injector #3: malfunction in fuel injector #3.

Able to start engine (depending on the number of faulty cylinders)
Fail-safe system
Able to drive vehicle (depending on the number of faulty cylinders)
Diagnostic code No. 38
Actuates fuel injector #3 five times at one-second intervals.
Actuation The check indicator on the Yamaha diagnostic tool screen comes on
each time the fuel injector is actuated.
Disconnect the fuel pump coupler. Check that fuel injector #3 is actuated
Procedure
five times by listening for the operating sound.
Probable cause of malfunc- Confirmation of service corn-
Item Maintenance job
tion and check pletion

8-74
 FUEL INJECTION SYSTEM

Fault code No. P0203

Item Fuel injector #3: malfunction in fuel injector #3.

1 Connection of fuel injector #3
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).
2 Defective fuel injector #3.
3 Connection of ECU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
4 Wire harness continuity.
5 Malfunction in ECU.
6 Delete the fault code and check
that the engine trouble warning
light goes off.
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
Measure the fuel injector resis-
tance.
Replace if out of specification.
Refer to "CHECKING THE
FUEL INJECTORS" on page
8-203.
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
Open or short circuit ➔ Replace
the wire harness.
Between fuel injector coupler
and ECU coupler.
blue/black-blue/black
Between fuel injector coupler
and relay unit coupler.
red/blue-red/blue
Replace the ECU.
Refer to "REPLACING THE
ECU (Engine Control Unit)" on
page 8-189.
Start the engine and let it idle for
approximately 5 seconds.
Confirm that the fault code has
a condition of "Recover" using
the malfunction mode of the
Yamaha diagnostic tool, and
then delete the fault code.
Execute the diagnostic mode.
(Code No. 38)
Operating sound ➔ Go to item
6.
No operating sound ➔ Go to
item 2.
Execute the diagnostic mode.
(Code No. 38)
Operating sound ➔ Go to item
6.
No operating sound ➔ Go to
item 3.
Execute the diagnostic mode.
(Code No. 38)
Operating sound ➔ Go to item
6.
No operating sound ➔ Go to
item 4.
Execute the diagnostic mode.
(Code No. 38)
Operating sound ➔ Go to item
6.
No operating sound ➔ Go to
item 5.

Fault code No. P0335

Fault code No. P0335

Crankshaft position sensor: no normal signals are received from the

Item
crankshaft position sensor.
Unable to start engine
Fail-safe system
Unable to drive vehicle
Diagnostic code No. -
Tool display -
Procedure -

8-75

Fault code No. P0335
Crankshaft position sensor: no normal signals are received from the
Item
crankshaft position sensor.
Probable cause of malfunc-
Item
tion and check
1 Connection of crankshaft posi-
tion 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).
2 Connection of ECU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
3 Wire harness continuity.
4 Installed condition of crankshaft
position sensor.
Check for looseness or pinch-
ing.
5 Defective crankshaft position
sensor.
6 Malfunction in ECU.
FUEL INJECTION SYSTEM
Maintenance job
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
Open or short circuit ➔ Replace
the wire harness.
Between crankshaft position
sensor coupler and ECU cou-
pler.
gray-gray
black/blue-black/blue
Improperly installed sensor ➔
Reinstall or replace the sensor.
Refer to "GENERATOR AND
STARTER CLUTCH" on page
5-38.
Check the crankshaft position
sensor.
Refer to "CHECKING THE
CRANKSHAFT POSITION
SENSOR" on page 8-194.
Replace if defective.
Replace the ECU.
Refer to "REPLACING THE
ECU (Engine Control Unit)" on
page 8-189.
8-76
Confirmation of service com-
pletion
Crank the engine, and then
check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 2.
Crank the engine, and then
check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 3.
Crank the engine, and then
check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 4.
Crank the engine, and then
check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 5.
Crank the engine, and then
check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 6.
Service is finished.
 FUEL INJECTION SYSTEM

Fault code No. P0335

Crankshaft position sensor: no normal signals are received from the

Item
crankshaft position sensor.
7 Delete the fault code and check Confirm that the fault code has
that the engine trouble warning a condition of "Recover" using
light goes off. the Yamaha diagnostic tool, and
then delete the fault code.

Fault code No. P0351

Fault code No. P0351

Cylinder-#1 ignition coil: open or short circuit detected in the prima-

Item
ry lead of the cylinder-#1 ignition coil.
Able to start engine (depending on the number of faulty cylinders)
Fail-safe system
Able to drive vehicle (depending on the number of faulty cylinders)
Diagnostic code No. 30
Actuates the cylinder-# 1 ignition coil five times at one-second intervals.
Actuation The check indicator on the Yamaha diagnostic tool screen comes on
each time the ignition coil is actuated.
Check that a spark is generated five times.
Procedure
• Connect an ignition checker.
Probable cause of malfunc- Confirmation of service corn-
Item Maintenance job
tion and check pletion
1 Connection of cylinder-#1 igni- Improperly connected ➔ Con- Start the engine and let it idle for
tion coil coupler. nect the coupler securely or re- approximately 5 seconds.
Check the locking condition of place the wire harness. Check the condition of the fault
the coupler. code using the malfunction
Disconnect the coupler and mode of the Yamaha diagnostic
check the pins (bent or broken tool.
terminals and locking condition Condition is "Recover" ➔ Go to
of the pins). item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 2.
2 Connection of ECU coupler. Improperly connected ➔ Con- Start the engine and let it idle for
Check the locking condition of nect the coupler securely or re- approximately 5 seconds.
the coupler. place the wire harness. Check the condition of the fault
Disconnect the coupler and code using the malfunction
check the pins (bent or broken mode of the Yamaha diagnostic
terminals and locking condition tool.
of the pins). Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 3.
3 Wire harness continuity. Open or short circuit ➔ Replace Start the engine and let it idle for
the wire harness. approximately 5 seconds.
Between cylinder-# 1 ignition coil Check the condition of the fault
coupler and ECU coupler. code using the malfunction
orange-orange mode of the Yamaha diagnostic
Between cylinder-# 1 ignition coil tool.
coupler and handlebar switch Condition is "Recover" ➔ Go to
coupler (right). item 7 and finish the service.
red/black-red/black Condition is "Malfunction" ➔ Go
to item 4.

8-77
 FUEL INJECTION SYSTEM

Fault code No. P0351

Cylinder-#1 ignition coil: open or short circuit detected in the prima-

Item
ry lead of the cylinder-#1 ignition coil.
4 Installed condition of cylinder-#1
ignition coil.
5 Defective cylinder-#1 ignition
coil.
6 Malfunction in ECU.
7 Delete the fault code and check
that the engine trouble warning
light goes off.
Check for looseness or pinch-
1ng.
Improperly installed ignition coil
➔ Reinstall or replace the igni-
tion coil.
Measure the primary coil resis-
tance of the cylinder- #1 ignition
coil.
Refer to "CHECKING THE IG-
NITION COILS" on page 8-193.
Replace if out of specification.
Execute the diagnostic mode.
(Code No. 30)
No spark ➔ Replace the ECU.
Refer to "REPLACING THE
ECU (Engine Control Unit)" on
page 8-189.
Confirm that the fault code has
a condition of "Recover" using
the Yamaha diagnostic tool, and
then delete the fault code.
Start the engine and let it idle for
approximately 5 seconds.
Check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 5.
Start the engine and let it idle for
approximately 5 seconds.
Check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 6.
Service is finished.

Fault code No. P0352

Fault code No. P0352

Cylinder-#2 ignition coil: open or short circuit detected in the prima-

Item
ry lead of the cylinder-#2 ignition coil.
Able to start engine (depending on the number of faulty cylinders)
Fail-safe system
Able to drive vehicle (depending on the number of faulty cylinders)
Diagnostic code No. 31
Actuates the cylinder-#2 ignition coil five times at one-second intervals.
Actuation The check indicator on the Yamaha diagnostic tool screen comes on
each time the ignition coil is actuated.
Check that a spark is generated five times.
Procedure
• Connect an ignition checker.
Probable cause of malfunc- Confirmation of service corn-
Item Maintenance job
tion and check pletion

8-78

Fau lt code No. P0352
Cylinder-#2 ignition coil: open or short circuit detected in the prima-
Item
ry lead of the cylinder-#2 ignition coil.
1 Connection of cylinder-#2 igni-
tion coil coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
2 Connection of ECU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
3 Wire harness continuity.
4 Installed condition of cylinder-#2
ignition coil.
5 Defective cylinder-#2 ignition
coil.
FUEL INJECTION SYSTEM
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
Open or short circuit ➔ Replace
the wire harness.
Between cylinder-#2 ignition coil
coupler and ECU coupler.
gray/red- gray/red
Between cylinder-#2 ignition coil
coupler and handlebar switch
coupler (right).
red/black- red/black
Check for looseness or pinch-
ing.
Improperly installed ignition coil
➔ Reinstall or replace the igni-
tion coil.
Measure the primary coil resis-
tance of the cylinder- #2 ignition
coil.
Refer to "CHECKING THE IG-
NITION COILS" on page 8-193.
Replace if out of specification.
8-79
Start the engine and let it idle for
approximately 5 seconds.
Check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 2.
Start the engine and let it idle for
approximately 5 seconds.
Check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 3.
Start the engine and let it idle for
approximately 5 seconds.
Check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 4.
Start the engine and let it idle for
approximately 5 seconds.
Check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 5.
Start the engine and let it idle for
approximately 5 seconds.
Check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 6.
 FUEL INJECTION SYSTEM

Fault code No. P0352

Cylinder-#2 ignition coil: open or short circuit detected in the prima-

Item
ry lead of the cylinder-#2 ignition coil.
6 Malfunction in ECU.
7 Delete the fault code and check
that the engine trouble warning
light goes off.
Execute the diagnostic mode. Service is finished.
(Code No. 31)
No spark ➔ Replace the ECU.
Refer to "REPLACING THE
ECU (Engine Control Unit)" on
page 8-189.
Confirm that the fault code has
a condition of "Recover" using
the Yamaha diagnostic tool, and
then delete the fault code.

Fault code No. P0353

Fault code No. P0353

Cylinder-#3 ignition coil: open or short circuit detected in the prima-

Item
ry lead of the cylinder-#3 ignition coil.
Able to start engine (depending on the number of faulty cylinders)
Fail-safe system
Able to drive vehicle (depending on the number of faulty cylinders)
Diagnostic code No. 32
Actuates the cylinder-#3 ignition coil five times at one-second intervals.
Actuation The check indicator on the Yamaha diagnostic tool screen comes on
each time the ignition coil is actuated.
Check that a spark is generated five times.
Procedure
• Connect an ignition checker.
Probable cause of malfunc- Confirmation of service corn-
Item Maintenance job
tion and check pletion
1 Connection of cylinder-#3 igni- Improperly connected ➔ Con- Start the engine and let it idle for
tion coil coupler. nect the coupler securely or re- approximately 5 seconds.
Check the locking condition of place the wire harness. Check the condition of the fault
the coupler. code using the malfunction
Disconnect the coupler and mode of the Yamaha diagnostic
check the pins (bent or broken tool.
terminals and locking condition Condition is "Recover" ➔ Go to
of the pins). item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 2.
2 Connection of ECU coupler. Improperly connected ➔ Con- Start the engine and let it idle for
Check the locking condition of nect the coupler securely or re- approximately 5 seconds.
the coupler. place the wire harness. Check the condition of the fault
Disconnect the coupler and code using the malfunction
check the pins (bent or broken mode of the Yamaha diagnostic
terminals and locking condition tool.
of the pins). Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 3.

8-80

Fault code No. P0353
Cylinder-#3 ignition coil: open or short circuit detected in the prima-
Item
ry lead of the cylinder-#3 ignition coil.
3 Wire harness continuity.
4 Installed condition of cylinder-#3
ignition coil.
5 Defective cylinder-#3 ignition
coil.
6 Malfunction in ECU.
7 Delete the fault code and check
that the engine trouble warning
light goes off.
Fault code No. POSOO, P1500
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
In case "POSOO" is detected , or both "POSOO" and "P1500" are detected, proceed from item A-1 .
FUEL INJECTION SYSTEM
Open or short circuit ➔ Replace
the wire harness.
Between cylinder-#3 ignition coil
coupler and ECU coupler.
orange/green-orange/green
Between cylinder-#3 ignition coil
coupler and handlebar switch
coupler (right).
red/black-red/black
Check for looseness or pinch-
ing.
Improperly installed ignition coil
➔ Reinstall or replace the igni-
tion coil.
Measure the primary coil resis-
tance of the cylinder-#3 ignition
coil.
Refer to "CHECKING THE IG-
NITION COILS" on page 8-193.
Replace if out of specification.
Execute the diagnostic mode.
(Code No. 32)
No spark ➔ Replace the ECU.
Refer to "REPLACING THE
ECU (Engine Control Unit)" on
page 8-189.
Confirm that the fault code has
a condition of "Recover" using
the Yamaha diagnostic tool, and
then delete the fault code.
8-81
Start the engine and let it idle for
approximately 5 seconds.
Check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 4.
Start the engine and let it idle for
approximately 5 seconds.
Check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 5.
Start the engine and let it idle for
approximately 5 seconds.
Check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 6.
Service is finished.
 FUEL INJECTION SYSTEM

Fault code No. P0500,P1500

Rear wheel sensor: no normal signals are received from the

A
rear wheel sensor.
Item
B Gear position switch: open or short circuit is detected.

C Clutch switch: open or short circuit is detected.

Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 07
Rear wheel speed pulse
Tool display
0-999
Check that the number increases when the rear wheel is rotated. The
Procedure
number is cumulative and does not reset each time the wheel is stopped.
Probable cause of malfunc- Confirmation of service corn-
Item Maintenance job
tion and check pletion
A-1 Locate the malfunction. (Fault code No. P0500 or P0500 Value does not increase ➔ Go
and P1500 detected.) to item A-2.
Execute the diagnostic mode.
(Code No. 07)
Rotate the rear wheel by hand
and check that the indicated val-
ue increases.
(Fault code No. P1500 detect- Incorrect indication ➔ Go to
ed.) item B-2 for the gear position
Execute the diagnostic mode. switch.
(Code No. 21)
When the transmission is in
neutral: "ON"
When the transmission is in
gear with the clutch lever re-
leased: "OFF"
When the transmission is in Incorrect indication ➔ Go to
gear with the clutch lever item C-2 for the clutch switch.
squeezed and the sidestand re-
tracted: "ON"
A-2 Connection of rear wheel sen- Improperly connected ➔ Con- Execute the diagnostic mode.
sor coupler. nect the coupler securely or re- (Code No. 07)
Check the locking condition of place the wire harness. Rotate the rear wheel by hand
the coupler. and check that the indicated val-
Disconnect the coupler and ue increases.
check the pins (bent or broken Value increases ➔ Go to item
terminals and locking condition A-8.
of the pins). Value does not increase ➔ Go
to item A-3.
A-3 Connection of ABS ECU cou- Improperly connected ➔ Con- Execute the diagnostic mode.
pier. nect the coupler securely or re- (Code No. 07)
Check the locking condition of place the wire harness. Rotate the rear wheel by hand
the coupler. and check that the indicated val-
Disconnect the coupler and ue increases.
check the pins (bent or broken Value increases ➔ Go to item
terminals and locking condition A-8.
of the pins). Value does not increase ➔ Go
to item A-4.

8-82
 FUEL INJECTION SYSTEM

Fault code No. P0500,P1500

Rear wheel sensor: no normal signals are received from the
A
rear wheel sensor.
Item
B Gear position switch: open or short circuit is detected.

C Clutch switch: open or short circuit is detected.

A-4 Connection of ECU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
A-5 Rear wheel sensor lead continu- Open or short circuit, or defec-
ity, or defective rear wheel sen- tive sensor ➔ Replace the rear
sor.
A-6 Malfunction in ECU.
A-7 Malfunction in ABS ECU.
A-8 Delete the fault code and check
that the engine trouble warning
light goes off.
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
wheel sensor.
Between rear wheel sensor cou-
pier and ABS ECU coupler.
black-black
white-white
Between ABS ECU coupler and
ECU coupler.
white/yellow-white/yellow
Replace the ECU.
Refer to "REPLACING THE
ECU (Engine Control Unit)" on
page 8-189.
Replace the ABS ECU.
Turn the main switch to "ON",
and then rotate the rear wheel
by hand.
Start the engine, and input the
vehicle speed signals by operat-
ing the vehicle at 20 to 30 km/h
(12 to 19 mph).
Confirm that the fault code has
a condition of "Recover" using
the malfunction mode of the
Yamaha diagnostic tool, and
then delete the fault code.
Delete this fault code even if it
has a condition of "Malfunction".
Execute the diagnostic mode.
(Code No. 07)
Rotate the rear wheel by hand
and check that the indicated val-
ue increases.
Value increases ➔ Go to item
A-8.
Value does not increase ➔ Go
to item A-5.
Execute the diagnostic mode.
(Code No. 07)
Rotate the rear wheel by hand
and check that the indicated val-
ue increases.
Value increases ➔ Go to item
A-8.
Value does not increase ➔ Go
to item A-6.
Execute the diagnostic mode.
(Code No. 07)
Rotate the rear wheel by hand
and check that the indicated val-
ue increases.
Value increases ➔ Go to item
A-8.
Value does not increase ➔ Go
to item A-7.
Go to item A-8.

8-83
 FUEL INJECTION SYSTEM

Fault code No. P0500,P1500

Rear wheel sensor: no normal signals are received from the

A
rear wheel sensor.
Item
B Gear position switch: open or short circuit is detected.

C Clutch switch: open or short circuit is detected.

Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 21
Gear position switch
Tool display • "ON" (when the transmission is in neutral)
• "OFF" (when the transmission is in gear with the clutch lever released)
Procedure Operate the transmission and clutch lever.
Probable cause of malfunc- Confirmation of service corn-
Item Maintenance job
tion and check pletion
B-1 Locate the malfunction. (Fault code No. P0500 or P0500 Value does not increase ➔ Go
and P1500 detected.) to item A-2 for the rear wheel
Execute the diagnostic mode. sensor.
(Code No. 07)
Rotate the rear wheel by hand
and check that the indicated val-
ue increases.
(Fault code No. P1500 detect- Incorrect indication ➔ Go to
ed.) item B-2.
Execute the diagnostic mode.
(Code No. 21)
When the transmission is in
neutral: "ON"
When the transmission is in
gear with the clutch lever re-
leased: "OFF"
When the transmission is in Incorrect indication ➔ Go to
gear with the clutch lever item C-2 for the clutch switch.
squeezed and the sidestand is
retracted: "ON"
B-2 Connection of gear position Improperly connected ➔ Con- Execute the diagnostic mode.
switch coupler. nect the coupler securely or re- (Code No. 21)
Check the locking condition of place the wire harness. When the transmission is in
the coupler. neutral: "ON"
Disconnect the coupler and When the transmission is in
check the pins (bent or broken gear with the clutch lever re-
terminals and locking condition leased: "OFF"
of the pins). Correct indication ➔ Go to item
B-9.
Incorrect indication ➔ Go to
item B-3.

8-84
 FUEL INJECTION SYSTEM

Fault code No. P0500,P1500

Rear wheel sensor: no normal signals are received from the
A
rear wheel sensor.
Item
B Gear position switch: open or short circuit is detected.

C Clutch switch: open or short circuit is detected.

B-3 Connection of ECU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
B-4 Wire harness continuity.
B-5 Defective relay unit.
B-6 Defective gear position switch.
Improperly connected ➔ Con- Execute the diagnostic mode.
nect the coupler securely or re- (Code No. 21)
place the wire harness. When the transmission is in
neutral: "ON"
When the transmission is in
gear with the clutch lever re-
leased: "OFF"
Correct indication ➔ Go to item
B-9.
Incorrect indication ➔ Go to
item B-4.
Open or short circuit ➔ Replace Execute the diagnostic mode.
the wire harness. (Code No. 21)
Between relay unit coupler and When the transmission is in
ECU coupler. neutral: "ON"
black/yellow-black/yellow When the transmission is in
Between relay unit coupler and gear with the clutch lever re-
gear position switch coupler. leased: "OFF"
sky blue-sky blue Correct indication ➔ Go to item
B-9.
Incorrect indication ➔ Go to
item B-5.
Check the relay unit. Execute the diagnostic mode.
Refer to "CHECKING THE RE- (Code No. 21)
LAY UNIT (DIODE)" on page When the transmission is in
8-192. neutral: "ON"
Replace if defective. When the transmission is in
gear with the clutch lever re-
leased: "OFF"
Correct indication ➔ Go to item
B-9.
Incorrect indication ➔ Go to
item B-6.
Check the gear position switch. Execute the diagnostic mode.
Replace if defective. (Code No. 21)
Refer to "CHECKING THE When the transmission is in
GEAR POSITION SWITCH" on neutral: "ON"
page 8-202. When the transmission is in
gear with the clutch lever re-
leased: "OFF"
Correct indication ➔ Go to item
B-9.
Incorrect indication ➔ Go to
item B-7.

8-85
 FUEL INJECTION SYSTEM

Fault code No. P0500,P1500

Rear wheel sensor: no normal signals are received from the

A
rear wheel sensor.
Item
B Gear position switch: open or short circuit is detected.

C Clutch switch: open or short circuit is detected.

B-7 Faulty shift drum (neutral detec- Malfunction ➔ Replace the shift Execute the diagnostic mode.
tion area). drum. (Code No. 21)
Refer to "TRANSMISSION" on When the transmission is in
page 5-89. neutral: "ON"
When the transmission is in
gear with the clutch lever re-
leased: "OFF"
Correct indication ➔ Go to item
B-9.
Incorrect indication ➔ Go to
item B-8.
B-8 Malfunction in ECU. Replace the ECU. Service is finished.
Refer to "REPLACING THE
ECU (Engine Control Unit)" on
page 8-189.
B-9 Delete the fault code and check Turn the main switch to "ON",
that the engine trouble warning and then rotate the rear wheel
light goes off. by hand.
Start the engine, and input the
vehicle speed signals by operat-
ing the vehicle at 20 to 30 km/h
(12 to 19 mph).
Confirm that the fault code has
a condition of "Recover" using
the malfunction mode of the
Yamaha diagnostic tool, and
then delete the fault code.
Delete this fault code even if it
has a condition of "Malfunction".

Fault code No. P0500,P1500

Rear wheel sensor: no normal signals are received from the

A
rear wheel sensor.
Item
B Gear position switch: open or short circuit is detected.

C Clutch switch: open or short circuit is detected.

Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 21
Clutch switch
• "ON" (when the clutch lever is squeezed with the transmission in gear
Tool display and when the sidestand is retracted)
• "OFF" (when the clutch lever is squeezed with the transmission in gear
and when the sidestand is extended)
Procedure Operate the transmission, clutch lever, and sidestand.
Probable cause of malfunc- Confirmation of service corn-
Item Maintenance job
tion and check pletion

8-86
 FUEL INJECTION SYSTEM

Fau lt code No. P0500, P1 500

Rear wheel sensor: no normal signals are recei ved from the
A
rear wheel sensor.
Item
B Gear position switch: open or short circuit is detected.

C Clutch switch: open or short circuit is detected.

C-1 Locate the malfunction.
C-2 Clutch lever adjustment.
C-3 Connection of clutch switch cou- Improperly connected ➔ Con-
pler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
(Fault code No. P0500 or P0500 Value does not increase ➔ Go
and P1500 detected.)
Execute the diagnostic mode.
(Code No. 07)
Rotate the rear wheel by hand
and check that the indicated val-
ue increases.
(Fault code No. P1500 detect-
ed.)
Execute the diagnostic mode.
(Code No. 21)
When the transmission is in
neutral: "ON"
When the transmission is in
gear with the clutch lever re-
leased: "OFF"
When the transmission is in
gear with the clutch lever
squeezed and the sidestand re-
tracted: "ON"
Refer to "ADJUSTING TH E
CLUTCH LEVER FREE PLAY"
on page 3-12.
nect the coupler securely or re-
place the wire harness.
to item A-2 for the rear wheel
sensor.
Incorrect indication ➔ Go to
item B-2 for the gear position
switch.
Incorrect indication ➔ Go to
item C-2.
Execute the diagnostic mode.
(Code No. 21)
When the clutch lever is re-
leased with the transmission in
gear and when the sidestand is
retracted: "OFF"
When the clutch lever is
squeezed with the transmission
in gear and when the sidestand
is retracted: "ON"
Correct indication ➔ Go to item
C-8.
Incorrect indication ➔ Go to
item C-3.
Execute the diagnostic mode.
(Code No. 21)
When the clutch lever is re-
leased with the transmission in
gear and when the sidestand is
retracted: "OFF"
When the clutch lever is
squeezed with the transmission
in gear and when the sidestand
is retracted: "ON"
Correct indication ➔ Go to item
C-8.
Incorrect indication ➔ Go to
item C-4.

8-87
 FUEL INJECTION SYSTEM

Fault code No. P0500,P1500

Rear wheel sensor: no normal signals are received from the
A
rear wheel sensor.
Item
B Gear position switch: open or short circuit is detected.

C Clutch switch: open or short circuit is detected.

C-4 Connection of ECU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
C-5 Wire harness continuity.
C-6 Defective clutch switch.
C-7 Malfunction in ECU.
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
Open or short circuit ➔ Replace
the wire harness.
For MTT9K/MTT9KC
Between ECU coupler and joint
coupler.
black/yellow-black/yellow
black/red-black/red
Between joint coupler and relay
unit coupler.
black/yellow-black/yellow
black/red-black/red
Between clutch switch coupler
and joint coupler.
black/yellow-black/yellow
black/red-black/red
For MTT9GTK/MTT9GTKC
Between clutch switch coupler
to relay unit coupler.
black/red-black/red
black/yellow-black/yellow
Check the clutch switch.
Refer to "CHECKING THE
SWITCHES" on page 8-187.
Replace if defective.
Replace the ECU.
Refer to "REPLACING THE
ECU (Engine Control Unit)" on
page 8-189.
Execute the diagnostic mode.
(Code No. 21)
When the clutch lever is re-
leased with the transmission in
gear and when the sidestand is
retracted: "OFF"
When the clutch lever is
squeezed with the transmission
in gear and when the sidestand
is retracted: "ON"
Correct indication ➔ Go to item
C-8.
Incorrect indication ➔ Go to
item C-5.
Execute the diagnostic mode.
(Code No. 21)
When the clutch lever is re-
leased with the transmission in
gear and when the sidestand is
retracted: "OFF"
When the clutch lever is
squeezed with the transmission
in gear and when the sidestand
is retracted: "ON"
Correct indication ➔ Go to item
C-8.
Incorrect indication ➔ Go to
item C-6.
Execute the diagnostic mode.
(Code No. 21)
When the clutch lever is re-
leased with the transmission in
gear and when the sidestand is
retracted: "OFF"
When the clutch lever is
squeezed with the transmission
in gear and when the sidestand
is retracted: "ON"
Correct indication ➔ Go to item
C-8.
Incorrect indication ➔ Go to
itemC-7.
Service is finished.

8-88
 FUEL INJECTION SYSTEM

Fault code No. P0500,P1500

Rear wheel sensor: no normal signals are received from the

A
rear wheel sensor.
Item
B Gear position switch: open or short circuit is detected.

C Clutch switch: open or short circuit is detected.

C-8 Delete the fault code and check
that the engine trouble warning
light goes off.
Turn the main switch to "ON",
and then rotate the rear wheel
by hand.
Start the engine, and input the
vehicle speed signals by operat-
ing the vehicle at 20 to 30 km/h
(12 to 19 mph).
Confirm that the fault code has
a condition of "Recover" using
the malfunction mode of the
Yamaha diagnostic tool, and
then delete the fault code.
Delete this fault code even if it
has a condition of "Malfunction".

Fault code No. P0560

Fault code No. POSSO

Item Charging voltage is abnormal.

Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. -
Tool display -
Procedure -
Probable cause of malfunc- Confirmation of service corn-
Item Maintenance job
tion and check pletion
1 Malfunction in charging system. Check the charging system. Start the engine and let it idle for
Refer to "CHARGING SYSTEM" approximately 5 seconds.
on page 8-17. Check the condition of the fault
Defective rectifier/regulator or code using the malfunction
AC magneto ➔ Replace. mode of the Yamaha diagnostic
Defective connection in the tool.
charging system circuit ➔ Prop- Condition is "Recover" ➔ Go to
erly connect or replace the wire item 2 and finish the service.
harness. Condition is "Malfunction" ➔
Repeat item 1.
2 Delete the fault code and check Confirm that the fault code has
that the engine trouble warning a condition of "Recover" using
light goes off. the Yamaha diagnostic tool, and
then delete the fault code.

8-89
 FUEL INJECTION SYSTEM

Fault code No. P0601 , P0606

Fault code No. P0601 , P0606

Internal malfunction in ECU. (When this malfunction is detected in

Item the ECU, the fault code number might not appear on the tool dis-
play.)
Able/Unable to start engine
Fail-safe system
Able/Unable to drive vehicle
Diagnostic code No. -
Tool display -
Procedure -
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Malfunction in ECU. Replace the ECU. Turn the main switch to "ON".
Refer to "REPLACI NG TH E Check that the engine trouble
ECU (Engine Control Unit)" on warning light does not come on.
page 8-189.

Fault code No. P062F

Fault code No. P062F

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

Item
writing on EEPROM.
Able/Unable to start engine
Fail-safe system
Able/Unable to drive vehicle
Diagnostic code No. 60
00
• No malfunctions detected (If the self-diagnosis fault code P062F is indi-
cated, the ECU is defective.)
01 - 03 (CO adjustment value)
• (If more than one cylinder is defective, the display alternates every two
Tool display seconds to show all the detected cylinder numbers. When all cylinder
numbers are shown, the display repeats the same process.)
11 (Data error for ISC (idle speed control) learning values)
12 (0 2 feedback learning value)
13 (OBD memory value)
Procedure -
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Locate the malfunction Execute the diagnostic mode.
(Code No. 60)
00: Go to item 7.
0 1: Go to item 2.
02: Go to item 3.
03: Go to item 4.
11-1 3: go to item 2.

8-90

Fault code No. P062F
EEPROM fault code number: an error is detected while reading or
Item
writing on EEPROM.
2 "01 " is indicated in diagnostic
mode (code No. 60). EEP-ROM
data error for adjustment of CO
concentration of cylinder #1.
3 "02" is indicated in diagnostic
mode (code No. 60). EEP-ROM
data error for adjustment of CO
concentration of cylinder #2.
4 "03" is indicated in diagnostic
mode (code No. 60). EEP-ROM
data error for adjustment of CO
concentration of cylinder #3.
5 "11 " is indicated in diagnostic
mode (Code No. 60). EEPROM
data error for ISC (idle speed
control) learning values.
"12" is indicated in the diagnos-
tic mode (Code No. 60). EE-
PROM data error for 0 2
feedback learning values.
"13" is indicated in the diagnos-
tic mode (Code No. 60). EE-
PROM data error for OBD
memory values.
6 Malfunction in ECU.
FUEL INJECTION SYSTEM
Change the CO concentration of
cylinder #1, and rewrite in EE-
PROM.
To adjust it, use the CO adjust-
ing mode of the Yamaha diag-
nostic tool.
After this adjustment is made,
the memory is not recovered
when the main switch is turned
to "OFF". ➔ Replace the ECU.
Refer to "REPLACING THE
ECU (Engine Control Unit)" on
page 8-189.
Change the CO concentration of
cylinder #2, and rewrite in EE-
PROM.
To adjust it, use the CO adjust-
ing mode of the Yamaha diag-
nostic tool.
After this adjustment is made,
the memory is not recovered
when the main switch is turned
to "OFF". ➔ Replace the ECU.
Refer to "REPLACING THE
ECU (Engine Control Unit)" on
page 8-189.
Change the CO concentration of
cylinder #3, and rewrite in EE-
PROM.
To adjust it, use the CO adjust-
ing mode of the Yamaha diag-
nostic tool.
After this adjustment is made,
the memory is not recovered
when the main switch is turned
to "OFF". ➔ Replace the ECU.
Refer to "REPLACING THE
ECU (Engine Control Unit)" on
page 8-189.
Turn the main switch to "OFF".
Replace the ECU.
Refer to "REPLACING THE
ECU (Engine Control Unit)" on
page 8-189.
8-91
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔
Repeat item 1.
If the same number is indicated,
go to item 6.
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔
Repeat item 1.
If the same number is indicated,
go to item 6.
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔
Repeat item 1.
If the same number is indicated,
go to item 6.
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔
Repeat item 1.
If the same number is indicated,
go to item 6.
Service is finished.
 FUEL INJECTION SYSTEM

Fault code No. P062F

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

Item
writing on EEPROM.
7 Delete the fault code and check Confirm that the fault code has
that the engine trouble warning a condition of "Recover" using
light goes off. the Yamaha diagnostic tool, and
then delete the fault code.

Fault code No. P0638

Fault code No. P0638

Item YCC-T drive system: malfunction detected.

Able/Unable to start engine
Fail-safe system
Able/Unable to drive vehicle
Diagnostic code No. -
Tool display -
Procedure -
Probable cause of malfunc- Confirmation of service corn-
Item Maintenance job
tion and check pletion
1 Connection of throttle servo mo- Improperly connected ➔ Con- Turn the main switch to "ON",
tor coupler. nect the coupler securely or re- and then check the condition of
Check the locking condition of place the wire harness. the fault code using the mal-
the coupler. function mode of the Yamaha di-
Disconnect the coupler and agnostic tool.
check the pins (bent or broken Condition is "Recover'' ➔ Go to
terminals and locking condition item 8 and finish the service.
of the pins). Condition is "Malfunction" ➔ Go
to item 2.
2 Connection of wire harness Improperly connected ➔ Con- Turn the main switch to "ON",
ECU coupler. nect the coupler securely or re- and then check the condition of
Disconnect the coupler and place the wire harness. the fault code using the mal-
check the pins (bent or broken function mode of the Yamaha di-
terminals and locking condition agnostic tool.
of the pins). Condition is "Recover'' ➔ Go to
item 8 and finish the service.
Condition is "Malfunction" ➔ Go
to item 3.
3 Check the electronic throttle Blown fuse ➔ Replace the elec- Turn the main switch to "ON",
valve fuse. tronic throttle valve fuse. and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover'' ➔ Go to
item 8 and finish the service.
Condition is "Malfunction" ➔ Go
to item 4.

8-92
 FUEL INJECTION SYSTEM

Fau lt code No. P0638

Item YCC-T drive system: malfunction detected.
4 Wire harness continuity.
5 Defective throttle servo motor.
6 Defective throttle bodies.
7 Malfunction in ECU.
8 Delete the fault code and check
that the engine trouble warning
light goes off.
Open or short circuit ➔ Replace
the wire harness.
For MTT9K/MTT9KC
Between throttle servo motor
coupler and ECU coupler.
yellow/red- yellow/ red
yellow/white- yellow/ white
Between ECU coupler and elec-
tronic throttle valve fuse.
red/white- red/ white
For MTT9GTK/MTT9GTKC
Between throttle servo motor
coupler and ECU coupler.
yellow/red- yellow/ red
yellow/green-yellow/green
Between ECU coupler and elec-
tronic throttle valve fuse.
red/white- red/ white
Check the throttle servo motor.
Replace the throttle bodies if
defective.
Refer to "CHECKING THE
THROTTLE SERVO MOTOR"
on page 8-200.
Check the throttle bodies.
Replace if defective.
Refer to "CHECKING THE
THROTTLE SERVO MOTOR"
on page 8-200.
Replace the ECU.
Refer to "REPLACING THE
ECU (Engine Control Unit)" on
page 8-189.
Confirm that the fault code has
a condition of "Recover" using
the Yamaha diagnostic tool, and
then delete the fault code.
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover'' ➔ Go to
item 8 and finish the service.
Condition is "Malfunction" ➔ Go
to item 5.
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover'' ➔ Go to
item 8 and finish the service.
Condition is "Malfunction" ➔ Go
to item 6.
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover'' ➔ Go to
item 8 and finish the service.
Condition is "Malfunction" ➔ Go
to item 7.
Service is finished.

Fault code No. P0657

Fault code No. P0657
Fuel system voltage: incorrect voltage supplied to the fuel injector,
Item
fuel pump and relay unit.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 09, 50

8-93
 FUEL INJECTION SYSTEM

Fault code No. P0657

Fuel system voltage: incorrect voltage supplied to the fuel injector,

Item
fuel pump and relay unit.
Fuel system voltage (battery voltage)
Tool display
Approximately 12.0
09 Set the start/engine stop switch to "o", and then compare the actually
Procedure measured battery voltage with the tool display value. (If the actually mea-
sured battery voltage is low, recharge the battery.)
Actuates the relay unit five times at one-second intervals.
Actuation The check indicator on the Yamaha diagnostic tool screen come on each
50 time the relay is actuated.
Check that the relay unit is actuated five times by listening for the operat-
Procedure
ing sound.
Probable cause of malfunc- Confirmation of service corn-
Item Maintenance job
tion and check pletion
1 Connection of relay unit coupler. Improperly connected ➔ Con- Start the engine and let it idle for
Check the locking condition of nect the coupler securely or re- approximately 5 seconds.
the coupler. place the wire harness. Check the condition of the fault
Disconnect the coupler and code using the malfunction
check the pins (bent or broken mode of the Yamaha diagnostic
terminals and locking condition tool.
of the pins). Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 2.
2 Connection of ECU coupler. Improperly connected ➔ Con- Start the engine and let it idle for
Check the locking condition of nect the coupler securely or re- approximately 5 seconds.
the coupler. place the wire harness. Check the condition of the fault
Disconnect the coupler and code using the malfunction
check the pins (bent or broken mode of the Yamaha diagnostic
terminals and locking condition tool.
of the pins). Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 3.
3 Wire harness continuity. Open or short circuit ➔ Replace Start the engine and let it idle for
the wire harness. approximately 5 seconds.
Between battery and starter re- Check the condition of the fault
lay (fuel injection system fuse). code using the malfunction
red-red mode of the Yamaha diagnostic
Between starter relay (fuel injec- tool.
tion system fuse) and relay unit Condition is "Recover" ➔ Go to
coupler. item 7 and finish the service.
red-red Condition is "Malfunction" ➔ Go
Between relay unit coupler and to item 4.
ECU coupler.
red/blue-red/blue
blue/yellow-blue/yellow

8-94
 FUEL INJECTION SYSTEM

Fault code No. P0657

Fuel system voltage: incorrect voltage supplied to the fuel injector,

Item
fuel pump and relay unit.
4 Defective relay unit.
5 Defective relay unit.
6 Malfunction in ECU.
7 Delete the fault code and check
that the engine trouble warning
light goes off.
Execute the diagnostic mode.
(Code No. 50)
No operating sound ➔ Replace
the relay unit.
Execute the diagnostic mode.
(Code No. 09)
Fuel system voltage is below 3
V ➔ Replace the relay unit.
Replace the ECU.
Refer to "REPLACING THE
ECU (Engine Control Unit)" on
page 8-189.
Confirm that the fault code has
a condition of "Recover" using
the Yamaha diagnostic tool, and
then delete the fault code.
Start the engine and let it idle for
approximately 5 seconds.
Check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 5.
Start the engine and let it idle for
approximately 5 seconds.
Check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 6.
Service is finished.

Fault code No. P1004

Fault code No. P1004

Intake air pressure sensor 1 or intake air pressure sensor 2: when

Item the main switch is turned to "ON", the intake air pressure sensor 1
voltage and intake air pressure sensor 2 voltage differ greatly.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 03, 04
03 Tool display Displays the intake air pressure 1.
Procedure Operate the throttle while pushing the"(?)" side of the start/engine stop
switch. (If the display value changes, the performance is OK.)
04 Tool display Displays the intake air pressure 2.
Procedure Operate the throttle while pushing the"(?)" side of the start/engine stop
switch. (If the display value changes, the performance is OK.)
Probable cause of malfunc- Confirmation of service corn-
Item Maintenance job
tion and check pletion

8-95
 FUEL INJECTION SYSTEM

Fault code No. P1004

Intake air pressure sensor 1 or intake air pressure sensor 2: when
Item the main switch is turned to "ON", the intake air pressure sensor 1
voltage and intake air pressure sensor 2 voltage differ greatly.
1 Defective intake air pressure
sensor 1.
2 Defective intake air pressure
sensor 2.
3 Malfunction in ECU.
4 Delete the fault code and check
that the engine trouble warning
light goes off.
Execute the diagnostic mode. Turn the main switch to "ON",
(Code No. 03) and then check the condition of
When engine is stopped: the fault code using the mal-
Atmospheric pressure at the function mode of the Yamaha di-
current altitude and weather agnostic tool.
conditions is indicated. Condition is "Recover'' ➔ Go to
0 m above sea level: Approx. item 4 and finish the service.
101 kPa (757.6 mmHg, 29.8 Condition is "Malfunction" ➔ Go
inHg) to item 2.
3000 m (9800 ft) above sea lev-
el: Approx. 70 kPa (525.0
mmHg, 20.7 inHg)
Displayed value is incorrect ➔
Check the intake air pressure
sensor 1.
Refer to "CHECKING THE IN-
TAKE AIR PRESSURE SEN-
SOR" on page 8-201.
Replace if defective.
Execute the diagnostic mode. Turn the main switch to "ON",
(Code No. 04) and then check the condition of
When engine is stopped: the fault code using the mal-
Atmospheric pressure at the function mode of the Yamaha di-
current altitude and weather agnostic tool.
conditions is indicated. Condition is "Recover'' ➔ Go to
0 m above sea level: Approx. item 4 and finish the service.
101 kPa (757.6 mmHg, 29.8 Condition is "Malfunction" ➔ Go
inHg) to item 3.
3000 m (9800 ft) above sea lev-
el: Approx. 70 kPa (525.0
mmHg, 20.7 inHg)
Displayed value is incorrect ➔
Check the intake air pressure
sensor 2.
Refer to "CHECKING THE IN-
TAKE AIR PRESSURE SEN-
SOR" on page 8-201.
Replace if defective.
Replace the ECU. Service is finished.
Refer to "REPLACING THE
ECU (Engine Control Unit)" on
page 8-189.
Confirm that the fault code has
a condition of "Recover" using
the Yamaha diagnostic tool, and
then delete the fault code.

Fault code No. P1400

Fault code No. P1400
Item Air induction system solenoid: open or short circuit detected.
Able to start engine
Fail-safe system
Able to drive vehicle

8-96
 FUEL INJECTION SYSTEM

Fau lt code No. P1400

Item Air induction system solenoid: open or short circuit detected.

Diagnostic code No. 48
Actuates the air induction system solenoid five times at one-second inter-
vals.
Actuation
The check indicator on the Yamaha diagnostic tool screen come on each
48 time the air induction system solenoid is actuated.
Check that the air induction system solenoid is actuated five times by lis-
Procedure
tening for the operating sound.
Probable cause of malfunc- Confirmation of service corn-
Item Maintenance job
tion and check pletion
1 Connection of air induction sys- Improperly connected ➔ Con- Turn the main switch to "ON",
tern solenoid coupler. nect the coupler securely or re- and then check the condition of
Check the locking condition of place the wire harness. the fault code using the mal-
the coupler. function mode of the Yamaha di-
Disconnect the coupler and agnostic tool.
check the pins (bent or broken Condition is "Recover'' ➔ Go to
terminals and locking condition item 6 and finish the service.
of the pins). Condition is "Malfunction" ➔
Start the engine and check the
status of the fault code.

Condition is "Recover'' ➔ Go to
item 6 and finish the service.
Condition is "Malfunction" ➔ Go
to item 2.
TIP
Check that the start/engine stop
switch is turned to "ON" then.

2 Connection of ECU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover'' ➔ Go to
item 6 and finish the service.
Condition is "Malfunction" ➔
Start the engine and check the
status of the fault code.

Condition is "Recover'' ➔ Go to
item 6 and finish the service.
Condition is "Malfunction" ➔ Go
to item 3.
TIP
Check that the start/engine stop
switch is turned to "ON" then.

8-97
 FUEL INJECTION SYSTEM

Fault code No. P1400

Item Air induction system solenoid: open or short circuit detected.

3 Wire harness continuity.
Open or short circuit ➔ Replace
the wire harness.
Between air induction system
solenoid coupler and ECU cou-
pler.
brown/red-brown/red
Between air induction system
solenoid coupler and ignition
fuse.
red/white-red/white
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover'' ➔ Go to
item 6 and finish the service.
Condition is "Malfunction" ➔
Start the engine and check the
status of the fault code.

Condition is "Recover'' ➔ Go to
item 6 and finish the service.
Condition is "Malfunction" ➔ Go
to item 4.
TIP _ _ _ _ _ _ _ _ __
Check that the start/engine stop
switch is turned to "ON" then.

4 Defective air induction system
solenoid.
Refer to "CHECKING THE AIR
INDUCTION SYSTEM SOLE-
NOID" on page 8-201.
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover'' ➔ Go to
item 6 and finish the service.
Condition is "Malfunction" ➔
Start the engine and check the
status of the fault code.

Condition is "Recover'' ➔ Go to
item 6 and finish the service.
Condition is "Malfu nction" ➔ Go
to item 5.
TIP
Check that the start/engine stop
switch is turned to "ON" then.

5 Malfunction in ECU. Replace the ECU. Service is finished.

6 Delete the fault code and check
that the engine trouble warning
light goes off.
Refer to "REPLACING THE
ECU (Engine Control Unit)" on
page 8-189.
Confirm that the fault code has
a condition of "Recover" using
the Yamaha diagnostic tool, and
then delete the fault code.

Fault code No. P1601

Fault code No. P1601

Sidestand switch: open or short circuit of the black/red lead of the

Item
ECU is detected.
Unable to start engine
Fail-safe system
Unable to drive vehicle

8-98
 FUEL INJECTION SYSTEM

Fault code No. P1601

Sidestand switch: open or short circuit of the black/red lead of the

Item
ECU is detected.
Diagnostic code No. 20
Sidestand switch
Tool display • "ON" (sidestand retracted)
• "OFF" (sidestand extended)
Procedure Extend and retract the sidestand (with the transmission in gear).
Probable cause of malfunc- Confirmation of service corn-
Item Maintenance job
tion and check pletion
1 Connection of sidestand switch Improperly connected ➔ Con- Turn the main switch to "ON",
coupler. nect the coupler securely or re- and then extend and retract the
Check the locking condition of place the wire harness. sidestand.
the coupler. Check the condition of the fault
Disconnect the coupler and code using the malfunction
check the pins (bent or broken mode of the Yamaha diagnostic
terminals and locking condition tool.
of the pins). Condition is "Recover" ➔ Go to
item 8 and finish the service.
Condition is "Malfunction" ➔ Go
to item 2.
2 Connection of ECU coupler. Improperly connected ➔ Con- Turn the main switch to "ON",
Check the locking condition of nect the coupler securely or re- and then extend and retract the
the coupler. place the wire harness. sidestand.
Disconnect the coupler and Check the condition of the fault
check the pins (bent or broken code using the malfunction
terminals and locking condition mode of the Yamaha diagnostic
of the pins). tool.
Condition is "Recover" ➔ Go to
item 8 and finish the service.
Condition is "Malfunction" ➔ Go
to item 3.
3 Connection of main switch cou- Improperly connected ➔ Con- Turn the main switch to "ON",
pier. nect the coupler securely or re- and then extend and retract the
Check the locking condition of place the wire harness. sidestand.
the coupler. Check the condition of the fault
Disconnect the coupler and code using the malfunction
check the pins (bent or broken mode of the Yamaha diagnostic
terminals and locking condition tool.
of the pins). Condition is "Recover" ➔ Go to
item 8 and finish the service.
Condition is "Malfunction" ➔ Go
to item 4.
4 Connection of relay unit coupler. Improperly connected ➔ Con- Turn the main switch to "ON",
Check the locking condition of nect the coupler securely or re- and then extend and retract the
the coupler. place the wire harness. sidestand.
Disconnect the coupler and Check the condition of the fault
check the pins (bent or broken code using the malfunction
terminals and locking condition mode of the Yamaha diagnostic
of the pins). tool.
Condition is "Recover" ➔ Go to
item 8 and finish the service.
Condition is "Malfunction" ➔ Go
to item 5.

8-99
 FUEL INJECTION SYSTEM

Fault code No. P1601

Sidestand switch: open or short circuit of the black/red lead of the

Item
ECU is detected.
5 Wire harness continuity.
6 Defective sidestand switch.
7 Malfunction in ECU.
8 Delete the fault code and check
that the engine trouble warning
light goes off.
Open or short circuit ➔ Replace Turn the main switch to "ON",
the wire harness. and then extend and retract the
For MTT9K/MTT9KC sidestand.
Between ECU coupler and main Check the condition of the fault
switch coupler. code using the malfunction
black/red-black/red mode of the Yamaha diagnostic
Between main switch coupler tool.
and joint coupler. Condition is "Recover" ➔ Go to
brown/red-brown/red item 8 and finish the service.
Between joint coupler and relay Condition is "Malfunction" ➔ Go
unit coupler. to item 6.
black/red-black/red
Between relay unit coupler and
sidestand switch coupler.
blue/black-blue/black
For MTT9GTK/MTT9GTKC
Between ECU coupler and main
switch coupler.
black/red-black/red
Between main switch coupler
and relay unit coupler.
brown/red-brown/red
black/red-black/red
Between relay unit coupler and
sidestand switch coupler.
blue/black-blue/black
Execute the diagnostic mode. Turn the main switch to "ON",
(Code No. 20) and then extend and retract the
Shift the transmission into gear. sidestand.
Sidestand retracted: "ON" Check the condition of the fault
Sidestand extended: "OFF" code using the malfunction
Replace if defective. mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item 8 and finish the service.
Condition is "Malfunction" ➔ Go
to item 7.
Replace the ECU. Service is finished.
Refer to "REPLACING THE
ECU (Engine Control Unit)" on
page 8-189.
Confirm that the fault code has
a condition of "Recover" using
the Yamaha diagnostic tool, and
then delete the fault code.

Fault code No. P1602

Fault code No. P1602

Malfunction in ECU internal circuit (malfunction of ECU power cut-

Item
off function).
Able/Unable to start engine
Fail-safe system
Able/Unable to drive vehicle
Diagnostic code No. -

8-100

Fault code No. P1602
Malfunction in ECU internal circuit (malfunction of ECU power cut-
Item
off function).
Tool display -
Procedure -
Probable cause of malfunc-
Item
tion and check
1 Installed condition of battery
leads. Check the installed con-
dition of the battery and battery
leads (loose bolts).
2 Connection of starter relay cou-
pier. Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
3 Check the fuel injection system
fuse.
4 Wire harness continuity be-
tween starter relay and ECU
coupler.
5 Wire harness continuity be-
tween starter relay and battery.
6 Malfunction in ECU.
FUEL INJECTION SYSTEM
Maintenance job
Improperly installed battery or
battery leads ➔ Reinstall or re-
place the battery leads.
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
Blown fuse ➔ Replace the fuse. Turn the main switch to "ON",
Open or short circuit ➔ Replace
the wire harness.
Between starter relay and ECU
coupler.
red-red
Open or short circuit ➔ Replace
the wire harness.
Between battery terminal and
starter relay.
red-red
Replace the ECU.
8-101
Confirmation of service corn-
pletion
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 2.
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 3.
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 4.
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 5.
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 6.
Service is finished.
 FUEL INJECTION SYSTEM

Fault code No. P1602

Malfunction in ECU internal circuit (malfunction of ECU power cut-

Item
off function).
7 Delete the fault code and check Confirm that the fault code has
that the engine trouble warning a condition of "Recover" using
light goes off. the Yamaha diagnostic tool, and
then delete the fault code.

Fault code No. P1604, P1605

Fault code No. P1604,P1605

[P1604] Lean angle sensor: ground short circuit detected.

Item
[P1605] Lean angle sensor: open or power short circuit detected.
Unable to start engine
Fail-safe system
Unable to drive vehicle
Diagnostic code No. 08
Lean angle sensor output voltage
Tool display • 0.4-1.4 (upright)
• 3.7-4.4 (overturned)
Procedure Remove the lean angle sensor and incline it more than 65 degrees.
Probable cause of malfunc- Confirmation of service corn-
Item Maintenance job
tion and check pletion
1 Connection of lean angle sensor Improperly connected ➔ Con- Turn the main switch to "ON",
coupler. nect the coupler securely or re- then to "OFF", and then back to
Check the locking condition of place the wire harness. "ON".
the coupler. Check the condition of the fault
Disconnect the coupler and code using the malfunction
check the pins (bent or broken mode of the Yamaha diagnostic
terminals and locking condition tool.
of the pins). Condition is "Recover" ➔ Go to
item 6 and finish the service.
Condition is "Malfunction" ➔ Go
to item 2.
2 Connection of ECU coupler. Improperly connected ➔ Con- Turn the main switch to "ON",
Check the locking condition of nect the coupler securely or re- then to "OFF", and then back to
the coupler. place the wire harness. "ON".
Disconnect the coupler and Check the condition of the fault
check the pins (bent or broken code using the malfunction
terminals and locking condition mode of the Yamaha diagnostic
of the pins). tool.
Condition is "Recover" ➔ Go to
item 6 and finish the service.
Condition is "Malfunction" ➔ Go
to item 3.
3 Wire harness continuity. Open or short circuit ➔ Replace Turn the main switch to "ON",
the wire harness. then to "OFF", and then back to
"ON".
Check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item 6 and finish the service.
Condition is "Malfunction" ➔ Go
to item 4.

8-102
 FUEL INJECTION SYSTEM

Fault code No. P1604, P1605

[P1604] Lean angle sensor: ground short circuit detected.

Item
(P1605] Lean angle sensor: open or power short circuit detected.
3-1
2
1 sv sv
--r- ~,-
L
3 L
< >

4
: >> AA
Y/G Y/G vvv -

B/L 5 B/L
1

1. Lean angle sensor

2. ECU
3. Sensor input lead
4. Sensor output lead
5. Sensor ground lead
3-2 Disconnect the ECU coupler from the ECU.
Disconnect the lean angle sensor coupler from the lean angle sensor.
3-3 [For P1604] Ground short circuit
Between lean angle sensor coupler and ground: yellow/green- ground
If there is continuity, replace the wire harness.
[Al [ID

lfk~ \\\ \\\\\\\\\%

❖

Ilk~\\,,,,,,,,,,%
A

'• ' •
Q Q

-:t-
- --
--

A. MTT9K/MTT9KC
B. MTT9GTK/MTT9GTKC
3-4 [For P1605] Open circuit
Between lean angle sensor coupler and ECU coupler: blue-blue
If there is no continuity, replace the wire harness.
[Al [ID

' I I I I

. ' ' . ly/1 IX B G/B X r/R Y/G Y/R w,j R 'W

" ~
1,...
B G/8 X BdR M Y/R
B YA. B .,,, X B YA. B
L Y/G M.
\\ 0/G Y/8 B lJB P/8 ,A >< V
L Y/G 8/L
\\ ~JG '!.!l. B l./8 P/B 1' ;<, V X
0 G/Y lfY R/8 IX X A. L B/11 0 GM lJI RIB ( I~ y ~ R
llM

Q Q

A. MTT9K/MTT9KC
B. MTT9GTK/MTT9GTKC

8-103
 FUEL INJECTION SYSTEM

Fau lt code No. P1 604, P1 605

[P1604] Lean angle sensor: ground short circuit detected.

Item
(P1605] Lean angle sensor: open or power short circuit detected.
3-5 [For P1605] Open circuit
Between lean angle sensor coupler and ECU coupler: yellow/green- yellow/green
If there is no continuity, replace the wire harness.

V/R AIL G/Y

B V/1. B B B Br/W Lg/W B V/1. B 8/R l./W G/B G B B Br
L VIG 811.. P L L L Y/G 8/L 8/1. fJ/W W/L V/B PNI P L L
WN WIG Gy/G V/G L 811.. B/Y GN VIL

~----n----~
A. MTT9K/MTT9KC
B. MTT9GTK/MTT9GTKC
3-6 [For P1605] Open circuit
Between lean angle sensor coupler and ECU coupler: black/blue-black/blue
If there is no continuity, replace the wire harness.
[Al [ID

B V/1. B B B Br/W Lg/W B Y/1. B

L VIG 811.. L Y/G 8/L
B/[ B/L 8/Y BN GN VIL

A. MTT9K/MTT9KC
B. MTT9GTK/MTT9GTKC
3-7 Disconnect the couplers from the parts that are connected to the ECU.
Refer to "Parts connected to the ECU" on page 8-51.
3-8 [For P1604/P1605] Short circuit
Between lean angle sensor output terminal (yellow/green) "a" of ECU coupler and any other ECU
coupler terminal "b".
If there is continuity, replace the wire harness.
[Al [ID
a a
1• • • • • • • • • • • • • • • •••••••I
'("""T'---i<c"71<,F'l,----,-,-"T"','
' YfAM. W W
•
lllll lJ\Y 8 8

A. MTT9K/MTT9KC
B. MTT9GTK/MTT9GTKC

8-104
 FUEL INJECTION SYSTEM

Fault code No. P1604,P1605

[P1604] Lean angle sensor: ground short circuit detected.

Item
(P1605] Lean angle sensor: open or power short circuit detected.
4 Defective lean angle sensor.
5 Malfunction in ECU.
6 Delete the fault code and check
that the engine trouble warning
light goes off.
Refer to "CHECKING THE
LEAN ANGLE SENSOR" on
page 8-195.
Replace the ECU.
Refer to "REPLACING THE
ECU (Engine Control Unit)" on
page 8-189.
Confirm that the fault code has
a condition of "Recover" using
the Yamaha diagnostic tool, and
then delete the fault code.
Turn the main switch to "ON",
then to "O FF", and then back to
"ON".
Check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item 6 and finish the service.
Condition is "Malfunction" ➔ Go
to item 5.
Service is finished.

Fault code No. P1606, P1607

Fault code No. P1606, P1607

[P1606] Intake air pressure sensor 2: ground short circuit detected.

Item [P1607] Intake air pressure sensor 2: open or power short circuit de-
tected.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 04
Tool display Displays the intake air pressure 2.
Operate the throttle while pushing the "0>" side of the start/engine stop
Procedure
switch. (If the display value changes, the performance is OK.)
Probable cause of malfunc- Confirmation of service corn-
Item Maintenance job
tion and check pletion
1 Connection of Intake air pres- Improperly connected ➔ Con- Turn the main switch to "ON",
sure sensor 2 coupler. nect the coupler securely or re- and then check the condition of
Check the locking condition of place the wire harness. the fault code using the mal-
the coupler. function mode of the Yamaha di-
Disconnect the coupler and agnostic tool.
check the pins (bent or broken Condition is "Recover" ➔ Go to
terminals and locking condition item 7 and finish the service.
of the pins). Condition is "Malfunction" ➔ Go
to item 2.
2 Connection of ECU coupler. Improperly connected ➔ Con- Turn the main switch to "ON",
Check the locking condition of nect the coupler securely or re- and then check the condition of
the coupler. place the wire harness. the fault code using the mal-
Disconnect the coupler and function mode of the Yamaha di-
check the pins (bent or broken agnostic tool.
terminals and locking condition Condition is "Recover" ➔ Go to
of the pins). item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 3.

8-105
 FUEL INJECTION SYSTEM

Fault code No. P1606,P1607

[P1606] Intake air pressure sensor 2: ground short circuit detected.

Item (P1607] Intake air pressure sensor 2: open or power short circuit de-
tected.
3 Wire harness continuity. Open or short circuit ➔ Replace Turn the main switch to "ON",
the wire harness. and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 4.
3-1
2
1 sv sv
- l
3
----- L -r- ~ ,-

"- f PNI/
4
/
5
B/L - - ' " - - - - B/l -i--~
1-

1. Intake air pressure sensor

2. ECU
3. Sensor input lead
4. Sensor output lead
5. Sensor ground lead
3-2 Disconnect the ECU coupler from the ECU.
Disconnect the Intake air pressure sensor 2 coupler from the Intake air pressure sensor 2.
3-3 [For P1606] Ground short circuit
Between Intake air pressure sensor 2 coupler and ground: pink/white-ground
If there is continuity, replace the wire harness.

a ,,,,,,,,,,, ,s
Q

--
--

8-106
 FUEL INJECTION SYSTEM

Fault code No. P1606,P1607

[P1606] Intake air pressure sensor 2: ground short circuit detected.

Item (P1607] Intake air pressure sensor 2: open or power short circuit de-
tected.
3-4 [For P 1607] Open circuit
Between Intake air pressure sensor 2 coupler and ECU coupler: blue-blue
If there is no continuity, replace the wire harness.

0 G/Y UY

A. MTT9K/MTT9KC
B. MTT9GTK/MTT9GTKC
3-5 [For P 1607] Open circuit
Between Intake air pressure sensor 2 coupler and ECU coupler: pink/white-pink/white
If there is no continuity, replace the wire harness.
[Al [ID

Y/R AIL G/Y

8/R l./W G/B G B B Br
8/l. 8/W W/L Y/B PNI P L L
B/L 8/L 8/Y 8/L Bit. 8/Y G/Y YI~ ,V/Y WIG

~--n---
A. MTT9K/MTT9KC
B. MTT9GTK/MTT9GTKC
3-6 [For P 1607] Open circuit
Between Intake air pressure sensor 2 coupler and ECU coupler: black/blue-black/blue
If there is no continuity, replace the wire harness.
[ID

Y/R AIL Y/R AIL G/Y

~
8/R l./W G/B G B B Br

A. MTT9K/MTT9KC
B. MTT9GTK/MTT9GTKC
3-7 Disconnect the couplers from the parts that are connected to the ECU.
Refer to "Parts connected to the ECU" on page 8-51.

8-107
 FUEL INJECTION SYSTEM

Fault code No. P1606,P1607

[P1606] Intake air pressure sensor 2: ground short circuit detected.

Item (P1607] Intake air pressure sensor 2: open or power short circuit de-
tected.
3-8 [For P1606/P1607] Short circuit
Between Intake air pressure sensor 2 output terminal (pink/white) "a" of ECU coupler and any other
ECU coupler terminal "b".
If there is continuity, replace the wire harness.
[§]
a
:- - - - - - - - - -.=.=.~-. - - - - - - -:
: YIR IAII. IGIYI · 1G V VI IG/1/h nA I;
\\ 'B/RlN/GillG B s~ :
,\ \ \ \ \ \ \ \ B/1. BIWW!I. YIB PNII P llll)i :
b/ __t__________________ _
'' B/I. IB/1. IBIYIGIYIY/l •'/YhVIGn-.-iGI Y/G ''
' '

:_ ...... Q

A. MTT9K/MTT9KC
B. MTT9GTK/MTT9GTKC
4 Installed condition of Intake air
pressure sensor 2.
5 Defective Intake air pressure
sensor 2.
Check for looseness or pinch- Turn the main switch to "ON",
ing. and then check the condition of
Improperly installed sensor ➔ the fault code using the mal-
Reinstall or replace the sensor. function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 7 and finish the service.
Condition is "Malfunction" ➔ Go
to item 5.
Execute the diagnostic mode. Turn the main switch to "ON",
(Code No. 04) and then check the condition of
When engine is stopped: the fault code using the mal-
Atmospheric pressure at the function mode of the Yamaha di-
current altitude and weather agnostic tool.
conditions is indicated. Condition is "Recover" ➔ Go to
At sea level: Approx. 101 kPa item 7 and finish the service.
(757.6 mmHg, 29.8 inHg) Condition is "Malfunction" ➔ Go
1000 m (3300 ft) above sea lev- to item 6.
el: Approx. 90 kPa (675.1
mmHg, 26.6 inHg)
2000 m (6700 ft) above sea lev-
el: Approx. 80 kPa (600.0
mmHg, 23.6 inHg)
3000 m (9800 ft) above sea lev-
el: Approx. 70 kPa (525.0
mmHg, 20.7 in Hg)
When engine is cranking: Make
sure that the indication value
changes.
The value does not change
when engine is cranking. ➔
Check the Intake air pressure
sensor 2.
Refer to "CHECKING THE IN-
TAKE AIR PRESSURE SEN-
SOR" on page 8-201.
Replace if defective.

8-108
 FUEL INJECTION SYSTEM

Fault code No. P1606,P1607

[P1606] Intake air pressure sensor 2: ground short circuit detected.

Item (P1607] Intake air pressure sensor 2: open or power short circuit de-
tected.
6 Malfunction in ECU. Replace the ECU. Service is finished.
Refer to "REPLACING THE
ECU (Engine Control Unit)" on
page 8-189.
7 Delete the fault code and check Confirm that the fault code has
that the engine trouble warning a condition of "Recover" using
light goes off. the Yamaha diagnostic tool, and
then delete the fault code.

Fault code No. P2122, P2123, P2127, P2128, P2138

TIP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
lf a fault code other than No. P2138 (P2122/P2123/P2127/P2128) is detected, perform troubleshooting
first.

Fault code No. P2122, P2123, P2127, P2128,P2138

[P2122] Accelerator position sensor: open or ground short circuit

detected.
[P2123] Accelerator position sensor: power short circuit detected.
Item [P2127] Accelerator position sensor: ground short circuit detected.
[P2128] Accelerator position sensor: open or power short circuit de-
tected.
[P2138] Accelerator position sensor: output voltage deviation error.
Able/Unable to start engine
Fail-safe system
Able/Unable to drive vehicle
Diagnostic code No. 14, 15
Accelerator position sensor signal 1
Tool display • 12-22 (fully closed position)
14 • 97-107 (fully open position)
• Check with throttle grip in fully closed position.
Procedure
• Check with throttle grip in fully open position.
Accelerator position sensor signal 2
Tool display • 10-24 (fully closed position)
15 • 95-109 (fully open position)
• Check with throttle grip in fully closed position.
Procedure
• Check with throttle grip in fully open position.
Probable cause of malfunc- Confirmation of service corn-
Item Maintenance job
tion and check pletion
1 Connection of accelerator posi- Improperly connected ➔ Con- Turn the main switch to "ON",
tion sensor coupler. nect the coupler securely or re- and then check the condition of
Check the locking condition of place the wire harness. the fault code using the mal-
the coupler. function mode of the Yamaha di-
Disconnect the coupler and agnostic tool.
check the pins (bent or broken Condition is "Recover" ➔ Go to
terminals and locking condition item 8 and finish the service.
of the pins). Condition is "Malfunction" ➔ Go
to item 2.

8-109
 FUEL INJECTION SYSTEM

Fault code No. P2122,P2123, P2127, P2128, P2138

[P2122] Accelerator position sensor: open or ground short circuit

detected.
[P2123] Accelerator position sensor: power short circuit detected.
Item (P2127] Accelerator position sensor: ground short circuit detected.
[P2128] Accelerator position sensor: open or power short circuit de-
tected.
[P2138] Accelerator position sensor: output voltage deviation error.
2 Connection of ECU coupler. Improperly connected ➔ Con- Turn the main switch to "ON",
Check the locking condition of nect the coupler securely or re- and then check the condition of
the coupler. place the wire harness. the fault code using the mal-
Disconnect the coupler and function mode of the Yamaha di-
check the pins (bent or broken agnostic tool.
terminals and locking condition Condition is "Recover" ➔ Go to
of the pins). item 8 and finish the service.
Condition is "Malfunction" ➔ Go
to item 3.
3 Wire harness continuity. Open or short ci rcuit ➔ Replace Turn the main switch to "ON",
the wire harness. and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 8 and finish the service.
Condition is "Malfunction" ➔ Go
to item 4.
3-1

2
1 sv
l
3 l
~
--
•
; w 4 w
•
• -
~
- 5V
~

- <
<
<
>
>
>

- ,... 5
<
< ~ ~

~
'= - - B B
A A A
y Vy

-- Bit. 6 B/l
1-

1. Accelerator position sensor

2. ECU
3. Sensor input lead
4. Sensor output lead 1
5. Sensor output lead 2
6. Sensor ground lead
3-2 Disconnect the ECU coupler from the ECU.
Disconnect the accelerator position sensor coupler from the accelerator position sensor.

8-110
 FUEL INJECTION SYSTEM

Fault code No. P2122,P2123, P2127, P2128,P2138

[P2122] Accelerator position sensor: open or ground short circuit

detected.
[P2123] Accelerator position sensor: power short circuit detected.
Item (P2127] Accelerator position sensor: ground short circuit detected.
[P2128] Accelerator position sensor: open or power short circuit de-
tected.
[P2138] Accelerator position sensor: output voltage deviation error.
3-3 [For P2122] Ground short circuit
[For P2138] Deviation error
Between accelerator position sensor coupler and ground: white-ground
If there is continuity, replace the wire harness.

[ [wIBILI L IB ~:J.-..l-l.""--'--'....l.....l....~W,)
---.....

3-4 [For P2122] Open circuit

[For P2138] Deviation error
Between accelerator position sensor coupler and ECU coupler: white-white
If there is no continuity, replace the wire harness.

Y/R AIL G/Y

8/R l./W G/B G 8 B Br
{~@@Jffi~~B/L~B/W*W;;/G~~B+~8r8~r/WT7~~
B/L 8/L 8/Y

A. MTT9K/MTT9KC
B. MTT9GTK/MTT9GTKC
3-5 [For P2127] Ground short circuit
[For P2138] Deviation error
Between accelerator position sensor coupler and ground: black-ground
If there is continuity, replace the wire harness.

@Jfiliis~:J.-..l-l.....!.....l........l.....l.........,,__,,_;W,)

8-111
 FUEL INJECTION SYSTEM

Fault code No. P2122,P2123, P2127, P2128,P2138

[P2122] Accelerator position sensor: open or ground short circuit

detected.
[P2123] Accelerator position sensor: power short circuit detected.
Item (P2127] Accelerator position sensor: ground short circuit detected.
[P2128] Accelerator position sensor: open or power short circuit de-
tected.
[P2138] Accelerator position sensor: output voltage deviation error.
3-6 [For P2128] Open circuit
[For P2138] Deviation error
Between accelerator position sensor coupler and ECU coupler: black-black
If there is no continuity, replace the wire harness.
[ID

Y/R AIL GN

Y/L WN WIG Gy/G Y/G L 8/1. BN GN Y/L

A. MTT9K/MTT9KC
B. MTT9GTK/MTT9GTKC
3-7 [For P2122/P2128] Open circuit
[For P2138] Deviation error
Between accelerator position sensor coupler and ECU coupler: blue-blue
If there is no continuity, replace the wire harness.
[Al

Y/R AIL GN
8/R L/W G/8 G B B Br

A. MTT9K/MTT9KC
B. MTT9GTK/MTT9GTKC

8-112
 FUEL INJECTION SYSTEM

Fault code No. P2122,P2123, P2127, P2128,P2138

[P2122] Accelerator position sensor: open or ground short circuit

detected.
[P2123] Accelerator position sensor: power short circuit detected.
Item (P2127] Accelerator position sensor: ground short circuit detected.
[P2128] Accelerator position sensor: open or power short circuit de-
tected.
[P2138] Accelerator position sensor: output voltage deviation error.
3-8 [For P2122/P2128] Open circuit
[For P2138] Deviation error
Between accelerator position sensor coupler and ECU coupler: black/blue-black/blue
If there is no continuity, replace the wire harness.
[ID

Y/R AIL GN

WN WIG Gy/G Y/G L 8/1. BN GN Y/L

A. MTT9K/MTT9KC
B. MTT9GTK/MTT9GTKC
3-9 Disconnect the couplers from the parts that are connected to the ECU.
Refer to "Parts connected to the ECU" on page 8-51.
3-10 [For P2122/P2123] Short circuit
[For P2138] Deviation error
Between accelerator position sensor output terminal (white) "a" of ECU coupler and any other ECU
coupler terminal "b".
If there is continuity, replace the wire harness.
[Al
a
:· -------------t -----·:
: v~ RA. G/'f G VI VIGNi :
1
B,IR UW~ G 8 3 :

I &\.SN : 811. BIW \VII. Y/B PNI P L L :

'' 811. ''
b/ ··t········· ......... .
' M.M.e/Y WIG
• =""-'='-'-"'-"'-"='l:..c:::= 'I
b /··t··········........ .
'
B/1. B/Y G/Y VII.
'

·-' ------ ',_ -------

A. MTT9K/MTT9KC
B. MTT9GTK/MTT9GTKC

8-113
 FUEL INJECTION SYSTEM

Fault code No. P2122,P2123, P2127, P2128,P2138

[P2122] Accelerator position sensor: open or ground short circuit

detected.
[P2123] Accelerator position sensor: power short circuit detected.
Item (P2127] Accelerator position sensor: ground short circuit detected.
[P2128] Accelerator position sensor: open or power short circuit de-
tected.
[P2138] Accelerator position sensor: output voltage deviation error.
3-11 [For P2127 /P2128] Short circuit
[For P2138] Deviation error
Between accelerator position sensor output terminal (black) "a" of ECU coupler and any other ECU
coupler terminal "b".
If there is continuity, replace the wire harness.
[ru

A. MTT9K/MTT9KC
B. MTT9GTK/MTT9GTKC
4 Installed condition of accelera-
tor position sensor.
5 Accelerator position sensor re-
sistance.
Check for looseness or pinch-
ing.
Improperly installed sensor ➔
Reinstall or adjust the sensor.
Refer to "ADJUSTING THE AC-
CELERATOR POSITION SEN-
SOR" on page 7-19.
Measure the accelerator posi-
tion sensor resistance.
black/blue-blue
Refer to "CHECKING THE AC-
CELERATOR POSITION SEN-
SOR" on page 8-200.
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 8 and finish the service.
Condition is "Malfunction" ➔ Go
to item 5.
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 8 and finish the service.
Condition is "Malfunction" ➔ Go
to item 6.

8-114
 FUEL INJECTION SYSTEM

Fault code No. P2122,P2123, P2127, P2128,P2138

[P2122] Accelerator position sensor: open or ground short circuit

detected.
[P2123] Accelerator position sensor: power short circuit detected.
Item (P2127] Accelerator position sensor: ground short circuit detected.
[P2128] Accelerator position sensor: open or power short circuit de-
tected.
[P2138] Accelerator position sensor: output voltage deviation error.
6 Defective accelerator position Check accelerator position sen- Turn the main switch to "ON",
sensor. sor signal 1. and then check the condition of
Execute the diagnostic mode. the fault code using the mal-
(Code No. 14) function mode of the Yamaha di-
When the throttle grip is fully agnostic tool.
closed: Condition is "Recover" ➔ Go to
A value of 12-22 is indicated. item 8 and finish the service.
When throttle grip is are fully Condition is "Malfunction" ➔ Go
open: to item 7.
A value of 97-107 is indicated.

Check accelerator position sen-

sor signal 2.
Execute the diagnostic mode.
(Code No. 15)
When the throttle grip is fully
closed:
A value of 10-24 is indicated.
When the throttle grip is fully
open:
A value of 95-109 is indicated.

An indicated value is out of the

7 Malfunction in ECU.
8 Delete the fault code and check
that the engine trouble warning
light goes off.
specified range ➔ Replace the
accelerator position sensor.
Replace the ECU. Service is finished.
Refer to "REPLACING THE
ECU (Engine Control Unit)" on
page 8-189.
Confirm that the fault code has
a condition of "Recover" using
the Yamaha diagnostic tool, and
then delete the fault code.

Fault code No. P2158

Fault code No. P2158

Front wheel sensor: no normal signals are received from the front
Item
wheel sensor.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 16
Front wheel speed pulse
Tool display
0-999
Check that the number increases when the front wheel is rotated. The
Procedure
number is cumulative and does not reset each time the wheel is stopped.
Probable cause of malfunc- Confirmation of service corn-
Item Maintenance job
tion and check pletion

8-115

Fau lt code No. P2158
Front wheel sensor: no normal signals are received from the front
Item
wheel sensor.
1 Connection of front wheel sen-
sor 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).
2 Connection of ABS ECU cou-
pler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
3 Connection of ECU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
4 Wire harness continuity.
5 Defective front wheel sensor.
6 Malfunction in ECU.
7 Malfunction in ABS ECU.
FUEL INJECTION SYSTEM
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
Open or short circuit ➔ Replace
the wire harness.
Between front wheel sensor
coupler and ABS ECU coupler.
black-black
white-white
Between ABS ECU coupler and
ECU coupler.
white/green- white/green
Improperly installed sensor ➔
Reinstall or replace the sensor.
Replace the ECU.
Refer to "REPLACING THE
ECU (Engine Control Unit)" on
page 8-189.
Replace the ABS ECU.
8-116
Execute the diagnostic mode.
(Code No. 16)
Rotate the front wheel by hand
and check that the indicated val-
ue increases.
Value increases ➔ Go to item 8
and finish the service.
Value does not increase ➔ Go
to item 2.
Execute the diagnostic mode.
(Code No. 16)
Rotate the front wheel by hand
and check that the indicated val-
ue increases.
Value increases ➔ Go to item 8
and finish the service.
Value does not increase ➔ Go
to item 3.
Execute the diagnostic mode.
(Code No. 16)
Rotate the front wheel by hand
and check that the indicated val-
ue increases.
Value increases ➔ Go to item 8
and finish the service.
Value does not increase ➔ Go
to item 4.
Execute the diagnostic mode.
(Code No. 16)
Rotate the front wheel by hand
and check that the indicated val-
ue increases.
Value increases ➔ Go to item 8
and finish the service.
Value does not increase ➔ Go
to item 5.
Execute the diagnostic mode.
(Code No. 16)
Rotate the front wheel by hand
and check that the indicated val-
ue increases.
Value increases ➔ Go to item 8
and finish the service.
Value does not increase ➔ Go
to item 6.
Execute the diagnostic mode.
(Code No. 16)
Rotate the front wheel by hand
and check that the indicated val-
ue increases.
Value increases ➔ Go to item 8
and finish the service.
Value does not increase ➔ Go
to item 7.
Go to item 8.
 FUEL INJECTION SYSTEM

Fault code No. P2158

Front w heel sensor: no normal signals are received from the front
Item
wheel sensor.
8 De lete the fault code and check Tu rn the main switch to "O N",
that the engine trouble warning and then rotate the front wheel
light goes off. by hand.
Sta rt the e ngine, and input the
vehicle speed signals by operat-
ing the ve hicle at 20 to 30 km/h
(12 to 19 mph) .
Confirm that the fault code has
a condition of "Recover" using
the malfunction mode of the
Yamaha diagnostic tool, and
then delete the fault code.
Delete this fault code even if it
has a condition of "Malfunction".

Fault code No. P2195

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
If fault code numbers "P2 195" and "P0030" are both indicated, take the actions specified for fault code
number "P0030" first.

Fault code No. P2195

Item 0 2 sensor: open circuit detected.

Able to sta rt engine

Fail-safe system
Able to drive vehicle
Diagnostic code No. -
Tool display -
Procedure -
Probable cause of malfunc- Confirmation of service corn-
Item Maintenance job
tion and check pletion
1 Installed condition of 0 2 se nsor. Check for looseness or pinch- Start the e ngine and let it idle for
1ng. approximately 10 seconds.
Imprope rly installed se nso r ➔ Check the condition of the fault
Re install o r replace the se nsor. code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item 8 and finish the se rvice.
Condition is "Malfunction" ➔ Go
to item 2.
Also, delete this fault code,
which has a condition of "Mai-
function".

8-117

Fau lt code No. P2195
Item 0 2 sensor: open circuit detected.
2 Connection of 0 2 sensor cou-
pler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
3 Connection of ECU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
4 Wire harness continuity.
5 Check fuel pressure.
FUEL INJECTION SYSTEM
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
Open or short circuit ➔ Replace
the wire harness.
Between 0 2 sensor coupler and
ECU coupler.
gray/green- gray/green
pink/black- pink/black
black/blue-black/blue
Between 0 2 sensor coupler and
ignition coil.
red/white- red/white
Refer to "CHECKING THE
FUEL PRESSURE" on page
7-17.
8-118
Start the engine and let it idle for
approximately 10 seconds.
Check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item 8 and finish the service.
Condition is "Malfunction" ➔ Go
to item 3.
Also, delete this fault code,
which has a condition of "Mal-
function".
Start the engine and let it idle for
approximately 10 seconds.
Check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item 8 and finish the service.
Condition is "Malfunction" ➔ Go
to item 4.
Also, delete this fault code,
which has a condition of "Mal-
function".
Start the engine and let it idle for
approximately 10 seconds.
Check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item 8 and finish the service.
Condition is "Malfunction" ➔ Go
to item 5.
Also, delete this fault code,
which has a condition of "Mal-
function".
Start the engine and let it idle for
approximately 10 seconds.
Check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item 8 and finish the service.
Condition is "Malfunction" ➔ Go
to item 6.
Also, delete this fault code,
which has a condition of "Mal-
function".
 FUEL INJECTION SYSTEM

Fault code No. P2195

Item 0 2 sensor: open circuit detected.

6 Defective 0 2 sensor.
7 Malfunction in ECU.
8 Delete the fault code and check
that the engine trouble warning
light goes off.
Check the 0 2 sensor.
Refer to "ENGINE REMOVAL:'
on page 5-9.
Replace if defective.
Replace the ECU.
Refer to "REPLACING THE
ECU (Engine Control Unit)" on
page 8-189.
Confirm that the fault code has
a condition of "Recover" using
the Yamaha diagnostic tool, and
then delete the fault code.
Start the engine and let it idle for
approximately 10 seconds.
Check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item 8 and finish the service.
Condition is "Malfunction" ➔ Go
to item 7.
Also, delete this fault code,
which has a condition of "Mai-
function".
Service is finished.

Event code No. U0155 or "Err"

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
"Err'' is displayed on the clock display of the multi-function meter, but the engine trouble warning light
does not come on.

Event code No. U0155 or "Err"

Multi-function meter: signals cannot be transmitted between the

Item
ECU and the multi-function meter.
Probable cause of malfunc-
Item
tion and check
1 Connection of meter assembly
coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
2 Connection of ECU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Maintenance job
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
Confirmation of service corn-
pletion
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 6 and finish the service.
Condition is "Malfunction" ➔ Go
to item 2.
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 6 and finish the service.
Condition is "Malfunction" ➔ Go
to item 3.

8-119
 FUEL INJECTION SYSTEM

Event code No. U0155 or "Err"

Multi-function meter: signals cannot be transmitted between the

Item
ECU and the multi-function meter.
3 Wire harness continuity.
4 Defective meter assembly.
5 Malfunction in ECU.
6 Delete the fault code and check
that the engine trouble warning
light goes off.
Open or short circuit ➔ Replace
the wire harness.
Between meter assembly cou-
pier and joint coupler.
light green/blue-light green/blue
light green/white-light green/
white
Between joint coupler and ECU
coupler.
light green/blue-light green/blue
light green/white-light green/
white
Replace the meter assembly.
Replace the ECU.
Refer to "REPLACING THE
ECU (Engine Control Unit)" on
page 8-189.
Confirm that the fault code has
a condition of "Recover" using
the Yamaha diagnostic tool, and
then delete the fault code.
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 6 and finish the service.
Condition is "Malfunction" ➔ Go
to item 4.
Turn the main switch to "ON",
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is "Recover" ➔ Go to
item 6 and finish the service.
Condition is "Malfunction" ➔ Go
to item 5.
Service is finished.

8-120
 CRUISE CONTROL SYSTEM (MTT9GTK/MTT9GTKC)

EAS20087

CRUISE CONTROL SYSTEM (MTT9GTK/MTT9GTKC)

EAS30544

CIRCUIT DIAGRAM

.-• ----------
•
•
•
'
'
'
- - - ''
•

,- - - - - - - - - ~

·rlJ=::;i,..
'
'
'
'
'
'
'

' • •
• ' •
.A•
' ' ' ''
' ' '

-- ·1·w- -...
'
'
'
' =
... - ... .. .. - - -
•
... f

8-121
 CRUISE CONTROL SYSTEM (MTT9GTK/MTT9GTKC)

3. Main switch
4. Main fuse
8. Backup fuse
11. Ignition fuse
13. Signaling system fuse
14. Brake light fuse
16.Battery
17.Engine ground
18. Fuel injection system fuse
21.Joint coupler
22.Grip cancel switch
23.Clutch switch
24. Front brake light switch
25. Rear brake light switch
29.Brake light relay
35. ECU (Engine Control Unit)
59. Yamaha diagnostic tool coupler
60.Meter assembly
64.Multi-function meter
69.Cruise control system indicator light
70. Cruise control setting indicator light
79. Handlebar switch (left)
86.Cruise control power switch
87.Cruise control setting switch
102.Cruise control fuse
A. Wire harness
B. Negative battery sub-wire harness

8-122
 CRUISE CONTROL SYSTEM (MTT9GTK/MTT9GTKC)

EAS30666

CRUISE CONTROL CIRCUIT OPERATION

,
'' '
.'
------ ' ------ ~

'
'
'
- '
'
'
'
- - ' I•• • • • • •
'
' ''
' '' '
,-0 0--:
4 5 '' ' '' ' '
- - - '
'
'
.' '
'
'
' '
'
8 :'
''

6 ,''' ''~- -----·

',' ______ 7 ''' ,' _______
I

-==
-
-- -- -- -- --- --'
''
' 13 '
'
'' '
'
10 11 12 '
''
''
- 0-0
,..,_ ------------ ..'
~
9 20
14

16,~
~
r
' 18
_, 17
3 -
-c.=-

15

2 -c.=-
-
19

-
1 -- -

l
1. Battery 19. Fuel injection system fuse
2. Main fuse 20. ECU (Engine Control Unit)
3. Main switch
4. Signaling system fuse
5. Brake light fuse
6. Front brake light switch
7. Rear b rake light switch
8. Brake light relay
9. Ignition fuse
10.Cruise control fuse
11.Grip cancel switch
12. Clutch switch
13.Cruise control setting switch
14.Cruise control power switch
15.Backup fuse
16.Cruise control system indicator light
17.Cruise control setting indicator light
18. Meter assembly

8-123
 CRUISE CONTROL SYSTEM (MTT9GTK/MTT9GTKC)

EAS30667

BASIC INSTRUCTIONS FOR TROUBLESHOOTING

EWA17420

AwARNING
• 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 cruise control system indicator light.
[B] Use the Yamaha diagnostic tool to determine the cause of the malfunction for the stored fault code
from the condition and place where the malfunction occurred .
TIP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
For information about using the Yamaha diagnostic tool, refer to "YAMAHA DIAGNOSTIC TOOL" on
page 8-50.
[C] Servicing the cruise control system.
Execute the final check after disassembly and assembly.

8-124
 CRUISE CONTROL SYSTEM (MTT9GTK/MTT9GTKC)

EAS30668

BASIC PROCESS FOR TROUBLESHOOTING

[A) Push the cruise control Fails to come on • The cruise control power switch is
power switch, and check
defective.
the cruise control system
indicator light. Flashes • The cruise control system fuse is
TIP blown. .
. (Return to [Al)
• If the engine trouble warning • The ECU is defective.
light is on, check the condition
of the fault code using the
malfunc tion mode of the
Yamaha diagnostic tool.
Refer to 'TROUBLESHOOTING
DETAILS" (FAULT CODE). . [B-1JDiagnosis using the fault
[C- 1) Delete the fault codes. .• ( Return to [AJ.)
codes.
' •
Comes on
•
[B-2) Check the malfunc tion
history using the malfunction Yes
mode o f the Yamaha
diagnostic tool.
Is there any malfunction
history?

No

[B-3 ) Is there automatic Yes . Explain the conditions for

deactivation history for the
. automatically deactivating the
cruise control system? cruise control system to the
customer.
No
OK
•

[C-2) Final check. .

Fault code number is

not displayed.

Finished.

8-125
 CRUISE CONTROL SYSTEM (MTT9GTK/MTT9GTKC)

EWA1744 1

AwARNING
When maintenance or checks have been performed on components related to the cruise control
system, be sure to perform a final check before delivering the vehicle to the customer.
Refer to "[C-2] FI NAL CHECK" on page 8-136.
EAS30669

[A] CHECKING THE CRUISE CONTROL SYSTEM INDICATOR LIGHT

Turn the main switch to "ON", and then push the cruise control power switch.
1. The cruise control system indicator light does not come on.
• Check the control power switch for continuity. Refer to "CHECKING TH E SWITCHES" on page
8-187. If there is no continuity, replace the left handlebar switch.
• Check the fuse for continuity. Refer to "CH ECKING THE FUSES" on page 8-189. If the cruise con-
trol system fuse is blown, replace the fuse.
• Check for continuity between the green/yellow terminal of the left handlebar switch coupler and
green/yellow terminal of the ECU (engine control unit) coupler. If there is no continuity, the wire har-
ness is defective. Replace the wire harness.
2. The cruise control system indicator light flashes. [B-1]
3. The cruise control system indicator light come on. [B-2]
EAS30670

[B-1] DIAGNOSIS USING THE FAULT CODES

1. Information for the fault codes from the cruise control system is contained in the following table. Re-
fer to this table for troubleshooting.
Fault code table

Fault code
Symptom Check point
No.
P056C No normal signals from the switch are re- • Wire harness (ECU coupler and front or rear
ceived by the ECU. brake light switch coupler)
• Signaling system and brake light fuses
• Connection of the brake light relay coupler
• Connection of the main switch coupler
• Front brake light switch
• Rear brake light switch
P0564 No normal signals from the switch are re- • Wire harness (ECU coupler and left handlebar
ceived by the ECU. switch coupler)
• Signaling system fuse
• Connection of the main switch coupler
• Cruise control setting switch

Fault code No. P056C

Fault code No. P056C

A Front brake light switch: open or short circuit is detected.

Item
B Rear brake light switch: open or short circuit is detected.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 82,83
"ON" (when the brakes are applied)
Tool display
"OFF" (when the brakes are not applied)
Procedure Operate the brake lever.

8-126
 CRUISE CONTROL SYSTEM (MTT9GTK/MTT9GTKC)
Fault code No. P056C
A Front brake light switch: open or short circuit is detected.
Item
B Rear brake light switch: open or short circuit is detected.
Probable cause of malfunc-
Item
tion and check
A-1 Locate the malfunction.
A-2 Connection of front brake light
switch 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).
A-3 Connection of brake light relay
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).
A-4 Connection of main switch cou-
pler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
A-5 Connection of wire harness
ECU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Maintenance job
Execute the diagnostic mode.
(Code 82, 83)
When the front brake is applied:
"ON"
When the front brake is not ap-
plied: "OFF"
When the rear brake is applied:
"ON"
When the rear brake is not ap-
plied: "OFF"
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
8-127
Confirmation of service com-
pletion
Malfunction ➔ Goto item A-2.
Malfunction ➔ Go to item B-2
for the rear brake light switch.
Turn the main switch to "ON".
Operate the brake lever, and
then check the condition of the
fault code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item A-10 and finish the service.
Condition is "Malfunction" ➔ Go
to item A-3.
Turn the main switch to "ON".
Operate the brake lever, and
then check the condition of the
fault code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item A-10 and finish the service.
Condition is "Malfunction" ➔ Go
to item A-4.
Turn the main switch to "ON".
Operate the brake lever, and
then check the condition of the
fault code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item A-10 and finish the service.
Condition is "Malfunction" ➔ Go
to item A-5.
Turn the main switch to "ON".
Operate the brake lever, and
then check the condition of the
fault code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item A-10 and finish the service.
Condition is "Malfunction" ➔ Go
to item A-6.
 CRUISE CONTROL SYSTEM (MTT9GTK/MTT9GTKC)

Fau lt code No. P056C

A Front brake light switch: open or short circuit is detected.

Item
B Rear brake light switch: open or short circuit is detected.
A-6 Check the fuse. (main fuse, sig- Abnormality ➔ Replace the Turn the main switch to "ON".
naling system fuse, brake light fuse. (main fuse, signaling sys- Operate the brake lever, and
fuse) tem fuse, brake light fuse) then check the condition of the
fault code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item A-10 and finish the service.
Condition is "Malfunction" ➔ Go
to item A-7.
A-7 Wire harness continuity. Open or short circuit ➔ Replace Turn the main switch to "ON".
the wire harness. Operate the brake lever, and
Between signaling system fuse then check the condition of the
and brake light fuse. fault code using the malfunction
brown- brown mode of the Yamaha diagnostic
Between brake light fuse and tool.
front brake light switch coupler. Condition is "Recover" ➔ Go to
green/white-green/white item A- 10 and finish the service.
Between front brake light switch Condition is "Malfunction" ➔ Go
coupler and rear brake light to item A-8.
switch coupler.
green/yellow- green/yellow
Between rear brake light switch
coupler and brake light relay
coupler.
green/yellow- green/yellow
Between brake light relay cou-
pler and ECU.
green/yellow- green/yellow
Between brake light relay cou-
pler and battery.
black-black
A-8 Defective front brake light Replace the front brake light Turn the main switch to "ON".
switch. switch. Operate the brake lever, and
then check the condition of the
fault code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item A-10 and finish the service.
Condition is "Malfunction" ➔ Go
to item A-9.
A-9 Malfunction in ECU. Replace the ECU.
Refer to "REPLACING THE
ECU (Engine Control Unit)" on
page 8-189.
A- 10 Delete the fault code and check Confirm that the fault code has
that the engine trouble warning a condition of "Recover" using
light goes off. the Yamaha diagnostic tool, and
then delete the fault code.

8-128
 CRUISE CONTROL SYSTEM (MTT9GTK/MTT9GTKC)

Fault code No. P056C

A Front brake light switch: open or short circuit is detected.

Item
B Rear brake light switch: open or short circuit is detected.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 82, 83
"ON" (when the brakes are applied)
Tool display
"OFF" (when the brakes are not applied)
Procedure Operate the brake pedal.
Probable cause of malfunc- Confirmation of service corn-
Item Maintenance job
tion and check pletion
B-1 Locate the malfunction. Execute the diagnostic mode.
(Code 82, 83)
When the front brake is applied: Malfunction ➔ Go to item A-2
"ON" for the front brake light switch.
When the front brake is not ap-
plied: "OFF"
When the rear brake is applied: Malfunction ➔ Go to item B-2.
"ON"
When the rear brake is not ap-
plied: "OFF"
B-2 Connection of rear brake light Improperly connected ➔ Con- Turn the main switch to "ON".
switch coupler. nect the coupler securely or re- Operate the brake pedal, and
Check the locking condition of place the wire harness. then check the condition of the
the coupler. fault code using the malfunction
Disconnect the coupler and mode of the Yamaha diagnostic
check the pins (bent or broken tool.
terminals and locking condition Condition is "Recover" ➔ Go to
of the pins). item B-10 and finish the service.
Condition is "Malfunction" ➔ Go
to item B-3.
B-3 Connection of brake light relay Improperly connected ➔ Con- Turn the main switch to "ON".
coupler. nect the coupler securely or re- Operate the brake pedal, and
Check the locking condition of place the wire harness. then check the condition of the
the coupler. fault code using the malfunction
Disconnect the coupler and mode of the Yamaha diagnostic
check the pins (bent or broken tool.
terminals and locking condition Condition is "Recover" ➔ Go to
of the pins). item B-10 and finish the service.
Condition is "Malfunction" ➔ Go
to item B-4.
B-4 Connection of main switch cou- Improperly connected ➔ Con- Turn the main switch to "ON".
pier. nect the coupler securely or re- Operate the brake pedal, and
Check the locking condition of place the wire harness. then check the condition of the
the coupler. fault code using the malfunction
Disconnect the coupler and mode of the Yamaha diagnostic
check the pins (bent or broken tool.
terminals and locking condition Condition is "Recover" ➔ Go to
of the pins). item B-10 and finish the service.
Condition is "Malfunction" ➔ Go
to item B-5.

8-129
 CRUISE CONTROL SYSTEM (MTT9GTK/MTT9GTKC)
Fau lt code No. P056C
A Front brake light switch: open or short circuit is detected.
Item
B Rear brake light switch: open or short circuit is detected.
B-5 Connection of wire harness Improperly connected ➔ Con-
ECU coupler. nect the coupler securely or re-
Check the locking condition of place the wire harness.
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
B-6 Check the fuse. (main fuse, sig- Abnormality ➔ Replace the
naling system fuse, brake light fuse. (main fuse, signaling sys-
fuse) tem fuse, brake light fuse)
B-7 Wire harness continuity. Open or short circuit ➔ Replace
the wire harness.
Between signaling system fuse
and brake light fuse.
brown- brown
Between brake light fuse and
front brake light switch coupler.
green/white-green/white
Between front brake light switch
coupler and rear brake light
switch coupler.
green/yellow- green/yellow
Between rear brake light switch
coupler and brake light relay
coupler.
green/yellow- green/yellow
Between brake light relay cou-
pler and ECU.
green/yellow- green/yellow
Between brake light relay cou-
pler and battery.
black-black
B-8 Defective rear brake light Replace the rear brake light
switch. switch.
8-130
Turn the main switch to "ON".
Operate the brake pedal, and
then check the condition of the
fault code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item B-10 and finish the service.
Condition is "Malfunction" ➔ Go
to item B-6.
Turn the main switch to "ON".
Operate the brake pedal, and
then check the condition of the
fault code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item B-10 and finish the service.
Condition is "Malfunction" ➔ Go
to item B-7.
Turn the main switch to "ON".
Operate the brake pedal, and
then check the condition of the
fault code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item B-10 and finish the service.
Condition is "Malfunction" ➔ Go
to item B-8.
Turn the main switch to "ON".
Operate the brake pedal, and
then check the condition of the
fault code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item B-10 and finish the service.
Condition is "Malfunction" ➔ Go
to item B-9.
 CRUISE CONTROL SYSTEM (MTT9GTK/MTT9GTKC)

Fault code No. P056C

A Front brake light switch: open or short circuit is detected.

Item
B Rear brake light switch: open or short circuit is detected.
B-9 Malfunction in ECU. Replace the ECU.
Refer to "REPLACI NG THE
ECU (Engine Control Unit)" on
page 8-189.
B-10 Delete the fault code and check Confirm that the fault code has
that the engine trouble warning a condition of "Recover" using
light goes off. the Yamaha diagnostic tool, and
then delete the fault code.

Fault code No. P0564

Fault code No. P0564

Cruise control setting switch "RES+": open or short circuit is de-

A
tected.
Item
Cruise control setting switch "SET-": open or short circuit is de-
B
tected.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 80, 81
"ON" (when the switch is pushed)
Tool display
"OFF" (when the switch is released)
Procedure Push and release the "RES+" side of the cruise control setting switch.
Probable cause of malfunc- Confirmation of service corn-
Item Maintenance job
tion and check pletion
A- 1 Locate the malfunction. Execute the diagnostic mode.
(Code 80)
W hen the cruise control setting Malfunction ➔ Go to item A-2 .
switch "RES+" is pushed: "ON"
W hen the cruise control setting
switch is released: "O FF"
Execute the diagnostic mode.
(Code 81)
W hen the cruise control setting Malfunction ➔ Go to item B-2
switch "SET- " is pushed: "ON" for the cruise control setting
W hen the cruise control setting switch "SET-".
switch is released: "O FF"
A-2 Connection of left handlebar Improperly connected ➔ Con- Turn the main switch to "ON".
switch coupler. nect the coupler securely or re- Push and release the "RES+"
Check the locking condition of place the wire harness. side of the cruise control setting
the coupler. switch, and then check the con-
Disconnect the coupler and dition of the fault code using the
check the pins (bent or broken malfunction mode of the
terminals and locking condition Yamaha diagnostic tool.
of the pins). Condition is "Recover" ➔ Go to
item A-9 and finish the service.
Condition is "Malfunction" ➔ Go
to item A-3.

8-131
 CRUISE CONTROL SYSTEM (MTT9GTK/MTT9GTKC)

Fau lt code No. P0564

A Cruise control setting switch "RES+" : open or short circuit is de-

tected.
Item
Cruise control setting switch "SET-": open or short circuit is de-
8
tected.
A-3 Connection of main switch cou-
pler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
A-4 Connection of ECU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
A-5 Check the fuse. (main fuse, ig-
nition fuse, cruise control sys-
tem fuse)
A-6 Wire harness continuity.
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
Abnormality ➔ Replace the
fuse. (main fuse, ignition fuse,
cruise control system fuse)
Open or short circuit ➔ Replace
the wire harness.
Between battery and main fuse.
red-red
Between main fuse and main
switch coupler.
red-red
Between main switch coupler
and ignition fuse.
brown/blue- brown/blue
Between ignition fuse and
cruise control fuse.
red/white-red/white
Between cruise control fuse and
left handlebar switch coupler.
yellow/black-yellow/black
Between left handlebar switch
coupler and ECU coupler.
green/black-green/black
Turn the main switch to "ON".
Push and release the "RES+"
side of the cruise control setting
switch, and then check the con-
dition of the fault code using the
malfunction mode of the
Yamaha diagnostic tool.
Condition is "Recover" ➔ Go to
item A-9 and finish the service.
Condition is "Malfunction" ➔ Go
to item A-4.
Turn the main switch to "ON".
Push and release the "RES+"
side of the cruise control setting
switch, and then check the con-
dition of the fault code using the
malfunction mode of the
Yamaha diagnostic tool.
Condition is "Recover" ➔ Go to
item A-9 and finish the service.
Condition is "Malfunction" ➔ Go
to item A-5.
Turn the main switch to "ON".
Push and release the "RES+"
side of the cruise control setting
switch, and then check the con-
dition of the fault code using the
malfunction mode of the
Yamaha diagnostic tool.
Condition is "Recover" ➔ Go to
item A-9 and finish the service.
Condition is "Malfunction" ➔ Go
to item A-6.
Turn the main switch to "ON".
Push and release the "RES+"
side of the cruise control setting
switch, and then check the con-
dition of the fault code using the
malfunction mode of the
Yamaha diagnostic tool.
Condition is "Recover" ➔ Go to
item A-9 and finish the service.
Condition is "Malfunction" ➔ Go
to item A-7.

8-132
 CRUISE CONTROL SYSTEM (MTT9GTK/MTT9GTKC)

Fault code No. P0564

Cruise control setting switch "RES+" : open or short circuit is de-

A
tected.
Item
Cruise control setting switch "SET-": open or short circuit is de-
B
tected.
A-7 Defective cruise control setting Replace the left handlebar Turn the main switch to "ON".
switch. switch. Push the "RES+" side and
"SET- " side of the cruise con-
trol setting switch, and then
check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item A-9 and finish the service.
Condition is "Malfunction" ➔ Go
to item A-8.
A-8 Malfunction in ECU. Replace the ECU.
Refer to "REPLACI NG TH E
ECU (Engine Control Unit)" on
page 8-189.
A-9 Delete the fault code and check Confirm that the fault code has
that the engine trouble warning a condition of "Recover" using
light goes off. the Yamaha diagnostic tool, and
then delete the fault code.

Fault code No. P0564

Cruise control setting switch "RES+" : open or short circuit is de-

A
tected.
Item
Cruise control setting switch "SET-": open or short circuit is de-
B
tected.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 80, 81
"ON" (when the switch is pushed)
Tool display
"OFF" (when the switch is released)
Procedure Push the "SET_!' side of the cruise control setting switch.
Probable cause of malfunc- Confirmation of service corn-
Item Maintenance job
tion and check pletion
B-1 Locate the malfunction. Execute the diagnostic mode.
(Code 80)
W hen the cruise control setting Malfunction ➔ Go to item A-2
switch "RES+" is pushed: "ON" for the cruise control setting
W hen the cruise control setting switch "RES+".
switch is released: "O FF"
Execute the diagnostic mode.
(Code 81)
W hen the cruise control setting Malfunction ➔ Go to item B-2.
switch "SET- " is pushed: "ON"
W hen the cruise control setting
switch is released: "O FF"

8-133
 CRUISE CONTROL SYSTEM (MTT9GTK/MTT9GTKC)
Fault code No. P0564
A Cruise control setting switch "RES+": open or short circuit is de-
tected.
Item
Cruise control setting switch "SET-": open or short circuit is de-
8
tected.
B-2 Connection of left handlebar
switch 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).
B-3 Connection of main switch cou-
pler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
B-4 Connection of ECU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
B-5 Check the fuse. (main fuse, ig-
nition fuse, cruise control sys-
tem fuse)
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
Improperly connected ➔ Con-
nect the coupler securely or re-
place the wire harness.
Abnormality ➔ Replace the
fuse. (main fuse, ignition fuse,
cruise control system fuse)
8-134
Turn the main switch to "ON".
Push and "SET-" side of the
cruise control setting switch,
and then check the condition of
the fault code using the mal-
function mode of the Yamaha
diagnostic tool.
Condition is "Recover" ➔ Go to
item B-9 and finish the service.
Condition is "Malfunction" ➔ Go
to item B-3.
Turn the main switch to "ON".
Push and "SET-" side of the
cruise control setting switch,
and then check the condition of
the fault code using the mal-
function mode of the Yamaha
diagnostic tool.
Condition is "Recover" ➔ Go to
item B-9 and finish the service.
Condition is "Malfunction" ➔ Go
to item B-4.
Turn the main switch to "ON".
Push and "SET-" side of the
cruise control setting switch,
and then check the condition of
the fault code using the mal-
function mode of the Yamaha
diagnostic tool.
Condition is "Recover" ➔ Go to
item B-9 and finish the service.
Condition is "Malfunction" ➔ Go
to item B-5.
Turn the main switch to "ON".
Push and "SET-" side of the
cruise control setting switch,
and then check the condition of
the fault code using the mal-
function mode of the Yamaha
diagnostic tool.
Condition is "Recover" ➔ Go to
item B-9 and finish the service.
Condition is "Malfunction" ➔ Go
to item B-6.
 CRUISE CONTROL SYSTEM (MTT9GTK/MTT9GTKC)

Fau lt code No. P0564

A Cruise control setting switch "RES+": open or short circuit is de-

tected.
Item
Cruise control setting switch "SET-": open or short circuit is de-
8
tected.
B-6 Wire harness continuity. Open or short circuit ➔ Replace Turn the main switch to "ON".
the wire harness. Push and "SET-" side of the
Between battery and main fuse. cruise control setting switch,
red-red and then check the condition of
Between main fuse and main the fault code using the mal-
switch coupler. function mode of the Yamaha
red-red diagnostic tool.
Between main switch coupler Condition is "Recover" ➔ Go to
and ignition fuse. item B-9 and finish the service.
brown/blue- brown/blue Condition is "Malfunction" ➔ Go
Between ignition fuse and to item B-7.
cruise control fuse.
red/white-red/white
Between cruise control fuse and
left handlebar switch coupler.
yellow/black-yellow/black
Between left handlebar switch
coupler and ECU coupler.
green- green
B-7 Defective cruise control setting Replace the left handlebar Turn the main switch to "ON".
switch. switch. Push the "RES+" side and
"SET-" side of the cruise con-
trol setting switch, and then
check the condition of the fault
code using the malfunction
mode of the Yamaha diagnostic
tool.
Condition is "Recover" ➔ Go to
item B-9 and finish the service.
Condition is "Malfunction" ➔ Go
to item B-8.
B-8 Malfunction in ECU. Replace the ECU.
Refer to "REPLACING THE
ECU (Engine Control Unit)" on
page 8-189.
B-9 Delete the fault code and check Confirm that the fault code has
that the engine trouble warning a condition of "Recover" using
light goes off. the Yamaha diagnostic tool, and
then delete the fault code.

EAS30671

[B-2] DIAGNOSIS USING THE MALFUNCTION HISTORY CODES

Check the malfunction history using the malfunction mode of the Yamaha diagnostic tool.
• Malfunction history is displayed on the Yamaha diagnostic tool. [B-1]
• Malfunction history is not displayed on the Yamaha diagnostic tool. [B-3]
EAS31924

[B-3] MALFUNCTION HISTORY IS NOT DISPLAYED

Use the Yamaha diagnostic tool to check whether automatic deactivation history for the cruise control
system exists.
1. There is automatic deactivation history for the cruise control system.
• Explain the conditions for automatically deactivating the cruise control system to the customer.

8-135
 CRUISE CONTROL SYSTEM (MTT9GTK/MTT9GTKC)

• For information about the conditions for automatically deactivating the cruise control system.
Refer to "Automatic deactivation of the cruise control system" on page 8-136.
TIP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
lf you do not have a Yamaha diagnostic tool , the automatic deactivation history cannot be checked.
Therefore, explain the automatic deactivation function of the cruise control system to the customer and
explain that this is not a malfunction.

Automatic deactivation of the cruise control system

The cruise control system for this model is electronically controlled and is linked with the other control
systems. The cruise control system will automatically become deactivated under the following condi-
tions:
• The cruise control system is not able to maintain the set cruising speed.
• Wheel slip or wheel spin is detected. (If the traction control system has not been turned off, the traction
control system will work.)
• The start/engine stop switch is set to the "~ " position.
• The engine stalls.
• The sidestand is extended.
Automatic deactivation condi- Vehicle condition for de-
Multi-function meter indication
tion tection
Unable to maintain the set Cruise control system is Cruise control system indicator light"~" goes
cruising speed turned on and cruising off and cruise control setting indicator light
speed is set "SET" flashes for 4 seconds
Traction control system is en-
gaged
Wheel slip or wheel spin is de-
tected
Start/engine stop switch is set Cruise control system is
to the "~" position turned on
Engine stalls
Sidestand is extended

Because the automatic deactivation of the cruise control system is stored in the memory of the ECU ,
the deactivation can be checked using the Yamaha diagnostic tool.
TIP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
ln some cases, the cruise control system may not be able to maintain the set cruising speed when the
vehicle is traveling uphill or downhill.
• When the vehicle is traveling uphill , the actual traveling speed may become lower than the set cruising
speed. If this occurs, accelerate to the desired traveling speed using the throttle.
• When the vehicle is traveling downhill , the actual traveling speed may become higher than the set
cruising speed. If this occurs, the setting switch cannot be used to adjust the set cruising speed. To
reduce the traveling speed, apply the brakes. When the brakes are applied, the cruise control system
will become deactivated.

EAS30674

[C-1] DELETING THE FAULT CODES

1. Delete the fault code using the malfunction of the Yamaha diagnostic tool , and check that the engine
trouble warning light goes off.
EAS30675

[C-2] FINAL CHECK

1. Check the brake lever and brake pedal operation.
2. Check the rear brake light switches.
Refer to "ADJUSTING THE REAR BRAKE LIGHT SWITCH" on page 3-30.

8-136
 CRUISE CONTROL SYSTEM (MTT9GTK/MTT9GTKC)

3. Execute the diagnostic mode (code Nos. 82 and 83) to check the operation of the front brake light
switch, rear brake light switch , and grip cancel switch .
Refer to "SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE" on page 9-1 .
4. Execute the diagnostic mode (code Nos. 80 and 81) to check the operation of the cruise control set-
ting switch .
Refer to "SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE" on page 9-1 .
5. Delete the fault codes.
Refer to "SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE" on page 9-1 .
6. Check the operation of the cruise control system.
Test ride the vehicle and confirm that the cruise control system is operating normally.

8-137
CRUISE CONTROL SYSTEM (MTT9GTK/MTT9GTKC)

8-138
 FUEL PUMP SYSTEM

EAS20081

FUEL PUMP SYSTEM

EAS30513

CIRCUIT DIAGRAM (MTT9K/MTT9KC)

!I· . . ····· . . . • ····· : .

, : • . . . . : . . • . •5 . . . . . . . .•s :i• . . . . . . : . : . . .. 1 I
®. . :. . ·-·
, ... · ·...... ,
= ················'~~
I I I I : ........
' .:r
I ,
~
I

•
...,.,_,
I,, ···- '
•
GH ' '
\(SM . !--..-........ ~

,·rJ ·r·u·.. .
:..~ . . ... .:
j

8-139
 FUEL PUMP SYSTEM

3. Main switch
4. Main fuse
11. Ignition fuse
15.Battery
16. Engine ground
17.Fuel injection system fuse
22.Joint coupler
23. Handlebar switch (right)
26.Start/engine stop switch
28. Relay unit
30. Fuel pump relay
33. ECU (Engine Control Unit)
72.Fuel pump
A. Wire harness
B. Negative battery sub-wire harness

8-140
 FUEL PUMP SYSTEM

EAS3 1342

CIRCUIT DIAGRAM (MTT9GTK/MTT9GTKC)

; -: - - - - - - ; I =-.......... - 11 1 1 i l l l f t -• : :::i.,...

.: .. _-·-______ : ______________ -~i=~===,=--,1,

, 0~:II

----'
' '
~ - ---,,y~

I·

aii ~
~ Eil

8-141
 FUEL PUMP SYSTEM

3. Main switch
4. Main fuse
11. Ignition fuse
16.Battery
17.Engine ground
18. Fuel injection system fuse
21.Joint coupler
26. Handlebar switch (right)
28.Start/engine stop switch
30.Relay unit
32. Fuel pump relay
35. ECU (Engine Control Unit)
76.Fuel pump
A. Wire harness
B. Negative battery sub-wire harness

8-142
 FUEL PUMP SYSTEM

EAS30514

TROUBLESHOOTING
If the fuel pump fails to operate.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Before troubleshooting, remove the following part(s):
1. Fuel tank front cover/Front side panel/Front side cowling
2. Passenger seat/Rider seat
3. Fuel tank cover
4. Fuel tank

1. Check the fuses. NG ➔

(Main, ignition and fuel injection
system) Replace the fuse(s) .
Refer to "CHECKING THE FUS-
ES" on page 8-189.

OKt

2. Check the battery.

Refer to "CHECKING AND • Clean the battery terminals.
CHARG ING THE BATTERY" on • Recharge or replace the battery.
page 8-190.

OKt

3. Check the main switch .

Refer to "CHECKING THE Replace the main switch.
SWITCHES" on page 8-187.

OKt

4. Check the start/engine stop switch.

Refer to "CHECKING THE Replace the handlebar switch (right).
SWITCHES" on page 8-187.

OKt

5. Check the relay unit (fuel pump re-

lay).
Replace the relay unit.
Refer to "CHECKING THE RE-
LAYS" on page 8-190.

OKt

6. Check the fuel pump.

Refer to "CHECKING THE FUEL Replace the fuel pump.
PUMP OPERATION" on page 7-3.

OKt

8-143
 FUEL PUMP SYSTEM

7. Check the entire fuel pump sys- NG ➔

tem's wiring .
Refer to "CIRCU IT DIAGRAM
Properly connect or replace the fuel pump
(MTT9K/MTT9KC)" on page 8-139,
system's wiring.
or refer to "CIRCU IT DIAGRAM
(MTT9GTK/MTT9GTKC)" on page
8-141 .

OK.J,
Replace the ECU.
Refer to "REPLACING THE ECU (En-
gine Control Unit)" on page 8-189.

8-144
 ABS (ANTI-LOCK BRAKE SYSTEM)

EAS20085

ABS (ANTI-LOCK BRAKE SYSTEM)

EAS30843

CIRCUIT DIAGRAM (MTT9K/MTT9KC)

.- - - - - - - - - - - - - - - - - - - - - - - - - - - '. a .:v s-

i n~~◊r'....l...il..1.L ~ ~~b2®®i ;
. .. ' o6l> ' •
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---- - - ---''

~-. ..
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+ •--➔ I

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- ''

''-- ----- _,'

8-145
 ABS (ANTI-LOCK BRAKE SYSTEM)

3. Main switch
4. Main fuse
5. ABS motor fuse
6. ABS solenoid fuse
11. Ignition fuse
12.ABS control unit fuse
13. Signaling system fuse
15.Battery
16. Engine ground
17.Fuel injection system fuse
21. Rear brake light switch
22.Joint coupler
23. Handlebar switch (right)
24. Front brake light switch
26.Start/engine stop switch
28. Relay unit
29.Starting circuit cut-off relay
33. ECU (Engine Control Unit)
54. Front wheel sensor
55. Rear wheel sensor
56.ABS ECU (electronic control unit)
57. Yamaha diagnostic tool coupler
58.Meter assembly
68.ABS warning light
69.Multi-function meter
A. Wire harness
B. Negative battery sub-wire harness

8-146
 ABS (ANTI-LOCK BRAKE SYSTEM)

EAS3 1957

CIRCUIT DIAGRAM (MTT9GTK/MTT9GTKC)

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8-147
 ABS (ANTI-LOCK BRAKE SYSTEM)

3. Main switch
4. Main fuse
5. ABS motor fuse
6. ABS solenoid fuse
8. Backup fuse
11. Ignition fuse
12.ABS control unit fuse
13. Signaling system fuse
14. Brake light fuse
16.Battery
17.Engine ground
18. Fuel injection system fuse
21.Joint coupler
24. Front brake light switch
25. Rear brake light switch
26. Handlebar switch (right)
28.Start/engine stop switch
29.Brake light relay
30. Relay unit
31.Starting circuit cut-off relay
35. ECU (Engine Control Unit)
56. Front wheel sensor
57.Rear wheel sensor
58.ABS ECU (electronic control unit)
59. Yamaha diagnostic tool coupler
60.Meter assembly
64.Multi-function meter
72.ABS warning light
A. Wire harness
B. Negative battery sub-wire harness

8-148
 ABS (ANTI-LOCK BRAKE SYSTEM)

EAS30525

ABS COMPONENTS CHART

8 9

. . ...

1 2 3

7
4

6
1. Hydraulic unit assembly
2. Fuse box 3
3. Yamaha diagnostic tool coupler
4. Rear wheel sensor
5. Rear wheel sensor rotor
6. Front wheel sensor
7. Front wheel sensor rotor
8. ABS warning light
9. Fuse box 2

8-149
 ABS (ANTI-LOCK BRAKE SYSTEM)

EAS30844

ABS COUPLER LOCATION CHART (MTT9K/MTT9KC)

~-----------------------------------------------------------

Ii r r - l n 1
- ~

RIG RIG R/W IX X X IX B/W BNI X Y/GIX G/R p w Gy

Ch Dg G/W W/L WIG W/R Lg/L LgNI rx sb!WJ v X IX 0 W/R YNI
______________________________ J

~------------------------
I
:2
------------------------------ ~
I I
I
I
5 I
I
I
I I
I I
I I
I
I
I
'------------------------~
I I
L-----------------------------J

Lg/Llg/W
0 ------------------------------~
A BN./ 3

------------------------~

___________________________________ J

1. Meter assembly coupler

2. Rear wheel sensor coupler
3. ABS ECU coupler
4. Yamaha diagnostic tool coupler
5. Front wheel sensor coupler

8-150
 ABS (ANTI-LOCK BRAKE SYSTEM)

EAS32698

ABS COUPLER LOCATION CHART (MTT9GTK/MTT9GTKC)

~-----------------------------------------------------------

W WIG W/B
______________________________ J

~------------------------
I
:2
------------------------------ ~
I I
I
I
5 I
I
I
I I
I I
I I
I
I
I
'------------------------~
I I
L-----------------------------J

Lg/Llg/W
0 ------------------------------~
A BN./ 3

------------------------~

___________________________________ J

1. Meter assembly coupler

2. Rear wheel sensor coupler
3. ABS ECU coupler
4. Yamaha diagnostic tool coupler
5. Front wheel sensor coupler

8-151
 ABS (ANTI-LOCK BRAKE SYSTEM)

EAS30845

MAINTENANCE OF THE ABS ECU

Checking the ABS ECU

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

1
2

EAS30528

ABS TROUBLESHOOTING OUTLINE

This section describes the troubleshooting for the ABS in detail. Read this service manual carefully and
make sure you fully understand the information provided before repairing any malfunctions or perform-
. .
1ng service.
The ABS ECU (electronic control unit) has a self-diagnosis function. When failures occur in the system,
the ABS warning light on the meter assembly indicates a malfunction.
The following troubleshooting describes the problem identification and service method using the
Yamaha diagnostic tool. For information about using the Yamaha diagnostic tool, refer to "[B-2] DIAG-
NOSIS USING THE FAULT CODES" on page 8-156. For troubleshooting items other than the following
items, follow the normal service method.
EWA167l0

A 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] FI NAL CHECK" on page 8-177.

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 1O km/h (6 mi/h).
2. The ABS warning light comes on after the engine starts, and then goes off when the vehicle starts
moving (traveling at a speed of approximately 10 km/h (6 mi/h)). ➔ ABS operation is normal.
3. The ABS warning light flashes ➔ ABS operation is normal.
• Refer to "BASIC INSTRUCTIONS FOR TROUBLESHOOTING" on page 8-153.

8-152
 ABS (ANTI-LOCK BRAKE SYSTEM)

Self-diagnosis and servicing

The ABS ECU has a self-diagnosis function. By utilizing this function , quick problem identification and
service are possible. Previous malfunctions can be checked since the ABS ECU also stores the mal-
function history.
The fault codes recorded in the ABS ECU can be checked using the Yamaha diagnostic tool. When the
service is finished, check the normal operation of the vehicle, and then delete the fault code(s). For in-
formation about deleting the fault codes, refer to "[B-3] DELETING THE FAULT CODES" on page
8-177. 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 under the seat,
and if the brake lever or brake pedal are even slightly applied, a vibration can be felt at the lever and
pedal , but these do not indicate a malfunction.

Self-diagnosis using the ABS ECU

The ABS ECU performs a static check of the entire system when the main switch is turned to "ON". It also
checks for malfunctions while the vehicle is ridden. Since all malfunctions are recorded after they are detect-
ed, it is possible to check the recorded malfunction data by utilizing the Yamaha diagnostic tool when the
ABS ECU has entered the self-diagnosis mode.

Special precautions for handling and servicing a vehicle equipped with ABS
ECA1 7620

NOTICE
----------------------------------
Care should be taken not to damage components by subjecting them to shocks or pulling on
them with too much force since the ABS components are precisely adjusted.
• The ABS ECU and hydraulic unit are united assemblies and cannot be disassembled.
• The malfunction history is stored in the memory of the ABS ECU . Delete the fault codes when the ser-
vice is finished. (This is because the past fault codes will be displayed again if another malfunction
occurs.)
EAS30529

BASIC INSTRUCTIONS FOR TROUBLESHOOTING

EWA1 7420

AwARNING
• Perform the troubleshooting [A] ➔ [B] ➔[C] in order. Be sure to follow the order since a wrong
diagnosis could result if the steps are followed in a different order or omitted.
• Use sufficiently charged regular batteries only.
[A] Malfunction check using the ABS warning light
[B] Use the Yamaha diagnostic tool and determine the location of the malfunction and the cause from
the recorded fault code.
Determine the cause of the malfunction from the condition and place where the malfunction occurred.
[C] Servicing the ABS
Execute the final check after disassembly and assembly.

8-153
 ABS (ANTI-LOCK BRAKE SYSTEM)

EAS30530

BASIC PROCESS FOR TROUBLESHOOTING

[A] Turn the main switch to "ON", Fails to

[A- 1] Does only the ABS • The ABS warning light (LED)
and check the ABS warning come on
• Yes is defective.
light.
warning light fail to · ~ Return to [A].
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.
(A-2] Do all indicator lights Yes . • The battery voltage is low. • ,r Return to [A] ..)
fail to come on? •
• The main fuse is blown.
• The meter assembly circuit is
defective.

'
Cannot
(A-3] The ABS warning light comes communicate Yes • The ABS ECU fuse is blown.
[A-4] Only the ABS ECU
on. . fails to communicate . • The ABS ECU coupler is : Return to [AJ.)
Connect the Yamaha disconnected.
diagnostic tool, and then
• The wire harness is defective.
execute functional diagnosis.
Can the tool communicate with • The hydraulic unit assembly
the ABS ECU? is defective.
No
Can communicate
[A-5) ABS ECU and FI ECU Yes • The connection with the Yamaha
fail to communicate. : Return to [AJ.)
diagnostic tool is defective.
• The wire harness is defective.

' '
[B· 1) Check for ABS fault
codes in the screen for the
Yamaha diagnostic tool.
Execute fault diagnosis.
Are fault codes displayed on
the screen?
No
' '
[C· 1J Perform the final checks.
Were all of the final checks
completed normally?
Yes
(The ABS warning light
goes off when the light is
checked.)
Yes . (B-2) Diagnose by the fault [B-3] Delete the fault codes.
code.
~ Return to [AJ.)
The reaction force generated
during brake line routing
confirmation is incorrect. Refer to
"[C-1 ] FINAL CHECK".
No .. • The brake hoses and brake
• ,' Return to (A].
pipes are not connected
correctly.
The ABS warning light does
not go off when the light is
checked. Refer to "(C-1]
FINAL CHECK".
• The malfunction is not
corrected.
• There is a break in the wire
harness between the ABS ECU
and the meter assembly.
• The meter assembly circuit
is defective.
• The ABS warning light circuit
in the hydraulic unit assembly
is defective.

' '
Finished.

8-154
 ABS (ANTI-LOCK BRAKE SYSTEM)

EWA16710

AwARNING
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] FI NAL CHECK" on page 8-177.

EAS30531

[A] CHECKING THE ABS WARNING LIGHT

Turn the main switch to "ON". (Do not start the engine.)
1. The ABS warning light does not come on.
• Only the ABS warning light fails to come on. [A-1]
• The ABS warning light and all other indicator lights fail to come on. [A-2]
2. The ABS warning light comes on . [A-3]
EAS30532

[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON

1. Check for a short circuit to the ground between the green/ red terminal of the ABS ECU coupler and
green/red 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.
EAS30533

[A-2] THE ABS WARNING LIGHT AND OTHER INDICATOR LIGHTS FAIL TO COME ON
1. Main switch
• Check the main switch for continuity.
Refer to "CHECKING THE SWITCHES" on page 8-187.
• If there is no continuity, replace the main switch .
2. Battery
• Check the condition of the battery.
Refer to "CHECKING AND CHARG ING THE BATTERY" on page 8-190.
• If the battery is defective, clean the battery term inals and recharge it, or replace the battery.
3. Main fuse
• Check the fuse for continuity.
Refer to "CHECKING THE FUSES" on page 8-189.
• If the main fuse is blown , replace the fuse.
4. C ircuit
• Check the meter assembly circuit.
Refer to "CIRCUIT DIAGRAM (MTT9K/MTT9KC)" on page 8-145, or refer to "CIRCUIT DIAGRAM
(MTT9GTK/MTT9GTKC)" on page 8-147.
• If the meter assembly circuit is open , replace the wire harness.
EAS31162

[A-3] THE ABS WARNING LIGHT COMES ON

Connect the Yamaha diagnostic tool to the 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.)

8-155
 ABS (ANTI-LOCK BRAKE SYSTEM)

EAS31163

[A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE

1. ABS ECU fuse
• Check the ABS ECU fuse for continuity.
Refer to "CHECKING THE FUSES" on page 8-189.
• If the ABS ECU fuse is blown , replace the fuse.
2. ABS ECU coupler
• Check that the ABS ECU coupler is connected properly.
For information about connecting the ABS ECU coupler properly, refer to "INSTALLING THE HY-
DRAULIC UNIT ASSEMBLY" on page 4-63.
3. Wire harness
• Open circuit between the main switch and the ABS ECU , or between the ABS ECU and the ground.
Check for continuity between brown/blue terminal of the main switch coupler and brown/red terminal
of the ABS ECU coupler.
Check for continuity between black/yellow term inal of the ABS ECU coupler and the ground.
If there is no continuity, the wire harness is defective. Replace the wire harness.
• Open circuit in the wire harness between the ABS ECU coupler and the Yamaha diagnostic tool cou-
pler.
Check for continuity between light green/blue terminal of the ABS ECU coupler and light green/blue
terminal of the Yamaha diagnostic tool coupler. (CANH)
Check for continuity between light green/white terminal of the ABS ECU coupler and light green/
white terminal of the Yamaha diagnostic tool coupler. (CANL)
4. ABS ECU malfunction
Replace the hydraulic unit assembly.
EAS31164

[A-5] ABS ECU AND FI ECU FAIL TO COMMUNICATE

1. Yamaha diagnostic tool
Check that the Yamaha diagnostic tool is properly connected.
2. Wire harness
• Open circuit in the wire harness between the ABS ECU coupler and the Yamaha diagnostic tool cou-
pler.
Check for continuity between light green/blue terminal of the ABS ECU coupler and light green/blue
terminal of the Yamaha diagnostic tool coupler. (CANH)
Check for continuity between light green/white terminal of the ABS ECU coupler and light green/
white terminal of the Yamaha diagnostic tool coupler. (CANL)
EAS31165

[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]
EAS31166

[B-2] DIAGNOSIS USING THE FAULT CODES

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

Yamaha diagnostic tool USB (US)

90890-03257
Yamaha diagnostic tool (A/1)
90890-03262

8-156
 ABS (ANTI-LOCK BRAKE SYSTEM)

Connecting the Yamaha diagnostic tool

Removing the rider seat. Refer to "GENERAL CHASSIS (1 )" on page 4-1.
Removing the protective cap "1 ", and then connect the Yamaha diagnostic tool to the coupler.
~ -, - - - - - - - ,

0
0

r-r--..=-----==~
Details about the displayed fault codes are shown in the following chart. Refer to this chart and check
the vehicle.
Once all the work is complete, delete the fault codes. [B-3]
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Check the inspection points after terminating the connection with the Yamaha diagnostic tool and turn-
ing the main switch off.

Fault code table

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Record all of the fault codes displayed and inspect the check points.

Fault code
Item Symptom
No.
11 * Front wheel sensor (intermit- Front wheel sensor signal is • Foreign material adhered
25* tent pulses or no pulses) not received properly. (Puls-
es are not received or are re-
ceived intermittently while
the vehicle is traveling.)
12 Rear wheel sensor (intermit- Rear wheel sensor signal is • Foreign material adhered
tent pulses or no pulses) not received properly. (Puls-
es are not received or are re-
ceived intermittently while
the vehicle is traveling.)
Check point
around the front wheel sen-
sor
• Incorrect installation of the
front wheel
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective front wheel sen-
sor or incorrect installation
of the sensor
around the rear wheel sen-
sor
• Incorrect installation of the
rear wheel
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective rear wheel sen-
sor or incorrect installation
of the sensor

8-157
 ABS (ANTI-LOCK BRAKE SYSTEM)

Fault code
Item Symptom Check point
No.
13* Front wheel sensor (abnor- Front wheel sensor signal is • Foreign material adhered
26* mal pulse period) not received properly. (The around the front wheel sen-
pulse period is abnormal sor
while the vehicle is traveling.) • Incorrect installation of the
front wheel
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective front wheel sen-
sor or incorrect installation
of the sensor
14* Rear wheel sensor (abnor- Rear wheel sensor signal is • Foreign material adhered
27* mal pulse period) not received properly. (The around the rear wheel sen-
pulse period is abnormal sor
while the vehicle is traveling.) • Incorrect installation of the
rear wheel
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective rear wheel sen-
sor or incorrect installation
of the sensor
15 Front wheel sensor (open or Open or short circuit is de- • Defective coupler between
short circuit) tected in the front wheel sen- the front wheel sensor and
sor. the hydraulic unit assembly
• Open or short circuit in the
wire harness between the
front wheel sensor and the
hydraulic unit assembly
• Defective front wheel sen-
sor or hydraulic unit as-
sembly
16 Rear wheel sensor (open or Open or short circuit is de- • Defective coupler between
short circuit) tected in the rear wheel sen- the rear wheel sensor and
sor. the hydraulic unit assembly
• Open or short circuit in the
wire harness between the
rear wheel sensor and the
hydraulic unit assembly
• Defective rear wheel sen-
sor or hydraulic unit as-
sembly
17* Front wheel sensor (missing Front wheel sensor signal is • Foreign material adhered
45* pulses) not received properly. (Miss- around the front wheel sen-
ing pulses are detected in sor
the signal while the vehicle is • Incorrect installation of the
traveling.) front wheel
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective front wheel sen-
sor or incorrect installation
of the sensor

8-158
 ABS (ANTI-LOCK BRAKE SYSTEM)

Fault code
Item Symptom Check point
No.
18* Rear wheel sensor (missing Rear wheel sensor signal is • Foreign material adhered
46* pulses) not received properly. (Miss- around the rear wheel sen-
ing pulses are detected in sor
the signal while the vehicle is • Incorrect installation of the
traveling.) rear wheel
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective rear wheel sen-
sor or incorrect installation
of the sensor
21 Hydraulic unit assembly (de- Solenoid drive circuit in the • Defective hydraulic unit as-
fective solenoid drive circuit) hydraulic unit assembly is sembly
open or short-circuited.
24 Brake light switch or tail/ Brake light signal is not re- • Defective signaling system
brake light ceived properly while the ve- (tail/brake light or brake
hicle is traveling. (Brake light light switch)
circuit, or front or rear brake • Defective coupler between
light switch circuit.) the signaling system (tail/
brake light or brake light
switch) and the hydraulic
unit assembly
• Open or short circuit in the
wire harness between the
signaling system (tail/brake
light or brake light switch)
and the hydraulic unit as-
sembly
• Defective hydraulic unit as-
sembly
31 Hydraulic unit assembly (ab- Power is not supplied to the • Blown ABS solenoid fuse
normal ABS solenoid power solenoid circuit in the hy- • Defective coupler between
supply) draulic unit assembly. the battery and the hydrau-
lie unit assembly
• Open or short circuit in the
wire harness between the
battery and the hydraulic
unit assembly
• Defective hydraulic unit as-
sembly
32 Hydraulic unit assembly Short circuit is detected in • Defective hydraulic unit as-
(short circuit in ABS solenoid the solenoid power supply sembly
power supply circuit) circuit in the hydraulic unit
assembly.
33 Hydraulic unit assembly (ab- Power is not supplied to the • Blown ABS motor fuse
normal ABS motor power motor circuit in the hydraulic • Defective coupler between
supply) unit assembly. the battery and the hydrau-
lie unit assembly
• Open or short circuit in the
wire harness between the
battery and the hydraulic
unit assembly
• Defective hydraulic unit as-
sembly

8-159

Fault code
Item
No.
34 Hydraulic unit assembly
(short circuit in ABS motor
power supply circuit)
41 Front wheel ABS (intermit-
tent wheel speed pulses or
incorrect depressurization)
42 Rear wheel ABS (intermit-
47 tent wheel speed pulses or
incorrect depressurization)
43 Front wheel sensor (missing
pulses)
44 Rear wheel sensor (missing
pulses)
51 • Vehicle system power sup-
52 ply (voltage of ABS ECU
power supply is high) (for
fault code No. 51)
• Vehicle system power sup-
ply (voltage of wheel sen-
sor power supply is high)
(for fault code No. 52)
ABS (ANTI-LOCK BRAKE SYSTEM)
Symptom
Short circuit is detected in
the motor power supply cir-
cuit in the hydraulic unit as-
sembly.
• Pulses from the front wheel
sensor are received inter-
mittently while the vehicle
is traveling.
• Front wheel will not recover
from the locking tendency
even though the signal is
transmitted from the ABS
ECU to reduce the hydrau-
lie pressure.
• Pulses from the rear wheel
sensor are received inter-
mittently while the vehicle
is traveling. (for fault code
No. 42)
• Rear wheel will not recover
from the locking tendency
even though the signal is
transmitted from the ABS
ECU to reduce the hydrau-
lie pressure.
Front wheel sensor signal is
not received properly. (Miss-
ing pulses are detected in
the signal while the vehicle is
traveling.)
Rear wheel sensor signal is
not received properly. (Miss-
ing pulses are detected in
the signal while the vehicle is
traveling.)
• Power voltage supplied to
the ABS ECU in the hy-
draulic unit assembly is too
high. (for fault code No. 51) • Defective charging system
• Power voltage supplied to
the wheel sensor is too
high. (for fault code No. 52)
8-160
Check point
• Defective hydraulic unit as-
sembly
• Incorrect installation of the
front wheel sensor
• Incorrect rotation of the
front wheel
• Front brake dragging
• Defective hydraulic unit as-
sembly
• Incorrect installation of the
rear wheel sensor (for fault
code No. 42)
• Incorrect rotation of the
rear wheel
• Rear brake dragging
• Defective hydraulic unit as-
sembly
• Foreign material adhered
around the front wheel sen-
sor
• Incorrect installation of the
front wheel
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective front wheel sen-
sor or incorrect installation
of the sensor
• Foreign material adhered
around the rear wheel sen-
sor
• Incorrect installation of the
rear wheel
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective rear wheel sen-
sor or incorrect installation
of the sensor
• Defective battery
• Disconnected battery ter-
minal
 ABS (ANTI-LOCK BRAKE SYSTEM)

Fault code
Item Symptom Check point
No.
53 Vehicle system power supply Power voltage supplied to • Defective battery
(voltage of ABS ECU power the ABS ECU in the hydrau- • Defective coupler between
supply is low) lie unit assembly is too low. the battery and the hydrau-
lie unit assembly
• Open or short circuit in the
wire harness between the
battery and the hydraulic
unit assembly
• Defective charging system
54 Hydraulic unit assembly (de- Abnormality is detected in • Defective battery
fective ABS solenoid and the solenoid or motor power • Defective coupler between
ABS motor power supply cir- supply circuit in the hydraulic the battery and the hydrau-
cuits) unit assembly. lie unit assembly
• Open or short circuit in the
wire harness between the
battery and the hydraulic
unit assembly
• Defective charging system
• Defective hydraulic unit as-
sembly
55 Hydraulic unit assembly (de- Abnormal data is detected in • Defective hydraulic unit as-
fective ABS ECU) the hydraulic unit assembly. sembly
56 Hydraulic unit assembly (ab- Abnormality is detected in • Defective hydraulic unit as-
normal internal power sup- the power supply circuit in sembly
ply) the hydraulic unit assembly.
63 Front wheel sensor power Power voltage supplied from • Short circuit in the wire har-
supply (voltage of power the ABS ECU to the front ness between the front
supply is low) wheel sensor is too low. wheel sensor and the hy-
draulic unit assembly
• Defective front wheel sen-
sor
• Defective hydraulic unit as-
sembly
64 Rear wheel sensor power Power voltage supplied from • Short circuit in the wire har-
supply (voltage of power the ABS ECU to the rear ness between the rear
supply is low) wheel sensor is too low. wheel sensor and the hy-
draulic unit assembly
• Defective rear wheel sen-
sor
• Defective hydraulic unit as-
sembly

* The fault code number varies according to the vehicle conditions. For details, refer to the "Trouble-
shooting details".

8-161
 ABS (ANTI-LOCK BRAKE SYSTEM)

Troubleshooting details

Fault code No. 11, 25

11
Fault code No.
25
Item Front wheel sensor (intermittent pulses or no pulses)

Front wheel sensor signal is not received properly. (Pulses are not
Symptom
received or are received intermittently while the vehicle is traveling.)

Order Item/components and probable cause Check or maintenance job

1 Foreign material adhered around the front
wheel sensor
2 Incorrect installation of the front wheel
3 Defective sensor rotor or incorrect instal-
lation of the rotor
4 Defective front wheel sensor or incorrect
installation of the sensor
Check the surface of the sensor rotor and wheel sensor
for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.
Check the components for looseness, distortion, and
bends.
Refer to "CHECKING THE FRONT WHEEL'.' on page
4-22.
Check the surface of the sensor rotor for damage.
Replace the sensor rotor if there is visible damage.
Refer to "MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR" on page 4-24.
Check the wheel sensor for damage and the installed
condition of the sensor. Repair or replace the wheel
sensor if necessary.
Refer to "MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR" on page 4-24.

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
With the front wheel stopped, the rear wheel was rotated for longer than about 20 seconds (fault code
No. 11) or for longer than about 2 seconds (fault code No. 25).

Fault code No. 12

Fault code No. 12

Item Rear wheel sensor (intermittent pulses or no pulses)

Rear wheel sensor signal is not received properly. (Pulses are not re-
Symptom
ceived or are received intermittently while the vehicle is traveling.)

Order Item/components and probable cause Check or maintenance job

1 Foreign material adhered around the rear
wheel sensor
2 Incorrect installation of the rear wheel
3 Defective sensor rotor or incorrect instal-
lation of the rotor
Check the surface of the sensor rotor and wheel sensor
for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.
Check the components for looseness, distortion, and
bends.
Refer to "CHECKING THE REAR WHEEL'.' on page
4-30.
Check the surface of the sensor rotor for damage.
Replace the sensor rotor if there is visible damage.
Refer to "MAINTENANCE OF THE REAR WHEEL
SENSOR AND SENSOR ROTOR" on page 4-32.

8-162
 ABS (ANTI-LOCK BRAKE SYSTEM)

Fault code No. 12

Item Rear wheel sensor (intermittent pulses or no pulses)

Rear wheel sensor signal is not received properly. (Pulses are not re-
Symptom
ceived or are received intermittently while the vehicle is traveling.)

Order Item/components and probable cause Check or maintenance job

4 Defective rear wheel sensor or incorrect
installation of the sensor
Check the wheel sensor for damage and the installed
condition of the sensor. Repair or replace the wheel
sensor if necessary.
Refer to "MAINTENANCE OF THE REAR WHEEL
SENSOR AND SENSOR ROTOR" on page 4-32.

Fault code No. 13, 26

13
Fault code No.
26
Item Front wheel sensor (abnormal pulse period)

Front wheel sensor signal is not received properly. (The pulse period
Symptom
is abnormal while the vehicle is traveling.)

Order Item/components and probable cause Check or maintenance job

1 Foreign material adhered around the front
wheel sensor
2 Incorrect installation of the front wheel
3 Defective sensor rotor or incorrect instal-
lation of the rotor
4 Defective front wheel sensor or incorrect
installation of the sensor
Check the surface of the sensor rotor and wheel sensor
for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.
Check the components for looseness, distortion, and
bends.
Refer to "CHECKING THE FRONT WHEEL'.' on page
4-22.
Check the surface of the sensor rotor for damage. Re-
place the sensor rotor if there is visible damage.
Refer to "MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR" on page 4-24.
Check the wheel sensor for damage and the installed
condition of the sensor. Repair or replace the wheel
sensor if necessary.
Refer to "MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR" on page 4-24.

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• If the front brake ABS operates continuously for 20 seconds or more, fault code No. 26 will be record-
ed. If the front brake ABS operates continuously for 36 seconds or more, fault code No. 13 will be re-
corded.
• Vehicle possibly ridden on uneven roads.

8-163
 ABS (ANTI-LOCK BRAKE SYSTEM)

Fault code No. 14, 27

14
Fault code No.
27
Item Rear wheel sensor (abnormal pulse period)

Rear wheel sensor signal is not received properly. (The pulse period
Symptom
is abnormal while the vehicle is traveling.)

Order Item/components and probable cause Check or maintenance job

1 Foreign material adhered around the rear
wheel sensor
2 Incorrect installation of the rear wheel
3 Defective sensor rotor or incorrect instal-
lation of the rotor
4 Defective rear wheel sensor or incorrect
installation of the sensor
Check the surface of the sensor rotor and wheel sensor
for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.
Check the components for looseness, distortion, and
bends.
Refer to "CHECKING THE REAR WHEEL'.' on page
4-30.
Check the surface of the sensor rotor for damage.
Replace the sensor rotor if there is visible damage.
Refer to "MAINTENANCE OF THE REAR WHEEL
SENSOR AND SENSOR ROTOR" on page 4-32.
Check the wheel sensor for damage and the installed
condition of the sensor. Repair or replace the wheel
sensor if necessary.
Refer to "MAINTENANCE OF THE REAR WHEEL
SENSOR AND SENSOR ROTOR" on page 4-32.

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• If the rear brake ABS operates continuously for 20 seconds or more, fault code No. 27 will be record-
ed. If the rear brake ABS operates continuously for 36 seconds or more, fault code No. 14 will be re-
corded.
• Vehicle possibly ridden on uneven roads.

Fault code No. 15

Fault code No. 15

Item Front wheel sensor (open or short circuit)

Symptom Open or short circuit is detected in the front wheel sensor.

Order Item/components and probable cause Check or maintenance job

1 Defective coupler between the front wheel
sensor and the hydraulic unit assembly
• Check the coupler for any pins that may be pulled out.
• Check the locking condition of the coupler.
• If there is a malfunction, repair it and connect the cou-
pier securely.
TIP
Turn the main switch to "OFF" before disconnecting or
connecting a coupler.

8-164
 ABS (ANTI-LOCK BRAKE SYSTEM)

Fault code No. 15

Item Front wheel sensor (open or short circuit)

Symptom Open or short circuit is detected in the front wheel sensor.

Order Item/components and probable cause Check or maintenance job

2 Open or short circuit in the wire harness
between the front wheel sensor and the
hydraulic unit assembly
• Check for continuity between the white terminal "1"
and the white terminal "4" and between the black ter-
minal "2" and the black terminal "5".
• If there is no continuity, the wire harness is defective.
Replace the wire harness.
• Check that there is no short circuit between the white
terminal "1" and the black terminal "2" and between
the white terminal "4" and the black terminal "5" .
• If there is short circuit, the wire harness is defective.
Replace the wire harness.
• Check that there is no short circuit between the black/
yellow terminal "3" and the white terminal "4" and be-
tween the black/yellow terminal "3" and the black ter-
minal "5".
• If there is short circuit, the wire harness is defective.
Replace the wire harness.

1~ 5 4

i:;1IvIBI 8 IBr~ILgtl¼Wl~t!
2 1L.! -=,~&I'/ j

,_
3

~ 6
\'
7

3 Defective front wheel sensor or hydraulic
unit assembly
6. ABS ECU
7. Wheel sensor
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 4-20 and "ABS (AN-
TI-LOCK BRAKE SYSTEM)" on page 4-60.

Fault code No. 16

Fault code No. 16

Item Rear wheel sensor (open or short circuit)

Symptom Open or short circuit is detected in the rear wheel sensor.

Order Item/components and probable cause Check or maintenance job

1 Defective coupler between the rear wheel
sensor and the hydraulic unit assembly
• Check the coupler for any pins that may be pulled out.
• Check the locking condition of the coupler.
• If there is a malfunction, repair it and connect the cou-
pier securely.
TIP
Turn the main switch to "OFF" before disconnecting or
connecting a coupler.

8-165
 ABS (ANTI-LOCK BRAKE SYSTEM)

Fault code No. 16

Item Rear wheel sensor (open or short circuit)

Symptom Open or short circuit is detected in the rear wheel sensor.

Order Item/components and probable cause Check or maintenance job

2 Open or short circuit in the wire harness
between the rear wheel sensor and the
hydraulic unit assembly
• Check for continuity between the white terminal "1"
and the white terminal "4" and between the black ter-
minal "2" and the black terminal "5".
• If there is no continuity, the wire harness is defective.
Replace the wire harness.
• Check that there is no short circuit between the white
terminal "1" and the black terminal "2" and between
the white terminal "4" and the black terminal "5" .
• If there is short circuit, the wire harness is defective.
Replace the wire harness.
• Check that there is no short circuit between the black/
yellow terminal "3" and the white terminal "4" and be-
tween the black/yellow terminal "3" and the black ter-
minal "5".
• If there is short circuit, the wire harness is defective.
Replace the wire harness.

1~ :::si2 5 4

llir1'
I • I" I" l" I ~'
~ 8 IBr,ll ltgt l¼Wl~t! SI'/
JJr.;, j Y
1

2 _=,~ 3 ,_

~ 6
\'
7

3 Defective rear wheel sensor or hydraulic
unit assembly
6. ABS ECU
7. Wheel sensor
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 4-27 and "ABS (ANTI-
LOCK BRAKE SYSTEM)" on page 4-60.

Fault code No. 17, 45

17
Fault code No.
45
Item Front wheel sensor (missing pulses)

Front wheel sensor signal is not received properly. (Missing pulses

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

Order Item/components and probable cause Check or maintenance job

1 Foreign material adhered around the front Check the surface of the sensor rotor and wheel sensor
wheel sensor for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.

8-166
 ABS (ANTI-LOCK BRAKE SYSTEM)

17
Fault code No.
45
Item Front wheel sensor (missing pulses)

Front wheel sensor signal is not received properly. (Missing pulses

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

Order Item/components and probable cause Check or maintenance job

2 Incorrect installation of the front wheel
3 Defective sensor rotor or incorrect instal-
lation of the rotor
4 Defective front wheel sensor or incorrect
installation of the sensor
Check the components for looseness, distortion, and
bends.
Refer to "CHECKING THE FRONT WHEEL'.' on page
4-22.
Check the surface of the sensor rotor for damage.
Replace the sensor rotor if there is visible damage.
Refer to "MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR" on page 4-24.
Check the wheel sensor for damage and the installed
condition of the sensor. Repair or replace the wheel
sensor if necessary.
Refer to "MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR" on page 4-24.

TIP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
lf pulse gaps are detected when the vehicle is traveling at a speed of 30 km/h (19 mi/h) or more, fault
code No. 17 will be recorded. If the vehicle is traveling at a speed of 29 km/h (18 mi/h) or less, fault code
No. 45 will be recorded first and fault code No. 17 will be recorded if the condition continues.

Fault code No. 18, 46

18
Fault code No.
46
Item Rear wheel sensor (missing pulses)

Rear wheel sensor signal is not received properly. (Missing pulses

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

Order Item/components and probable cause Check or maintenance job

1 Foreign material adhered around the rear
wheel sensor
2 Incorrect installation of the rear wheel
3 Defective sensor rotor or incorrect instal-
lation of the rotor
4 Defective rear wheel sensor or incorrect
installation of the sensor
Check the surface of the sensor rotor and wheel sensor
for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.
Check the components for looseness, distortion, and
bends.
Refer to "CHECKING THE REAR WHEEL'.' on page
4-30.
Check the surface of the sensor rotor for damage.
Replace the sensor rotor if there is visible damage.
Refer to "MAINTENANCE OF THE REAR WHEEL
SENSOR AND SENSOR ROTOR" on page 4-32.
Check the wheel sensor for damage and the installed
condition of the sensor. Repair or replace the wheel
sensor if necessary.
Refer to "MAINTENANCE OF THE REAR WHEEL
SENSOR AND SENSOR ROTOR" on page 4-32.

8-167
 ABS (ANTI-LOCK BRAKE SYSTEM)

TIP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
lf pulse gaps are detected when the vehicle is traveling at a speed of 30 km/h (19 mi/h) or more, fault
code No. 18 will be recorded. If the vehicle is traveling at a speed of 29 km/h (18 mi/h) or less, fault code
No. 46 will be recorded first and fault code No. 18 will be recorded if the condition continues.

Fault code No. 21

Fault code No. 21

Item Hydraulic unit assembly (defective solenoid drive circuit)

Solenoid drive circuit in the hydraulic unit assembly is open or

Symptom
short-circuited.

Order Item/components and probable cause Check or maintenance job

1 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to "ABS (ANTI-LOCK BRAKE SYSTEM)" on page
4-60.

Fault code No. 24

Fault code No. 24
Item Brake light switch or tail/brake light

Brake light signal is not received properly while the vehicle is travel-
Symptom
ing (Brake light circuit, or front or rear brake light switch circuit).

Order Item/components and probable cause Check or maintenance job

1 Defective signaling system (tail/brake light
or brake light switch)
2 Defective coupler between the signaling
system (tail/brake light or brake light
switch) and the hydraulic unit assembly
3 Open or short circuit in the wire harness
between the signaling system (tail/brake
light or brake light switch) and the hydrau-
lie unit assembly
4 Defective hydraulic unit assembly
Check the tail/brake light and brake light switches.
Refer to "CHECKING THE SWITCHES" on page 8-187.
• Check the coupler for any pins that may be pulled out.
• Check the locking condition of the coupler.
• If there is a malfunction, repair it and connect the cou-
pier securely.
• Between ABS ECU coupler and front brake light switch
coupler.
(yellow-yellow)
• Between ABS ECU coupler and rear brake light switch
coupler.
(yellow-yellow)
If the above items were performed and no malfunctions
were found, replace the hydraulic unit assembly.
Refer to "ABS (ANTI-LOCK BRAKE SYSTEM)" on page
4-60.

Fault code No. 31

Fault code No. 31

Item Hydraulic unit assembly (abnormal ABS solenoid power supply)

Power is not supplied to the solenoid circuit in the hydraulic unit as-
Symptom
sembly.

Order Item/components and probable cause Check or maintenance job

1 Blown ABS solenoid fuse Check the ABS solenoid fuse. If the ABS solenoid fuse
is blown, replace the fuse and check the wire harness.
Refer to "CHECKING THE FUSES" on page 8-189.

8-168
 ABS (ANTI-LOCK BRAKE SYSTEM)

Fault code No. 31

Item Hydraulic unit assembly (abnormal ABS solenoid power supply)

Power is not supplied to the solenoid circuit in the hydraulic unit as-
Symptom
sembly.

Order Item/components and probable cause Check or maintenance job

2 Defective coupler between the battery
and the hydraulic unit assembly
• Check the locking condition of the coupler.
• If there is a malfunction, repair it and connect the cou-
pier securely.
TIP
Turn the main switch to "OFF" before disconnecting or
connecting a coupler.

3 Open or short circuit in the wire harness
between the battery and the hydraulic unit
assembly
4 Defective hydraulic unit assembly
• Replace if there is an open or short circuit.
• Between ABS ECU coupler and ABS solenoid fuse.
(red/ white-red/white)
If the above items were performed and no malfunctions
were found, replace the hydraulic unit assembly.
Refer to "ABS (ANTI-LOCK BRAKE SYSTEM)" on page
4-60.

Fault code No. 32

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

Short circuit is detected in the solenoid power supply circuit in the

Symptom
hydraulic unit assembly.

Order Item/components and probable cause Check or maintenance job

1 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to "ABS (ANTI-LOCK BRAKE SYSTEM)" on page
4-60.

Fault code No. 33

Fault code No. 33

Item Hydraulic unit assembly (abnormal ABS motor power supply)

Power is not supplied to the motor circuit in the hydraulic unit as-
Symptom
sembly.

Order Item/components and probable cause Check or maintenance job

1 Blown ABS motor fuse
2 Defective coupler between the battery
and the hydraulic unit assembly
Check the ABS motor fuse. If the ABS motor fuse is
blown, replace the fuse and check the wire harness.
Refer to "CHECKING THE FUSES" on page 8-189.
• Check the coupler for any pins that may be pulled out.
• Check the locking condition of the coupler.
• If there is a malfunction, repair it and connect the cou-
pier securely.
TIP
Turn the main switch to "OFF" before disconnecting or
connecting a coupler.

8-169
 ABS (ANTI-LOCK BRAKE SYSTEM)

Fault code No. 33

Item Hydraulic unit assembly (abnormal ABS motor power supply)

Power is not supplied to the motor circuit in the hydraulic unit as-
Symptom
sembly.

Order Item/components and probable cause Check or maintenance job

3 Open or short circuit in the wire harness
between the battery and the hydraulic unit
assembly
4 Defective hydraulic unit assembly
• Replace if there is an open or short circuit.
• Between ABS ECU coupler and starter relay coupler
(AB S motor fuse).
(red/blue-red/blue)
• Between ABS ECU coupler and ground.
(black- black)
If the above items were performed and no malfunctions
were found, replace the hydraulic unit assembly.
Refer to "ABS (ANTI-LOCK BRAKE SYSTEM)" on page
4-60.

Fault code No. 34

Fault code No. 34
Hydraulic unit assembly (short circuit in ABS motor power supply
Item
circuit)

Short circuit is detected in the motor power supply circuit in the hy-
Symptom
draulic unit assembly.

Order Item/components and probable cause Check or maintenance job

1 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to "ABS (ANTI-LOCK BRAKE SYSTEM)" on page
4-60.

Fault code No. 41

Fault code No. 41

Front wheel ABS (intermittent wheel speed pulses or incorrect de-

Item
pressurization)

• Pulses from the front wheel sensor are received intermittently

while the vehicle is traveling.
Symptom • Front wheel will not recover from the locking tendency even though
the signal is transmitted from the ABS ECU to reduce the hydraulic
pressure.

Order Item/components and probable cause Check or maintenance job

1 Incorrect installation of the front wheel
sensor
2 Incorrect rotation of the front wheel
Check the components for looseness, distortion, and
bends.
Refer to "CHECKING TH E FRONT WH EEL'.' on page
4-22.
Check that there is no brake disc drag on the front wheel
and make sure that it rotates smoothly.
Refer to "CHECKING THE FRONT WH EEL'.' on page
4-22 and "CHECKING THE FRONT BRAKE DISCS" on
page 4-41.

8-170
 ABS (ANTI-LOCK BRAKE SYSTEM)

Fault code No. 41

Front wheel ABS (intermittent wheel speed pulses or incorrect de-

Item
pressurization)

• Pulses from the front wheel sensor are received intermittently

while the vehicle is traveling.
Symptom • Front wheel will not recover from the locking tendency even though
the signal is transmitted from the ABS ECU to reduce the hydraulic
pressure.

Order Item/components and probable cause Check or maintenance job

3 Front brake dragging
4 Defective hydraulic unit assembly
Check that the brake fluid pressure is correctly transmit-
ted to the brake caliper when the brake lever is operated
and that the pressure decreases when the lever is re-
leased.
Refer to "CHECKING THE FRONT BRAKE DISCS" on
page 4-41.
If the above items were performed and no malfunctions
were found, replace the hydraulic unit assembly.
Refer to "ABS (ANTI-LOCK BRAKE SYSTEM)" on page
4-60.

Fault code No. 42, 47

42
Fault code No.
47

Rear wheel ABS (intermittent wheel speed pulses or incorrect de-

Item
pressurization)

• Pulses from the rear wheel sensor are received intermittently while
the vehicle is traveling. (for fault code No. 42)
Symptom • Rear wheel will not recover from the locking tendency even though
the signal is transmitted from the ABS ECU to reduce the hydraulic
pressure.

Order Item/components and probable cause Check or maintenance job

1 Foreign material adhered around the front
wheel sensor
2 Incorrect installation of the rear wheel
sensor (for fault code No. 42)
3 Incorrect rotation of the rear wheel
4 Rear brake dragging
5 Defective hydraulic unit assembly
Check the surface of the sensor rotor and wheel sensor
for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.
Check the components for looseness, distortion, and
bends.
Refer to "CHECKING THE REAR WHEEL'.' on page
4-30.
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
4-30.
Check that the brake fluid pressure is correctly transmit-
ted to the brake caliper when the brake pedal is operat-
ed and that the pressure decreases when the pedal is
released.
Refer to "CHECKING THE REAR BRAKE DISC" on
page 4-54.
If the above items were performed and no malfunctions
were found, replace the hydraulic unit assembly.
Refer to "ABS (ANTI-LOCK BRAKE SYSTEM)" on page
4-60.

8-171
 ABS (ANTI-LOCK BRAKE SYSTEM)

Fault code No. 43

Fault code No. 43
Item Front wheel sensor (missing pulses)

Front wheel sensor signal is not received properly. (Missing pulses

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

Order Item/components and probable cause Check or maintenance job

1 Foreign material adhered around the front
wheel sensor
2 Incorrect installation of the front wheel
3 Defective sensor rotor or incorrect instal-
lation of the rotor
4 Defective front wheel sensor or incorrect
installation of the sensor
Check the surface of the sensor rotor and wheel sensor
for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.
Check the components for looseness, distortion, and
bends.
Refer to "CHECKING THE FRONT WHEEL'.' on page
4-22.
Check the surface of the sensor rotor for damage. Re-
place the sensor rotor if there is visible damage.
Refer to "MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR" on page 4-24.
Check the wheel sensor for damage and the installed
condition of the sensor. Repair or replace the wheel
sensor if necessary.
Refer to "MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR" on page 4-24.

Fault code No. 44

Fault code No. 44
Item Rear wheel sensor (missing pulses)

Rear wheel sensor signal is not received properly. (Missing pulses

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

Order Item/components and probable cause Check or maintenance job

1 Foreign material adhered around the rear
wheel sensor
2 Incorrect installation of the rear wheel
3 Defective sensor rotor or incorrect instal-
lation of the rotor
4 Defective rear wheel sensor or incorrect
installation of the sensor
Check the surface of the sensor rotor and wheel sensor
for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.
Check the components for looseness, distortion, and
bends.
Refer to "CHECKING THE REAR WHEEL'.' on page
4-30.
Check the surface of the sensor rotor for damage. Re-
place the sensor rotor if there is visible damage.
Refer to "MAINTENANCE OF THE REAR WHEEL
SENSOR AND SENSOR ROTOR" on page 4-32.
Check the wheel sensor for damage and the installed
condition of the sensor. Repair or replace the wheel
sensor if necessary.
Refer to "MAINTENANCE OF THE REAR WHEEL
SENSOR AND SENSOR ROTOR" on page 4-32.

8-172
 ABS (ANTI-LOCK BRAKE SYSTEM)

Fault code No. 51, 52

51
Fault code No.
52

• Vehicle system power supply (voltage of ABS ECU power supply is

high) (for fault code No. 51)
Item
• Vehicle system power supply (voltage of wheel sensor power sup-
ply is high) (for fault code No. 52)

• Power voltage supplied to the ABS ECU in the hydraulic unit as-
sembly is too high. (for fault code No. 51)
Symptom
• Power voltage supplied to the wheel sensor is too high. (for fault
code No. 52)

Order Item/components and probable cause Check or maintenance job

1 Defective battery
2 Disconnected battery terminal
3 Defective charging system
Recharge or replace the battery.
Refer to "CHECKING AND CHARGING TH E BATTERY"
on page 8-190.
Check the connection. Replace or reconnect the termi -
nal if necessary.
Check the charging system.
Refer to "CHARGI NG SYST EM" on page 8-17.

Fault code No. 53

Fault code No. 53
Vehicle system power supply (voltage of ABS ECU power supply is
Item
low)

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

Order Item/components and probable cause Check or maintenance job

1 Defective battery
2 Defective coupler between the battery
and the hydraulic unit assembly
Recharge or replace the battery.
Refer to "CHECKING AND CHARGING THE BATTERY"
on page 8-190.
• Check the coupler for any pins that may be pulled out.
• Check the locking condition of the coupler.
• If there is a malfunction, repair it and connect the cou-
pier securely.
TIP
Turn the main switch to "O FF" before disconnecting or
connecting a coupler.

3 Open or short circuit in the wire harness
between the battery and the hydraulic unit
assembly
4 Defective charging system
• Replace if there is an open or short circuit.
• Between A BS ECU coupler and ABS ECU fuse.
(brown/ red- brown/red)
Check the charging system.
Refer to "CHARGI NG SYSTEM" on page 8-17.

8-173
 ABS (ANTI-LOCK BRAKE SYSTEM)

Fault code No. 54

Fault code No. 54
Hydraulic unit assembly (defective ABS solenoid and ABS motor
Item
power supply circuits)

Abnormality is detected in the solenoid or motor power supply cir-

Symptom
cuit in the hydraulic unit assembly.

Order Item/components and probable cause Check or maintenance job

1 Defective battery
2 Defective coupler between the battery
and the hydraulic unit assembly
Recharge or replace the battery.
Refer to "CHECKING AND CHARGING THE BATTERY"
on page 8-190.
• Check the coupler for any pins that may be pulled out.
• Check the locking condition of the coupler.
• If there is a malfunction, repair it and connect the cou-
pier securely.
TIP
Turn the main switch to "OFF" before disconnecting or
connecting a coupler.

3 Open or short circuit in the wire harness
between the battery and the hydraulic unit
assembly
4 Defective charging system
5 Defective hydraulic unit assembly
• Replace if there is an open or short circuit.
• Between ABS ECU coupler and starter relay coupler
(ABS motor fuse).
(red/blue-red/blue)
• Between ABS ECU coupler and ABS solenoid fuse.
(red/ white-red/white)
Check the charging system.
Refer to "CHARGING SYSTEM" on page 8-17.
If the above items were performed and no malfunctions
were found, replace the hydraulic unit assembly.
Refer to "ABS (ANTI-LOCK BRAKE SYSTEM)" on page
4-60.

Fault code No. 55

Fault code No. 55
Item Hydraulic unit assembly (defective ABS ECU)

Symptom Abnormal data is detected in the hydraulic unit assembly.

Order Item/components and probable cause Check or maintenance job

1 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to "ABS (ANTI-LOCK BRAKE SYSTEM)" on page
4-60.

8-174
 ABS (ANTI-LOCK BRAKE SYSTEM)

Fault code No. 56

Fault code No. 56
Item Hydraulic unit assembly (abnormal internal power supply)

Abnormality is detected in the power supply circuit in the hydraulic

Symptom
unit assembly.

Order Item/components and probable cause Check or maintenance job

1 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to "ABS (ANTI-LOCK BRAKE SYSTEM)" on page
4-60.

Fault code No. 63

Fault code No. 63
Item Front wheel sensor power supply (voltage of power supply is low)

Power voltage supplied from the ABS ECU to the front wheel sensor
Symptom
is too low.

Order Item/components and probable cause Check or maintenance job

1 Short circuit in the wire harness between
the front wheel sensor and the hydraulic
unit assembly
• Check that there is no short circuit between the white
terminal "1" and the black terminal "2".
• Check that there is no short circuit between the black/
yellow terminal "3" and the white terminal "1".
• If there is a short circuit, the wire harness is defective.
Replace the wire harness.

2 1

~ l•l•I' I. [w, [o, [,w[ ~' JJ.

lvl al a ler~lt9t l1.gwl~t l s,y J
' I

_=,~ 3 .....

~ 4
\'
5

2 Defective front wheel sensor
4. ABS ECU
5. W heel sensor
• Check that there is no short circuit between the black
terminal "1" and the white terminal "2".
• If there is a short circuit, the wheel sensor is defective.
Repair or replace the wheel sensor.

2 1

.,~ I BlwI BI wlvt,G IG.IJl lwlY I ~ i::i[ B!W)ll~

Rl lvl ale ler,ll lt9t l1.gwlB1t l SI'/
l/ 'i

.....

~ 3
\'
4
3. ABS ECU
4. W heel sensor

8-175
 ABS (ANTI-LOCK BRAKE SYSTEM)

Fault code No. 63

Item Front w heel sensor power supply (voltage of power supply is low)

Power voltage supplied from the ABS ECU to the front wheel sensor
Symptom
is too low.

Order Item/components and probable cause Check or maintenance job

3 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to "ABS (ANTI-LOCK BRAKE SYSTEM)" on page
4-60.

Fault code No. 64

Fault code No. 64
Item Rear wheel sensor power supply (voltage of power supply is low)

Power voltage supplied from the ABS ECU to the rear wheel sensor
Symptom
is too low.

Order Item/components and probable cause Check or maintenance job

1 Short circuit in the wire harness between
the rear wheel sensor and the hydraulic
unit assembly
• Check that there is no short circuit between the white
terminal "1" and the black terminal "2".
• Check that there is no short circuit between the black/
yellow terminal "3" and the white terminal "1".
• If there is a short circuit, the wire harness is defective.
Replace the wire harness.

2 1

~ l•l•I•I• i" i" i"'i ~' ~ -

Iv I ale ler~lt9t l1.gwlB1t l s,y )
G•I
Y

_=,~ .... 3

~ 4
\'
5

2 Defective rear wheel sensor
4. ABS ECU
5. W heel sensor
• Check that there is no short circuit between the gray
terminal "1" and the white terminal "2".
• If there is a short circuit, the wheel sensor is defective.
Repair or replace the wheel sensor.

2 1

✓~ Ie lwIa I wlvt,GIGIR lwlYI ~ .::i[ B!W)l~IG/

Rt lvl ale ler,ll lt9t l1.gwlBJL I SI'/

....

~ 3
\'
4
3. ABS ECU
4. W heel sensor

8-176
 ABS (ANTI-LOCK BRAKE SYSTEM)

Fault code No. 64

Item Rear wheel sensor power supply (voltage of power supply is low)

Power voltage supplied from the ABS ECU to the rear wheel sensor
Symptom
is too low.

Order Item/components and probable cause Check or maintenance job

3 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to "ABS (ANTI-LOCK BRAKE SYSTEM)" on page
4-60.
EAS31167

[B-3] DELETING THE FAULT CODES

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

Yamaha diagnostic tool USB (US)

90890-03257
Yamaha diagnostic tool (A/1)
90890-03262

Connecting the Yamaha diagnostic tool

Remove the protective cap "1", and then connect the Yamaha diagnostic tool to the coupler.
~ -. - - - - - - - ,

•
(

-
@
,~
1

EAS31168

[C-1] FINAL CHECK

Check all the following items to complete the inspection.
If the process is not completed properly, start again from the beginning.

Checking procedures
1. Check the brake fluid level in the brake master cylinder reservoir and brake fluid reservoir.
Refer to "CHECKING THE BRAKE FLUID LEVEL" on page 3-13.
2. Check the wheel sensors for proper installation.
Refer to "INSTALLING THE FRONT WHEEL (DISC BRAKE)" on page 4-25 and "INSTALLING THE
REAR WHEEL (DISC BRAKE)" on page 4-32.
3. Perform brake line routing confirmation.
Refer to "HYDRAULIC UNIT OPERATION TESTS" on page 4-65.
If it does not have reaction-force properly, the brake hose is not properly routed or connected.
4. Delete the fault codes.
Refer to "[B-3] DELETING THE FAULT CODES" on page 8-177.
5. Checking the ABS warning light.
Refer to "CHECKING THE ABS WARNING LIGHT' on page 4-68.
If the ABS warning light does not turn off, the possible causes are following:
• The problem is not solved.

8-177
 ABS (ANTI-LOCK BRAKE SYSTEM)

• Open circuit between the ABS ECU and the meter assembly.
Check for continuity between green/red terminal of the ABS ECU coupler and green/red terminal of
the meter assembly coupler.
• Malfunction in the meter assembly circuit.
• Malfunction in the ABS warning light circuit in the hydraulic unit assembly.

8-178
 GRIP WARMER SYSTEM (MTT9GTK/MTT9GTKC)

EAS20167

GRIP WARMER SYSTEM (MTT9GTK/MTT9GTKC)

EAS31007

CIRCUIT DIAGRAM

-:.;:--=-
I - - - - ;:...

''
- - -=-=--=-1
- i;:..;.
- -=-=--=- '
- -:.;: - -;:..::-~,e,;,,~~ 0
--=-
'
'
' '
''
''
'
-------
® •

't t- - --tr-i~=f-•·- 1
---•
@

~I: i-IJ-rJ-ri
:~i :-r
J--r-UJ
,____[l!: . 1-dJ_
--:
.
t ~:~,! :___ f --- -- __ ;
~---+<: ',,__,_f
~~
~ Eil

'""'
,,o,
'
'
'
'------·

8-179
 GRIP WARMER SYSTEM (MTT9GTK/MTT9GTKC)

3. Main switch
4. Main fuse
8. Backup fuse
11. Ignition fuse
16.Battery
17.Engine ground
18. Fuel injection system fuse
21.Joint coupler
26. Handlebar switch (right)
27.Wheel switch
28.Start/engine stop switch
30.Relay unit
31.Starting circuit cut-off relay
35. ECU (Engine Control Unit)
43.Grip warmer (left)
44.Grip warmer (right)
60.Meter assembly
64.Multi-function meter
A. Wire harness
B. Negative battery sub-wire harness

8-180
 GRIP WARMER SYSTEM (MTT9GTK/MTT9GTKC)

EAS3 1008

TROUBLESHOOTING
TIP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
• Before troubleshooting, remove the following part(s):
1. Fuel tank front cover/Front side panel/Front side cowling
2. Passenger seat/Rider seat
3. Fuel tank cover
4. Fuel tank

The grip warmers do not become warm at all.

1. Check that the engine trouble warn- NG ➔ Perform the troubleshooting for fault code
ing light is on and that "Err'' is dis- No. U0155. Refer to "TROUBLESHOOT-
played in the multi-function meter 1NG DETAILS (FAULT CODE)" on page
center display. 8-51 .

OKt

2. Check that the grip warmers are not Adjust the temperature levels of the grip
turned off. warmer settings.

OKt

3. Check the fuses. (Main , ignition,

backup, and fuel injection system)
Replace the fuse(s) .
Refer to "CHECKING THE FUS-
ES" on page 8-189.

OKt

4. Check that the engine is started. Start the engine.

OKt

5. Check the grip warmers.

Refer to "CIRCU IT DIAGRAM" on Replace the grip warmer(s).
page 8-179.

OKt

6. Check the entire grip warmer sys-

tem wiring. Properly connect or replace the wiring har-
Refer to "CIRCU IT DIAGRAM" on ness.
page 8-179.

OKt

7. Execute the diagnostic mode (code

Replace the ECU. Refer to "REPLAC ING
No. 57) to turn on the grip warmers,
THE ECU (Engine Control Unit)" on page
and then check that they become
8-189.
warm .

OKt

Replace the meter assembly.

8-181
 GRIP WARMER SYSTEM (MTT9GTK/MTT9GTKC)

The qrip warmers are abnormally hot while the enqine is idlinq.

1. Check that the temperature level of NG ➔

Adjust the temperature levels of the grip
the low grip warmer setting is set to
warmer settings.
"1".

OKt

Replace the ECU. Refer to "REPLAC-

ING THE ECU (Engine Control Unit)"
on page 8-189.

The qrip warmers do not become very warm while the vehicle is travelinq.

1. Check that the temperature level of NG ➔

Adjust the temperature levels of the grip
the high grip warmer setting is set
warmer settings.
to "1O".

OKt

2. Check that the engine trouble warn- NG ➔ Perform the troubleshooting for fault code
ing light is on and that fault code No. POSOO. Refer to ''TROUBLESHOOT-
No. POSOO is displayed in the ING DETAILS (FAULT CODE)" on page
Yamaha diagnostic tool display. 8-51 .

OKt

Replace the ECU. Refer to "REPLAC-

ING THE ECU (Engine Control Unit)"
on page 8-189.

The temgerature levels of the grig warmer settings cannot be changed.

1. Check the wheel switch . NG ➔

Refer to "CHECKING THE WHEEL • The wheel switch is faulty.
SWITCH (MTT9GTK/MTT9GTKC)" • Replace the right handlebar switch.
on page 8-204.

OKt

2. Check the wire harness between

Properly connect or replace the wiring har-
the right handlebar switch and the
ness.
meter assembly.

OKt

Replace the meter assembly.

8-182
 ELECTRICAL COMPONENTS

EAS20089

ELECTRICAL COMPONENTS
For MTT9K/MTT9KC

4
3 5

~
2
6
1

20
"7 8
~
19 •
~ ~ 9

10
18 ...,,
,0

'

11

12

17
13
16 15 14
1. Main switch 18. Ignition coil
2. Clutch switch 19. Radiator fan motor
3. Front brake light switch 20. Horn
4. Hydraulic unit assembly
5. Battery
6. Fuse box 3
7. Main fuse
8. Fuel injection system fuse
9. Starter relay
10. Rectifier/regulator
11. Rear wheel sensor
12. Rear brake light switch
13. Gear position switch
14. Sidestand switch
15. 0 2 sensor
16. Oil level switch
17. Front wheel sensor

8-183
 ELECTRICAL COMPONENTS

2 4
1
20 3

19 6

18
7

17
8

16

14

10

9
13

11

12
1. Intake air temperature sensor
2. ECU (Engine Control Unit)
3. Fuel pump
4. Fuelsender
5. Lean angle sensor
6. Radiator fan motor relay
7. Turn signal/hazard relay
8. Relay unit
9. Stator coil
10. Crankshaft position sensor
11. Coolant temperature sensor
12. Throttle servo motor
13. Accelerator position sensor
14. Throttle position sensor
15. Intake air pressure sensor 1
16. Intake air pressure sensor 2
17. Injector
18. Air induction system solenoid
19. Fuse box 1
20. Fuse box 2

8-184
 ELECTRICAL COMPONENTS

For MTT9GTK/MTT9GTKC

5
3

20

~
19
9

10

18

11

12
17

16 13
15
1. Main switch 20. Horn
2. Clutch switch
3. Front brake light switch
4. Hydraulic unit assembly
5. Battery
6. Fuse box 3
7. Main fuse
8. Fuel injection system fuse
9. Starter relay
10. Rectifier/regulator
11. Rear wheel sensor
12. Rear brake light switch
13. Gear position switch
14. Sidestand switch
15. 0 2 sensor
16. Oil level switch
17. Front wheel sensor
18. Ignition coil
19. Radiator fan motor

8-185
 ELECTRICAL COMPONENTS

1 2
4

23

22

21 7

20

10

15 11

13

1. Intake air temperature sensor 21. Air induction system solenoid

2. ECU (Engine Control Unit) 22. Fuse box 1
3. Fuel pump 23. Fuse box 2
4. Fuelsender
5. Lean angle sensor
6. Radiator fan motor relay
7. Turn signal/hazard relay
8. Relay unit
9. Brake light relay
10. Shift switch
11. Stator coil
12. Crankshaft position sensor
13. Coolant temperature sensor
14. Throttle servo motor
15. Accelerator position sensor
16. Throttle position sensor
17. Intake air pressure sensor 1
18. Intake air pressure sensor 2
19. Grip cancel switch
20. Injector

8-186
 ELECTRICAL COMPONENTS

EAS30549

CHECKING THE SWITCHES

Check each switch for continuity with the digital circuit tester. If the continuity reading is incorrect, check
the wiring connections and if necessary, replace the switch.

For MTT9K/MTT9KC
-----------------------,
1 :
X VJB Ch Dr ~--,-;-;-i=:r=,'
BNI/ W! y ~~\ l!O YYIBYi
1' 1D 1
1
B/Y NI B LlF11S~Sw;j±QLJ -
VII( Br BIR 1/G ~w X
Ch oV Dg
2 Ch Br/W D
c::>
10 ~

R
RIB W/L B
~

3 Br B "' "
DO ()
(,) )

,---------------------,
1
12
: I
I
I
I
I
~ - . -,
---------------------~ I
I
'
'
'
'
'
'
6 I s}R : ' '
B/Y I
I
·'--·-~ '
BI\.
I

, _____ _ ,---------------------------,
' 1
I
13 I
I
,---,;:-::,:,-::-c,-:=-:,:r.=,

7
I
I @'IRI-"'-
l/8 IllYj:
I

I
ON
OFF :
I
P' :
I
I I
I
I
~---------------------------
I
I
--------------------- I

8 I
LIB
,-~----,
I B I

'b '
ll~~~Bj
~
1. Dimmer/pass switch
2. Turn signal switch
3. Horn switch
4. Select switch
5. Menu switch
6. Clutch switch
7. Oil level switch
8. Sidestand switch
9. Hazard switch
10. Start/engine stop switch
11. Drive mode switch
12. Front brake light switch
13. Main switch
14. Rear brake light switch

8-187
 ELECTRICAL COMPONENTS

For MTT9GTK/MTT9GTKC
r----------------------- ,---------------------~
t =,,,,,,,.~ !=,;,::= , : : 13
oo ttt~l~fgtl ~ l~I
(0) (0)
i
1
R/W RIB W/L B

I
...___ y Y/B y I
1 10 I
(i)

'
~D
PASS • ) i [lNltRNi] i=="'I
: (B) R B RIB
...___ Ch Br/W Or I
2 I (B)
c::>
-
' ----------------------
I

<;:,

3 ~
UR B
c,,. ' '
-
...___ W/L BNJ
4
- ' '
MODE

I 1

I 15 :
I ,--,,---=-,.,,..-,:r-'.'.""'.-r--=-i ..L:.... I
,WBr/1. r/ UY UB fBriRILIBIUYJ ':
I ON I

I 0 :; ~ i
:l-------------------------
lJEill:J
7 ~

SET
G Y/B G/B
'
-
RES ' ~ -----,
'' '

al?lobbl
______________________ J
I
'
:''i@ffil:
'
'

'
'
_____ 1

r-------------------
---.. Y/8 YNJ BIY B/R Y
i
9 :I
PIJSli '
FAEE ' ' -------------
,---------------------,
l:~~l
__________________ J
1 ---- ·
' 10 ~ 1 -----
,-----
: 12 J8
(B)
: ~+-----, GN GN YNJ Y/8

:-
---t:
I • • • • • I 11 I I B I
OFF

ll l !~ Il
'
'
'
' I I O I
ON

@fill
: :1(ml:
I I I rwl'vm1
~
I I I
, (Gy) , I '- ____ _I
I ••••••' I

0/W
I
' '
'................... .'
~ :
I
~ (8)
"------------..J
1. Dimmer/pass switch
2. Turn signal switch
3. Horn switch
4. Mode switch
5. Traction control system switch
6. Cruise control power switch
7. Cruise control setting switch
8. Hazard switch
9. Clutch switch
10. Shift switch
11. Oil level switch
12. Sidestand switch
13. Start/engine stop switch
14. Front brake light switch
15. Main switch
16. Grip cancel switch
17. Rear brake light switch

8-188
 ELECTRICAL COMPONENTS

EAS30551

CHECKING THE FUSES Amperage

Fuses Q'ty
The following procedure applies to all of the fus- rating
es. Plug + 12 V fuse (DC jack,
2A 1
ECA13680 option)
NOTICE
- - - - - - - - - - - - - Backup 7.5 A 1
To avoid a short circuit, always set the main
Electronic throttle valve 7.5 A 1
switch to "OFF" when checking or replacing
a fuse. Brake light (MTT9GTK/
1A 1
MTT9GTKC)
1. Remove: Cruise control (MTT9GTK/
• Passenger seat/Rider seat 1A 1
MTT9GTKC)
Refer to "GENERAL CHASSIS (1 )" on page
Spare 30A 1
4-1.
2. Check: Spare 20A 1
• Fuse Spare 15 A 1
a. Connect the digital circuit tester to the fuse Spare 7.5 A 1
and check the continuity. Spare 2A 1

)lb Digital circuit tester (CD732)

90890-03243
Model 88 Multimeter with ta-
EWA13310

& WARNING
Never use a fuse with an amperage rating
chometer other than that specified. Improvising or us-
YU-A1927 ing a fuse with the wrong amperage rating
may cause extensive damage to the electri-
b. If there is no continuity, replace the fuse. cal system, cause the lighting and ignition
3. Replace:
systems to malfunction and could possibly
• Blown fuse
cause a fire.
a. Set the main switch to "OFP'.
b. Install a new fuse of the correct amperage 4. Install:
rating. • Rider seat/Passenger seat
c. Set on the switches to verify if the electri- Refer to "GENERAL CHASSIS (1)" on page
cal circuit is operational. 4-1.
d. If the fuse immediately blows again , check EAS31006
the electrical circuit. REPLACING THE ECU (Engine Control Unit)
Amperage 1. Turn the main switch to "OFF".
Fuses Q'ty
rating 2. Replace the ECU (Engine Control Unit).
3. Clean the throttle bodies and reset the ISC
Main 50A 1
(idle speed control) learning value.
Headlight 7.5 A 1 Refer to "CHECKING AND CLEANING THE
Fog lamp 2A 1 THROTTLE BODIES" on page 7-14.
Signaling system 7.5 A 1 4. Reset the 0 2 feedback learning value.
Ignition 15 A 1 Refer to "SELF-DIAGNOSTIC FUNCTION
Radiator fan motor 15 A 1
AND DIAGNOSTIC CODE TABLE" on page
9-1.
Parking lighting 10.0 A 1 5. Check:
Fuel injection system 20A 1 • Engine idling speed
ABS motor 30A 1 Start the engine, warm it up, and then mea-
ABS control unit 7.5 A 1 sure the engine idling speed.
ABS solenoid 15 A 1 Engine idling speed
Seat heater (option) 7.5 A 1 1100-1300 r/min
Plug + 12 V fuse (DC jack) 2A 1

8-189
 ELECTRICAL COMPONENTS

EAS30552

CHECKING AND CHARGING THE BATTERY

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Refer to "CHECKING AND CHARG ING TH E
BATTERY" in "BASIC INFORMATION" (sepa-
rate volume).
1. Remove:
• Passenger seat/Rider seat
Refer to "GENERAL CHASSIS (1)" on page
4-1.
2. Disconnect: 7. Check:
• Battery leads • Battery terminals
(from the battery terminals) D i rt ➔ Clean with a wire brush .
ECA13640 Loose connection ➔ Connect properly.
NOTICE 8. Lubricate:
------------- • Battery terminals
First, disconnect the negative battery lead
"1", and then positive battery lead "2".
Recommended lubricant
I Dielectric grease

9. Install:
• Rider seat/Passenger seat
Refer to "GENERAL CHASSIS (1 )" on page
4-1 .
EAS30553

CHECKING THE RELAYS

Check each switch for continuity with the digital
circuit tester. If the continuity reading is incor-
3. Remove: rect, replace the relay.
• Battery
Refer to "GENERAL CHASSIS (1 )" on page Digital circuit tester (CD732)
4-1. 90890-03243
4. Check: Model 88 Multimeter with ta-
• Battery charge chometer
5. Install: YU-A1 927
• Battery
1. Disconnect the relay from the wire harness.
Refer to "GENERAL CHASSIS (1)" on page
2. Connect the digital circuit tester (Q) and bat-
4-1.
tery (12 V) to the relay terminal as shown .
6. Connect:
Check the relay operation .
• Battery leads
Out of specification ➔ Replace.
(to the battery terminals)
ECA13630

NOTICE Starter relay

-------------
First, connect the positive battery lead "1 ", ,...._,,, 3
and then the negative battery lead "2". ,---- --------------------'
'
'
'
' A

•
R R
\\\V

L/W R/'N '

'
'
1 :2
............................................'
4
1. Positive battery terminal

8-190
 ELECTRICAL COMPONENTS

2. Negative battery terminal Radiator fan motor relay

3. Positive tester probe
4. Negative tester probe
3
, '
Relay operation R/L
4
Continuity
(between "3" and "4")
L
- -

~
RNJ G/Y

Relay unit (starting circuit cut-off relay) 2 1

3 1 2 4, 1. Positive battery terminal

\ .
2. Negative battery terminal
I 3. Positive tester probe
- 111 II ~

4. Negative tester probe

RIB W/L R/1.

~
Result
Continuity
(between "3" and "4")
1. Positive battery terminal
2. Negative battery terminal Brake light relay (MTT09DK)
3. Positive tester probe
4. Negative tester probe 3 - 1 (
4 + I 1-
' ,..._

~
Result - ' ,-
Continuity
#

' I
2 1
(between "3" and "4")
B y G/Y
Relay unit (fuel pump relay)

3 2 1 4 1. Positive battery terminal

2. Negative battery terminal
I 3. Positive tester probe
- 1111 II - 4. Negative tester probe
RIB W/L R/L

~
Result
Continuity
(between "3" and "4")
1. Positive battery terminal
2. Negative battery terminal EAS30794

CHECKING THE TURN SIGNAL/HAZARD

3. Positive tester probe
RELAY
4. Negative tester probe
1. Check:
• Turn signal/hazard relay input voltage

~
Result Out of specification ➔ The wiring circuit from
Continuity the main switch to the turn signal/hazard re-
(between "3" and "4") lay coupler is faulty and must be repaired.

Turn signal/ hazard relay input

voltage
DC 12V

8-191
 ELECTRICAL COMPONENTS

a. Connect the digital circuit tester (DC V) to

the turn signal/hazard relay terminal as
shown.

Digital circuit tester (CD732)

90890-03243
Model 88 Multimeter with ta-
UR 1'----1
chometer
YU-A1927

• Positive tester probe

blue/red "1" b. Turn the main switch to "ON".
• Negative tester probe c. Measure the turn signal/hazard relay out-
Ground
put voltage.
EAS30795

CHECKING THE RELAY UNIT (DIODE)

1. Check:
• Relay unit (diode)
Out of specification ➔ Replace.

UR
Digital circuit tester (CD732)
90890-03243
~ 1 Model 88 Multimeter with ta-
chometer
YU-A1927
b. T urn the main switch to "ON".
c. Measure the turn signal/hazard relay input TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
voltage. The digital circuit tester readings are shown in
2. Check: the following table.
• Turn signal/hazard relay output voltage
Out of specification ➔ Replace.

Turn signal/hazard relay output

voltage
DC 12 V

a. Connect the digital circuit tester (DC V) to

the turn signal/hazard relay terminal as
shown.

Digital circuit tester (CD732)

90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927

• Positive tester probe

brown/white "1"
• Negative tester probe
Ground

8-192
 ELECTRICAL COMPONENTS

c. Check the relay unit (diode) for continuity.

Continuity d. Check the relay unit (diode) for no continu-
Positive tester probe ity.
sky blue "1"
Negative tester probe EAS30558

black/yellow "2" CHECKING THE IGNITION COILS

No continuity The following procedure applies to all of the igni-
Positive tester probe tion coils.
black/yellow "2" 1. Check:
Negative tester probe • Primary coil resistance
sky blue "1" Out of specification ➔ Replace.
Continuity
Positive tester probe Primary coil resistance
sky blue "1" 1.19-1.61 Q
Negative tester probe
black/red "3" a. Remove the ignition coil from the spark
No continuity plug.
Positive tester probe b. Connect the digital circuit tester (Q) to the
black/red "3" ignition coil as shown .
Negative tester probe
sky blue "1" Digital circuit tester (CD732)
Continuity 90890-03243
Positive tester probe Model 88 Multimeter with ta-
sky blue "1" chometer
Negative tester probe YU-A1927
sky blue/white "4"
No continuity
• Positive tester probe ➔
Positive tester probe red/black " 1"
sky blue/white "4" • Negative tester probe ➔
Negative tester probe Cylinder-# 1 ignition coil
sky blue "1" orange "2"
Continuity Cylinder-#2 ignition coil
Positive tester probe gray/red "2"
blue/black "5" Cylinder-#3 ignition coil
Negative tester probe orange/green "2"
black/red "3"
No continuity
Positive tester probe
black/red "3"
Negative tester probe
blue/black "5"

.o
53 1 2 4

I c. Measure the primary coil resistance.

~
II II ~

2. Check:
RIB W/L R/1. • Secondary coil resistance
Out of specification ➔ Replace.

Secondary coil resistance

a. Disconnect the relay unit coupler from the 9.35-12.65 kQ
wire harness.
b. Connect the digital circuit tester (Q) to the a. Connect the digital circuit tester (Q) to the
relay unit terminal as shown . ignition coil as shown.

8-193
 ELECTRICAL COMPONENTS

Digital circuit tester (CD732)

90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1 927 a

• Negative tester probe ➔

red/black "1" 2
• Positive tester probe ➔ 1
spark plug terminal "2"
2. Ignition coil

c. Turn the main switch to "ON".

1
d. Measure the ignition spark gap "a".
CJ
poQ) e. Crank the engine by pushing the "(J)" side
of the start/engine stop switch and gradu-
ally increase the spark gap until a misfire
occurs.
EAS30560

2 CHECKING THE CRANKSHAFT POSITION

SENSOR
b. Measure the secondary coil resistance. 1. Disconnect:
EAS30556
• Crankshaft position sensor coupler
CHECKING THE IGNITION SPARK GAP (from the wire harness)
1. Check: 2. Check:
• Ignition spark gap • Crankshaft position sensor resistance
Out of specification ➔ Perform the ignition Out of specification ➔ Replace the crank-
system troubleshooting, starting with step 5. shaft position sensor.
Refer to "TROUBLESHOOTING" on page

~
8-6. Crankshaft position sensor resis-
tance
Minimum ignition spark gap 228-342 Q
6.0 mm (0.24 in)
a. Connect the digital circuit tester (Q) to the
TIP _ _ _ _ _ _ _ _ _ _ _ _ __ crankshaft position sensor coupler as
shown.
If the ignition spark gap is within specification ,
the ignition system circuit is operating normally. Digital circuit tester (CD732)
a. Remove the ignition coil from the spark 90890-03243
plug. Model 88 Multimeter with ta-
b. Connect the ignition checker "1" as chometer
YU-A1927
shown.

Ignition checker • Positive tester probe

90890-06754 gray " 1"
Oppama pet-4000 spark checker • Negative tester probe
black "2"
YM-34487

8-194
 ELECTRICAL COMPONENTS

1 ---+Gy B + - - 2

b. Measure the crankshaft position sensor

c. Set the main switch to "ON".
resistance.
d. Turn the lean angle sensor to 65°.
EAS30561 e. Measure the lean angle sensor output
CHECKING THE LEAN ANGLE SENSOR voltage.
1. Remove:
EAS30562
• Lean angle sensor
CHECKING THE STARTER MOTOR
(from the fuel tank bracket)
OPERATION
2. Check:
1. Check:
• Lean angle sensor output voltage
• Starter motor operation
Out of specification ➔ Replace.
Does not operate ➔ Perform the electric

~
Lean angle sensor output voltage starting system troubleshooting, starting with
Less than 65° step 4.
0.4-1.4 V Refer to "TROUBLESHOOTING" on page
More than 65° 8-15.
3.7-4.4 V a. Connect the positive battery terminal "1"
and starter motor lead "2" with a jumper
a. Connect the test harness- lean angle sen- lead "3".
sor (6P) "1" to the lean angle sensor and EWA13810

wire harness as shown. & WARNING

b. Connect the digital circuit tester (DC V) to • A wire that is used as a jumper lead must
the test harness- lean angle sensor (6P). have at least the same capacity of the bat-
tery lead, otherwise the jumper lead may
Digital circuit tester (CD732) burn.
90890-03243 • This check is likely to produce sparks,
Model 88 Multimeter with ta-
therefore, make sure no flammable gas or
chometer
fluid is in the vicinity.
YU-A1927
Test harness- lean angle sensor
(6P)
90890-03209
Test harness- lean angle sensor 2
(6P)
YU-03209
M
• Positive tester probe
yellow/green (wire harness color)
• Negative tester probe
-- --
black/blue (wire harness color)
b. Check the starter motor operation.

8-195
 ELECTRICAL COMPONENTS

EAS30566
a. Connect the digital circuit tester to the bat-
CHECKING THE STATOR COIL
tery terminals as shown.
1. Disconnect:
• Stator coil coupler
(from the wire harness)
2. Check:
fb Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
• Stator coil resistance chometer
O ut of specification ➔ Replace the stator coil. YU-A1927

Stator coil resistance • Positive tester probe ➔

0.152-0.228 Q positive battery terminal "1"
• Negative tester probe ➔
a. Connect the digital circuit tester to the sta- negative battery terminal "2"
tor coil coupler as shown.

fb Digital circuit tester (CD732)

90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927

• Positive tester probe

white "1"
• Negative tester probe
white "2"
b. Start the engine and let it run at approxi-
• Positive tester probe mately 5000 r/min.
white "1" c. Measure the charging voltage.
• Negative tester probe
EAS30846
white "3"
CHECKING THE ENGINE OIL LEVEL
• Positive tester probe SWITCH
white "2" 1. Drain:
• Negative tester probe • Engine oil
white "3" 2. Remove:
• Oil level switch
(from the oil pan)
3. Check:
1 2 3 • Oil level switch resistance

Oil level switch

Oil level switch resistance (maxi-
mum level position)
484.0-536.0 Q (MTT9K,
MTT9KC)
484.5-535.5 Q (MTT9GTK,
MTT9GTKC)
b. Measure the stator coil resistance. Oil level switch resistance (mini-
EAS30680
mum level position)
CHECKING THE RECTIFIER/REGULATOR 114.0-126.0 Q
1. Check:
• Charging voltage a. Connect the digital circuit tester (Q) to the
O ut of specification ➔ Replace the rectifier/ oil level switch terminal as shown.
regulator.

Charging voltage
14.0 V at 5000 r/min

8-196
 ELECTRICAL COMPONENTS

Digital circuit tester (CD732) Digital circuit tester (CD732)

90890-03243 90890-03243
Model 88 Multimeter with ta- Model 88 Multimeter with ta-
chometer chometer
YU-A1927 YU-A1927

Minimum level position "A" • Positive tester probe ➔

• Positive tester probe Fuel sender term inal "1"
Coupler (gray) "1" • Negative tester probe ➔
• Negative tester probe Fuel sender term inal "2"
Body earth "2"

Maximum level position "B"

• Positive tester probe
Coupler (gray) "1"
• Negative tester probe
Body earth "2"

IA] ffil

2
b. Move the fuel sender float to maximum "3"
and minimum "4" level position.
1
1

b. Measure the oil level switch resistance.

EAS30573

CHECKING THE FUEL SENDER

1. Disconnect:
• Fuel pump coupler
(from the fuel pump) EAS31372

2. Remove: CHECKING THE FUEL METER

• Fuel tank This model is equipped with a self-diagnosis de-
3. Remove: vice for the fuel level detection circuit.
• Fuel pump 1. Check:
(from the fuel tank) • Fuel meter "1"
4. Check: (Turn the main switch to "ON".)
• Fuel sender resistance Fuel meter comes on for a few seconds, then
Out of specification ➔ Replace the fuel pump goes off ➔ Fuel meter is OK.
assembly. Fuel meter does not come on ➔ Replace the
meter assembly.
Sender unit resistance (full) Fuel meter flashes repeatedly ➔ Replace the
9.0--11.0 Q
fuel pump assembly.
Sender unit resistance (empty)
213.0-219.0 Q

a. Connect the digital circuit tester (Q) to the

fuel sender terminals as shown.

8-197
 ELECTRICAL COMPONENTS

00 •••• CICICR 2

00 '-------=-=--=-------r

1
[ID 1 [ID
~ • 12:00

/•--···••iiiiiii
· 1000 <lmin
4 5 6 7 8 9 10 11

F -]

□ 1,'i -
Mil -"- = il Err
N
,. _ km/h_
m••·• 4 5 6 7 8 9 10 11
•=
123 4. 5 1un ECO - ·• 1000 r/ min

m1P-2
MODE-STD
123 4. 5 ,m
TCS 1
-~~--
In " C 25
II
t,1\11 ,,,._.
2 3
iiiiiiiiiiiiiiii

A. MTT9K/MTT9KC A. MTT9K/MTT9KC
B. MTT9GTK/MTT9GTKC B. MTT9GTK/MTT9GTKC

EAS30575 EAS305n

CHECKING THE OIL LEVEL WARNING CHECKING THE RADIATOR FAN MOTOR
LIGHT 1. Check:
This model is equipped with a self-diagnosis de- • Radiator fan motor
vice for the oil level detection circuit. Faulty/rough movement ➔ Replace.
1. Check: a. Disconnect the radiator fan motor coupler
• O il level warning light "1" from the wire harness.
(Turn the main switch to "ON".) b. Connect the battery (DC 12 V) as shown.
Warning light comes on for a few seconds, • Positive tester probe
then goes off ➔ Warning light is OK. blue "1"
Warning light does not come on ➔ Replace • Negative tester probe
the meter assembly. black "2"
Warning light flashes ten times, then goes off
for 2.5 seconds in a repeated cycle (malfunc-
tion detected in oil level switch) ➔ Replace
the oil level switch. 2
r;::=::::::::!:::;;r
B
L~- - - .
+
1
12V

c. Measure the radiator fan motor move-

ment.
EAS30578

CHECKING THE COOLANT TEMPERATURE

SENSOR
1. Remove:
• Coolant temperature sensor
Refer to "CYLINDER HEAD" on page 5-27.

8-198
 ELECTRICAL COMPONENTS

EWA14130 EAS30581

AwARNING CHECKING THE THROTTLE POSITION

• Handle the coolant temperature sensor SENSOR
with special care. 1. Remove:
• Never subject the coolant temperature sen- • Throttle position sensor
sor to strong shocks. If the coolant tem- (from the throttle bodies)
ECA17540
perature sensor is dropped, replace it. NOTICE
2. Check:
- - - - - - - - - - - - -
• Handle the throttle position sensor with
• Coolant temperature sensor resistance special care.
O ut of specification ➔ Replace. • Never subject the throttle position sensor
to strong shocks. If the throttle position
Coolant temperature sensor re-
sensor is dropped, replace it.
sistance
2513-2777 Q at 20 °C (2513- 2. Check:
2777 Q at 68 °F) • Throttle position sensor maximum resistance
Coolant temperature sensor re- Out of specification ➔ Replace the throttle
sistance position sensor.
210-221 Q at 100 °C (210-221 Q

~
at212 °F) Resistance
1.20-2.80 kQ
a. Connect the digital circuit tester (Q) to the
coolant temperature sensor as shown. a. Connect the digital circuit tester (Q) to the
throttle position sensor terminals as
Digital circuit tester (CD732) shown.
90890-03243
Model 88 Multimeter with ta- Digital circuit tester (CD732)
chometer 90890-03243
YU-A1927 Model 88 Multimeter with ta-
chometer
b. Immerse the coolant temperature sensor YU-A1927
"1" in a container filled with coolant "2".
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ • Positive tester probe ➔
Make sure the coolant temperature sensor ter- blue "1"
• Negative tester probe ➔
minals do not get wet. black/blue "2"
c. Place a thermometer "3" in the coolant.

3
- 1 ~
t~
(ooQ)
I 7
• 'i
~

--·1 ~-
~.o
I
-- -2 r '.7

b. Measure the throttle position sensor max-

d. Heat the coolant or let it cool down to the
imum resistance.
specified temperatures.
3. Install:
e. Measure the coolant temperature sensor
resistance. • Throttle position sensor
3. Install :
• Coolant temperature sensor

Coolant temperature sensor

16 N-m (1.6 kgf-m, 12 lb-ft)

8-199
 ELECTRICAL COMPONENTS

TIP _ _ _ _ _ _ _ _ _ _ _ _ __ b. Measure the accelerator position sensor

When install ing the throttle position sensor, ad-
just its angle properly. Refer to "ADJUSTING
THE THROTTLE POSIT ION SENSOR" on page
7-1 8.
EAS30582
CHECKING THE ACCELERATOR POSITION
SENSOR
1. Remove:
• Accelerator position sensor
maximum resistance.
3. Install:
• Accelerator position sensor
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
When installing the accelerator position sensor,
adjust its angle properly. Refer to "ADJUSTING
T HE ACCELERATOR POSIT ION SEN SOR" on
page 7-1 9.
EAS30592

(from the throttle bodies) CHECKING THE THROTTLE SERVO MOTOR

EWA15960
1. Remove:
A WARNING • A ir filter case
• Handle the accelerator position sensor with Refer to "GENERAL C HASSIS (3)" on page
special care. 4-13.
• Never subject the accelerator position sen- 2. Check:
sor to strong shocks. If the accelerator po- • Throttle valve operation
sition sensor is dropped, replace it. Throttle valves do not fully close ➔ Replace
2. Check: the throttle bodies.
• Accelerator position sensor maximum resis- a. Connect two C-size batteries to the throttle
tance servo motor terminals "1" as shown .
ECA17660
O ut of specification ➔ Replace the accelera- NOTICE
tor position sensor. -------------
Do not use a 12 V battery to operate the throt-
Resistance tle servo motor.
1.08-2.52 k..Q TIP _ _ _ _ _ _ _ _ _ _ _ _ __
a. Connect the digital circuit tester (.Q) to the Do not use old batteries to operate the throttle
accelerator position sensor terminals as servo motor.
shown.

Digital circuit tester (CD732) 1 +

~
90890-03243
Model 88 Multimeter with ta-
-
chometer +
YU-A1927 ~ JI
-
• Positive tester probe ➔ 1
blue "1"
• Negative tester probe ➔
black/blue "2"
ffil
+
1 2
+
l ~~ I I Q I

~BILlstLlw~ .........,,
C '.7
/ .___,___ 3V
~

A. Check that the throttle valves "2" open.

B. Check that the throttle valves "2" fully close.

8-200
 ELECTRICAL COMPONENTS

EAS30587 ECA20920

CHECKING THE AIR INDUCTION SYSTEM NOTICE

SOLENOID --------------
Pay attention to the installing direction of the
1. Check: test harness S- pressure sensor (3P) cou-
• Air induction system solenoid resistance pler.
Out of specification ➔ Replace.
b. Connect the digital circuit tester (DCV) to
Solenoid resistance the test harness S- pressure sensor (3P).
20-24 Q
Digital circuit tester (CD732)
a. Remove the air induction system solenoid 90890-03243
coupler from the air induction system sole- Model 88 Multimeter with ta-
noid. chometer
b. Connect the digital circuit tester (Q) to the YU-A1927
Test harness S- pressure sensor
air induction system solenoid terminal as
(3P)
shown.
90890-03207
Test harness S- pressure sensor
Digital circuit tester (CD732)
90890-03243 (3P)
YU-03207
Model 88 Multimeter with ta-
chometer
YU-A1927 • Positive tester probe
pink (wire harness color) (intake air pressu re
sensor 1)
• Positive tester probe ➔ pink/white (wire harness color) (intake air pres-
Air induction system solenoid terminal "1" sure sensor 2)
• Negative tester probe ➔ • Negative tester probe
Air induction system solenoid terminal "2" black/blue (wire harness color)

2 1 \

c. Measure the air induction system solenoid [ID

resistance. 1
EAS30593

CHECKING THE INTAKE AIR PRESSURE

SENSOR
1. Check:
• Intake air pressure sensor output voltage
O ut of specification ➔ Replace.

Intake air pressure sensor output

voltage A. Intake air pressure sensor 1
3.57-3.71 Vat 101.3 kPa B. Intake air pressure sensor 2

c. Set the main switch to "ON".

a. Connect the test harness S- pressure
d. Measure the intake air pressure sensor
sensor (3P) "1" to the intake air pressure
output voltage.
sensor and wire harness as shown.

8-201
 ELECTRICAL COMPONENTS

EAS30594
e. Measure the intake air temperature sen-
CHECKING THE INTAKE AIR
sor resistance.
TEMPERATURE SENSOR
3. Install:
1. Remove:
• Intake air temperature sensor
• Intake air temperature sensor
EWA14110
EAS31088

AwARNING CHECKING THE GEAR POSITION SWITCH

• Handle the intake air temperature sensor 1. Remove:
with special care. • Fuel tank
• Never subject the intake air temperature Refer to "FUEL TANK" on page 7-1 .
sensor to strong shocks. If the intake air • Gear position switch
temperature sensor is dropped, replace it. Refer to "CRANKCASE" on page 5-69.
2. Check:
2. Check:
• Gear position switch
• Intake air temperature sensor resistance
Out of specification ➔ Replace the gear posi-
O ut of specification ➔ Replace.
tion switch .
Intake air temperature sensor re-
Digital circuit tester (CD732)
sistance
90890-03243
5400-6600 Q at O °C (5400-6600
Model 88 Multimeter with ta-
Q at 32 °F)
Intake air temperature sensor re- chometer
YU-A1927
sistance
290-390 Q at 80 °C (290-390 Q
at 176 °F)

a. Connect the digital circuit tester (Q) to the

intake air temperature sensor terminal as
shown.

Digital circuit tester (CD732)

90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927

b. Immerse the intake air temperature sen-

sor "1" in a container filled with water "2".
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Make sure that the intake air temperature sensor
terminals do not get wet.
c. Place a thermometer "3" in the water.

3
1

d. Slowly heat the water, then let it cool down

to the specified temperature.

8-202
 ELECTRICAL COMPONENTS

EAS30681

Result CHECKING THE FUEL INJECTORS

Neutral position The following procedure applies to all of the fuel
Continuity injectors.
Positive tester probe 1. Remove:
sky blue "1" • Fuel injector
Negative tester probe Refer to "THROTTLE BO DIES" on page 7-5.
Sensor terminal "a" 2. Check:
1st position • Fuel injector resistance
Continuity Out of specification ➔ Replace the fuel injec-
Positive tester probe
tor.
white "2"

~
Negative tester probe Resistance
Sensor terminal "b" 12.0 Q
2nd position
Continuity a. Disconnect the fuel injector coupler from
Positive tester probe
the fuel injector.
pink "3"
b. Connect the digital circuit tester (Q) to the
Negative tester probe
Sensor terminal "c" fuel injector coupler as shown.
3rd position
Continuity
Positive tester probe
fb Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
yellow/ white "4"
Negative tester probe chometer
YU-A1927
Sensor terminal "d"
4th position
Continuity • Positive tester probe ➔
Positive tester probe Injector terminal "1"
white/red "5" • Negative tester probe ➔
Injector terminal "2"
Negative tester probe
Sensor terminal "e"
5th position
Continuity 1 2
Positive tester probe
orange "6"
Negative tester probe
Sensor terminal "f"
6th position
Continuity
Positive tester probe
gray "7"
Negative tester probe c. Measure the fuel injector resistance.
Sensor terminal "g"
EAS310 16

CHECKING THE GRIP WARMERS

(MTT9GTK/MTT9GTKC)
,.-~ 1
The following procedure applies to both of the
Sb
gnp warmers.
, ,.....--,-u,/.,4 2 1. Check:
0 Y/W W • G rip warmer resistance
g Out of specification ➔ Replace the grip
c (Q) b GyW/R P.-.... warmer.
7/- 3
a 5

8-203
 ELECTRICAL COMPONENTS

b. Turn the main switch to "ON".

Grip warmer resistance (L) c. When turning the wheel switch in direction
1.2-1.5 Q (MTT9GTK, "a" and "b", check that the output voltage is
MTT9GTKC) within the specified values.
Grip warmer resistance (R)
1.2-1.4 Q (MTT9GTK, Output voltage reading cycle
MTT9GTKC) More than 5 V to less than 0.5 V
then back to more than 5 V to
a. Disconnect the grip warmer coupler from less than 0.5 V
the wire harness.
b. Connect the digital circuit tester (Q) to the d. Connect the digital circuit tester (DC) to
grip warmer coupler as shown . the right handlebar switch coupler as
shown.
Digital circuit tester (CD732)
90890-03243 Digital circuit tester (CD732)
Model 88 Multimeter with ta- 90890-03243
chometer Model 88 Multimeter with ta-
YU-A1927 chometer
YU-A1927
• Positive tester probe ➔
black " 1" • Positive tester probe
• Negative tester probe ➔ white/black "4"
black "2" • Negative tester probe
black/white "3"

D
<==ij}
e. When turning the wheel switch in direction
"a", check that the output voltage is within
the specified values.

Output voltage
More than 5 V

\ f. When turning the wheel switch in direction

2 1 "b", check that the output voltage is within
c. Measure the grip warmer resistance. the specified values.

EAS31673 Output voltage

CHECKING THE WHEEL SWITCH Less than 0.5 V
(MTT9GTK/MTT9GTKC)
1. Check:
• Wheel switch "1" output voltage 3 2 4
Out of specification ➔ Replace the right han-
dlebar switch .
i
a. Connect the digital circuit tester (DC) to
the right handlebar switch coupler as
shown.

Digital circuit tester (CD732)

90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927

• Positive tester probe

white/green "2"
• Negative tester probe
black/white "3"

8-204
 ELECTRICAL COMPONENTS

8-205
 APPENDIX

SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE .. ......... . 9-1

SELF-DIAGNOSTIC FUNCTION TABLE
(FOR FUEL INJECTION SYSTEM) .. ......... .......... ......... .......... ......... ......... 9-1
COMMUNICATION ERROR WITH THE METER .. ........ .......... .......... ..... 9-10
DIAGNOSTIC CODE: SENSOR OPERATION TABLE .. ......... .......... ...... 9-11
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE ...... ......... ....... 9-14

EVENT CODE TABLE .. ......... .......... ......... .......... ........ .......... ......... ......... ....... 9-17
TROUBLESHOOTING DETAILS (EVENT CODE) ......... .......... ......... ...... 9-18
 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EAS203 11

SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EAS32423

SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM)

TIP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
For details of the fault code, refer to ''TROUBLESHOOTING METHOD" on page 8-49.

Fault code Pro bable caus e of Fail-safe system o p-

Ite m Vehicle symptom
No . malfunction eration
P0030 0 2 sensor heater (de- • Open circuit in wire (When the 0 2 sensor Display only (If the 0 2
fective heater control- harness. does not operate be- sensor does not oper-
ler detected) • Disconnected cou- cause the exhaust ate, 0 2 feedback is
pier. temperature is low) not carried out.)
• Defective 0 2 sensor Increased exhaust Cruise control system
. .
driver (malfunction em1ss1ons. cannot be operated.
in ECU). Fuel learning cannot (MTT9GTK/
• Open circuit in 0 2 be carried out. MTT9GTKC)
sensor heater lead.
P0107 (P0107] Intake air [PO 107] Low voltage Engine idling speed is Intake air pressure
P0108 pressure sensor 1 of the intake air pres- unstable. difference is fixed to 0
(ground short circuit sure sensor 1 circuit Engine response is [kPa].
detected) (0.5 V or less) poor. o..-N is fixed.
(P0108] Intake air [PO 108] High voltage Loss of engine power. Fuel is not cut off due
pressure sensor 1 of the intake air pres- Increased exhaust to the intake air pres-
. .
(open or power short sure sensor 1 circuit em1ss1ons. sure difference.
circuit detected) (4.8 V or more) Intake air pressure is
• Defective coupler fixed to 101.3 [kPa].
between intake air 0 2 feedback is not
pressure sensor 1 carried out.
and ECU. ISC feedback is not
• Open or short cir- carried out.
cuit in wire harness ISC learning is not
between intake air carried out.
pressure sensor 1 Cruise control system
and ECU. cannot be operated.
• Defective intake air (MTT9GTK/
pressure sensor 1. MTT9GTKC)
• Malfunction in ECU.

9-1
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Fault code Probable cause of Fail-safe system op-

Item Vehicle symptom
No. malfunction eration
P0112 [P0112] Intake air [PO 112] Low voltage Engine is difficult to The intake air tern-
P0113 temperature sensor of the intake air tern- start. perature is fixed to 20
(ground short circuit perature sensor circuit Increased exhaust [°C].
. .
detected) (0.1 V or less) em1ss1ons. 0 2 feedback is not
[P0113] Intake air [P0113] High voltage Engine idling speed is carried out.
temperature sensor of the intake air tern- unstable. ISC feedback is not
(open or power short perature sensor circuit carried out.
circuit detected) (4.8 V or more) ISC learning is not
• Defective coupler carried out.
between intake air Cruise control system
temperature sensor cannot be operated.
and ECU. (MTT9GTK/
• Open or short cir- MTT9GTKC)
cuit in wire harness
between intake air
temperature sensor
and ECU.
• Improperly installed
intake air tempera-
ture sensor.
• Defective intake air
temperature sensor.
• Malfunction in ECU.
P0117 [P0117] Coolant tern- [PO 117] Low voltage Engine is difficult to The radiator fan motor
P0118 perature sensor of the coolant tern- start. relay is on only when
(ground short circuit perature sensor circuit Increased exhaust the vehicle is traveling
. .
detected) (0.1 V or less) em1ss1ons. at low speeds .
[P0118] Coolant tern- [P0118] High voltage Engine idling speed is 0 2 feedback is not
perature sensor (open of the coolant tern- unstable. carried out.
or power short circuit perature sensor circuit ISC feedback is not
detected) (4.9 V or more) carried out.
• Defective coupler ISC learning is not
between coolant carried out.
temperature sensor The coolant tempera-
and ECU. ture is fixed to 60 [°C].
• Open or short cir- Cruise control system
cuit in wire harness cannot be operated.
between coolant (MTT9GTK/
temperature sensor MTT9GTKC)
and ECU.
• Improperly installed
coolant temperature
sensor.
• Defective coolant
temperature sensor.
• Malfunction in ECU.

9-2
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Fault code Probable cause of Fail-safe system op-

Item Vehicle symptom
No. malfunction eration
P0122 [P0122] Throttle posi- [P0122, P0222]Low Engine idling speed is Change in the throttle
P0123 tion sensor (ground voltage of the throttle high. opening is O (transient
P0222 short circuit detected) position sensor circuit Engine idling speed is control is not carried
P0223 [P0123] Throttle posi- (0.25 V or less) unstable. out).
P2135 tion sensor (open or [PO 123, P0223] High Engine response is D-j is fixed.
power short circuit de- voltage of the throttle poor. Throttle opening is
tected) position sensor circuit Loss of engine power. fixed to 125[0 ] .
[P0222] Throttle posi- (4.75 V or more) Deceleration is poor. Estimated atmospher-
tion sensor (ground [P2135] Difference in Increased exhaust ic pressure is fixed to
. .
short circuit detected) output voltage 1 and em1ss1ons. 101.3 [kPa].
[P0223] Throttle posi- output voltage 2 of the Vehicle cannot be 0 2 feedback is not
tion sensor (open or throttle position sen- driven. carried out.
power short circuit de- sor Fuel is not cut off due
tected) • Defective coupler to the throttle open-
[P2135] Throttle posi- between throttle po- 1ng.
tion sensor (output sition sensor and Output is restricted.
voltage deviation er- ECU. Air induction system
ror) • Open or short cir- solenoid is turned on
cuit in wire harness all the time (air induc-
between throttle po- tion system air cut
sition sensor and off).
ECU. ISC feedback is not
• Improperly installed carried out.
throttle position sen- ISC learning is not
sor. carried out.
• Defective throttle po- Cruise control system
sition sensor. cannot be operated.
• Malfunction in ECU. (MTT9GTK/
MTT9GTKC)
P0132 0 2 sensor (short cir- [PO 132] High voltage Increased exhaust
. .
0 2 feedback is not
cuit detected (power of the 0 2 sensor cir- em1ss1ons. carried out.
short circuit)) cuit (4.8 V or more) 0 2 feedback learning
• Improperly installed is not carried out.
0 2 sensor. Air induction system
• Defective coupler solenoid is turned on
between 0 2 sensor all the time (air induc-
and ECU. tion system air cut
• Open or short cir- off).
cuit in wire harness Cruise control system
between 0 2 sensor cannot be operated.
and ECU. (MTT9GTK/
• Incorrect fuel pres- MTT9GTKC)
sure.
• Defective 0 2 sensor.
• Malfunction in ECU.

9-3
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Fault code Probable cause of Fail-safe system op-

Item Vehicle symptom
No. malfunction eration
P0201 [P0201] Fuel injector • Defective coupler Loss of engine power. 0 2 feedback is not
P0202 #1 (malfunction in fuel between injector Engine is difficult to carried out.
P0203 injector #1) and ECU. start. Air induction system
[P0202] Fuel injector • Open or short cir- Engine cannot be solenoid is turned on
#2 (malfunction in fuel cuit in wire harness started. all the time (air induc-
injector #2) between injector Engine stops. tion system air cut
[P0203] Fuel injector and ECU. Engine idling speed is off).
#3 (malfunction in fuel • Defective injector. unstable. ISC feedback is not
injector #3) • Malfunction in ECU. Increased exhaust carried out.
. .
• Improperly installed em1ss1ons. ISC learning is not
injector. carried out.
Cruise control system
cannot be operated.
(MTT9GTK/
MTT9GTKC)
P0335 Crankshaft position • Defective coupler Engine cannot be Does not operate.
sensor (no normal between crankshaft started. ISC feedback is not
signals are received position sensor and carried out.
from the crankshaft ECU. ISC learning is not
position sensor) • Open or short cir- carried out.
cuit in wire harness Cruise control system
between crankshaft cannot be operated.
position sensor and (MTT9GTK/
ECU. MTT9GTKC)
• Improperly installed
crankshaft position
sensor.
• Malfunction in gen-
erator rotor.
• Defective crank-
shaft position sen-
sor.
• Malfunction in ECU.
P0351 [ P0351 ] Cylinder-#1 • Defective coupler Engine stops. Injection to the appli-
P0352 ignition coil (open or between ignition coil Loss of engine power. cable cylinder group is
P0353 short circuit detected and ECU. Engine is difficult to cut off.
in the primary lead of • Open or short cir- start. Air induction system
the cylinder-#1 igni- cuit in wire harness Engine cannot be solenoid is turned on
tion coil.) between ignition coil started. all the time (air induc-
[P0352] Cylinder-#2 and ECU. Engine idling speed is tion system air cut
ignition coil (open or • Improperly installed unstable. off).
short circuit detected ignition coil. Increased exhaust
. .
0 2 feedback is not
in the primary lead of • Defective ignition em1ss1ons. carried out.
the cylinder-#2 igni- coil. ISC feedback is not
tion coil.) • Malfunction in ECU. carried out.
[P0353] Cylinder-#3 ISC learning is not
ignition coil (open or carried out.
short circuit detected Cruise control system
in the primary lead of cannot be operated.
the cylinder-#3 igni- (MTT9GTK/
tion coil.) MTT9GTKC)

9-4
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Fault code Probable cause of Fail-safe system op-

Item Vehicle symptom
No. malfunction eration
P0500 [P0500, P1500)Rear • Open or short cir- Vehicle speed is not Vehicle speed dis-
P1500 wheel sensor (no nor- cuit in wire harness displayed on the me- played on the meter=
mal signals are re- between rear wheel ter. 0 [km/h)
ceived from the rear sensor and ABS Indication of the neu- 0 2 feedback is not
wheel sensor) unit. tral indicator light is in- carried out.
[P 1500) Gear posi- • Open or short cir- correct. Fuel cut-off control
tion switch (open or cuit in wire harness Engine idling speed is when the rear wheel
short circuit is detect- between ABS unit unstable. sensor or gear pos1-
ed) and ECU. Traction control does tion switch malfunc-
[P 1500) Clutch switch • Open or short cir- not work. tions is carried out.
(open or short circuit cuit in wire harness ISC feedback is not
is detected) between gear posi- carried out.
tion switch and ISC learning is not
ECU. carried out.
• Open or short cir- Traction control does
cuit in wire harness not work.
between clutch Cruise control system
switch and ECU. cannot be operated.
• Defective rear wheel (MTT9GTK/
sensor. MTT9GTKC)
• Defective gear posi-
tion switch.
• Defective clutch
switch.
• Improper adjust-
ment of clutch lever.
• Malfunction in ECU.
P0560 Charging voltage is • Battery overcharg- Engine is difficult to 0 2 feedback is not
abnormal. ing (defective rectifi- start. carried out.
er/regulator). Increased exhaust Cruise control system
. .
• Battery overcharg- em1ss1ons. cannot be operated.
ing (broken or dis- Battery performance (MTT9GTK/
connected lead in has deteriorated or MTT9GTKC)
rectifier/regulator battery is defective.
wire harness).
• Battery over-dis-
charging (broken or
disconnected lead in
charging system).
• Battery over-dis-
charging (defective
rectifier/regulator).
P0564 Cruise control setting • Open or short cir- Cruise control system Cruise control system
(MTT9GT switch "RES+" (open cuit in wire harness. cannot be operated. cannot be operated.
K/ or short circuit detect- • Defective cruise
MTT9GTK ed) control setting
C) switch.
Cruise control setting
• Malfunction in ECU.
switch "SET-" (open
or short circuit detect-
ed)
P056C Front brake light • Open or short cir- Cruise control system Cruise control system
(MTT9GT switch ( open or short cuit in wire harness. cannot be operated. cannot be operated.
K/ circuit detected) • Defective cruise
MTT9GTK control setting
Rear brake light
C) switch.
switch ( open or short
• Malfunction in ECU.
circuit detected)

9-5
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Fault code Probable cause of Fail-safe system op-

Item Vehicle symptom
No. malfunction eration
P0601 Internal malfunction in • Malfunction in ECU. Engine cannot be Engine cannot be
ECU (ROM data er- started. started.
ror) (When this mal-
function is detected in
the ECU, the fault
code number might
not appear on the tool
display.)
P0606 Internal malfunction in • Malfunction in ECU. Engine cannot be Engine cannot be
ECU (processor error) started. started.
(When this malfunc- Engine response is Ignition and injection
tion is detected in the poor. are not carried out.
ECU, the fault code Loss of engine power. Judgment for other
number might not ap- fault codes is not car-
pear on the tool dis- ried out.
play.) Load control is not
carried out. (The relay
unit and other relays
are all turned off.)
The CO adjustment
mode and diagnostic
mode cannot be acti-
vated.
Output is restricted.
Cruise control system
cannot be operated.
(MTT9GTK/
MTT9GTKC)
P062F EEPROM fault code • CO adjustment val- Increased exhaust CO adjustment value
. .
number (an error is ue is not properly em1ss1ons. for the faulty cylinder
detected while read- written. Engine cannot be = 0 (default value)
ing or writing on EE- • ISC learning value is started or is difficult to ISC learning values =
PROM) not properly written. start. Default values
• OBD memory value Engine idling speed is OBD memory value is
is not properly writ- unstable. initialized.
ten. OBD memory value is Initialization of 0 2
• Malfunction in ECU. not correct. feedback learning val-
ue.
Cruise control system
cannot be operated.
(MTT9GTK/
MTT9GTKC)
P0638 YCC-T drive system: • Defective coupler Engine response is 0 2 feedback is not
malfunction detected. between throttle ser- poor. carried out.
vo motor and ECU. Loss of engine power. YCC-T evacuation is
• Open or short cir- Engine idling speed is activated.
cuit in wire harness unstable. Output is restricted.
between throttle ser- ISC feedback is not
vo motor and ECU. carried out.
• Defective throttle ISC learning is not
servo motor. carried out.
• Throttle servo mo- Cruise control system
tor is stuck (mecha- cannot be operated.
nism or motor). (MTT9GTK/
• Malfunction in ECU. MTT9GTKC)
• Blown electric throt-
tie valve fuse.

9-6
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Fault code Probable cause of Fail-safe system op-

Item Vehicle symptom
No. malfunction eration
P0657 Fuel system voltage • Open or short cir- Engine is difficult to Monitor voltage = 12
(incorrect voltage sup- cuit in wire harness start. [V]
plied to the fuel injec- between relay unit Increased exhaust
. .
0 2 feedback is not
tor, fuel pump and and ECU. em1ss1ons. carried out.
relay unit) • Open circuit in wire Cruise control system
harness between cannot be operated.
battery and ECU. (MTT9GTK/
• Defective relay unit. MTT9GTKC)
• Malfunction in ECU.
P1004 Intake air pressure • Malfunction in ECU. Engine is difficult to Intake air pressure is
sensor 1 or intake air • Hose of intake air start. fixed to 101.3 [kPa].
pressure sensor 2: pressure sensor 1 or Engine idling speed is Intake air pressure
when the main switch intake air pressure unstable. difference is fixed to 0
is turned to "ON" the sensor 2 is de- Increased exhaust [kPa].
' . .
intake air pressure tached, clogged, em1ss1ons. Atmospheric pres-
sensor 1 voltage and twisted or bent. Loss of engine power. sure is fixed to 101.3
intake air pressure • Intake air pressure [kPa].
sensor 2 voltage differ sensor 1 or intake o,-N is fixed.
greatly. air pressure sensor Fuel is not cut off due
2 is defective. to the intake air pres-
sure difference.
Corrected output val-
ue of atmospheric
pressure sensor 1s
fixed to 0.
0 2 feedback is not
carried out.
ISC feedback is not
carried out.
ISC learning is not
carried out.
Cruise control system
cannot be operated.
(MTT9GTK/
MTT9GTKC)
P1400 Air induction system • Open circuit in wire Increased exhaust Electric current in air
. .
solenoid (open or harness. em1ss1ons. induction system so-
ground short circuit • Disconnected cou- lenoid is prohibited
detected) pier. (air induction system
• Defective air induc- air in) .
tion system sole- 0 2 feedback is not
noid. carried out.
• Defective air induc- Cruise control system
tion system sole- cannot be operated.
noid controller. (MTT9GTK/
(malfunction in MTT9GTKC)
ECU)

9-7
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Fault code Probable cause of Fail-safe system op-

Item Vehicle symptom
No. malfunction eration
P1601 Sidestand switch • Defective coupler Engine cannot be Engine is forcefully
(open or short circuit between relay unit started. stopped (the injector
of the black/red lead and ECU. output is stopped).
of the ECU is detect- • Open or short cir- Cruise control system
ed) cuit in wire harness cannot be operated.
between relay unit (MTT9GTK/
and ECU. MTT9GTKC)
• Defective coupler
between sidestand
switch and relay
unit.
• Open or short cir-
cuit in wire harness
between sidestand
switch and relay
unit.
• Defective sidestand
switch.
• Malfunction in ECU.
P1602 Malfunction in ECU • Open or short cir- Engine idling speed is 0 2 feedback learning
internal circuit (mal- cuit in wire harness unstable. is not carried out.
function of ECU pow- between ECU and Engine idling speed is 0 2 feedback learning
er cut-off function) battery. high. value is not written.
• Open or short cir- Increased exhaust Cruise control system
. .
cuit in wire harness em1ss1ons. cannot be operated.
between ECU and Engine is difficult to (MTT9GTK/
main switch. start. MTT9GTKC)
• Blown backup fuse.
• Malfunction in ECU.
P1604 (P1604] Lean angle (P1604] Low voltage Engine cannot be Engine cannot be
P1605 sensor (ground short of the lean angle sen- started. started.
circuit detected) sor circuit (0.2 V or
(P 1605] Lean angle less)
sensor (open or pow- (P1605] High voltage
er short circuit detect- of the lean angle sen-
ed) sor circuit (4.8 V or
more)
• Open or short cir-
cuit in wire harness
between lean angle
sensor and ECU.
• Defective lean an-
gle sensor.
• Malfunction in ECU.

9-8
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Fault code Probable cause of Fail-safe system op-

Item Vehicle symptom
No. malfunction eration
P1606 [P1606] Intake air [P1606] Low voltage Engine is difficult to o,-N is fixed.
P1607 pressure sensor 2 of the intake air pres- start. Intake air pressure
(ground short circuit sure sensor 2 circuit Increased exhaust difference is fixed to 0
. .
detected) (0.5 V or less) em1ss1ons. [kPa] .
[P1607] Intake air [P1607] High voltage Power on high ground Atmospheric pres-
pressure sensor 2 of the intake air pres- is insufficient. sure is fixed to 101.3
(open or power short sure sensor 2 circuit Engine idling speed is [kPa].
circuit detected) (4.8 V or more) unstable. Corrected output val-
• Defective coupler ue of atmospheric
between intake air pressure sensor 1s
pressure sensor 2 fixed to 0.
and ECU. Fuel is not cut off due
• Open or short cir- to the intake air pres-
cuit in wire harness sure difference.
between intake air 0 2 feedback is not
pressure sensor 2 carried out.
and ECU. ISC feedback is not
• Improperly installed carried out.
intake air pressure ISC learning is not
sensor 2. carried out.
• Defective intake air
pressure sensor 2.
• Malfunction in ECU.
P2122 [P2 122] Accelerator [P2 122, P2127] Low Engine response is No change in acceler-
P2123 position sensor (open voltage of the acceler- poor. ator opening. (tran-
P2127 or ground short cir- ator position sensor Loss of engine power. sient control is not
P2128 cuit detected) circuit (0.25 V or less) Engine idling speed is carried out).
P2138 [P2 123] Accelerator [P2 123, P2128] High unstable. Accelerator opening is
position sensor (pow- voltage of the acceler- fixed to 0[0 ].
er short circuit detect- ator position sensor 0 2 feedback is not
ed) circuit (4.75 V or carried out.
[P2 127] Accelerator more) YCC-T evacuation is
position sensor [P2 138] Difference in activated.
(ground short circuit output voltage 1 and Fuel cut is prohibited
detected) output voltage 2 of the by accelerator open-
[P2 128] Accelerator accelerator position 1ng.
position sensor (open sensor. Output is restricted.
or power short circuit • Defective coupler ISC feedback is not
detected) between accelera- carried out.
[P2 138] Accelerator tor position sensor ISC learning is not
position sensor (out- and ECU. carried out.
put voltage deviation • Open or short cir-
error) cuit in wire harness
between accelera-
tor position sensor
and ECU.
• Improperly installed
accelerator position
sensor.
• Defective accelera-
tor position sensor.
• Malfunction in ECU.

9-9
 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Fault code Probable cause of Fail-safe system op-

Item Vehicle symptom
No. malfunction eration
P2158 Front wheel sensor • Open or short cir- Traction control does Traction control does
(no normal signals are cuit in wire harness not work. not work.
received from the between front wheel Traction control sys- Cruise control system
front wheel sensor) sensor and ECU. tern indicator on the cannot be operated.
• Defective front meter comes on. (MTT9GTK/
wheel sensor. Traction control sys- MTT9GTKC)
• Malfunction in ECU. tern switch is dis-
abled. (Traction
control system indica-
tor on the meter goes
OFF.)
P2195 0 2 sensor (open cir- • Signal voltage is Increased exhaust
. .
0 2 feedback is not
cuit detected) 0.25-0.53 V. em1ss1ons. carried out.
• Improperly installed 0 2 feedback learning
0 2 sensor. is not carried out.
• Defective coupler Air induction system
between 0 2 sensor solenoid is turned on
and ECU. all the time (air induc-
• Open or short cir- tion system air cut
cuit in wire harness off).
between 0 2 sensor Cruise control system
and ECU. cannot be operated.
• Defective 0 2 sensor. (MTT9GTK/
• Malfunction in ECU. MTT9GTKC)

EAS32487

COMMUNICATION ERROR WITH THE METER

Fault code Probable cause of Fail-safe system op-
Item Vehicle symptom
No. malfunction eration
U0155 CAN communication Communication be- Defective meter dis- Grip warmer output:
(Yamaha error (with the meter) tween the ECU and play. OFF is fixed.
diagnostic the meter is not possi- Traction control does (MTT9GTK/
tool) ble not work. MTT9GTKC)
Err (multi- • Defective meter cou- MAP changeover:
function pier and ECU cou- State is fixed.
meter dis- pier Traction control does
play) • Open or short cir- not work.
cuit in the wire har- Meter switch input:
ness between the OFF is fixed.
meter and the ECU Cruise control system
• Defective meter cannot be operated.
• Defective ECU (MTT9GTK/
MTT9GTKC)

9-10
 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EAS32425

DIAGNOSTIC CODE: SENSOR OPERATION TABLE

Diagnostic
Item Tool display Procedure
code No.
01 Throttle position sensor sig-
nal 1
• Fully closed position 11-21 Check with throttle valves ful-
ly closed.
• Fully open position 96- 106 Check with throttle valves ful-
ly open.
03 Intake air pressure 1 Displays the intake air pres- Operate the throttle while
sure. pushing the "(i)" side of the
start/engine stop switch. (If
the display value changes,
the performance is OK.)
04 Intake air pressure 2 Displays the intake air pres- Operate the throttle while
sure. pushing the "(i)" side of the
start/engine stop switch. (If
the display value changes,
the performance is OK.)
05 Air temperature When engine is cold: Dis- Compare the actually mea-
plays temperature closer to sured air temperature with
air temperature. the tool display value.
When engine is hot: Air tern-
perature + approx. 20 °C (68
OF).
06 Coolant temperature When engine is cold: Dis- Compare the actually mea-
plays temperature closer to sured coolant temperature
air temperature. with the tool display value.
When engine is hot: Displays
current coolant temperature.
07 Rear wheel vehicle speed Rear wheel speed pulse Check that the number in-
pulses 0-999 creases when the rear wheel
is rotated. The number is cu-
mulative and does not reset
each time the wheel is
stopped.
08 Lean angle sensor Lean angle sensor output Remove the lean angle sen-
voltage sor and incline it more than
0.4-1.4 65 degrees.
• Upright
• Overturned 3.7-4.4
09 Fuel system voltage Fuel system voltage Set the start/engine stop
(battery voltage) Approximately 12.0 switch to "()", and then corn-
pare the actually measured
battery voltage with the tool
display value. (If the actually
measured battery voltage is
low, recharge the battery.)
13 Throttle position sensor sig-
nal2
• Fully closed position 9- 23 Check with throttle valves ful-
ly closed.
• Fully open position 94- 108 Check with throttle valves ful-
ly open.

9-11
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Diagnostic
Item Tool display Procedure
code No.
14 Accelerator position sensor
signal 1
• Fully closed position 12- 22 Check with throttle grip fully
closed position.
• Fully open position 97- 107 Check with throttle grip fully
open position.
15 Accelerator position sensor
signal 2
• Fully closed position 10- 24 Check with throttle grip fully
closed position.
• Fully open position 95- 109 Check with throttle grip fully
open position.
16 Front wheel vehicle speed Front wheel speed pulse Check that the number in-
pulses 0-999 creases when the front wheel
is rotated. The number is cu-
mulative and does not reset
each time the wheel is
stopped.
20 Sidestand switch Extend and retract the side-
stand (with the transmission
• Stand retracted ON
in gear).
• Stand extended OFF
21 Gear position switch and Operate the transmission,
clutch switch clutch lever, and sidestand.
• Transmission is in neutral ON
• Transmission is in gear or OFF
the clutch lever released
• Clutch lever is squeezed ON
with the transmission in
gear and when the side-
stand is retracted
• Clutch lever is squeezed OFF
with the transmission in
gear and when the side-
stand is extended

9-12
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Diagnostic
Item Tool display Procedure
code No.
60 EEPROM fault code display -
• No history 00
• No malfunctions detected
(If the self-diagnosis fault
code P062F is indicated,
the ECU is defective.)
• History exists 01 - 03 (CO adjustment val-
Display the EEPROM writ- ue)
ing error for fault code No. • (If more than one cylinder is
P062F. defective, the display alter-
If more than one item is de- nates every two seconds to
fective, the displays alter- show all the detected cylin-
nates every two seconds to der numbers.
show all the detected num- When all cylinder numbers
bers. are shown, the display re-
peats the same process.)
11 (Data error for ISC (idle
speed control) learning val-
ues)
12 (0 2 feedback learning val-
ue)
13 (OBD memory value)
67 ISC (idle speed control) 00 To erase the ISC (idle speed
learning condition display ISC (idle speed control) control) learning data, set the
ISC (idle speed control) learning data has been start/engine stop switch from
learning data erasure erased. "!:XS" to "O " 3 times in 5 sec-
01 onds.
It is not necessary to erase
the ISC (idle speed control)
learning data.
02
It is necessary to erase the
ISC (idle speed control)
learning data.
70 Control number 0- 254 [-] -
80 Cruise control setting switch Push and release the
(MTT9GTK/ "RES+" "RES+" side of the cruise
MTT9GTKC) control setting switch.
• Switch is pushed ON
• Switch is released OFF
81 Cruise control setting switch Push and release the "SET-"
(MTT9GTK/ "SET- " side of the cruise control set-
MTT9GTKC) ting switch.
• Switch is pushed ON
• Switch is released OFF

9-13
 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Diagnostic
Item Tool display Procedure
code No.
82 Cruise control cancel circuit Operate the clutch lever,
(MTT9GTK/ brake lever, brake pedal, and
MTT9GTKC)
• Clutch lever is squeezed ON throttle grip.
• Clutch lever is released OFF
• Brake lever is squeezed ON
• Brake lever is released OFF
• Brake pedal is depressed ON
• Brake pedal is released OFF
• Throttle grip is turned past ON
the closed position in the
deceleration direction
• Throttle grip is released OFF
83 Front brake light switch and Operate the brake lever and
(MTT9GTK/ rear brake light switch brake pedal.
MTT9GTKC)
• Brake lever is squeezed ON
• Brake lever is released OFF
• Brake pedal is depressed ON
• Brake pedal is released OFF
86. Shift switch Check the switch condition
by operating the shift pedal.
• Shift pedal up position ON
• Other position than the shift OFF
pedal up position
87 0 2 feedback learning data 00 To erase the 0 2 feedback
erasure 0 2 feedback learning data learning data, set the start/
has been erased. engine stop switch from "~"
01 to "n" 3 times in 5 seconds.
0 2 feedback learning data
has not been erased.

* Diagnostic code No. 86 is the diagnostic code number for the optional shift switch. (MTT9K/MTT9KC)

EAS32426

DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE

Diagnostic
Item Actuation Procedure
code No.
30 Cylinder-#1 ignition coil Actuates the cylinder-#1 igni- Check that a spark is gener-
tion coil five times at one- ated five times.
second intervals. • Connect an ignition check-
The check indicator on the er.
Yamaha diagnostic tool
screen come on each time
the ignition coil is actuated.
31 Cylinder-#2 ignition coil Actuates the cylinder-#2 igni- Check that a spark is gener-
tion coil five times at one- ated five times.
second intervals. • Connect an ignition check-
The check indicator on the er.
Yamaha diagnostic tool
screen come on each time
the ignition coil is actuated.

9-14
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Diagnostic
Item Actuation Procedure
code No.
32 Cylinder-#3 ignition coil Actuates the cylinder-#3 igni- Check that a spark is gener-
tion coil five times at one- ated five times.
second intervals. • Connect an ignition check-
The check indicator on the er.
Yamaha diagnostic tool
screen come on each time
the ignition coil is actuated.
36 Injector #1 Actuates the injector #1 five Disconnect the fuel pump
times at one-second inter- coupler.
vals. Check that injector #1 is ac-
The check indicator on the tuated five times by listening
Yamaha diagnostic tool for the operating sound.
screen come on each time
the injector is actuated.
37 Injector #2 Actuates the injector #2 five Disconnect the fuel pump
times at one-second inter- coupler.
vals. Check that injector #2 is ac-
The check indicator on the tuated five times by listening
Yamaha diagnostic tool for the operating sound.
screen come on each time
the injector is actuated.
38 Injector #3 Actuates the injector #3 five Disconnect the fuel pump
times at one-second inter- coupler.
vals. Check that injector #3 is ac-
The check indicator on the tuated five times by listening
Yamaha diagnostic tool for the operating sound.
screen come on each time
the injector is actuated.
48 Air induction system solenoid Actuates the air induction Check that the air induction
system solenoid five times at system solenoid is actuated
one-second intervals. five times by listening for the
The check indicator on the operating sound.
Yamaha diagnostic tool
screen come on each time
the air induction system sole-
noid is actuated.
50 Relay unit Actuates the relay unit five Check that the relay unit is
times at one-second inter- actuated five times by listen-
vals. ing for the operating sound.
The check indicator on the
Yamaha diagnostic tool
screen come on each time
the relay is actuated.
51 Radiator fan motor relay Actuates the radiator fan mo- Check that the radiator fan
tor relay five times at five- motor relay is actuated five
second intervals. times by listening for the op-
The check indicator on the erating sound.
Yamaha diagnostic tool
screen come on each time
the relay is actuated.

9-15
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Diagnostic
Item Actuation Procedure
code No.
52 Headlight relay Actuates the headlight relay Check that the headlight re-
five times at five-second in- lay is actuated five times by
tervals. listening for the operating
The check indicator on the sound.
Yamaha diagnostic tool
screen come on each time
the relay is actuated.
• Grip warmer Turns on the grip warmers for Check that the grip warmers
57
2 minutes. become warm.

* Diagnostic code No. 57 is the diagnostic code number for the optional grip warmer. (MTT9K/
MTT9KC)

9-16
 EVENT CODE TABLE

EAS20316

EVENT CODE TABLE

No. Item Symptom Possible causes Note
192 Intake air pres- Brief abnormality de- Same as for fault code Perform the checks and
sure sensor 1 tected in the intake air number P0107 and maintenance jobs for fault
pressure sensor 1 P0108 code number P0107 and
P0108.
193 Throttle position Brief abnormality de- Same as for fault code Perform the checks and
sensor tected in the throttle number P0122, P0123, maintenance jobs for fault
position sensor P0222, P0223 and code number P0122,
P2135 PO 123, P0222, P0223 and
P2135
195 Sidestand switch Brief abnormality de- Same as for fault code Perform the checks and
tected in the ECU number P1601 maintenance jobs for fault
(black/red lead) input code number P1601.
line
196 Coolant tempera- Brief abnormality de- Same as for fault code Perform the checks and
ture sensor tected a in the coolant number P0117 and maintenance jobs for fault
temperature sensor P0118 code number P0117 and
P0118.
197 Intake air tern- Brief abnormality de- Same as for fault code Perform the checks and
perature sensor tected in the intake air number P0112 and maintenance jobs for fault
temperature sensor P0113 code number P0112 and
P0113.
199 Intake air pres- Brief abnormality de- Same as for fault code Perform the checks and
sure sensor 2 tected in the intake air number P1606 and maintenance jobs for fault
pressure sensor 2 P1607 code number P1606 and
P1607.
203 Lean angle sen- Brief abnormality de- Same as for fault code Perform the checks and
sor tected in the lean an- number P1604 and maintenance jobs for fault
gle sensor P1605 code number P1604 and
P1605.
207 Accelerator posi- Brief abnormality de- Same as for fault code Perform the checks and
tion sensor tected in the acceler- number P2122, P2123, maintenance jobs for fault
ator position sensor P2127, P2128 and code number P2122,
P2138 P2123, P2127, P2128 and
P2138.
240 0 2 sensor During 0 2 feedback, • Open or short circuit in • If a fault code is occurring,
(Stuck at the up- the adjustment is the wire harness be- respond to that first.
per limit for ad- maintained at the up- tween the sensor and * Rarely, Code 240 occurs
justment) per limit ECU even when the system is
• Drop in fuel pressure functioning properly.
• Clogged fuel injector
• Fault in sensor
• Malfunction in ECU
• Malfunction in the fuel
injection system
241 0 2 sensor During 0 2 feedback, • Open or short circuit in • If a fault code is occurring,
(Stuck at the low- the adjustment is the wire harness be- respond to that first.
er limit for adjust- maintained at the low- tween the sensor and * Rarely, Code 241 occurs
ment) er limit ECU even when the system is
• Drop in fuel pressure functioning properly.
• Clogged fuel injector
• Fault in sensor
• Malfunction in ECU
• Malfunction in the fuel
injection system

9-17
 EVENT CODE TABLE

No. Item Symptom Possible causes Note

242 ISC During idling, the ad- Idling engine speed is • Implement diagnosis
(Stuck at the up- justment is main- slow mode (diagnostic code
per limit for ad- tained at the upper • Clogged throttle body number 67), and check
justment) limit • Poorly adjusted throttle the ISC maintenance re-
cable quest.
• Poorly adjusted clutch • If a fault code is occurring,
cable respond to that first.
• Malfunction in the fuel * Rarely, Code 242 occurs
injection system even when the system is
• Dirty or worn spark functioning properly.
plug
• Malfunction in the bat-
tery
• Malfunction in ECU
243 ISC During idling, the ad- Idling engine speed is • If a fault code is occurring,
(Stuck at the low- justment is main- fast respond to that first.
er limit for adjust- tained at the lower • Poorly adjusted throttle * Rarely, Code 243 occurs
ment) limit cable even when the system is
• Poorly adjusted clutch functioning properly.
cable
• Malfunction in the fuel
injection system
• Dirty or worn spark
plug
• Malfunction in the bat-
tery
• Malfunction in ECU
244 Poor starting/ in- Poor starting/inability • No gasoline • If a fault code is occurring,
ability to start to start detected • Malfunction in the fuel respond to that first.
injection system * Rarely, Code 244 occurs
• Dirty or worn spark even when the system is
plug functioning properly.
• Malfunction in the bat-
tery
• Malfunction in ECU
245 Engine stop Engine stop detected • No gasoline • If a fault code is occurring,
• Poorly adjusted throttle respond to that first.
cable * Rarely, Code 245 occurs
• Poorly adjusted clutch even when the system is
cable functioning properly.
• Malfunction in the fuel
injection system
• Dirty or worn spark
plug
• Malfunction in the bat-
tery
• Malfunction in ECU

EAS32525

TROUBLESHOOTING DETAILS (EVENT CODE)

Event code No. 30

Event code No. 30
Item Latch up detected.
Unable to start engine
Fail-safe system
Unable to drive vehicle

9-18
 EVENT CODE TABLE

Event code No. 30

Item Latch up detected.
Diagnostic code No. 08
Lean angle sensor output voltage
Tool display • 0.4-1.4 (upright)
• 3.7-4.4 (overturned)
Procedure Remove the lean angle sensor and incline it more than 65 degrees.
Probable cause of malfunc- Confirmation of service corn-
Item Maintenance job
tion and check pletion
1 The vehicle has overturned. Raise the vehicle upright. Turn the main switch to "ON",
then to "O FF", and then back to
"ON".
Engine trouble warning light
does not come on ➔ Service is
finished.
Engine trouble warning light
comes on ➔ Go to item 2.
2 Installed condition of lean angle Check the installed direction Turn the main switch to "ON",
sensor. and condition of the sensor. then to "O FF", and then back to
"ON".
Engine trouble warning light
does not come on ➔ Service is
finished.
Engine trouble warning light
comes on ➔ Go to item 3.
3 Defective lean angle sensor. Execute the diagnostic mode. Turn the main switch to "ON",
(Code No. 08) then to "O FF", and then back to
Replace if defective. "ON".
Refer to "CHECKING THE Engine trouble warning light
LEAN ANGLE SENSOR" on does not come on ➔ Service is
page 8-195. finished.
Engine trouble warning light
comes on ➔ Go to item 4.
4 Malfunction in ECU. Replace the ECU. Service is finished.
Refer to "REPLACING THE
ECU (Engine Control Unit)" on
page 8-189.

Event code No. 70

TIP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
lf another error code is displayed at the same time, check the other error code first and repair it.

Event code No. 70

Engine forcibly stops when the vehicle is left idling for a long period
Item
of time.
Probable cause of malfunc- Confirmation of service corn-
Item Maintenance job
tion and check pletion
1 Allow to idle for a long period of Turn the main switch to "OFF" . Check whether it is possible to
time. start the engine.
Able to start the engine ➔ Ser-
vice is finished.
Unable to start the eng ine ➔ Go
to item 2.

9-19
 EVENT CODE TABLE

Event code No. 70

Engine forcibly stops when the vehicle is left idling for a long period
Item
of time.
2 Malfunction in ECU. Replace the ECU. Service is finished .
Refer to "REPLACI NG THE
ECU (Engine Control Unit)" on
page 8-189.

9-20
EAS20091
WIRING DIAGRAM
MTT9K/MTT9KC 201 9
1. AC magneto
2. Rectifier/ regu lator
3. Main switch
4. Main fuse
5. ABS motor fuse
6. ABS solenoid fuse
7. Electronic throttle valve fuse
8. Backup fuse
9. Radiator fan motor fuse
10. Seat heater fuse (option)
11. Ignition fuse
12. ABS control unit fuse
13. Signaling system fuse
14. Fog lamp fuse (option)
15. Battery
16. Engine ground
17. Fuel injection system fuse
18. Starter relay
19. Starter motor
20. Radiator fan motor relay
21. Rear brake light switch
22. Joint coupler
23. Handlebar switch (right)
24. Front brake light switch
25. Hazard switch
26. Start/engine stop switch
27. Drive mode switch
28. Relay unit
29. Starting circuit cut-off relay
30. Fuel pump relay
31. Sidestand switch
32. Shift switch (option)
33. ECU (Engine Control Unit)
34. Ignition coil #1
35. Ignition coil #2
36. Ignition coil #3
37. Spark plug
38. Injector #1
39. Injector #2
40. Injector #3
41. Grip warmer (left) (option)
42. Grip warmer (right) (option)
43. Air induction system solenoid
44. 0 2 sensor
45. Crankshaft position sensor
46. Intake air temperature sensor
47. Coolant temperature sensor
48. Intake air pressure sensor 1
49. Intake air pressure sensor 2
50. Lean angle sensor
51. Throttle servo motor
52. Accelerator position sensor
53. Throttle position sensor
54. Front wheel sensor
55. Rear wheel sensor
56. ABS ECU (electronic control
unit)
57. Yamaha diagnostic tool coupler
58. Meter assembly
59. Neutral indicator light
60. Meter light
61. Tachometer
62. Oil level warning light
63. Engine trouble warning light
64. Traction control system indica-
tor light
65. High beam indicator light
66. Turn signal indicator light (left)
67. Turn signal indicator light (right)
68. ABS warning light
69. Multi-function meter
70. Gear position switch
71. Oil level switch
72. Fuel pump
73. Fuel sender
74. Turn signal/hazard relay
75. Handlebar switch (left)
76. Dimmer/pass switch
77. Turn signal switch
78. Horn switch
79. Horn
80. Menu switch
81 . Select switch
82. Clutch switch
83. Rear turn signal light (right)
84. Rear turn signal light (left)
85. Front turn signal/position light
(right)
86. Front turn signal/position light
(left)
87. Headlight control unit
88. Headlight (high beam)
89. Headlight (low beam)
90. Auxiliary light (right)
91. Auxiliary light (left)
92. License plate light
93. Tail/ brake light
94. Radiator fan motor
95. Parking lighting fuse
96. Plug + 12 V fuse (DC jack)
97. Plug + 12 V fuse (DC jack, op-
tion)
98. Headlight fuse
99.Auxiliary DC connector 1
1GO.Auxiliary DC connector 2
101.Auxiliary DC jack
102.Auxiliary DC jack (option)
A. Wire harness
B. Negative battery sub-wire har-
ness
C. Sub-wire harness (injector #2)
D. Sub-wire harness (coolant tem-
perature sensor)
MTT9GTK/MTT9GTKC 201 9
1 . AC magneto
2. Rectifier/regulator
3. Main switch
4. Main fuse
5. ABS motor fuse
6. ABS solenoid fuse
7. Electronic throttle valve fuse
8. Backupfuse
9. Radiator fan motor fuse
10. Seat heater fuse (option)
11. Ignition fuse
12. ABS control unit fuse
13. Signaling system fuse
14. Brake light fuse
15. Fog lamp fuse (option)
16. Battery
17. Engine ground
18. Fuel injection system fuse
19. Starter relay
20. Starter motor
21. Joint coupler
22. Grip cancel switch
23. Clutch switch
24. Front brake light switch
25. Rear brake light switch
26. Handlebar switch (right)
27. Wheel switch
28. Start/engine stop switch
29. Brake light relay
30. Relay unit
31. Starting circu it cut-off relay
32. Fuel pump relay
33. Sidestand switch
34. Shift switch
35. ECU (Engine Control Unit)
36. Ignition coil #1
37. Ignition coil #2
38. Ignition coil #3
39. Spark plug
40. Injector #1
41. Injector #2
42. Injector #3
43. Grip warmer (left)
44. Grip warmer (right)
45. Air induction system solenoid
46. 0 2 sensor
4 7. Crankshaft position sensor
48. Intake air temperature sensor
49. Coolant temperature sensor
50. Intake air pressure sensor 1
51. Intake air pressure sensor 2
52. Lean angle sensor
53. Throttle servo motor
54. Accelerator position sensor
55. Throttle position sensor
56. Front wheel sensor
57. Rear wheel sensor
58. ABS ECU (electronic control
unit)
59. Yamaha diagnostic tool coupler A. Wire harness EAS30613

60. Meter assembly B. Negative battery sub-wire har- COLOR CODE

61. Engine oil and coolant warning ness B Black
light C. Sub-wire harness (injector #2) Gy Gray
62. Neutral indicator light D. Sub-wire harness (coolant tem- L Blue
63. Shift timing indicator light perature sensor) Br Brown
64. Multi-function meter Ch Chocolate
65. Traction control system indica- Dg Dark green
tor light G Green
66. Engine trouble warning light Lg Light green
0 Orange
67. Turn signal indicator light (left) p Pink
68. Turn signal indicator light (right)
R Red
69. Cruise control system indicator
Sb Sky blue
light V Violet
70. Cruise control setting indicator w White
light y Yellow
71. Meter light B/L Black/Blue
72. ABS warning light B/R Black/Red
73. High beam indicator light B/W Black/White
74. Oil level switch B/Y Black/Yellow
75. Gear position switch Br/B Brown/Black
76. Fuel pump Br/ L Brown/Blue
77.Fuelsender Br/ R Brown/Red
78. Turn signal/hazard relay Br/W Brown/White
79. Handlebar switch (left) Br/Y Brown/Yellow
80. Dimmer/pass switch G/B Green/Black
81. Turn signal switch G/R Green/ Red
82. Horn switch G/W Green/White
83. Horn G/Y Green/Yellow
84. Mode switch Gy/G Gray/Green
85. Traction control system switch Gy/R Gray/Red
86. Cruise control power switch UB Blue/ Black
UR Blue/ Red
87. Cruise control setting switch
88. Hazard switch
uw Blue/White
UY Blue/Yellow
89. Rear turn signal light (right) Light green/Blue
Lg/L
90. Rear turn signal light (left) Lg/W Light green/White
91. Front turn signal/position light 0/G Orange/Green
(right) P/B Pink/Black
92. Front turn signal/position light P/W Pink/White
(left) R/B Red/Black
93. Headlight control unit R/G Red/Green
94. Headlight (high beam) R/L Red/Blue
95. Headlight (low beam) R/W Red/White
96. Auxiliary light (right) Sb/W Sky blue/White
97. Auxiliary light (left) WIG White/Green
98. License plate light W/L White/Blue
99. Tail/brake light W/ R White/Red
1GO.Radiator fan motor relay W/Y White/Yellow
101.Radiator fan motor Y/B Yellow/Black
102.Cruise control fuse Y/G Yellow/Green
103.Parking lighting fuse Y/L Yellow/Blue
104.Plug + 12 V fuse (DC jack) Y/R Yellow/ Red
105.Plug + 12 V fuse (DC jack, op- Y/W Yellow/White
W/B White/Black
tion)
106.Headlight fuse
107.Auxiliary DC connector 1
108.Auxiliary DC connector 2
109.Auxiliary DC jack (option)
11 a.Auxiliary DC jack
 MTT9K/MTT9KC 2019 WIRING DIAGRAM

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