2022

SERVICE MANUAL

NMAX

GPD155-A
BBD-F8197-EK
EAS20003

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

EAS30001

IMPORTANT MANUAL INFORMATION

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

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

result in death or serious injury.

NOTICE A NOTICE indicates special precautions that must be taken to avoid

damage to the vehicle or other property.

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

GPD155-A
SERVICE MANUAL
©2022 by PT Yamaha Indonesia Motor
Manufacturing
First edition, November 2021
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
PT Yamaha Indonesia Motor Manufacturing
is expressly prohibited.
EAS20004

HOW TO USE THIS MANUAL

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

CYLINDER AND PISTON CYLINDER AND PISTON

EAS20046 EAS30289

CYLINDER AND PISTON REMOVING THE PISTON

1. Remove:
Removing the cylinder and piston • Piston pin clips “1”
• Piston pin “2”
• Piston “3”
ECA13810

NOTICE
Do not use a hammer to drive the piston pin
out.

TIP EAS30291

• Before removing the piston pin clips, cover the CHECKING THE CYLINDER AND PISTON
crankcase opening with a clean rag to prevent 1. Check:
them from falling into the crankcase. • Piston wall
• Before removing the piston pin, deburr the pis- • Cylinder wall
ton pin clip groove and the piston pin bore ar- Vertical scratches → Rebore or replace the
ea. If both areas are deburred and the piston cylinder, and replace the piston and piston
pin is still difficult to remove, remove it with the rings as a set.
piston pin puller set “4”. 2. Measure:
• Piston-to-cylinder clearance
a. Measure cylinder bore “C” with the cylinder
Piston pin puller set bore gauge.
90890-01304
TIP
Measure cylinder bore “C” by taking side-to-side
and front-to-back measurements of the cylinder.

Bore
52.000–52.010 mm (2.0472–
2.0476 in)
Wear limit
52.060 mm (2.0496 in)

“C” = maximum of D1 - D2

Order Job/Parts to remove Q’ty Remarks

Cylinder head Refer to “CYLINDER HEAD” on page 5-10.
1 Timing chain guide (exhaust side) 1
2 Cylinder 1
3 Cylinder gasket 1
4 Dowel pin 2
5 Piston pin clip 2 2. Remove:
• Top ring
6 Piston pin 1 b. If out of specification, rebore or replace the
• 2nd ring
7 Piston 1
• Oil ring cylinder, and replace the piston and piston
8 Top ring 1 rings as a set.
TIP
9 2nd ring 1 c. Measure piston skirt diameter P with the mi-
When removing a piston ring, open the end gap crometer.
10 Oil ring 1 with your fingers and lift the other side of the ring
11 Coolant drain bolt (cylinder side) 1 over the piston crown.

5-30 5-31
EAS20005

SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.

SYMBOL DEFINITION SYMBOL DEFINITION

Serviceable with engine mounted Gear oil

G

Filling fluid Molybdenum disulfide oil

M

Lubricant Brake fluid

BF

Special tool B Wheel bearing grease

Tightening torque LS Lithium-soap-based grease

T.
R.

Wear limit, clearance M Molybdenum disulfide grease

Engine speed S Silicone grease

Electrical data Apply locking agent (LOCTITE®).

LT

Engine oil New Replace the part with a new one.

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

IDENTIFICATION ............................................................................................ 1-1

VEHICLE IDENTIFICATION NUMBER .....................................................1-1
ENGINE SERIAL NUMBER ...................................................................... 1-1

FEATURES...................................................................................................... 1-2
1
MULTI-FUNCTION METER UNIT ............................................................. 1-2

SPECIAL TOOLS ............................................................................................ 1-7

 IDENTIFICATION

EAS20007

IDENTIFICATION
EAS30002

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped
onto the frame.

EAS30004

ENGINE SERIAL NUMBER

The engine serial number “1” is stamped onto
the crankcase.

1-1
 FEATURES

EAS20008
The multi-function meter unit is equipped with
FEATURES the following:
EAS30982
• a speedometer
MULTI-FUNCTION METER UNIT • a VVA indicator
• a clock
Multi-function meter unit • a fuel meter
• a Yamaha Motorcycle Connect icon
1 2 3 4 5 6 7 • a smartphone battery level meter
• a coolant temperature meter
• a multi-function display
TIP
Be sure to turn the main switch on before using
the “MENU” switch.

8
Yamaha Motorcycle Connect icon
1. Fuel meter This icon comes on when CCU and smartphone
2. Yamaha Motorcycle Connect icon is connected via Yamaha Motorcycle Connect.
3. VVA (variable valve actuation) indicator TIP
4. Clock Even if the smartphone is not connected, when
5. Speedometer the vehicle is turned on, this icon should come
6. Smartphone battery level meter on for a few seconds. Otherwise have a Yamaha
7. Coolant temperature meter dealer check the CCU and the electrical circuit.
8. Multi-function display
EWA12423

WARNING Smartphone battery level meter

This meter indicates the current battery level of
Be sure to stop the vehicle before making
the connected smartphone. The display seg-
any setting changes to the multi-function
ment of the meter disappears from full to blank
meter unit. Changing settings while riding
as the battery level decreases. When approxi-
can distract the operator and increase the
mately 10% or less of the battery remains, the
risk of an accident.
last segment starts flashing.
The “MENU” switch is located on the left side of TIP
handlebar. This switch allows you to control or Even if the smartphone is not connected, when
change the settings of multi-function meter unit. the vehicle is turned on, this icon should come
on for a few seconds. Otherwise have a Yamaha
1 dealer check the CCU and the electrical circuit.

Switching the display units

The display units can be switched between kilo-
meters and miles.

To switch the display units

1. Turn the vehicle off.
1. “MENU” switch 2. While pushing the “MENU” switch, turn the
vehicle on.
3. Continue to push the “MENU” switch until the
display unit setting screen comes on (approx-
imately 5 seconds).
4. Push the “MENU” switch once to switch the
display units.
5. Push the “MENU” switch for 1 second to con-
firm the setting.

1-2
 FEATURES

Speedometer TIP
The speedometer shows the vehicle’s traveling When CCU and smartphone is connected after
speed. vehicle power on, the clock is automatically ad-
justed.
Fuel meter

1 2 Coolant temperature meter

1. Fuel meter
The fuel meter indicates the amount of fuel in the 1. Coolant temperature meter
fuel tank. The display segments of the fuel meter
disappear from “F” (full) towards “E” (empty) as This meter shows the temperature of the cool-
the fuel level decreases. When approximately ant, and thereby the condition of the engine. The
1.7 L (0.45 US gal, 0.37 Imp.gal) of fuel remains, segments come on from “C” (cold) to “H” (hot) as
the last segment starts flashing. Refuel as soon the engine temperature increases. If the hot seg-
as possible. ment flashes, stop the engine as soon as possi-
TIP ble, and let the engine cool.
If a problem is detected in the electrical circuit, TIP
the fuel level segments will flash repeatedly. If If a problem is detected in the electrical circuit, all
this occurs, have a Yamaha dealer check the ve- segments will flash repeatedly. Have a Yamaha
hicle. dealer check the vehicle.

Clock VVA indicator

1
1

1. Clock 1. VVA (variable valve actuation) indicator

The clock uses a 12-hour time system. This model is equipped with variable valve actu-
ation (VVA) for good fuel economy and acceler-
To set the clock ation in both the low-speed and high-speed
1. Push the “MENU” switch until the hour digits ranges. The VVA indicator comes on when the
start flashing. variable valve actuation system has switched to
2. Use the “MENU” switch to set the hours. the high-speed range.
3. Push the “MENU” switch until the minute dig-
its start flashing.
4. Use the “MENU” switch to set the minutes.
5. Push the “MENU” switch until the minute dig-
its stop flashing. The setting is confirmed.

1-3
 FEATURES

To turn the VVA indicator on or off TIP

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

Multi-function display

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

1-4
 FEATURES

Fuel reserve tripmeter TIP

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

V-belt replacement tripmeter

1
1

1. Fuel reserve tripmeter

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

1-5
 FEATURES

Instantaneous fuel consumption display Average fuel consumption display

1 1

1. Instantaneous fuel consumption display 1. Average fuel consumption display

This display shows fuel consumption under cur- This display shows the average fuel consump-
rent riding conditions. It can be set to either “km/ tion since it was last reset. The average fuel con-
L” or “L/100 km”, or “MPG” when using miles. sumption display can be set to either “km/L” or
• “km/L”: the distance that can be traveled on 1.0 “L/100 km”, or “MPG” when using miles.
L of fuel. • “km/L”: the average distance that can be trav-
• “L/100 km”: the amount of fuel necessary to eled on 1.0 L of fuel.
travel 100 km. • “L/100 km”: the average amount of fuel neces-
• “MPG”: the distance that can be traveled on sary to travel 100 km.
1.0 Imp.gal of fuel. • “MPG”: the average distance that can be trav-
TIP eled on 1.0 Imp.gal of fuel.
When traveling under 10 km/h (6 mi/h), “_ _._” is TIP
displayed. • To reset the display, push the “MENU” switch
until it resets.
• After resetting, “_ _._” is shown until the vehicle
has traveled some distance.

Battery voltage display

1. Battery voltage meter

This display shows the current charge state of
the battery.
• Over 12.8 V = Full charge.
• Under 12.7 V = Charging is required.
TIP
If the battery voltage is less than 9.0 V, “_ _._” is
displayed.

1-6
 SPECIAL TOOLS

EAS20012

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

Reference
Tool name/Tool No. Illustration
pages
Yamaha diagnostic tool USB 3-4, 3-7, 4-63,
90890-03267 4-64, 7-15,
7-16, 9-3, 9-20,
9-21

Yamaha diagnostic tool (A/I) 3-4, 3-7, 4-63,

90890-03264 4-64, 7-15,
7-16, 9-3, 9-20,
9-21

Tappet adjusting tool 3-7

90890-01311
Six piece tappet set
YM-A5970

YM-A5970

ø8 ø9 ø10

ø3 ø4
Steering nut wrench 3-16, 3-17, 4-83
90890-01403
Exhaust flange nut wrench
YU-A9472

Thickness gauge 4-28

90890-03180
Feeler gauge set
YU-26900-9

T-handle 4-77, 4-78

90890-01326
T-handle 3/8" drive 60 cm long
YM-01326

1-7
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Fork seal driver weight 4-78, 4-79
90890-01367
Replacement hammer
YM-A9409-7

YM-A9409-7/YM-A5142-4

Fork seal driver attachment (ø30) 4-78, 4-79

90890-01400

Compression gauge 90890-03081 5-2

90890-03081
Engine compression tester
YU-33223

YU-33223

Compression gauge extension 122mm 5-2

90890-04136
Compression gauge extension 122mm
YM-04136

Camshaft wrench 5-14, 5-18

90890-04162
Camshaft wrench
YM-04162

Yamaha bond No. 1215 5-17, 5-59

90890-85505
Three bond No. 1215®

Slide hammer bolt (M8) 5-21

90890-01085
Slide hammer bolt 8 mm
YU-01083-2

1-8
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Weight 5-21
90890-01084
Weight
YU-01083-3

YU-01083-3

Valve spring compressor 5-25, 5-30

90890-04019
Valve spring compressor
YM-04019

Valve spring compressor attachment 5-25, 5-30

90890-04108
Valve spring compressor adapter 22 mm
YM-04108

Valve guide remover (ø5) 5-27

90890-04097
Valve guide remover (5.0 mm)
YM-04097

Valve guide installer (ø5) 5-27

90890-04098
Valve guide installer (5.0 mm)
YM-04098

Valve guide reamer (ø5) 5-27

90890-04099
Valve guide reamer (5.0 mm)
YM-04099

Piston pin puller set 5-32

90890-01304
Piston pin puller
YU-01304

YU-01304

1-9
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Rotor holding tool (including handle and 5-40, 5-46,
3 pins) 5-48, 5-48
90890-04195

Rotor holding tool attachment 7 x 12 mm 5-40, 5-46

90890-04197

ø7 12

Rotor holding tool 5-40, 5-40,

90890-04166 5-44, 5-45
Rotor holding tool
YM-04166

Socket wrench (39 mm) 5-40, 5-44

90890-01493

Sheave spring compressor 5-41, 5-44

90890-04134
Sheave spring compressor
YM-04134

Sheave fixed block 5-41, 5-44

90890-04135
Sheave fixed bracket
YM-04135

Oil seal guide (37 mm) 5-43

90890-04177

ø37

1-10
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Rotor holding tool attachment 7 x 5 mm 5-48, 5-48
90890-04198

ø7 5

Flywheel puller 5-48

90890-01189
Flywheel puller
YM-01189

Crankcase separating tool 5-57

90890-01135
Crankcase separator
YU-01135-B

Crankshaft installer pot 5-59

90890-01274
Installing pot
YU-90058

YU-90058/YU-90059

Crankshaft installer bolt 5-59

90890-01275
Bolt
YU-90060

Adapter (M12) 5-59

90890-01278
Adapter #3
YU-90063

1-11
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Spacer (crankshaft installer) 5-59
90890-04081
Pot spacer
YM-91044

YM-91044

Radiator cap tester 6-4, 6-4

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

YU-24460-A

Radiator cap tester adapter 31mm 6-4

90890-05375
Radiator cap tester adapter 31mm
YM-05375

Mechanical seal installer 6-10

90890-04145 ø30

ø10

Middle driven shaft bearing driver 6-10

90890-04058
Middle drive bearing installer 40 & 50 mm
YM-04058

Pressure gauge 7-5

90890-03153
Pressure gauge
YU-03153

Fuel pressure adapter 6.3mm 7-5

90890-03227

1-12
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Digital circuit tester (CD732) 8-36, 8-38,
90890-03243 8-39, 8-39,
Model 88 Multimeter with tachometer 8-39, 8-40,
YU-A1927 8-41, 8-41,
8-42, 8-42,
8-43, 8-43
Ignition checker 8-40
90890-06754
Oppama pet–4000 spark checker
YM-34487

1-13
 SPECIFICATIONS

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

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

CHASSIS SPECIFICATIONS ..........................................................................2-6

ELECTRICAL SPECIFICATIONS ...................................................................2-8

2
TIGHTENING TORQUES .............................................................................. 2-10
ENGINE TIGHTENING TORQUES......................................................... 2-10
CHASSIS TIGHTENING TORQUES.......................................................2-12

CABLE ROUTING ......................................................................................... 2-15

 GENERAL SPECIFICATIONS

EAS20013

GENERAL SPECIFICATIONS

Model
Model BBDC

Dimensions
Overall length 1935 mm (76.2 in)
Overall width 740 mm (29.1 in)
Overall height 1160 mm (45.7 in)
Wheelbase 1340 mm (52.8 in)
Ground clearance 125 mm (4.92 in)
Minimum turning radius 2.0 m (6.56 ft)

Weight
Curb weight 131 kg (289 lb)

Loading
Maximum load 167 kg (368 lb)
Riding capacity 2 person

2-1
 ENGINE SPECIFICATIONS

EAS20014

ENGINE SPECIFICATIONS

Engine
Combustion cycle 4-stroke
Cooling system Liquid cooled
Valve train SOHC
Displacement 155 cm³
Number of cylinders Single cylinder
Bore × stroke 58.0 × 58.7 mm (2.28 × 2.31 in)
Number of cylinders Single cylinder
Compression ratio 11.6 : 1
Compression pressure 1783–2296 kPa/1050 r/min (17.8–23.0 kgf/cm²/
1050 r/min, 253.7–326.6 psi/1050 r/min)

Fuel
Recommended fuel Regular unleaded gasoline (E10 acceptable)
Fuel tank capacity 7.1 L (1.9 US gal, 1.6 Imp.gal)
Fuel reserve amount 1.7 L (0.45 US gal, 0.37 Imp.gal)

Engine oil
Lubrication system Wet sump
Recommended brand YAMALUBE
SAE viscosity grades 10W-40
Recommended engine oil grade API service SG type or higher, JASO standard
MA or MB
Engine oil quantity
Quantity (disassembled) 1.00 L (1.06 US qt, 0.88 Imp.qt)
Oil change 0.90 L (0.95 US qt, 0.79 Imp.qt)

Final transmission oil

Type Motor oil SAE 10W-40 type SG or higher
Quantity (disassembled) 0.11 L (0.12 US qt, 0.10 Imp.qt)
Quantity 0.10 L (0.11 US qt, 0.09 Imp.qt)

Oil filter
Oil filter type Centrifugal

Cooling system
Coolant quantity
Radiator (including all routes) 0.46 L (0.49 US qt, 0.40 Imp.qt)
Coolant reservoir (up to the maximum level
mark) 0.13 L (0.14 US qt, 0.11 Imp.qt)
Radiator cap valve opening pressure 108.0–137.4 kPa (1.08–1.37 kgf/cm², 15.7–19.9
psi)
Cooling system leak test pressure 137.4 kPa (1.37 kgf/cm², 19.9 psi)

Thermostat
Valve opening temperature 74.0–78.0 °C (165.20–172.40 °F)
Valve full open temperature 90.0 °C (194.00 °F)

2-2
 ENGINE SPECIFICATIONS

Spark plug(s)
Manufacturer/model NGK/CPR8EA-9
Spark plug gap 0.8–0.9 mm (0.031–0.035 in)

Cylinder head
Warpage limit 0.05 mm (0.0020 in)

Camshaft
Camshaft lobe dimensions
Lobe height limit (Intake) 32.111 mm (1.2642 in)
Lobe height limit (Intake high speed) 32.487 mm (1.2790 in)
Lobe height limit (Exhaust) 29.320 mm (1.1543 in)

Rocker arm/rocker arm shaft

Rocker arm inside diameter limit 10.015 mm (0.3943 in)
Rocker arm shaft outside diameter limit 9.935 mm (0.3911 in)

Valve, valve seat, valve guide

Valve clearance (cold)
Intake 0.10–0.14 mm (0.0039–0.0055 in)
Exhaust 0.21–0.25 mm (0.0083–0.0098 in)
Valve dimensions
Valve seat contact width limit (intake) 1.3 mm (0.05 in)
Valve seat contact width limit (exhaust) 1.7 mm (0.07 in)
Valve stem diameter limit (intake) 4.945 mm (0.1947 in)
Valve stem diameter limit (exhaust) 4.930 mm (0.1941 in)
Valve guide inside diameter (intake) 5.000–5.012 mm (0.1969–0.1973 in)
Valve guide inside diameter (exhaust) 5.000–5.012 mm (0.1969–0.1973 in)
Valve-stem-to-valve-guide clearance limit
(intake) 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance limit
(exhaust) 0.100 mm (0.0039 in)
Valve stem runout 0.020 mm (0.0008 in)

Valve spring
Free length limit (intake) 32.10 mm (1.26 in)
Free length limit (exhaust) 32.10 mm (1.26 in)

Cylinder
Bore 58.000–58.010 mm (2.2835–2.2839 in)
Wear limit 58.060 mm (2.2858 in)

Piston
Piston-to-cylinder clearance 0.015–0.048 mm (0.0006–0.0019 in)
Diameter 57.962–57.985 mm (2.2820–2.2829 in)
Measuring point (from piston skirt bottom) 6.0 mm (0.24 in)
Piston pin bore inside diameter limit 14.043 mm (0.5529 in)
Piston pin outside diameter limit 13.975 mm (0.5502 in)

2-3
 ENGINE SPECIFICATIONS

Piston ring
Top ring
End gap limit 0.50 mm (0.0197 in)
Side clearance limit 0.115 mm (0.0045 in)
2nd ring
End gap limit 0.85 mm (0.0335 in)
Side clearance limit 0.115 mm (0.0045 in)

Crankshaft
Crank assembly width 51.45–51.50 mm (2.026–2.028 in)
Runout limit 0.030 mm (0.0012 in)

Clutch
Clutch type Dry, centrifugal, shoe

Automatic centrifugal clutch

Clutch shoe thickness limit 2.1 mm (0.08 in)
Clutch housing inside diameter limit 125.5 mm (4.94 in)
Compression spring free length limit 104.7 mm (4.12 in)
Weight outside diameter limit 19.5 mm (0.77 in)
Clutch-in revolution 2200–2600 r/min
Clutch-stall revolution 4700–5300 r/min

V-belt
V-belt width limit 21.6 mm (0.85 in)

Drivetrain
Transmission type V-belt automatic
Primary reduction ratio 1.000
Secondary reduction ratio 10.208 (56/16 x 35/12)
Transmission ratio 2.239–0.706 : 1

Air filter
Air filter element Oil-coated paper element
V-belt filter element Wet element

Fuel injector
Resistance 12.2 Ω

Fuel injection sensor

Intake air temperature sensor resistance 5700–6300 Ω at 0 °C (5700–6300 Ω at 32 °F)
Atmospheric pressure sensor output voltage 3.88–4.12 V at 101.3 kPa (3.88–4.12 V at 1.01
kgf/cm², 3.88–4.12 V at 14.7 psi)
Coolant temperature sensor resistance 2513–2777 Ω at 20 °C (2513–2777 Ω at 68 °F)
Coolant temperature sensor resistance 210–221 Ω at 100 °C (210–221 Ω at 212 °F)

2-4
 ENGINE SPECIFICATIONS

Idling condition
Engine idling speed 1500–1700 r/min
O2 feedback control Active
Coolant temperature 85 °C (185 °F)
CO% 0.0–1.0 %
Fuel line pressure (at idle) 220–300 kPa (2.2–3.0 kgf/cm², 31.9–43.5 psi)
Throttle grip free play 3.0–5.0 mm (0.12–0.20 in)

2-5
 CHASSIS SPECIFICATIONS

EAS20015

CHASSIS SPECIFICATIONS

Chassis
Caster angle 26.5 °
Trail 100 mm (3.9 in)

Front wheel
Wheel type Cast wheel
Rim size J13M/C x MT3.00
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 1.0 mm (0.04 in)
Wheel axle bending limit 0.25 mm (0.01 in)

Rear wheel
Wheel type Cast wheel
Rim size J13M/C x MT3.50
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 1.0 mm (0.04 in)
Wheel axle bending limit 0.25 mm (0.01 in)

Front tire
Type Tubeless
Size 110/70-13M/C 48P
Manufacturer/model DUNLOP/SCOOT SMART L

Rear tire
Type Tubeless
Size 130/70-13M/C 63P
Manufacturer/model DUNLOP/SCOOT SMART L

Tire air pressure (measured on cold tires)

1 person
Front 150 kPa (1.50 kgf/cm², 22 psi)
Rear 250 kPa (2.50 kgf/cm², 36 psi)
2 persons
Front 150 kPa (1.50 kgf/cm², 22 psi)
Rear 250 kPa (2.50 kgf/cm², 36 psi)

Front brake
Brake disc thickness limit 3.5 mm (0.14 in)
Brake disc runout limit (as measured on
wheel) 0.15 mm (0.0059 in)
Brake pad lining thickness limit 0.8 mm (0.03 in)
Master cylinder inside diameter 11.00 mm (0.43 in)
Caliper cylinder inside diameter (Right) 33.34 mm (1.31 in)
Specified brake fluid DOT 4

2-6
 CHASSIS SPECIFICATIONS

Rear brake
Brake disc thickness limit 4.0 mm (0.16 in)
Brake disc runout limit (as measured on
wheel) 0.15 mm (0.0059 in)
Brake pad lining thickness limit 0.8 mm (0.03 in)
Master cylinder inside diameter 12.7 mm (0.50 in)
Caliper cylinder inside diameter 33.34 mm (1.31 in)
Specified brake fluid DOT 4

Front suspension
Shock absorber Hydraulic damper
Fork spring free length limit 235.6 mm (9.28 in)
Inner tube bending limit 0.2 mm (0.01 in)
Recommended oil Yamaha Suspension Oil G10
Quantity (left) 89.0 cm³ (3.01 US oz, 3.14 Imp.oz)
Quantity (right) 89.0 cm³ (3.01 US oz, 3.14 Imp.oz)
Level (left) 77 mm (3.1 in)
Level (right) 77 mm (3.1 in)

Rear suspension
Shock absorber Hydraulic damper

Spring preload
Unit for adjustment Cam position
Adjustment value (STD) 1
Adjustment value (Hard) 2

2-7
 ELECTRICAL SPECIFICATIONS

EAS20016

ELECTRICAL SPECIFICATIONS

Voltage
System voltage 12 V

Engine control unit

Model TBDY88

Ignition system
Ignition timing (B.T.D.C.) 3.0–7.0 °/1600 r/min

Ignition coil
Primary coil resistance 2.16–2.64 Ω
Secondary coil resistance 8.64–12.96 kΩ

Spark plug cap

Resistance 3.75–6.25 kΩ

Charging system
Charging system Starter generator
Standard output 14.0 V, 50.4 A at 5000 r/min
Stator coil resistance 0.048–0.072 Ω

Rectifier/regulator
Regulated voltage (DC) 14.3–14.7 V

Battery
Model YTZ7V
Voltage, capacity 12 V, 6.0 Ah (10 HR)

Bulb wattage
Headlight LED
Brake/tail light LED
Front turn signal light 10.0 W
Rear turn signal light 10.0 W
Auxiliary light LED
License plate light 5.0 W
Meter lighting LED
Turn signal indicator light LED
High beam indicator light LED
Stop and Start System indicator light LED
ABS warning light LED
Smart key system indicator light LED
Traction control system indicator light LED
Engine trouble warning light LED

Fuel sender unit

Sender unit resistance (full) 10.0–14.0 Ω
Sender unit resistance (empty) 267.0–273.0 Ω

2-8
 ELECTRICAL SPECIFICATIONS

Fuse(s)
Main fuse 30.0 A
Headlight fuse 7.5 A
Signaling system fuse 7.5 A
Ignition fuse 7.5 A
Fuel injection system fuse 7.5 A
Terminal fuse 1 5.0 A
Backup fuse 7.5 A
ABS motor fuse 30.0 A
ABS solenoid fuse 15.0 A
ABS control unit fuse 2.0 A
Smart key system fuse 2.0 A

2-9
 TIGHTENING TORQUES

EAS20017

TIGHTENING TORQUES
EAS30016

ENGINE TIGHTENING TORQUES

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

Cylinder head bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Cylinder head nut M8 4 24 N·m (2.4 kgf·m, 18 lb·ft) M

VVA (variable valve actuator) so-

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

Crankcase bolt M6 11 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Transmission case cover bolt M8 6 20 N·m (2.0 kgf·m, 15 lb·ft)
Final transmission oil drain bolt M8 1 20 N·m (2.0 kgf·m, 15 lb·ft)
V-belt case bolt M6 10 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Engine oil drain bolt M12 1 20 N·m (2.0 kgf·m, 15 lb·ft)

2-10
 TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
V-belt case air filter element cov-
M6 6 7 N·m (0.7 kgf·m, 5.2 lb·ft)
er bolt
Primary fixed sheave nut M12 1 76 N·m (7.6 kgf·m, 56 lb·ft)
Clutch housing nut M12 1 45 N·m (4.5 kgf·m, 33 lb·ft)
Secondary sheave nut M28 1 55 N·m (5.5 kgf·m, 41 lb·ft)

Cylinder head tightening sequence:

3 4

1 2

6 5

2-11
 TIGHTENING TORQUES

EAS30017

CHASSIS TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Engine bracket nut M10 1 52 N·m (5.2 kgf·m, 38 lb·ft)
Engine mounting nut (front side) M10 2 50 N·m (5.0 kgf·m, 37 lb·ft)
Engine mounting nut (rear side) M10 2 28 N·m (2.8 kgf·m, 21 lb·ft)
Meter assembly panel bolt M6 2 3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
Grab bar bolt M8 4 17 N·m (1.7 kgf·m, 13 lb·ft)
Seat nut M6 3 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Storage box bolt M6 4 9 N·m (0.9 kgf·m, 6.6 lb·ft)
Front brake master cylinder hold-
M6 2 16 N·m (1.6 kgf·m, 12 lb·ft)
er bolt
Front brake hose union bolt (mas-
M10 1 29 N·m (2.9 kgf·m, 21 lb·ft)
ter cylinder side)
Rear brake hose union bolt (mas-
M10 1 29 N·m (2.9 kgf·m, 21 lb·ft)
ter cylinder side)
Throttle cable holder bolt (handle-
M5 1 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
bar switch side)
Rear brake master cylinder hold-
M6 2 16 N·m (1.6 kgf·m, 12 lb·ft)
er bolt
Brake light switch screw M4 2 1.2 N·m (0.12 kgf·m, 0.88 lb·ft)
Handlebar bracket nut M10 1 53 N·m (5.3 kgf·m, 39 lb·ft)
Lower ring nut M25 1 See TIP.
Upper ring nut M25 1 See TIP.
Lower bracket pinch bolt M10 4 53 N·m (5.3 kgf·m, 39 lb·ft)
Front fork damper rod bolt M10 2 23 N·m (2.3 kgf·m, 17 lb·ft) LT

Ignition coil bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)

Front wheel sensor bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Front brake caliper bolt M10 2 35 N·m (3.5 kgf·m, 26 lb·ft)
Front brake hose union bolt
M10 1 29 N·m (2.9 kgf·m, 21 lb·ft)
(brake caliper side)
Brake caliper bleed screw M8 2 6 N·m (0.6 kgf·m, 4.4 lb·ft)
Front wheel axle nut M10 1 26 N·m (2.6 kgf·m, 19 lb·ft)
Front brake disc bolt M8 3 23 N·m (2.3 kgf·m, 17 lb·ft) LT

Front wheel sensor rotor bolt M5 3 8 N·m (0.8 kgf·m, 5.9 lb·ft) LT

Rear brake disc bolt M8 3 23 N·m (2.3 kgf·m, 17 lb·ft) LT

Rear brake caliper bolt M10 2 35 N·m (3.5 kgf·m, 26 lb·ft)

Rear wheel axle nut M16 1 125 N·m (12.5 kgf·m, 92 lb·ft)
Rear shock absorber assembly
M10 2 21 N·m (2.1 kgf·m, 15 lb·ft)
nut
Rear shock absorber assembly
M8 2 21 N·m (2.1 kgf·m, 15 lb·ft)
bolt
Swingarm mounting bolt M10 2 57 N·m (5.7 kgf·m, 42 lb·ft)

2-12
 TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Fuel tank bolt M6 4 9 N·m (0.9 kgf·m, 6.6 lb·ft)
Coolant reservoir bolt M6 1 11 N·m (1.1 kgf·m, 8.1 lb·ft)
Sidestand switch bolt M5 2 7 N·m (0.7 kgf·m, 5.2 lb·ft) LT

Centerstand spring hook bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)

Sidestand nut M8 1 32 N·m (3.2 kgf·m, 24 lb·ft)

TIP
Steering column ring nut
1. Tighten the lower ring nut 38 N·m (3.8 kgf·m, 28 lb·ft) with a torque wrench and the steering nut
wrench, and then loosen the nut 1/4 turn.
2. Tighten the lower ring nut 17 N·m (1.7 kgf·m, 13 lb·ft) with a torque wrench and the steering nut
wrench.
3. Install the rubber washer and the center ring nut.
4. Finger tighten the center ring nut, align the slots of both ring nuts, and then install the lock washer.
5. Hold the lower and center ring nuts, and then tighten the upper ring nut 75 N·m (7.5 kgf·m, 55 lb·ft)
with a torque wrench and the steering nut wrench.

2-13
 TIGHTENING TORQUES

2-14
 CABLE ROUTING

EAS20021

CABLE ROUTING
Handlebar (front view)

A A
1 2

B 7

5
1 2

1 2

6 5 4 3

2-15
 CABLE ROUTING

1. Front brake hose

2. Rear brake hose
3. Rear brake light switch lead
4. Throttle cable (decelerator cable)
5. Throttle cable (accelerator cable)
6. Front brake light switch lead
7. Accessories coupler

A. 15° – 25°
B. Insert the projection on the wire harness
holder into the hole in the lower handlebar
cover.
C. Route the throttle cables through the hole
in the lower handlebar cover.

2-16
 CABLE ROUTING

Handlebar (side view)

5
2
1
3

4
2

4 B

2-17
 CABLE ROUTING

1. Rear brake hose

2. Throttle cable (decelerator cable)
3. Throttle cable (accelerator cable)
4. Wire harness
5. Front brake hose

A. Route the throttle cable (accelerator cable)

to the outside of the throttle cable (deceler-
ator cable).
B. Insert the projection on the wire harness
holder into the hole in the bracket.

2-18
 CABLE ROUTING

Front frame (front and left side view)

C 11 12 11 12

9 5
10
3
9 4 13 D
6
14
7

3 4 10
2 3
A 4
1 6 26
15
25
E
F
16
10

9 B
17
5
8
H G
6
6 18
19
7
B 7
20
24 22
23

21
18
20 18 20

26 25
13
8
3

28
6 3
13
7

I
27

26 25

29

2-19
 CABLE ROUTING

1. Front side cowling (right) I. Route the headlight lead through the head-
2. Meter assembly lead light lead guide (two places).
3. Headlight lead J. Route the front turn signal light lead (front
left turn signal light) through the guide of
4. Buzzer lead front side panel (left).
5. Fuse box
6. Front wheel sensor lead
7. Front brake hose (hydraulic unit to front
brake caliper)
8. Hydraulic unit assembly
9. SGCU (Starter Generator Control Unit)
10. Front turn signal light lead (front right turn
signal light)
11. Starter charger relay
12. Main relay
13. Front turn signal light lead (front left turn
signal light)
14. Meter assembly
15. Auxiliary DC jack lead
16. Auxiliary DC jack
17. Main switch
18. Seat lock cable
19. Fuel tank cap lid lock cable
20. Frame ground lead
21. Main switch steering lock assy
22. Throttle cable (accelerator)
23. Throttle cable (decelerator)
24. Frame
25. Rear brake hose (rear brake master cylin-
der to hydraulic unit)
26. Front brake hose (front brake master cylin-
der to hydraulic unit)
27. Wire harness
28. Headlight unit
29. Front turn signal light

A. Insert the projection of clamp wire harness

into the hole of front side cowling (right).
B. Insert the projection of clamp wire harness
into the hole of stay.
C. Make sure the white connector of wire har-
ness shall be connected to relay with white
paint.
D. Make sure the protrusion of wire harness
shall be assembled to the stay.
E. Make sure the auxiliary DC jack coupler
shall be assembled to protrusion of the
front side cowling (left).
F. Insert the projection of clamp wire harness
into the hole of frame.
G. Make sure the stopper of seat lock cable
and fuel tank cap lid lock cable shall be
assembled to the main switch.
H. Insert the projection of clamp front wheel
sensor into the hole of stay.

2-20
 CABLE ROUTING

Front fork (rear and right side view)

2 4

B C

2 4

B C

G
4

2
H
A
5

3
4
D
2
6 E
1

2-21
 CABLE ROUTING

1. Front wheel sensor

2. Front wheel sensor lead
3. Front brake caliper
4. Front brake hose
5. Horn
6. Front brake hose holder

A. Route the front brake hose through the

guide.
B. Backward
C. Frontward
D. Install the horn fit to the frame.
E. Install the guide fit to the lower bracket.
F. The front brake hose and front wheel sen-
sor lead should be passed through the
vehicle rear side of the guide.
G. Inward
H. Outward

2-22
 CABLE ROUTING

Frame (left side view)

F 3
G
4
8

H I

2 8
E 1

1 2 3 4

9 9 10
9

A
K 4
B 2
D 3
1 9
5

13
12

12
J
D
6 11 2

2 6
1
1 C
7

7
12

6
7 2 1

2
6 6
1

12

2-23
 CABLE ROUTING

1. Throttle cable (decelerator cable)

2. Throttle cable (accelerator cable)
3. Fuel tank cap lid lock cable
4. Seat lock cable
5. Fuel tank overflow tray
6. Sidestand switch lead
7. Fuel tank overflow hose
8. Main switch cover
9. Wire harness
10. Frame ground lead
11. Fuel hose
12. Frame
13. Horn

A. Insert the projection on the seat lock cable

clamp into the hole in the inner panel.
B. Clamp in the fuel tank cap lid lock cable
shall be assembled into the inner panel.
And the fuel tank cap lid lock cable with
white tape is fixed on the front side of the
vehicle. Do not cross the fuel tank cap lid
lock cable and seat lock cable.
C. Install the fuel tank overflow hose so that
this part of the fuel tank overflow hose
comes to the bottom than clamp.
D. Insert the projection on the wire harness
into the hole in the frame.
E. Install the throttle cable grommet into
guide of frame.
F. Pass the wire seat lock and fuel tank lid
lock cable in upper the main switch cover.
G. Push the coupler to forward of vehicle.
H. Tighten the bolt while pressing the terminal
against the projection of the frame.
I. Insert the projection on the wire harness
clamp into the hole in the main switch
cover.
J. Install the fuel hose grommet into guide of
frame.
K. Install the horn leads in any direction.

2-24
 CABLE ROUTING

Frame (left side view)

11 12

12
11
15 17
J
K 16
7 7 L

F 13
E
6 8 G P

9 14
N O N M
3
I

10
C
B

1 2

4 5

2-25
 CABLE ROUTING

1. Seat lock cable

2. Smart key unit lead
3. Fuel hose
4. Throttle cable (accelerator cable)
5. Throttle cable (decelerator cable)
6. Starter generator lead
7. O2 sensor lead
8. Throttle body sensor assembly
9. Engine ground lead
10. Injector lead
11. Positive battery lead
12. Yamaha diagnostic tool coupler lead
13. Negative battery lead
14. Wire harness
15. Rear brake hose
16. Rear wheel sensor lead
17. Frame

A. Insert the projection on the seat lock cable

clamp into the hole in the storage box.
B. Insert the projection on the seat lock cable
clamp into the hole in the frame.
C. Pass the seat lock cable in groove of the
rear fender.
D. Insert the throttle cable into the clamp.
E. Insert the wire harness clamp into the
plate.
F. Insert the O2 sensor connector into the
holder.
G. Insert the projection on the seat lock cable
clamp into the hole in the bracket.
H. Pass the wire harness inside of frame.
I. Insert the projection on the wire.
J. Insert the projection of clamp wire harness
into the hole of the battery stay.
K. Pass the wire harness in the inside of
frame.
L. Insert the projection of clamp wire harness
into the hole of the ignition coil stay.
M. Pass the coolant reservoir hose in upper
side of the holder.
N. Insert the projection of clamp wire harness
into the hole of the guide.
O. Pass the wire harness in the inside of pillar
guide.
P. Insert the projection of clamp wire harness
into the hole of the frame.

2-26
 CABLE ROUTING

Frame (right side view)

5
1 2 3

B
10

9 11 10

13 12
7

14 A
10

10

2-27
 CABLE ROUTING

1. CCU (Communication Control Unit)

2. Positive battery lead
3. Ignition coil
4. Joint
5. Frame ground lead
6. Hydraulic unit assembly
7. Wire harness
8. Footrest board
9. Coolant reservoir breather hose
10. Frame
11. Fuel pump lead
12. Starter generator lead
13. Wire harness (to battery)
14. Wire harness (to engine)

A. Insert the projection on the wire harness

into the hole in the frame.
B. White paint portion of the coolant reservoir
breather hose and clamp location should
be combined.

2-28
 CABLE ROUTING

Frame (right side view)

4 4

B
1

1 2

6 C 5

2-29
 CABLE ROUTING

1. Frame ground lead

2. Wire harness
3. Coolant temperature sensor lead
4. Frame
5. Rear fender
6. License light lead
7. O2 sensor lead

A. Pass the wire harness in groove of the rear

fender.
B. Insert the projection on the wire harness
clamp into the hole in the frame.
C. Pass the license light lead before assem-
bled the rear fender.

2-30
 CABLE ROUTING

Hydraulic unit (top and right side view)

1

3
4

5
1

7 4

2-31
 CABLE ROUTING

1. Hydraulic unit assembly

2. Rear brake hose (hydraulic unit to rear
brake caliper)
3. Rear brake hose (rear brake master cylin-
der to hydraulic unit)
4. Front brake hose (front brake master cylin-
der to hydraulic unit)
5. Front brake hose (hydraulic unit to front
brake caliper)
6. Main switch lead
7. Hydraulic unit assembly lead

A. Insert the projection of claim wire harness

into the hole of stay.

2-32
 CABLE ROUTING

Rear brake (right side view)

3
D
2
3 2 3
3 E
2

F 2
6 6 7

2 3 4 A B 5

8 9
3

2 7

2 G

2-33
 CABLE ROUTING

1. Rear brake caliper

2. Rear brake hose
3. Rear wheel sensor lead
4. Radiator
5. Coolant reservoir hose
6. Swingarm
7. Radiator fan cover
8. Rear brake hose bracket
9. Rear brake hose holder

A. Turn the clip to the left side of the vehicle.

The clip shall not be on the spool.
B. Turn the white paint mark to upper side of
the vehicle and insert the hose until the
radiator assy.
C. Connect the coolant reservoir hose to the
radiator, and then fasten the hose by
inserting the projection on the holder into
the hole in the rear brake hose bracket.
D. Position the clamp within the range shown
in the illustration.
E. Upward
F. Downward
G. The rear brake hose should be passed
through the guide.

2-34
 CABLE ROUTING

Fuel tank (top and bottom view)

4 3 2 A

D 7
1

8 E 4 B

2-35
 CABLE ROUTING

1. Rear brake hose

2. Coolant reservoir cap
3. Coolant reservoir breather hose
4. Rear wheel sensor lead
5. Coolant reservoir hose
6. Fuel hose
7. Clamp 1
8. Clamp 2

A. Install the coolant reservoir cap as shown

in the illustration.
B. Rear wheel sensor lead between the
clamp 1 and clamp 2 is gotten rid of the
slack by sliding the clamp 2 toward the
arrow mark.
After adjustment, the rear wheel sensor
lead shall be placed between the upper
limit line and lower limit line.
C. Slide direction
D. Upper limit line
E. Lower limit line

2-36
 CABLE ROUTING

Fuel tank (right side view)

H 5
4

4
F
E 3

8 10 I
7 3
G
F

1 2 3 3
G 4

A
5
D

8 6

1 4
C 7 B

3
12
K
6

7 11

2-37
 CABLE ROUTING

1. Ignition coil
2. Ignition coil cord
3. Rear brake hose
4. Rear wheel sensor lead
5. Coolant reservoir breather hose
6. Inner fender
7. Coolant reservoir hose
8. Fuel hose
9. Frame
10. Engine
11. Fuel tank overflow hose
12. Coolant reservoir

A. Install the coolant reservoir breather hose

on the frontward of vehicle.
B. Install the fuel hose grommet into guide of
frame.
C. Install the coolant reservoir hose so that
the hose protector is back of the guide
wire.
D. Insert the projection on the ignition coil
clamp into the hole in the frame.
E. Install the curved part of the coolant reser-
voir hose as close to the outside of the
vehicle.
F. Upward
G. Downward
H. Face the white paint mark on the recovery
tank upward.
I. Install the knob of coolant reservoir cap as
shown in illustration.
J. Face the white paint mark on the hose
upward.
K. Install the coolant reservoir hose fit to the
coolant reservoir.

2-38
 CABLE ROUTING

Canister

9
10

E 4 K

M
F

4
5
B A
11
5

12
O

G 10

2
I H
N

1
B
2 C

7 8 2
6
1 3
2 A
1

13

L 3
4
5
2 6
1

2
15
14

2-39
 CABLE ROUTING

1. Fuel tank breather hose (fuel tank to roll-

over valve)
2. Fuel tank breather hose (rollover valve to
canister)
3. Rollover valve
4. Canister breather hose
5. Canister purge hose
6. Frame
7. Main switch lead
8. Frame ground lead
9. Fuel hose
10. Canister
11. Throttle body assembly
12. Canister purge hose guide
13. Main switch cover
14. Fuel pump lead
15. Coolant reserver breather hose

A. Face the white paint mark on the hose to

the right. Install the hose completely onto
the hose fitting.
B. Point the ends of the hose clamp to the
right of the vehicle.
C. Face the yellow paint mark on the hose to
the rear of the vehicle. Install the hose
completely onto the hose fitting.
D. Route the fuel tank breather hose (rollover
valve to canister) grommet fit in the notch
of portion of the flange of fuel tank.
E. Face the white paint mark on the hose to
the upper. Install the hose completely onto
the hose fitting.
F. Insert the projection of clamp the canister
breather hose in to the hole of frame.
G. Face the white paint mark on the hose to
the rear and shall be located on this range.
H. Upward
I. Downward
J. Put the rollover valve through the clamp to
the main switch cover at rivet.
K. Insert the canister breather hose to the
hole of frame.
L. Pass the roll over valve to the clamp and
fasten it with rivet to the main switch cover.
M. Direction of the clamp insertion should be
aligned with white paint mark of the canis-
ter breather hose.
N. Face the white paint mark to the right.
O. Face the hose clip to the lower direction.

2-40
 CABLE ROUTING

Radiator (top and right side view)

2 D

1
E

G F 7
E

3
A
D
4

6 5 A D F
C
M L
5 6 H F D

7 B M L
I A 3 C
F

D
A

I
E
2

J
4
K
A

2-41
 CABLE ROUTING

1. Water pump
2. Water pump inlet hose
3. Thermostat assembly
4. Radiator outlet hose
5. Radiator
6. Coolant reservoir hose
7. Radiator inlet hose

A. Install the hose completely onto the hose

fitting.
B. Face the white paint mark on the hose to
the left.
C. 45°
D. Upward
E. Downward
F. Frontward
G. Backward
H. To coolant reservoir
I. Face the yellow paint mark on the hose to
the right.
J. Align the yellow paint mark on the hose
with the center of the thermostat assembly.
K. Face the white paint mark on the hose
downward.
L. Outward
M. Inward

2-42
 CABLE ROUTING

Air filter case (top and left side view)

A 3

3 2
2
B

A B C
2
C

1 F

A C

2-43
 CABLE ROUTING

1. V-belt case breather hose

2. Air filter case
3. Cylinder head breather hose

A. Point the ends of the hose clamp outward.

B. Face the yellow paint mark on the hose
outward.
C. Install the hose completely onto the hose
fitting.
D. Face the white paint mark on the hose out-
ward.
E. 5–6 mm (0.20–0.24 in)
F. 1–5 mm (0.04–0.20 in)

2-44
 CABLE ROUTING

2-45
 PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE ............................................................................3-1

INTRODUCTION .......................................................................................3-1
PERIODIC MAINTENANCE CHART
FOR THE EMISSION CONTROL SYSTEM .............................................3-1
GENERAL MAINTENANCE AND LUBRICATION CHART .......................3-1
CHECKING THE VEHICLE
USING THE YAMAHA DIAGNOSTIC TOOL............................................3-4
CHECKING THE FUEL LINE .................................................................... 3-4
CHECKING THE SPARK PLUG ............................................................... 3-5
ADJUSTING THE VALVE CLEARANCE .................................................. 3-6
CHECKING THE ENGINE IDLING SPEED ..............................................3-7
CHECKING THE EXHAUST SYSTEM......................................................3-8
CHECKING THE CANISTER .................................................................... 3-8
REPLACING THE AIR FILTER ELEMENT
AND CLEANING THE CHECK HOSE......................................................3-8
CHECKING THE BREATHER HOSES .....................................................3-9
3
CLEANING THE V-BELT CASE AIR FILTER ELEMENT
AND CLEANING THE CHECK HOSE....................................................3-10
CHECKING THE BRAKE OPERATION .................................................. 3-11
CHECKING THE FRONT BRAKE PADS ................................................ 3-11
CHECKING THE REAR BRAKE PADS .................................................. 3-11
CHECKING THE BRAKE FLUID LEVEL................................................. 3-11
CHECKING THE FRONT BRAKE HOSES ............................................. 3-12
CHECKING THE REAR BRAKE HOSES................................................ 3-12
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-12
CHECKING THE WHEELS ..................................................................... 3-14
CHECKING THE TIRES..........................................................................3-14
CHECKING THE WHEEL BEARINGS ....................................................3-15
CHECKING AND ADJUSTING THE STEERING HEAD ......................... 3-16
LUBRICATING THE STEERING HEAD.................................................. 3-17
CHECKING THE CHASSIS FASTENERS .............................................. 3-17
LUBRICATING THE LEVERS .................................................................3-17
CHECKING THE SIDESTAND................................................................3-17
LUBRICATING THE SIDESTAND........................................................... 3-17
CHECKING THE CENTERSTAND ......................................................... 3-17
LUBRICATING THE CENTERSTAND ....................................................3-17
CHECKING THE SIDESTAND SWITCH................................................. 3-17
CHECKING THE FRONT FORK ............................................................. 3-18
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES................ 3-18
CHECKING THE ENGINE OIL LEVEL....................................................3-18
CHANGING THE ENGINE OIL ...............................................................3-19
CHECKING THE COOLANT LEVEL.......................................................3-20
CHECKING THE COOLING SYSTEM ....................................................3-21
CHANGING THE COOLANT................................................................... 3-21
CHANGING THE FINAL TRANSMISSION OIL....................................... 3-24
REPLACING THE V-BELT ...................................................................... 3-24
CHECKING THE BRAKE LIGHT SWITCHES.........................................3-25
CHECKING AND LUBRICATING THE CABLES ................................... 3-25
CHECKING THE THROTTLE GRIP OPERATION .................................3-25
CHECKING THE SWITCHES, LIGHTS AND SIGNALS ......................... 3-26
ADJUSTING THE HEADLIGHT BEAM ...................................................3-26
 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.
TIP
• The annual checks must be performed every year, except if a distance-based maintenance is
performed instead.
• From 30000 km (17500 mi), repeat the maintenance intervals starting from 6000 km (3500 mi).
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.

EAS30614

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

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

EAS30615

GENERAL MAINTENANCE AND LUBRICATION CHART

ODOMETER READING
No. ITEM CHECK OR MAINTENANCE ANNUAL
JOB 1000 km 6000 km 12000 km 18000 km 24000 km CHECK
(600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi)

Diagnostic sys- • Perform dynamic inspection

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

4 * V-belt case air fil- • Clean. √ √ √ √ √

ter element • Replace if necessary.
• Check voltage.
5 * Battery √ √ √ √ √ √
• Charge if necessary.
• Check operation, fluid level,
and for fluid leakage.
6 * Front brake √ √ √ √ √ √
• Replace brake pads if neces-
sary.

3-1
 PERIODIC MAINTENANCE

ODOMETER READING
CHECK OR MAINTENANCE ANNUAL
No. ITEM
JOB 1000 km 6000 km 12000 km 18000 km 24000 km CHECK
(600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi)
• Check operation, fluid level,
7 * Rear brake and for fluid leakage. √ √ √ √ √ √
• Replace brake pads if neces-
sary.
• Check for cracks or damage. √ √ √ √ √
8 * Brake hose
• Replace. Every 4 years
9 * Brake fluid • Change. Every 2 years

10 * Wheels • Check runout and for damage. √ √ √ √

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

25 * Front and rear • Check operation. √ √ √ √ √ √

brake switches
Moving parts and
26 * • Lubricate. √ √ √ √ √
cables
• Check operation and free
play.
27 * Throttle grip • Adjust the throttle cable free √ √ √ √ √
housing and cable play if necessary.
• Lubricate the throttle grip
housing and cable.
Lights, signals • Check operation.
28 * and switches • Adjust headlight beam. √ √ √ √ √ √

3-2
 PERIODIC MAINTENANCE

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

3-3
 PERIODIC MAINTENANCE

EAS32024
5. Install:
CHECKING THE VEHICLE USING THE
• Battery cover
YAMAHA DIAGNOSTIC TOOL
Refer to “GENERAL CHASSIS (1)” on
Use the Yamaha diagnostic tool and check the
page 4-1.
vehicle according to the following procedure.
1. Remove: EAS30619

• Battery cover CHECKING THE FUEL LINE

Refer to “GENERAL CHASSIS (1)” on 1. Remove:
page 4-1. • Front side cover (left)
2. Disconnect the Yamaha diagnostic tool cou- Refer to “GENERAL CHASSIS (2)” on
pler from the CCU (Communication Control page 4-3.
Unit) “1”, and then connect the Yamaha diag- • Footrest board assembly (left)
nostic tool to the coupler. Refer to “GENERAL CHASSIS (5)” on
page 4-12.
Yamaha diagnostic tool USB 2. Check:
90890-03267 • Fuel hose “1”
Yamaha diagnostic tool (A/I) Cracks/damage → Replace.
90890-03264 Loose connections → Connect properly.

3. Install:
3. Check: • Footrest board assembly (left)
• Fault code Refer to “GENERAL CHASSIS (5)” on
TIP page 4-12.
Use the “Diagnosis of malfunction” function of • Front side cover (left)
the Yamaha diagnostic tool to check the fault Refer to “GENERAL CHASSIS (2)” on
codes. For information about using the Yamaha page 4-3.
diagnostic tool, refer to the operation manual
that is included with the tool.
Fault code number is displayed → Check and
repair the probable cause of the malfunction.
Refer to “SELF-DIAGNOSTIC FUNCTION
AND DIAGNOSTIC CODE TABLE” on
page 9-37.
4. Perform:
• Dynamic inspection
TIP
Use the “Dynamic inspection” function of the Ya-
maha diagnostic tool version 3.0 and after to
perform the dynamic inspection. For information
about using the Yamaha diagnostic tool, refer to
the operation manual that is included with the
tool.

3-4
 PERIODIC MAINTENANCE

EAS30620
6. Measure:
CHECKING THE SPARK PLUG
• Spark plug gap “a”
1. Remove:
(with a wire thickness gauge)
• Front side cover (right)
Out of specification → Regap.
Refer to “GENERAL CHASSIS (2)” on
page 4-3.
Spark plug gap
• Footrest board assembly (right) 0.8–0.9 mm (0.031–0.035 in)
Refer to “GENERAL CHASSIS (5)” on
page 4-12.
2. Remove:
• Spark plug cap
• Spark plug
ECA13330

NOTICE
Before removing the spark plug, blow away
any dirt accumulated in the spark plug well
with compressed air to prevent it from falling
into the cylinder.
7. Install:
3. Check:
• Spark plug “1”
• Spark plug type
• Spark plug cap
Incorrect → Change.
Spark plug
Manufacturer/model
13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.

NGK/CPR8EA-9
R.

4. Check: TIP
• Electrode “1” • Before installing the spark plug, clean the
Damage/wear → Replace the spark plug. spark plug and gasket surface.
• Insulator “2” • When tightening the spark plug, make sure
Abnormal color → Replace the spark plug. that the inside “a” of the spark plug wrench “2”
Normal color is medium-to-light tan. does not contact the portion “b” of the spark
plug.

b
a 2

5. Clean:
• Spark plug 8. Install:
(with a spark plug cleaner or wire brush) • Footrest board assembly (right)
Refer to “GENERAL CHASSIS (5)” on
page 4-12.
• Front side cover (right)
Refer to “GENERAL CHASSIS (2)” on
page 4-3.

3-5
 PERIODIC MAINTENANCE

EAS30622

ADJUSTING THE VALVE CLEARANCE

The following procedures are applied to all of
1
the valves.
TIP
• Valve clearance adjustment should be made
on a cold engine, at room temperature.
• When the valve clearance is to be measured or
adjusted, the piston must be at top dead center
(TDC) on the compression stroke.
4. Measure:
1. Remove: • Valve clearance
• Battery Out of specification → Adjust.
Refer to “GENERAL CHASSIS (1)” on
page 4-1. Valve clearance (cold)
• Front side cover Intake
Refer to “GENERAL CHASSIS (3)” on 0.10–0.14 mm (0.0039–0.0055
page 4-6. in)
• Fuel tank cover Exhaust
Refer to “GENERAL CHASSIS (3)” on 0.21–0.25 mm (0.0083–0.0098
page 4-6. in)
• Center lower cover
Refer to “GENERAL CHASSIS (5)” on a. Turn the crankshaft clockwise.
page 4-12.
• Fuel tank
Refer to “FUEL TANK” on page 7-1.
• Cylinder head cover
Refer to “CYLINDER HEAD” on page 5-9.
• Radiator cover
Refer to “RADIATOR” on page 6-2.
2. Move:
• Radiator “1”
TIP
b. When the piston is at the Top Dead Center
Move the rear of the radiator outward.
(TDC) on the compression stroke, align the
mark “a” on the camshaft sprocket with the
match mark “b” on the camshaft stopper
plate.
a b

3. Move:
• Water pump assembly “1”
TIP
Move the water pump assembly in the direction
shown in the illustration.

3-6
 PERIODIC MAINTENANCE

c. Measure the valve clearance with a thick- d. Hold the adjusting screw to prevent it from
ness gauge “1”. moving and tighten the locknut to specifica-
Out of specification → Adjust. tion.

Valve clearance adjusting screw

locknut

T.
R.
7 N·m (0.7 kgf·m, 5.2 lb·ft)

e. Measure the valve clearance again.

f. If the valve clearance is still out of specifica-
tion, repeat all of the valve clearance ad-
justment steps until the specified clearance
1 is obtained.
5. Adjust: 6. Install:
• Valve clearance • All removed parts
a. Loosen the locknut “1”. TIP
b. Insert a thickness gauge “2” between the For installation, reverse the removal procedure.
end of the adjusting screw and the valve tip.
EAS31017

CHECKING THE ENGINE IDLING SPEED

TIP
Prior to checking the engine idling speed, the air
1 filter element should be clean, and the engine
should have adequate compression.
1. Start the engine and let it warm up for several
minutes.
2 2. Check:
c. Turn the adjusting screw “3” with the tappet • Engine idling speed
adjusting tool “4” until the specified valve Out of specification → Go to next step.
clearance is obtained.
Engine idling speed
Tappet adjusting tool 1500–1700 r/min
90890-01311
3. Check:
Six piece tappet set
YM-A5970 • ISC (idle speed control) learning value
“00” or “01” → Check the intake system.
“02” → Clean the ISC (idle speed control) unit
and throttle body.
Refer to “CLEANING THE ISC (IDLE SPEED
CONTROL) UNIT AND THROTTLE BODY”
on page 7-13.
3
a. Connect the Yamaha diagnostic tool.
Use the diagnostic code number “67”.
Refer to “SELF-DIAGNOSTIC FUNCTION
4 AND DIAGNOSTIC CODE TABLE” on
page 9-37.

Yamaha diagnostic tool USB

90890-03267
Yamaha diagnostic tool (A/I)
90890-03264

3-7
 PERIODIC MAINTENANCE

EAS30625
3. Install:
CHECKING THE EXHAUST SYSTEM
• Center lower cover
1. Check:
Refer to “GENERAL CHASSIS (5)” on
• Muffler “1”
page 4-12.
Cracks/damage → Replace.
• Fuel tank cover
• Gasket “2”
Refer to “GENERAL CHASSIS (3)” on
Exhaust gas leaks → Replace.
page 4-6.
2. Check:
• Front side cover
Tightening torque
Refer to “GENERAL CHASSIS (2)” on
• Muffler nut “3”
page 4-3.
• Muffler bolt “4”
EAS31130

Muffler nut REPLACING THE AIR FILTER ELEMENT

20 N·m (2.0 kgf·m, 15 lb·ft) AND CLEANING THE CHECK HOSE
T.
R.

Muffler bolt TIP

53 N·m (5.3 kgf·m, 39 lb·ft) Check the air filter check hose “1” that is located
on the rear side of the air filter case. If dust or
water or both collects in the hose, clean the hose
and replace the air filter element.

4
1
1
2
4
4 3
EAS31922

CHECKING THE CANISTER

1. Remove:
• Front side cover 1. Remove:
Refer to “GENERAL CHASSIS (2)” on • Air filter case cover “1”
page 4-3. • Air filter element “2”
• Fuel tank cover 1
Refer to “GENERAL CHASSIS (3)” on
page 4-6.
• Center lower cover
Refer to “GENERAL CHASSIS (5)” on
page 4-12.
2. Check:
• Fuel tank breather hose (rollover valve to
canister)
• Canister purge hose
• Canister breather hose
• Canister
Damage → Replace. 2

3-8
 PERIODIC MAINTENANCE

2. Check: ECA21600

• Air filter element NOTICE

Damage → Replace. Make sure the cylinder head breather hose
TIP and transmission case breather hose are
routed correctly.
• Replace the air filter element every 18000 km
(10500 mi) of operation.
• The air filter needs more frequent service if you
are riding in unusually wet or dusty areas. 1
3. Install:
• Air filter element
• Air filter case cover

Air filter case cover screw

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

ECA20480

NOTICE
Never operate the engine without the air filter 2
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
tuning, leading to poor engine performance
and possible overheating.
3. Install:
TIP • Storage box
When installing the air filter element into the air Refer to “GENERAL CHASSIS (4)” on
filter case, make sure that the sealing surfaces page 4-9.
are aligned to prevent any air leaks. • Fuel tank cover
Refer to “GENERAL CHASSIS (3)” on
EAS31179
page 4-6.
CHECKING THE BREATHER HOSES • Front side cover
1. Remove: Refer to “GENERAL CHASSIS (2)” on
• Battery page 4-3.
Refer to “GENERAL CHASSIS (1)” on • Battery
page 4-1. Refer to “GENERAL CHASSIS (1)” on
• Front side cover page 4-1.
Refer to “GENERAL CHASSIS (2)” on
page 4-3.
• Fuel tank cover
Refer to “GENERAL CHASSIS (3)” on
page 4-6.
• Storage box
Refer to “GENERAL CHASSIS (4)” on
page 4-9.
2. Check:
• Cylinder head breather hose “1”
• Transmission case breather hose “2”
Cracks/damage → Replace.
Loose connections → Connect properly.

3-9
 PERIODIC MAINTENANCE

EAS31704
TIP
CLEANING THE V-BELT CASE AIR FILTER
ELEMENT AND CLEANING THE CHECK • The air filter needs more frequent service if you
HOSE are riding in unusually wet or dusty areas.
TIP
• After cleaning, gently squeeze the V-belt case
air filter element to remove the excess solvent.
Check the V-belt case air filter check hose “1”
that is located on the rear side of the V-belt case. ECA21590

If dust or water or both collects in the hose, clean NOTICE

the hose and replace the V-belt case air filter el- Do not twist the V-belt case air filter element
ement. when squeezing it.

1
1. Remove: 3. Check:
• V-belt case air filter element cover “1” • V-belt case air filter element
• V-belt case air filter element “2” Damage → Replace.
4. Apply the recommended oil to the entire sur-
face of the V-belt case air filter element and
squeeze out the excess oil. The V-belt case
air filter element should be wet but not drip-
1 ping.

Recommended oil
Engine oil

5. Install:
• V-belt case air filter element
• V-belt case air filter element cover

V-belt case air filter element cov-

er bolt
2
T.
R.

7 N·m (0.7 kgf·m, 5.2 lb·ft)

2. Clean:
• V-belt case air filter element
(with solvent)
EWA17971

WARNING
Never use low flash point solvents, such as
gasoline, to clean the V-belt case air filter el-
ement. Such solvents may cause a fire or an
explosion.

3-10
 PERIODIC MAINTENANCE

EAS30801 EAS30632

CHECKING THE BRAKE OPERATION CHECKING THE BRAKE FLUID LEVEL

1. Check: 1. Stand the vehicle on a level surface.
• Brake operation TIP
Brake not working properly → Check the • Place the vehicle on the centerstand.
brake system. • Make sure the vehicle is upright.
Refer to “FRONT BRAKE” on page 4-32 and • In order to ensure a correct reading of the
“REAR BRAKE” on page 4-46. brake fluid level, make sure the top of the brake
TIP fluid reservoir is horizontal.
Drive on the road, operate the front and rear
2. Check:
brakes separately and check to see if the brakes
• Brake fluid level
are operating properly.
Below the minimum level mark “a” → Add the
specified brake fluid to the proper level.
EAS30633

CHECKING THE FRONT BRAKE PADS

The following procedures are applied to all of Specified brake fluid
the brake pads. DOT 4
1. Operate the brake.
2. Check: A
a
• Front brake pad
Wear indicator grooves “a” almost disap-
peared → Replace the brake pads as a set.
Refer to “FRONT BRAKE” on page 4-32.

a
a
EAS30634

CHECKING THE REAR BRAKE PADS

The following procedures are applied to all of
the brake pads.
1. Operate the brake. A. Front brake
2. Check: B. Rear brake
• Rear brake pad
Wear indicators “a” almost touch the brake
disc → Replace the brake pads as a set.
Refer to “REAR BRAKE” on page 4-46.

3-11
 PERIODIC MAINTENANCE

EWA13540 EAS30636

WARNING CHECKING THE REAR BRAKE HOSES

• Use only the designated brake fluid. Other 1. Check:
brake fluids may cause the rubber seals to • Brake hose “1”
deteriorate, causing leakage and poor Cracks/damage/wear → Replace.
brake performance.
• Refill with the same type of brake fluid that 1
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 master cylinder reser- 1
voir. Water will significantly lower the boil-
ing point of the brake fluid and could cause
vapor lock.
2. Check:
ECA13540
• Brake hose holder
NOTICE Loose → Tighten the holder bolt.
Brake fluid may damage painted surfaces 3. Hold the vehicle upright and apply the rear
and plastic parts. Therefore, always clean up brake several times.
any spilt brake fluid immediately. 4. Check:
• Brake hose
EAS30635 Brake fluid leakage → Replace the brake
CHECKING THE FRONT BRAKE HOSES hose.
1. Check: Refer to “REAR BRAKE” on page 4-46.
• Brake hose “1”
Cracks/damage → Replace. EAS30893

BLEEDING THE HYDRAULIC BRAKE

SYSTEM
1 EWA14000

WARNING
Always bleed the brake system when the
brake related parts are removed.
ECA22780

NOTICE
• Bleed the brake system in the following or-
1 der.
2. Check: • 1st step: Front brake caliper
• Brake hose holder • 2nd step: Rear brake caliper
• Brake hose guide EWA16530

Loose → Tighten the holder and guide bolt. WARNING

3. Hold the vehicle upright and apply the front Bleed the ABS whenever:
brake several times. • the system is disassembled.
4. Check: • a brake hose is loosened, disconnected or
• Brake hose replaced.
Brake fluid leakage → Replace the damaged • the brake fluid level is very low.
hose. • brake operation is faulty.
Refer to “FRONT BRAKE” on page 4-32.

3-12
 PERIODIC MAINTENANCE

TIP g. Loosen the bleed screw.

• Be careful not to spill any brake fluid or allow TIP
the brake master cylinder reservoir to overflow. Loosening the bleed screw will release the pres-
• When bleeding the ABS, make sure that there sure and cause the brake lever to contact the
is always enough brake fluid before applying throttle grip or handlebar grip.
the brake. Ignoring this precaution could allow
h. Tighten the bleed screw and then release
air to enter the ABS, considerably lengthening
the brake lever.
the bleeding procedure.
i. Repeat steps (e) to (h) until all of the air
• If bleeding is difficult, it may be necessary to let
bubbles have disappeared from the brake
the brake fluid settle for a few hours.
fluid in the plastic hose.
• Repeat the bleeding procedure when the tiny
j. Check the operation of the hydraulic unit.
bubbles in the hose have disappeared.
Refer to “HYDRAULIC UNIT OPERATION
1. Bleed: TESTS” on page 4-62.
• ABS ECA18060

NOTICE
a. Fill the brake master cylinder reservoir to
Make sure that the main switch is turned to
the proper level with the specified brake flu-
“OFF” before checking the operation of the
id.
hydraulic unit.
b. Install the brake master cylinder dia-
phragm. k. After operating the ABS, repeat steps (e) to
c. Connect a clear plastic hose “1” tightly to (i), and then fill the brake master cylinder
the bleed screw “2”. reservoir to the proper level with the speci-
A fied brake fluid.
2 l. Tighten the bleed screw to specification.

Brake caliper bleed screw

1 6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.

m. Fill the brake master cylinder reservoir to

the proper level with the specified brake flu-
id.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-11.
B EWA13110

WARNING
After bleeding the hydraulic brake system,
check the brake operation.
1

A. Front brake caliper

B. Rear brake caliper
d. Place the other end of the hose into a con-
tainer.
e. Slowly apply the brake several times.
f. Fully squeeze the brake lever and hold it in
position.

3-13
 PERIODIC MAINTENANCE

EAS31428

CHECKING THE WHEELS

Tire air pressure (measured on
The following procedures are applied to all of cold tires)
the wheels. 1 person
1. Check: Front
• Wheel 150 kPa (1.50 kgf/cm², 22 psi)
Damage/out-of-round → Replace. Rear
EWA13260
250 kPa (2.50 kgf/cm², 36 psi)
WARNING 2 persons
Never attempt to make any repairs to the Front
wheel. 150 kPa (1.50 kgf/cm², 22 psi)
Rear
TIP
250 kPa (2.50 kgf/cm², 36 psi)
After a tire or wheel has been changed or re- * Total weight of rider, passenger, cargo
placed, always balance the wheel. and accessories
2. Measure: EWA13190

• Radial wheel runout WARNING

• Lateral wheel runout It is dangerous to ride with a worn-out tire.
Refer to “FRONT WHEEL” on page 4-22 and When the tire tread reaches the wear limit, re-
“REAR WHEEL” on page 4-29. place the tire immediately.
EAS31429
2. Check:
CHECKING THE TIRES
• Tire surfaces
The following procedures are applied to all of the
Damage/wear → Replace the tire.
tires.
1. Check:
• Tire pressure
Out of specification → Regulate.

1. Tire tread depth

2. Side wall
3. Wear indicator
EWA13181

WARNING Wear limit (front)

• The tire pressure should only be checked 1.0 mm (0.04 in)
and regulated when the tire temperature Wear limit (rear)
equals the ambient air temperature. 1.0 mm (0.04 in)
• The tire pressure and the suspension must
be adjusted according to the total weight
(including cargo, rider, passenger and ac-
cessories) and the anticipated riding
speed.
• Operation of an overloaded vehicle could
cause tire damage, an accident or an injury.
NEVER OVERLOAD THE VEHICLE.

3-14
 PERIODIC MAINTENANCE

EWA14080

WARNING Rear tire

• Do not use a tubeless tire on a wheel de- Size
signed only for tube tires to avoid tire fail- 130/70-13M/C 63P
ure and personal injury from sudden Manufacturer/model
deflation. DUNLOP/SCOOT SMART L
• When using a tube tire, be sure to install the EWA13210
correct tube. WARNING
• Always replace a new tube tire and a new New tires have a relatively low grip on the
tube as a set. road surface until they have been slightly
• To avoid pinching the tube, make sure the worn. Therefore, approximately 100 km
wheel rim band and tube are centered in the should be traveled at normal speed before
wheel groove. any high-speed riding is done.
• Patching a punctured tube is not recom-
mended. If it is absolutely necessary to do TIP
so, use great care and replace the tube as For tires with a direction of rotation mark “1”:
soon as possible with a good quality re- • Install the tire with the mark pointing in the di-
placement. rection of wheel rotation.
• Align the mark “2” with the valve installation
A B point.

2
1

A. Tire
B. Wheel

Tube wheel Tube tire only EAS30641

CHECKING THE WHEEL BEARINGS

Tubeless wheel Tube or tubeless tire The following procedures are applied to all of the
wheel bearings.
EWA14090
1. Check:
WARNING
• Wheel bearings
After extensive tests, the tires listed below Refer to “CHECKING THE FRONT WHEEL”
have been approved by Yamaha Motor Co., on page 4-25.
Ltd. for this model. The front and rear tires
should always be by the same manufacturer
and of the same design. No guarantee con-
cerning handling characteristics can be giv-
en if a tire combination other than one
approved by Yamaha is used on this vehicle.

Front tire
Size
110/70-13M/C 48P
Manufacturer/model
DUNLOP/SCOOT SMART L

3-15
 PERIODIC MAINTENANCE

EAS30645

CHECKING AND ADJUSTING THE

Steering nut wrench
STEERING HEAD 90890-01403
1. Stand the vehicle on a level surface. Exhaust flange nut wrench
EWA13120

WARNING YU-A9472
Securely support the vehicle so that there is
no danger of it falling over. Lower ring nut (initial tightening
torque)

T.
R.
TIP 38 N·m (3.8 kgf·m, 28 lb·ft)
Place the vehicle on a suitable stand so that the
front wheel is off ground.
2. Check:
• Steering head
Grasp the handlebar and gently rock the han-
dlebar.
Binding/looseness → Adjust the steering
head. 6
3. Remove:
• Front side covers 5
Refer to “GENERAL CHASSIS (2)” on c. Loosen the lower ring nut 1/4 of a turn, and
page 4-3. then tighten it to specification with a steer-
• Center lower cover ing nut wrench.
EWA13140
Refer to “GENERAL CHASSIS (5)” on
page 4-12. WARNING
• Front upper cowling assembly Do not overtighten the lower ring nut.
Refer to “GENERAL CHASSIS (6)” on
page 4-15. Lower ring nut (final tightening
• Handlebar torque)
T.
R.

Refer to “HANDLEBAR” on page 4-67. 17 N·m (1.7 kgf·m, 13 lb·ft)

4. Adjust:
• Steering head d. Check the steering head for looseness or
a. Remove the upper ring nut “1”, lock washer binding by turning the front fork all the way
“2”, center ring nut “3” and rubber washer in both directions. If any binding is felt, re-
“4”. move the lower bracket and check the up-
per and lower bearings.
Refer to “STEERING HEAD” on page 4-81.
e. Install the rubber washer.
f. Install the center ring nut.
1 g. Finger tighten the center ring nut, then align
the slots of both ring nuts. If necessary, hold
3 the lower ring nut and tighten the center ring
nut until their slots are aligned.
4
2
b. Loosen the lower ring nut “5” and then tight-
en it to specification with a steering nut
wrench “6”.
TIP
Set the torque wrench at a right angle to the
steering nut wrench.

3-16
 PERIODIC MAINTENANCE

h. Install the lock washer “2”. EAS31186

CHECKING THE CHASSIS FASTENERS

TIP
Make sure that all nuts, bolts, and screws are
Make sure the lock washer tabs “a” sit correctly properly tightened.
in the ring nut slots “b”. Refer to “TIGHTENING TORQUES” on page 2-
10.
EAS30648

2 LUBRICATING THE LEVERS

Lubricate the pivoting point and metal-to-metal
a moving parts of the levers.

Recommended lubricant
b Silicone grease

EAS30650

i. Hold the lower and center ring nuts with a CHECKING THE SIDESTAND
steering nut wrench and tighten the upper 1. Check:
ring nut with another steering nut wrench. • Sidestand operation
Check that the sidestand moves smoothly.
Steering nut wrench Rough movement → Repair or replace.
90890-01403 EAS30651
Exhaust flange nut wrench LUBRICATING THE SIDESTAND
YU-A9472 Lubricate the pivoting point, metal-to-metal mov-
ing parts and spring contact point of the side-
Upper ring nut stand.
75 N·m (7.5 kgf·m, 55 lb·ft)
T.
R.

Recommended lubricant
Lithium-soap-based grease
5. Install:
• Handlebar EAS30856

Refer to “HANDLEBAR” on page 4-67. CHECKING THE CENTERSTAND

• Front upper cowling assembly 1. Check:
Refer to “GENERAL CHASSIS (6)” on • Centerstand operation
page 4-15. Check that the centerstand moves smoothly.
• Center lower cover Rough movement → Repair or replace.
Refer to “GENERAL CHASSIS (5)” on
EAS30857
page 4-12. LUBRICATING THE CENTERSTAND
• Front side cover Lubricate the pivoting point, metal-to-metal mov-
Refer to “GENERAL CHASSIS (2)” on ing parts, and spring contact points of the center-
page 4-3. stand.
EAS30646

LUBRICATING THE STEERING HEAD Recommended lubricant

1. Lubricate: Lithium-soap-based grease
• Upper bearing
• Lower bearing EAS30652

CHECKING THE SIDESTAND SWITCH

• Lower bearing dust seal
Refer to “CHECKING THE SWITCHES” on
page 8-35.
Recommended lubricant
Lithium-soap-based grease

3-17
 PERIODIC MAINTENANCE

EAS30653
3. Check:
CHECKING THE FRONT FORK
• Rear shock absorber assembly operation
1. Stand the vehicle on a level surface.
EWA13120
Push down seat on the vehicle several times
WARNING and check if the rear shock absorber assem-
Securely support the vehicle so that there is bly rebounds smoothly.
no danger of it falling over. Rough movement → Replace.
Refer to “REAR SHOCK ABSORBER AS-
2. Check: SEMBLIES AND SWINGARM” on page 4-
• Inner tube 85.
Damage/scratches → Replace.
EAS30656
• Oil seal CHECKING THE ENGINE OIL LEVEL
Oil leakage → Replace. 1. Stand the vehicle on a level surface.
3. Hold the vehicle upright and apply the front
TIP
brake.
4. Check: • Place the vehicle on the centerstand.
• Front fork operation • Make sure the vehicle is upright.
Push down hard on the handlebar several 2. Start the engine, warm it up for several min-
times and check if the front fork rebounds utes, and then turn it off.
smoothly. 3. Remove:
Rough movement → Repair. • Dipstick “1”
Refer to “FRONT FORK” on page 4-74. 4. Check:
• Engine oil level
The engine oil level should be between the
minimum level mark “a” and maximum level
mark “b”.
Below the minimum level mark → Add the
recommended engine oil to the proper level.
TIP
• Before checking the engine oil level, wait a few
minutes until the oil has settled.
• Do not screw the dipstick in when inspecting
EAS30808

CHECKING THE REAR SHOCK ABSORBER the oil level.

ASSEMBLIES
The following procedures are applied to both of
the rear shock absorber assemblies.
1. Stand the vehicle on a level surface. 1
EWA13120

WARNING
Securely support the vehicle so that there is
no danger of it falling over.
1 b

2. Check: a
• Rear shock absorber assembly
Oil leaks → Replace the rear shock absorber
Recommended brand
assembly.
YAMALUBE
Refer to “CHECKING THE REAR SHOCK
SAE viscosity grades
ABSORBER ASSEMBLY” on page 4-87. 10W-40
Recommended engine oil grade
API service SG type or higher,
JASO standard MA or MB

3-18
 PERIODIC MAINTENANCE

ECA13370

NOTICE
Do not allow foreign materials to enter the
crankcase. 2
5. Start the engine, warm it up for several min- 3
utes, and then turn it off. 4
6. Check the engine oil level again. 1
TIP
Before checking the engine oil level, wait a few
minutes until the oil has settled. c. Clean the engine oil strainer with solvent,
and then check it for damage and replace it
EAS30657 if necessary.
CHANGING THE ENGINE OIL d. Install the oil strainer, spring, and oil strain-
1. Start the engine, warm it up for several min- er cover.
utes, and then turn it off.
2. Place a container under the engine oil drain Oil strainer cover
bolt. 20 N·m (2.0 kgf·m, 15 lb·ft)

T.
R.
3. Remove:
• Dipstick “1” 6. Install:
• Engine oil drain bolt “2” • Engine oil drain bolt
(along with the gasket “3”)
(along with the gasket New )

Engine oil drain bolt

20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.

7. Fill:
• Crankcase
1 (with the specified amount of the recom-
mended engine oil)

Engine oil quantity

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

3-19
 PERIODIC MAINTENANCE

12.Remove: EAS30811

CHECKING THE COOLANT LEVEL

• Front side cover (right)
1. Stand the vehicle on a level surface.
Refer to “GENERAL CHASSIS (2)” on
page 4-3. TIP
• Footrest board assembly (right) • Place the vehicle on the centerstand.
Refer to “GENERAL CHASSIS (5)” on • Make sure the vehicle is upright.
page 4-12. 2. Check:
13.Check: • Coolant level
• Engine oil pressure The coolant level should be between the min-
a. Slightly loosen the oil check bolt “1”. imum level mark “a” and maximum level mark
“b”.
Below the minimum level mark → Add the
recommended coolant to the proper level.

1
b
a

b. Start the engine and keep it idling until en-

gine oil starts to seep from the oil check
bolt. If no engine oil comes out after one
minute, turn the engine off so that it will not ECA13470

seize. NOTICE
c. Check the engine oil passages and the oil • Adding water instead of coolant lowers the
pump for damage or leakage. Refer to “OIL antifreeze content of the coolant. If water is
PUMP” on page 5-49. used instead of coolant check, and if nec-
d. Start the engine after solving the prob- essary, correct the antifreeze concentra-
lem(s) and check the engine oil pressure tion of the coolant.
again. • Use only distilled water. However, if dis-
e. Tighten the oil check bolt to specification. tilled water is not available, soft water may
be used.
Engine oil check bolt
7 N·m (0.7 kgf·m, 5.2 lb·ft) 3. Start the engine, warm it up for several min-
T.

utes, and then turn it off.

R.

4. Check:
14.Reset: • Coolant level
• Oil change indicator
TIP
Refer to “MULTI-FUNCTION METER UNIT”
on page 1-2. Before checking the coolant level, wait a few
minutes until the coolant has settled.

3-20
 PERIODIC MAINTENANCE

EAS30812
3. Remove:
CHECKING THE COOLING SYSTEM
• Coolant reservoir cap “2”
1. Remove:
• Coolant reservoir “1”
• Radiator cover
Refer to “RADIATOR” on page 6-2.
2. Check:
• Radiator “1” 1
• Coolant reservoir hose “2”
• Radiator inlet hose “3” 2
• Radiator outlet hose “4”
• Thermostat assembly “5”
• Water pump inlet hose “6”
Cracks/tears → Replace.
Refer to “RADIATOR” on page 6-2 and 4. Drain:
“THERMOSTAT” on page 6-6. • Coolant
(from the coolant reservoir)
5. Remove:
3 2
5 • Radiator cover “1”

4 6

3. Install:
• Radiator cover 1
Refer to “RADIATOR” on page 6-2.
EAS30813

CHANGING THE COOLANT

1. Remove:
• Front side cover (right)
Refer to “GENERAL CHASSIS (2)” on
page 4-3.
• Bottom cover
• Footrest board assembly (right)
Refer to “GENERAL CHASSIS (5)” on
page 4-12.
2. Disconnect:
• Coolant reservoir hose “1”
• Coolant reservoir breather hose “2”

2
1

3-21
 PERIODIC MAINTENANCE

6. Remove: 8. Drain:
• Radiator cap “1” • Coolant
(from the engine and radiator)
1 9. Install:
• Coolant drain bolt (cylinder side)
(along with the copper washer New )
• Coolant drain bolt (radiator side)
(along with the O-ring New )

Coolant drain bolt (cylinder side)

10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.
R.
EWA13030 Coolant drain bolt (radiator side)
WARNING 1.0 N·m (0.10 kgf·m, 0.73 lb·ft)
A hot radiator is under pressure. Therefore,
10.Connect:
do not remove the radiator cap when the en-
• Coolant reservoir breather hose
gine is hot. Scalding hot fluid and steam may
• Coolant reservoir hose
be blown out, which could cause serious in-
11.Fill:
jury. When the engine has cooled, open the
• Cooling system
radiator cap as follows:
(with the specified amount of the recom-
Place a thick rag or a towel over the radiator
mended coolant)
cap and slowly turn the radiator cap counter-
clockwise toward the detent to allow any re-
Recommended antifreeze
sidual pressure to escape. When the hissing High-quality ethylene glycol an-
sound has stopped, press down on the radi- tifreeze containing corrosion
ator cap and turn it counterclockwise to re- inhibitors for aluminum en-
move. gines
Mixing ratio
7. Remove:
1:1 (antifreeze: water)
• Coolant drain bolt (radiator side) “1”
Radiator (including all routes)
(along with the O-ring) 0.46 L (0.49 US qt, 0.40 Imp.qt)
• Coolant drain bolt (cylinder side) “2” Coolant reservoir (up to the
(along with the copper washer) maximum level mark)
0.13 L (0.14 US qt, 0.11 Imp.qt)

TIP
• Fill the coolant into the radiator, and then re-
move the air bleed bolt “1” until coolant comes
out.
• Tighten the air bleed bolt to specification.

1 Air bleed bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

1
2

3-22
 PERIODIC MAINTENANCE

Handling notes for coolant 14.Install:

Coolant is potentially harmful and should be • Coolant reservoir cap “1”
handled with special care. TIP
EWA13040
Point the tab “a” on the coolant reservoir cap for-
WARNING
ward.
• If coolant splashes in your eyes, thorough-
ly wash them with water and consult a doc-
tor.
• If coolant splashes on your clothes, quickly
wash it away with water and then with soap
and water. 1
• If coolant is swallowed, induce vomiting
and get immediate medical attention.
ECA13481

NOTICE a
• Adding water instead of coolant lowers the
15.Start the engine, warm it up for several min-
antifreeze content of the coolant. If water is
utes, and then turn it off.
used instead of coolant, check, and if nec-
16.Check:
essary, correct the antifreeze concentra-
• Coolant level
tion of the coolant.
Refer to “CHECKING THE COOLANT LEV-
• Use only distilled water. However, if dis-
EL” on page 3-20.
tilled water is not available, soft water may
TIP
be used.
• If coolant comes into contact with painted Before checking the coolant level, wait a few
surfaces, immediately wash them with wa- minutes until the coolant has settled.
ter. 17.Install:
• Do not mix different types of antifreeze. • Radiator cover
12.Install:
• Radiator cap Radiator cover bolt
• Coolant reservoir 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

18.Install:
Coolant reservoir bolt • Footrest board assembly (right)
11 N·m (1.1 kgf·m, 8.1 lb·ft)
Refer to “GENERAL CHASSIS (5)” on
T.
R.

13.Fill: page 4-12.

• Coolant reservoir • Front side cover (right)
(with the recommended coolant to the maxi- Refer to “GENERAL CHASSIS (2)” on
mum level mark “a”) page 4-3.

3-23
 PERIODIC MAINTENANCE

EAS31187
6. Fill:
CHANGING THE FINAL TRANSMISSION OIL
• Final transmission oil
1. Stand the vehicle on a level surface.
(with the specified amount of the recom-
TIP mended final transmission oil)
• Place the vehicle on the centerstand.
• Make sure the vehicle is upright. Final transmission oil
2. Start the engine, warm it up for several min- Type
Motor oil SAE 10W-40 type SG
utes, and then turn it off.
or higher
3. Place a container under the final transmis-
Quantity
sion. 0.10 L (0.11 US qt, 0.09 Imp.qt)
4. Remove:
• Final transmission oil filler cap “1” 7. Install:
(along with the O-ring “2”) • Final transmission oil filler cap
• Final transmission oil drain bolt “3” (along with the O-ring New )
(along with the copper washer “4”)
TIP
Completely drain the final transmission oil.
Lubricate the O-ring with lithium-soap-based
grease.
1
8. Start the engine, warm it up for several min-
utes, and then turn it off.
9. Check:
2 • Final transmission oil leakage
EAS31188

REPLACING THE V-BELT

1. Remove:
• Air filter case
Refer to “AIR FILTER CASE” on page 7-8.
• V-belt case
Refer to “V-BELT AUTOMATIC TRANSMIS-
SION” on page 5-37.
4 3 2. Check:
• V-belt
Damage/wear → Replace.
Grease/oil → Clean the primary and second-
ary pulleys.
5. Install: Refer to “V-BELT AUTOMATIC TRANSMIS-
• Final transmission oil drain bolt SION” on page 5-37.
(along with the copper washer New ) TIP
Replace the V-belt every 25000 km (15500 mi)
Final transmission oil drain bolt of operation.
20 N·m (2.0 kgf·m, 15 lb·ft)
T.

3. Install:
R.

• V-belt case
Refer to “V-BELT AUTOMATIC TRANSMIS-
SION” on page 5-37.
• Air filter case
Refer to “AIR FILTER CASE” on page 7-8.

3-24
 PERIODIC MAINTENANCE

EAS30658 EAS30861

CHECKING THE BRAKE LIGHT SWITCHES CHECKING THE THROTTLE GRIP

1. Check: OPERATION
• Front brake light switch operation 1. Check:
• Rear brake light switch operation • Throttle cable
When operating the brake levers, confirm Damage/deterioration → Replace.
that the brake light comes on. • Throttle cable installation
Faulty → Refer to “CHECKING THE Incorrect → Reinstall the throttle cables.
SWITCHES” on page 8-35. Refer to “HANDLEBAR” on page 4-67.
2. Check:
EAS31147

CHECKING AND LUBRICATING THE • Throttle grip movement

CABLES Rough movement → Lubricate or replace the
The following procedures are applied to all of the defective part(s).
inner and outer cables.
EWA13270 Recommended lubricant
WARNING Suitable cable lubricant
Damaged outer cable may cause the cable to
corrode and interfere with its movement. Re- TIP
place damaged outer cable and inner cables With the engine stopped, turn the throttle grip
as soon as possible. slowly and release it. Make sure that the throttle
grip turns smoothly and returns properly when
1. Check: released.
• Outer cable Repeat this check with the handlebar turned all
Damage → Replace. the way to the left and right.
2. Check:
• Cable operation 3. Check:
Rough movement → Lubricate. • Throttle grip free play “a”
Out of specification → Adjust.
Recommended lubricant
Engine oil or a suitable cable lu- Throttle grip free play
bricant 3.0–5.0 mm (0.12–0.20 in)

TIP
Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suit-
able lubricating device.

3-25
 PERIODIC MAINTENANCE

4. Adjust: EAS30663

CHECKING THE SWITCHES, LIGHTS AND

• Throttle grip free play
SIGNALS
a. Slide back the rubber cover “1”. 1. Check that all switches operate and that all
b. Loosen the locknut “2”. lights come on.
c. Turn the adjusting nut “3” until the specified Refer to “Instrument and control functions” in
throttle grip free play is obtained. OWNER’S MANUAL.
Faulty → Refer to “CHECKING THE
SWITCHES” on page 8-35.
EAS30664

ADJUSTING THE HEADLIGHT BEAM

1. Adjust:
• Headlight beam (vertically)
1 Turn the adjusting bolts “1” in direction left or
3 right.
2
• Headlight beam (horizontally)
d. Tighten the locknut. Turn the adjusting bolts “2” in direction left or
right.
Throttle cable adjusting locknut
3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
T.
R.

e. Slide the rubber cover to its original posi-

tion.
TIP
Make sure that the adjusting nut is covered com-
pletely by the rubber cover.
EWA17990
1 2
WARNING
After adjusting the throttle grip free play,
start the engine and turn the handlebars to
the right and to the left to ensure that this
does not cause the engine idling speed to
change.

3-26
 CHASSIS

GENERAL CHASSIS (1) ................................................................................. 4-1

REMOVING THE BATTERY COVER .......................................................4-2

GENERAL CHASSIS (2) ................................................................................. 4-3

REMOVING THE TAIL/BRAKE LIGHT OUTER COVER .......................... 4-4
INSTALLING THE TAIL/BRAKE LIGHT OUTER COVER.........................4-4
REMOVING THE FRONT SIDE COVER .................................................. 4-5
INSTALLING THE FRONT SIDE COVER................................................. 4-5

GENERAL CHASSIS (3) ................................................................................. 4-6

REMOVING THE FUEL TANK COVER .................................................... 4-7
INSTALLING THE FUEL TANK COVER................................................... 4-7
REMOVING THE FUEL TANK CAP LID COVER ..................................... 4-8
INSTALLING THE FUEL TANK CAP LID COVER....................................4-8

GENERAL CHASSIS (4) ................................................................................. 4-9

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

GENERAL CHASSIS (6) ............................................................................... 4-15

REMOVING THE FRONT UPPER PANEL ............................................. 4-16
INSTALLING THE FRONT UPPER PANEL............................................4-16
REMOVING THE FRONT COWLING ASSEMBLY.................................4-17
INSTALLING THE FRONT COWLING ASSEMBLY ...............................4-17
REMOVING THE FRONT SIDE COWLING............................................4-18
INSTALLING THE FRONT SIDE COWLING ..........................................4-18

GENERAL CHASSIS (7) ............................................................................... 4-19

REMOVING THE UPPER CENTER COVER..........................................4-21
INSTALLING THE UPPER CENTER COVER ........................................ 4-21

FRONT WHEEL............................................................................................. 4-22

REMOVING THE FRONT WHEEL.......................................................... 4-24
DISASSEMBLING THE FRONT WHEEL................................................ 4-24
CHECKING THE FRONT WHEEL .......................................................... 4-25
MAINTENANCE OF THE FRONT WHEEL SENSOR
AND SENSOR ROTOR ..........................................................................4-25
ASSEMBLING THE FRONT WHEEL......................................................4-26
ADJUSTING THE FRONT WHEEL STATIC BALANCE ......................... 4-26
INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC).................. 4-27
REAR WHEEL ...............................................................................................4-29
REMOVING THE REAR WHEEL (DISC) ................................................ 4-30
CHECKING THE REAR WHEEL............................................................. 4-30
MAINTENANCE OF THE REAR WHEEL SENSOR ROTOR ................. 4-30
ADJUSTING THE REAR WHEEL STATIC BALANCE............................ 4-30
INSTALLING THE REAR WHEEL (REAR BRAKE DISC) ......................4-31

FRONT BRAKE ............................................................................................. 4-32

INTRODUCTION .....................................................................................4-38
CHECKING THE FRONT BRAKE DISC ................................................. 4-38
REPLACING THE FRONT BRAKE PADS .............................................. 4-39
REMOVING THE FRONT BRAKE CALIPER..........................................4-41
DISASSEMBLING THE FRONT BRAKE CALIPER ................................4-41
CHECKING THE FRONT BRAKE CALIPER ..........................................4-42
ASSEMBLING THE FRONT BRAKE CALIPER ...................................... 4-42
INSTALLING THE FRONT BRAKE CALIPER ........................................ 4-42
REMOVING THE FRONT BRAKE MASTER CYLINDER .......................4-43
CHECKING THE FRONT BRAKE MASTER CYLINDER........................ 4-44
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ................... 4-44
INSTALLING THE FRONT BRAKE MASTER CYLINDER......................4-44

REAR BRAKE ...............................................................................................4-46

INTRODUCTION .....................................................................................4-51
CHECKING THE REAR BRAKE DISC....................................................4-51
REPLACING THE REAR BRAKE PADS................................................. 4-52
REMOVING THE REAR BRAKE CALIPER ............................................4-53
DISASSEMBLING THE REAR BRAKE CALIPER ..................................4-53
CHECKING THE REAR BRAKE CALIPER............................................. 4-54
ASSEMBLING THE REAR BRAKE CALIPER ........................................ 4-54
INSTALLING THE REAR BRAKE CALIPER...........................................4-54
REMOVING THE REAR BRAKE MASTER CYLINDER ......................... 4-55
CHECKING THE REAR BRAKE MASTER CYLINDER .......................... 4-56
ASSEMBLING THE REAR BRAKE MASTER CYLINDER......................4-56
INSTALLING THE REAR BRAKE MASTER CYLINDER ........................ 4-56

ABS (Anti-lock Brake System) .................................................................... 4-58

REMOVING THE HYDRAULIC UNIT ASSEMBLY .................................4-60
CHECKING THE HYDRAULIC UNIT ASSEMBLY..................................4-60
INSTALLING THE HYDRAULIC UNIT ASSEMBLY................................4-61
HYDRAULIC UNIT OPERATION TESTS................................................ 4-62
CHECKING THE ABS WARNING LIGHT ............................................... 4-66

HANDLEBAR ................................................................................................4-67
REMOVING THE UPPER HANDLEBAR COVER ASSEMBLY .............. 4-70
DISASSEMBLING THE UPPER HANDLEBAR COVER ASSEMBLY .... 4-70
REMOVING THE HANDLEBAR..............................................................4-70
CHECKING THE HANDLEBAR ..............................................................4-70
INSTALLING THE HANDLEBAR ............................................................ 4-71
ASSEMBLING THE UPPER HANDLEBAR COVER ASSEMBLY ..........4-72
INSTALLING THE UPPER HANDLEBAR COVER ASSEMBLY............. 4-73
FRONT FORK................................................................................................4-74
REMOVING THE FRONT FORK LEGS.................................................. 4-76
DISASSEMBLING THE FRONT FORK LEGS ........................................ 4-76
CHECKING THE FRONT FORK LEGS .................................................. 4-77
ASSEMBLING THE FRONT FORK LEGS .............................................. 4-77
INSTALLING THE FRONT FORK LEGS ................................................ 4-80

STEERING HEAD.......................................................................................... 4-81

REMOVING THE LOWER BRACKET.....................................................4-83
CHECKING THE STEERING HEAD .......................................................4-83
INSTALLING THE STEERING HEAD .....................................................4-84

REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM................... 4-85

REMOVING THE SWINGARM................................................................4-87
MAINTENANCE OF THE REAR WHEEL SENSOR ...............................4-87
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 4-87
CHECKING THE SWINGARM ................................................................4-88
INSTALLING THE SWINGARM ..............................................................4-88
 GENERAL CHASSIS (1)

EAS20026

GENERAL CHASSIS (1)

Removing the battery

3 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

2 1

6
5

Order Job/Parts to remove Q’ty Remarks

Seat Open.
1 Battery cover 1
2 Negative battery lead 1 Disconnect.
3 Positive battery lead 1 Disconnect.
4 Battery 1
5 CCU (Communication Control Unit) 1
6 Smart key unit 1

4-1
 GENERAL CHASSIS (1)

EAS31677

REMOVING THE BATTERY COVER

1. Remove:
• Battery cover “1”

a. Open the seat.

b. Remove the battery cover screws.
c. Slide the battery cover “1” rearward to re-
move from the storage box.

4-2
 GENERAL CHASSIS (2)

EAS20155

GENERAL CHASSIS (2)

Removing the grab bar and front side covers
17 N•m (1.7 kgf•m, 13 lb•ft) 17 N•m (1.7 kgf•m, 13 lb•ft)

T.R
.
T.R
.
T.R
. 1.8 N•m (0.18 kgf•m, 1.3 lb•ft) 1

1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.

1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

1 Grab bar 1
2 Tail/brake light upper cover 1
3 Front side cover (left) 1
4 Front side cover (right) 1

4-3
 GENERAL CHASSIS (2)

EAS31681 EAS31682

REMOVING THE TAIL/BRAKE LIGHT OUTER INSTALLING THE TAIL/BRAKE LIGHT

COVER OUTER COVER
1. Remove: 1. Install:
• Tail/brake light outer cover “1” • Tail/brake light outer cover “1”

1 1

a. Remove the tail/brake light outer cover a. Slide the tail/brake light outer cover for-
screws. ward, fit the projection “a” on the cover into
b. Slide the tail/brake light outer cover rear- the hole “b” in the tail/brake light.
ward to remove the projection “a” on the
cover from the hole “b” in the tail/brake light. a 1

a 1

a
b

b b. Install the tail/brake light outer cover

screws, and then tighten the screws to
specification.

Tail/brake light outer cover screw

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.

4-4
 GENERAL CHASSIS (2)

EAS31683 EAS31684

REMOVING THE FRONT SIDE COVER INSTALLING THE FRONT SIDE COVER
The following procedures are applied to both of The following procedures are applied to both of
the front side covers. the front side covers.
1. Remove: 1. Install:
• Front side cover “1” • Front side cover “1”

1 1

a. Remove the front side cover screws. a. Fit the projections “a” on the front side cover
b. Pull the front side cover outward to remove into the grommets “b”.
the projections “a” from the grommets “b”.

b a
b a
1
1
b a
b a
b. Install the front side cover screws, and then
tighten the screw to specification.

Front side cover screw

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.

4-5
 GENERAL CHASSIS (3)

EAS20156

GENERAL CHASSIS (3)

Removing the fuel tank cover and seat assembly

3
4 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

T.R
.
7 N·m (0.7 kgf·m, 5.2 lb·ft)

T.R
.
1

2
6
8

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (2)” on
Front side cover page 4-3.
1 Fuel tank cover 1
2 Fuel tank cap lid lock cable 1 Disconnect.
3 Fuel tank cap lid cover 1
4 Fuel tank cap lid 1
5 Center cover 1
6 Seat assembly 1
7 Owner’s tool kit 1
8 Seat 1

4-6
 GENERAL CHASSIS (3)

EAS31685 EAS31686

REMOVING THE FUEL TANK COVER INSTALLING THE FUEL TANK COVER
1. Remove: 1. Install:
• Fuel tank cover “1” • Fuel tank cover “1”

1 1

a. Remove the fuel tank cover screws. a. Slide the fuel tank cover forward and fit the
b. Slide the fuel tank cover rearward to re- projections “a” on the cover into the holes
move the projections “a” on the cover from “b” in the leg shield.
the holes “b” in the leg shield. b. Install the fuel tank cover screws, and then
tighten the screws to specification.

Fuel tank cover screw

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.

b a

b a

4-7
 GENERAL CHASSIS (3)

EAS32349 EAS32350

REMOVING THE FUEL TANK CAP LID INSTALLING THE FUEL TANK CAP LID
COVER COVER
1. Remove: 1. Install:
• Fuel tank cap lid cover “1” • Fuel tank cap lid cover “1”

1 1

a. Remove the screw. a. Fit the projections “a” on the fuel tank cap
b. Remove the projections “a” on the fuel tank lid cover into the holes “b” in the fuel tank
cap lid cover from the holes “b” in the fuel cap lid.
tank cap lid.
a
a b
b 1
1

b. Install the fuel tank cap lid cover screw, and

then tighten the screw to specification.

Fuel tank cap lid cover screw

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.

4-8
 GENERAL CHASSIS (4)

EAS20157

GENERAL CHASSIS (4)

Removing the rear side covers and storage box
9 N·m (0.9 kgf·m, 6.6 lb·ft)

T.R
.
10
11

13
3.8 N·m (0.38 kgf·m, 2.8 lb·ft)

T.R
.
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

T.R
.
5 9

12
6

8
4
3
1
2

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (1)” on
Battery page 4-1.
Refer to “GENERAL CHASSIS (2)” on
Front side cover page 4-3.
Refer to “GENERAL CHASSIS (3)” on
Fuel tank cover page 4-6.
1 Rear side cover assembly (left) 1
2 Center side cover (left) 1
3 Rear side cover (left) 1
4 Rear side cover assembly (right) 1
5 Center side cover (right) 1
6 Rear side cover (right) 1
7 Brake light coupler 1 Disconnect.
8 Taillight/rear turn signal coupler 1 Disconnect.
9 Tail/brake light lower cover 1

4-9
 GENERAL CHASSIS (4)

Removing the rear side covers and storage box

9 N·m (0.9 kgf·m, 6.6 lb·ft)

T.R
.
10
11

13
3.8 N·m (0.38 kgf·m, 2.8 lb·ft)

T.R
.
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

T.R
.
5 9

12
6

8
4
3
1
2

Order Job/Parts to remove Q’ty Remarks

10 Tail/brake light assembly 1
11 Storage box 1
12 Flap 1
13 Seat hinge 1

4-10
 GENERAL CHASSIS (4)

EAS31687 EAS31688

REMOVING THE REAR SIDE COVER INSTALLING THE REAR SIDE COVER
ASSEMBLY ASSEMBLY
The following procedures are applied to both of The following procedures are applied to both of
the rear side cover assembly. the rear side cover assembly.
1. Remove: 1. Install:
• Rear side cover assembly “1” • Rear side cover assembly “1”

1 1

a. Remove the quick fasteners, screw and a. Fit the projections “a” on the rear side cover
bolt. assembly into the holes “b” in the storage
b. Remove the projections “a” on the rear side box.
cover assembly from the holes “b” in the
storage box. 1
b
1
b

a
b. Install the quick fasteners, screw, and bolt,
and then tighten the screw and bolts to
specification.

4-11
 GENERAL CHASSIS (5)

EAS20158

GENERAL CHASSIS (5)

Removing the bottom cover, center lower cover and footrest board
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.R
.

3.8 N·m (0.38 kgf·m, 2.8 lb·ft) 32 N·m (3.2 kgf·m, 24 lb·ft)

T.R
T.R

.
.
7 N·m (0.7 kgf·m, 5.2 lb·ft)

T.R
.
4
11

9
12 2
LS

13
14
10 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.R
.

3.8 N·m (0.38 kgf·m, 2.8 lb·ft)

T.R
.

LS
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.R
.

2
5 6
8
1

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

T.R
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (1)” on
Battery page 4-1.
Refer to “GENERAL CHASSIS (2)” on
Front side cover page 4-3.
Refer to “GENERAL CHASSIS (3)” on
Seat assembly page 4-6.
Refer to “GENERAL CHASSIS (4)” on
Storage box page 4-9.
1 Bottom cover 1
2 Clamp 3
3 Footrest board mat (left) 2
4 Footrest board mat (right) 2
5 Center lower cover 1
6 Footrest board assembly (left) 1
7 Front lower cover (left) 1
8 Footrest board (left) 1

4-12
 GENERAL CHASSIS (5)

Removing the bottom cover, center lower cover and footrest board
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.R
.

3.8 N·m (0.38 kgf·m, 2.8 lb·ft) 32 N·m (3.2 kgf·m, 24 lb·ft)

T.R
T.R

.
.
7 N·m (0.7 kgf·m, 5.2 lb·ft)

T.R
.
4
11

9
12 2
LS

13
14
10 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.R
.

3.8 N·m (0.38 kgf·m, 2.8 lb·ft)

T.R
.

LS
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.R
.

2
5 6
8
1

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

T.R
.

Order Job/Parts to remove Q’ty Remarks

9 Footrest board assembly (right) 1
10 Front lower cover (right) 1
11 Coolant reservoir cap cover 1
12 Footrest board (right) 1
13 Sidestand spring 1
14 Sidestand 1

4-13
 GENERAL CHASSIS (5)

EAS31689

INSTALLING THE CENTER LOWER COVER

1. Install: a
• Center lower cover “1”
b

1
1
EAS31691

INSTALLING THE BOTTOM COVER

1. Install:
• Bottom cover “1”
TIP
Fit the end of the fuel tank overflow hose “2” into
the hole “a” in the center lower cover.

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

a b

Footrest board assembly bolt

3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
T.
R.

TIP
Make sure that the projection “a” on the frame
fits into the hole “b” in the footrest board assem-
bly.

4-14
 GENERAL CHASSIS (6)

EAS20159

GENERAL CHASSIS (6)

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

T.R
.

.
1

3
0.4 N·m (0.04 kgf·m, 0.30 lb·ft)
T.R
.

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

T.R
.

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

T.R
.

8 4
6 11
14 4 5
7 16
13 4
4
12
(6)
10

9
15
1.8 N·m (0.18 kgf·m, 1.3 lb·ft) 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.R

T.R
.

Order Job/Parts to remove Q’ty Remarks

1 Windshield 1
2 Front upper cowling 1
3 Front upper panel 1
4 Clamp 3
5 Headlight unit coupler 1 Disconnect.
6 Front turn signal light coupler (left) 1 Disconnect.
7 Front turn signal light coupler (right) 1 Disconnect.
8 Front cowling assembly 1
9 Front turn signal light (left) 1
10 Front turn signal light (right) 1
11 Front side cowling (left) 1
12 Front side panel (left) 1
13 Front side cowling (right) 1
14 Front side panel (right) 1
15 Front lower cowling 1
16 Headlight unit 1

4-15
 GENERAL CHASSIS (6)

EAS31197 EAS31198

REMOVING THE FRONT UPPER PANEL INSTALLING THE FRONT UPPER PANEL
1. Remove: 1. Install:
• Front upper panel “1” • Front upper panel “1”

1 1

a. Remove the front upper panel screw. a. Fit the projections “a” on the front upper
b. Remove the projections “a” on the front up- panel into the holes “b” in the headlight unit
per panel from the holes “b” in the leg shield and fit the projections “c” into the holes “d”
and remove the projections “c” from the in the leg shield.
holes “d” in the headlight unit.
1
1 a
a

d
d c c
c c b
b
b. Install the front upper panel screw, and then
tighten the screw to specification.

Front upper cowling assembly

screw
T.
R.

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

4-16
 GENERAL CHASSIS (6)

EAS31278 EAS31279

REMOVING THE FRONT COWLING INSTALLING THE FRONT COWLING

ASSEMBLY ASSEMBLY
1. Remove: 1. Install:
• Front cowling assembly “1” • Front cowling assembly “1”

1 1

a. Remove the front cowling assembly a. Fit the projections “a” on the leg shield into
screws. the holes “b” in the front cowling assembly.
b. Pull the front cowling assembly forward to
remove the projections “a” on the leg shield a a
from the holes “b” in the front cowling as- b
sembly. b
a a
b
b
1
b. Install the front cowling assembly screws,
and then tighten the screws to specification.
1 Front cowling assembly screw
(M5 × 15)
T.
R.

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

Front cowling assembly screw
(M5 × 11)
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

4-17
 GENERAL CHASSIS (6)

EAS31696 EAS31697

REMOVING THE FRONT SIDE COWLING INSTALLING THE FRONT SIDE COWLING
The following procedures are applied to both of The following procedures are applied to both of
the front side cowling. the front side cowling.
1. Remove: 1. Install:
• Front side cowling “1” • Front side cowling “1”

1 1

a. Removing the front side cowling screws. a. Fit the projections “a” on the front side cowl-
b. Remove the projections “a” on the front side ing into the holes “b” in the front lower cowl-
cowling from the holes “b” in the front lower ing.
cowling.

a
a
a
a
1 b
1 b
b
b
b. Install the front side cowling screws, and
then tighten the screws to specification.

Front side cowling screw

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.

4-18
 GENERAL CHASSIS (7)

EAS20193

GENERAL CHASSIS (7)

Removing the meter assembly

7 N·m (0.7 kgf·m, 5.2 lb·ft)

7 N·m (0.7 kgf·m, 5.2 lb·ft)

T.R
.
T.R
.

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

11
T.R
.

7
6

2
9
12
3 4
8 10

5 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

T.R
.

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (1)” on
Battery page 4-1.
Refer to “GENERAL CHASSIS (2)” on
Front side cover page 4-3.
Refer to “GENERAL CHASSIS (3)” on
Seat assembly page 4-6.
Refer to “GENERAL CHASSIS (4)” on
Storage box page 4-9.
Refer to “GENERAL CHASSIS (5)” on
Center lower cover page 4-12.
Refer to “GENERAL CHASSIS (6)” on
Front cowling assembly
page 4-15.
1 Upper center cover 1
2 Meter panel assembly 1
3 Meter assembly coupler 1 Disconnect.
4 Clamp 1
5 Buzzer coupler 1 Disconnect.
6 Meter assembly 1
7 Meter assembly inner panel 1

4-19
 GENERAL CHASSIS (7)

Removing the meter assembly

7 N·m (0.7 kgf·m, 5.2 lb·ft)

7 N·m (0.7 kgf·m, 5.2 lb·ft)

T.R
.
T.R
.

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

11
T.R
.

7
6

2
9
12
3 4
8 10

5 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

T.R
.

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

8 Meter assembly panel 1
9 Auxiliary DC jack coupler 1 Disconnect.
10 Auxiliary DC jack 1
11 Leg shield assembly 1
12 Clamp 2

4-20
 GENERAL CHASSIS (7)

EAS32329 EAS32330

REMOVING THE UPPER CENTER COVER INSTALLING THE UPPER CENTER COVER
1. Remove: 1. Install:
• Upper center cover “1” • Upper center cover “1”

1 1

a. Remove the quick fasteners. a. Fit the projections “a” on the upper center
b. Pull the upper center cover outward to re- cover into the holes “b” in the leg shield.
move the projections “a” on the cover from
the holes “b” in the leg shield.

b a
1
b a
1 b. Install the quick fasteners.

4-21
 FRONT WHEEL

EAS20028

FRONT WHEEL
Removing the front wheel and brake disc
26 N·m (2.6 kgf·m, 19 lb·ft)

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

LS

2 7
6
1

3 5 9
LS LT

7 N·m (0.7 kgf·m, 5.2 lb·ft)

New
T.R
.

New LT

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

T.R
.

Order Job/Parts to remove Q’ty Remarks

1 Front brake hose guide 1
2 Front brake caliper 1
3 Front wheel sensor 1
4 Front wheel axle nut 1
5 Front wheel axle 1
6 Collar 2
7 Front wheel 1
8 Front wheel sensor rotor 1
9 Front brake disc 1

4-22
 FRONT WHEEL

Disassembling the front wheel

New 1
New 2

LS

3
New 2
New 1

LS

Order Job/Parts to remove Q’ty Remarks

1 Oil seal 2
2 Wheel bearing 2
3 Spacer 1

4-23
 FRONT WHEEL

EAS30145 EAS30146

REMOVING THE FRONT WHEEL DISASSEMBLING THE FRONT WHEEL

ECA22340
1. Remove:
NOTICE • Oil seal
• Keep any type of magnets (including mag- • Wheel bearing
netic pick-up tools, magnetic screwdrivers,
a. Clean the surface of the front wheel hub.
etc.) away from the speed sensor or speed
b. Remove the oil seals “1” with a flat-head
sensor rotor; otherwise, the sensor or rotor
screwdriver.
may be damaged, resulting in improper op-
TIP
eration.
• Do not drop the speed sensor rotor or sub- To prevent damaging the wheel, place a rag “2”
ject it to shocks. between the screwdriver and the wheel surface.
• If any solvent gets on the speed sensor ro-
tor, wipe it off immediately.
1. Stand the vehicle on a level surface.
EWA13120

WARNING
Securely support the vehicle so that there is
2
no danger of it falling over.
2. Remove: 1
• Front brake caliper
ECA21830
c. Remove the wheel bearings “3” with a gen-
NOTICE
eral bearing puller.
Do not apply the brake lever when removing
the brake caliper.
3. Lift up:
• Front wheel
TIP 3
Place the vehicle on a suitable stand so that the
front wheel is elevated.

4-24
 FRONT WHEEL

EAS30147
4. Check:
CHECKING THE FRONT WHEEL
• Wheel bearing
1. Check:
Front wheel turns roughly or is loose → Re-
• Wheel axle
place the wheel bearings.
Roll the wheel axle on a flat surface.
• Oil seal
Bends → Replace.
EWA13460
Damage/wear → Replace.
WARNING
Do not attempt to straighten a bent wheel ax-
le.

EAS30155

MAINTENANCE OF THE FRONT WHEEL

SENSOR AND SENSOR ROTOR
ECA21630

2. Check: NOTICE
• Tire • The speed sensor cannot be disassembled.
• Front wheel Do not attempt to disassemble it. If faulty,
Damage/wear → Replace. replace with a new one.
Refer to “CHECKING THE TIRES” on • Keep magnets (including magnetic pick-up
page 3-14 and “CHECKING THE WHEELS” tools, magnetic screwdrivers, etc.) away
on page 3-14. from the speed sensor.
3. Measure: • Do not drop or shock the speed sensor or
• Radial wheel runout “1” the speed sensor rotor.
• Lateral wheel runout “2”
Over the specified limits → Replace. 1. Check:
• Front wheel sensor “1”
Radial wheel runout limit Cracks/bends/distortion → Replace.
1.0 mm (0.04 in) Iron powder/dust → Clean.
Lateral wheel runout limit
1.0 mm (0.04 in)

2
1

4-25
 FRONT WHEEL

2. Check: c. Install the new wheel bearing (left side).

• Front wheel sensor rotor “1” TIP
Cracks/damage/scratches → Replace the Place a suitable washer “1” between the socket
front wheel sensor rotor. “2” and the bearing so that both the inner race
Iron powder/dust/solvent → Clean. “3” and outer race “4” are pressed at the same
TIP time, and then press the bearing until the inner
When cleaning the wheel sensor rotor, be care- race makes contact with the spacer “5”.
ful not to damage the surface of the sensor rotor.

EAS30152

EAS30151 ADJUSTING THE FRONT WHEEL STATIC

ASSEMBLING THE FRONT WHEEL BALANCE
1. Lubricate: TIP
• Oil seal lips
• After replacing the tire, wheel or both, the front
wheel static balance should be adjusted.
Recommended lubricant
• Adjust the front wheel static balance with the
Lithium-soap-based grease
brake disc installed.
2. Install: 1. Remove:
• Wheel bearing New • Balancing weight(s)
• Oil seal New 2. Find:
a. Install the new wheel bearing (right side). • Front wheel’s heavy spot
ECA18110 3. Adjust:
NOTICE • Front wheel static balance
Do not contact the wheel bearing inner race 4. Check:
“1” or balls “2”. Contact should be made • Front wheel static balance
only with the outer race “3”.

TIP
Use a socket “4” that matches the diameter of
the wheel bearing outer race.

b. Install the spacer.

4-26
 FRONT WHEEL

EAS30932
3. Lubricate:
INSTALLING THE FRONT WHEEL (FRONT
• Wheel axle
BRAKE DISC)
1. Install:
Recommended lubricant
• Front brake disc “1” Lithium-soap-based grease
• Front wheel sensor rotor “2”
4. Install:
Front wheel sensor rotor bolt • Front wheel
8 N·m (0.8 kgf·m, 5.9 lb·ft) • Collar
T.
R.

LOCTITE® • Front wheel axle

Front brake disc bolt TIP
23 N·m (2.3 kgf·m, 17 lb·ft)
LOCTITE® Install the front wheel with the mark “a” on the
front tire pointing in the direction of wheel rota-
ECA21011
tion.
NOTICE
• Do not drop the wheel sensor rotor or sub-
ject it to shocks.
• If any solvent gets on the wheel sensor ro- a
tor, wipe it off immediately.
• Replace the brake disc bolts and wheel
sensor rotor bolts with new ones.

TIP
• Install the brake disc with its chamfered side
“a” facing inward.
• Install the front wheel sensor rotor with the 5. Tighten:
stamped mark “b” facing away from the wheel. • Front wheel axle nut
• Tighten the bolts in stages.
Front wheel axle nut
26 N·m (2.6 kgf·m, 19 lb·ft)
T.
R.

1
1 ECA14140

NOTICE
Before tightening the wheel axle nut, push
down hard on the handlebar(s) several times
and check if the front fork rebounds smooth-
a ly.
6. Install:
• Front wheel sensor

b Front wheel sensor bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.

ECA21020

NOTICE
Make sure there are no foreign materials in
2 the front wheel sensor rotor and front wheel
sensor. Foreign materials cause damage to
the front wheel sensor rotor and front wheel
sensor.
2. Check:
• Front brake disc
Refer to “CHECKING THE FRONT BRAKE
DISC” on page 4-38.

4-27
 FRONT WHEEL

TIP 8. Install:
• When installing the front wheel sensor, check • Front brake caliper
the front wheel sensor lead for twists. • Front brake hose guide “1”
• To route the front wheel sensor lead, refer to
“CABLE ROUTING” on page 2-15. Front brake caliper bolt
35 N·m (3.5 kgf·m, 26 lb·ft)

T.
R.
7. Measure: Front brake hose guide bolt
• Distance “a” 7 N·m (0.7 kgf·m, 5.2 lb·ft)
(between the front wheel sensor rotor “1” and EWA13500
front wheel sensor “2”)
WARNING
Out of specification → Check the wheel bear-
Make sure the brake hose is routed properly.
ing for looseness, and the front wheel sensor
and sensor rotor installation conditions TIP
(warpage caused by overtorque, wrong in- While holding the front brake hose guide so that
stallation direction, rotor decentering, LOC- the portions “a” of the guide and holder contact
TITE® on the mounting surface of the rotor, the front fork outer tube, tighten the bolts to
deformation caused by an impact during ser- specification.
vice and caught foreign materials). If there is
any defective part, repair or replace the de- a
fective part.

Distance “a” (between the front 1

wheel sensor rotor and front
wheel sensor)
0.65–1.66 mm (0.026–0.065 in)

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

Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9

a
2

2
1
1

4-28
 REAR WHEEL

EAS20029

REAR WHEEL
Removing the rear wheel and brake disc

8 N•m (0.8 kgf•m, 5.9 lb•ft)

T .R
.
23 N•m (2.3 kgf•m, 17 lb•ft)

T .R
.
LT
LT

LT
New

1 3

LT
2
LT
23 N•m (2.3 kgf•m, 17 lb•ft)
T .R

New
.

8 N•m (0.8 kgf•m, 5.9 lb•ft)

T .R
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (1)” on
Battery page 4-1.
Refer to “GENERAL CHASSIS (2)” on
Front side cover page 4-3.
Refer to “GENERAL CHASSIS (3)” on
Fuel tank cover page 4-6.
Refer to “GENERAL CHASSIS (4)” on
Storage box page 4-9.
Muffler Refer to “ENGINE REMOVAL” on page 5-4.
Radiator cover Refer to “RADIATOR” on page 6-2.
Refer to “REAR SHOCK ABSORBER
Swingarm assembly ASSEMBLIES AND SWINGARM” on
page 4-85.
1 Rear wheel 1
2 Rear wheel sensor rotor 1
3 Rear brake disc 1

4-29
 REAR WHEEL

EAS30156 EAS30167

REMOVING THE REAR WHEEL (DISC) MAINTENANCE OF THE REAR WHEEL

ECA22870
SENSOR ROTOR
NOTICE ECA22890

• Keep any type of magnets (including mag- NOTICE

netic pick-up tools, magnetic screwdrivers, • Handle the ABS components with care
etc.) away from the rear wheel sensor rotor; since they have been accurately adjusted.
otherwise, the rotor may be damaged, re- Keep them away from dirt and do not sub-
sulting in improper performance of the ABS ject them to shocks.
system. • Keep any type of magnets (including mag-
• Do not drop the rear wheel sensor rotor or netic pick-up tools, magnetic screwdrivers,
subject it to shocks. etc.) away from the rear wheel sensor rotor.
• If any solvent gets on the rear wheel sensor • Do not drop or shock the wheel sensor ro-
rotor, wipe it off immediately. tor.
1. Stand the vehicle on a level surface. 1. Check:
EWA13120
• Rear wheel sensor rotor
WARNING Refer to “MAINTENANCE OF THE FRONT
Securely support the vehicle so that there is WHEEL SENSOR AND SENSOR ROTOR”
no danger of it falling over. on page 4-25.
TIP EAS30164

Place the vehicle on the centerstand so that the ADJUSTING THE REAR WHEEL STATIC
rear wheel is off ground. BALANCE
TIP
EAS30159 • After replacing the tire, wheel or both, the rear
CHECKING THE REAR WHEEL wheel static balance should be adjusted.
1. Check: • Adjust the rear wheel static balance with the
• Tire brake disc installed.
• Rear wheel
Damage/wear → Replace. 1. Adjust:
Refer to “CHECKING THE TIRES” on • Rear wheel static balance
page 3-14 and “CHECKING THE WHEELS” Refer to “ADJUSTING THE FRONT WHEEL
on page 3-14. STATIC BALANCE” on page 4-26.
2. Measure:
• Radial wheel runout
• Lateral wheel runout
Refer to “CHECKING THE FRONT WHEEL”
on page 4-25.

Radial wheel runout limit

1.0 mm (0.04 in)
Lateral wheel runout limit
1.0 mm (0.04 in)

4-30
 REAR WHEEL

EAS30911

INSTALLING THE REAR WHEEL (REAR

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

Rear wheel sensor rotor bolt

8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.
R.

LOCTITE®
Rear brake disc bolt
23 N·m (2.3 kgf·m, 17 lb·ft)
LOCTITE®
ECA21011

NOTICE
• Do not drop the wheel sensor rotor or sub-
ject it to shocks.
• If any solvent gets on the wheel sensor ro-
tor, wipe it off immediately.
• Replace the brake disc bolts and wheel
sensor rotor bolts with new ones.

TIP
• Install the brake disc with its chamfered side
“a” facing inward.
• Install the rear wheel sensor rotor with the
stamped mark “b” facing away from the wheel.
• Tighten the bolts in stages.

1 1

b
2

2. Check:
• Rear brake disc
Refer to “CHECKING THE REAR BRAKE
DISC” on page 4-51.

4-31
 FRONT BRAKE

EAS20030

FRONT BRAKE
Removing the front brake pads

6 N·m (0.6 kgf·m, 4.4 lb·ft)

1
3

6
2
4

5 35 N·m (3.5 kgf·m, 26 lb·ft)

Order Job/Parts to remove Q’ty Remarks

1 Front brake caliper 1
2 Brake pad clip 2
3 Brake pad pin 1
4 Brake pad (inner) 1
5 Brake pad (outer) 1
6 Brake pad spring 1
7 Brake caliper bleed screw 1

4-32
 FRONT BRAKE

Removing the front brake master cylinder

16 N·m (1.6 kgf·m, 12 lb·ft)

11

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

3
29 N·m (2.9 kgf·m, 21 lb·ft)

T.R
12

.
8
6 N·m (0.6 kgf·m, 4.4 lb·ft)
9 New
T.R
.

6
S

7 10

5 4
6

6 N·m (0.6 kgf·m, 4.4 lb·ft) 1.2 N·m (0.12 kgf·m, 0.88 lb·ft)
T.R

T.R
.

Order Job/Parts to remove Q’ty Remarks

Upper handlebar cover assembly Refer to “HANDLEBAR” on page 4-67.
Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-12.
1 Brake master cylinder reservoir cap 1
Brake master cylinder reservoir diaphragm
2 1
holder
3 Brake master cylinder reservoir diaphragm 1
4 Front brake light switch connector 2 Disconnect.
5 Front brake light switch 1
6 Front brake lever pivot bolt/nut 1/1
7 Front brake lever 1
8 Front brake hose union bolt 1
9 Brake hose gasket 2

4-33
 FRONT BRAKE

Removing the front brake master cylinder

16 N·m (1.6 kgf·m, 12 lb·ft)

11

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

3
29 N·m (2.9 kgf·m, 21 lb·ft)

T.R
12

.
8
6 N·m (0.6 kgf·m, 4.4 lb·ft)
9 New
T.R
.

6
S

7 10

5 4
6

6 N·m (0.6 kgf·m, 4.4 lb·ft) 1.2 N·m (0.12 kgf·m, 0.88 lb·ft)
T.R

T.R
.

Order Job/Parts to remove Q’ty Remarks

10 Front brake hose 1 Disconnect.
11 Front brake master cylinder holder 1
12 Front brake master cylinder assembly 1

4-34
 FRONT BRAKE

Disassembling the front brake master cylinder

BF
S

BF
2

1 New

Order Job/Parts to remove Q’ty Remarks

1 Brake master cylinder kit 1
2 Brake master cylinder body 1

4-35
 FRONT BRAKE

Removing the front brake caliper

1 3

2 New
4
29 N·m (2.9 kgf·m, 21 lb·ft)
T.R
.

35 N·m (3.5 kgf·m, 26 lb·ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-12.
1 Front brake hose union bolt 1
2 Brake hose gasket 2
3 Front brake hose 1 Disconnect.
4 Front brake caliper 1

4-36
 FRONT BRAKE

Disassembling the front brake caliper

6
6 N·m (0.6 kgf·m, 4.4 lb·ft)

T .R
.
S

7
11 New 8
New 9
10

2 5

BF
S 3

4
1

Order Job/Parts to remove Q’ty Remarks

1 Brake pad clip 2
2 Brake pad pin 1
3 Brake pad (inner) 1
4 Brake pad (outer) 1
5 Brake pad spring 1
6 Front brake caliper bracket 1
7 Brake caliper piston 1
8 Brake caliper piston dust seal 1
9 Brake caliper piston seal 1
10 Brake caliper bleed screw 1
11 Brake caliper body 1

4-37
 FRONT BRAKE

EAS30168 EAS30169

INTRODUCTION CHECKING THE FRONT BRAKE DISC

EWA14101
1. Remove:
WARNING • Front wheel
Disc brake components rarely require disas- Refer to “FRONT WHEEL” on page 4-22.
sembly. Therefore, always follow these pre- 2. Check:
ventive measures: • Brake disc
• Never disassemble brake components un- Damage/galling → Replace.
less absolutely necessary. 3. Measure:
• If any connection on the hydraulic brake • Brake disc runout
system is disconnected, the entire brake Out of specification → Correct the brake disc
system must be disassembled, drained, runout or replace the brake disc.
cleaned, properly filled, and bled after reas-
sembly. Brake disc runout limit (as mea-
• Never use solvents on internal brake com- sured on wheel)
ponents. 0.15 mm (0.0059 in)
• Use only clean or new brake fluid for clean-
ing brake components. a. Place the vehicle on a suitable stand so that
• Brake fluid may damage painted surfaces the front wheel is off ground.
and plastic parts. Therefore, always clean b. Before measuring the front brake disc
up any spilt brake fluid immediately. runout, turn the handlebar to the left or right
• Avoid brake fluid coming into contact with to ensure that the front wheel is stationary.
the eyes as it can cause serious injury. c. Remove the brake caliper.
FIRST AID FOR BRAKE FLUID ENTERING d. Hold the dial gauge at a right angle against
THE EYES: the brake disc surface.
• Flush with water for 15 minutes and get im- e. Measure the runout 1.5 mm (0.06 in) below
mediate medical attention. the edge of the brake disc.

4-38
 FRONT BRAKE

4. Measure: 6. Install:
• Brake disc thickness • Front wheel
Measure the brake disc thickness at a few dif- Refer to “FRONT WHEEL” on page 4-22.
ferent locations.
EAS30170
Out of specification → Replace. REPLACING THE FRONT BRAKE PADS
TIP
Brake disc thickness limit
3.5 mm (0.14 in) 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 wear limit “a”
Out of specification → Replace the brake
pads as a set.

Brake pad lining thickness limit

0.8 mm (0.03 in)

5. Adjust: A
• Brake disc runout
a. Remove the brake disc.
a
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.

Front brake disc bolt

23 N·m (2.3 kgf·m, 17 lb·ft)
T.
R.

LOCTITE®
ECA19150 B
NOTICE
Replace the brake disc bolts with new ones.
a
TIP
• Install the brake disc “1” with its chamfered
side “a” facing inward.
• Tighten the brake disc bolts in stages.

1 A. Inner
1
B. Outer
2. Install:
• Brake pad spring
• Brake pads
a TIP
Always install new brake pads, and new brake
pad spring, as a set.
d. Measure the brake disc runout.
e. If out of specification, repeat the adjustment a. Connect a clear plastic hose “1” tightly to
steps until the brake disc runout is within the bleed screw “2”. Put the other end of the
specification. hose into an open container.
f. If the brake disc runout cannot be brought
within specification, replace the brake disc.

4-39
 FRONT BRAKE

b. Loosen the bleed screw and push the brake

caliper piston into the brake caliper with
your finger.

1
a

4. Check:
• Brake fluid level
Below the minimum level mark “a” → Add the
c. Tighten the bleed screw. specified brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
Brake caliper bleed screw LEVEL” on page 3-11.
6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.

a
d. Install new brake pad spring and new brake
pads.
TIP
The longer tangs “a” of the brake pad spring “1”
must point in the direction of the brake caliper
piston.

a 5. Check:
• Brake lever operation
Soft or spongy feeling → Bleed the brake sys-
tem.
Refer to “BLEEDING THE HYDRAULIC
1 BRAKE SYSTEM” on page 3-12.

3. Install:
• Brake pad pin
• Brake pad clips
• Front brake caliper
• Front brake caliper bolt

Front brake caliper bolt

35 N·m (3.5 kgf·m, 26 lb·ft)
T.
R.

TIP
While holding the front wheel sensor lead holder
so that the portion “a” of the holder contacts the
front fork outer tube, tighten the bolt to specifica-
tion.

4-40
 FRONT BRAKE

EAS31328 EAS30172

REMOVING THE FRONT BRAKE CALIPER DISASSEMBLING THE FRONT BRAKE

TIP CALIPER
Before removing the brake caliper, drain the 1. Remove:
brake fluid from the entire brake system. • Brake caliper piston “1”
• Brake caliper piston dust seal “2”
1. Remove: • Brake caliper piston seal “3”
• Brake hose union bolt “1”
• Brake hose gasket “2”
• Front brake hose “3”
TIP
3
Put the end of the brake hose into a container 2
and pump out the brake fluid carefully. 1

a. Blow compressed air into the brake hose

joint opening “a” to force out the piston from
1 the brake caliper “1”.
EWA13550

WARNING
2 • 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.

b. Remove the brake caliper piston dust seal

and brake caliper piston seal.

4-41
 FRONT BRAKE

EAS30173 EAS30174

CHECKING THE FRONT BRAKE CALIPER ASSEMBLING THE FRONT BRAKE CALIPER
EWA16560

Recommended brake component WARNING

replacement schedule • Before installation, all internal brake com-
Brake pads If necessary ponents should be cleaned and lubricated
Piston seal Every two years with clean or new brake fluid.
• Never use solvents on internal brake com-
Piston dust seal Every two years ponents as they will cause the brake caliper
Brake hose Every four years piston dust seals and brake caliper piston
Every two years and seals to swell and distort.
Brake fluid whenever the brake is • Whenever a brake caliper is disassembled,
disassembled replace the brake caliper piston dust seals
and brake caliper piston seals.
1. Check:
• Brake caliper piston “1”
Specified brake fluid
Rust/scratches/wear → Replace the brake DOT 4
caliper piston.
• Brake caliper cylinder “2” EAS30934

Scratches/wear → Replace the brake caliper INSTALLING THE FRONT BRAKE CALIPER
assembly. 1. Install:
• Brake caliper body “3” • Front brake caliper “1”
Cracks/damage → Replace the brake caliper (temporarily)
assembly. • Brake hose gasket “2” New
• Brake fluid delivery passages • Front brake hose “3”
(brake caliper body) • Brake hose union bolt “4”
Obstruction → Blow out with compressed air.
EWA17070
Front brake hose union bolt
WARNING (brake caliper side)
T.

Whenever a brake caliper is disassembled,

R.

29 N·m (2.9 kgf·m, 21 lb·ft)

replace the brake caliper piston dust seal
EWA13531
and brake caliper piston seal.
WARNING
Proper brake hose routing is essential to in-
sure safe vehicle operation.
2 3
ECA19080
1
NOTICE
When installing the brake hose onto the
brake caliper “1”, make sure the brake pipe
“a” passes between the projections “b” on
the brake caliper.

2. Check:
3
• Brake caliper bracket 1
Cracks/damage → Replace. b
a

4
New 2

4-42
 FRONT BRAKE

2. Remove: 6. Check:
• Front brake caliper • Brake fluid level
3. Install: Below the minimum level mark “a” → Add the
• Brake pad spring specified brake fluid to the proper level.
• Brake pads Refer to “BLEEDING THE HYDRAULIC
• Brake pad pin BRAKE SYSTEM” on page 3-12.
• Brake pad clips
• Front brake caliper a
• Front wheel sensor lead holder
• Front brake caliper bolt

Front brake caliper bolt

35 N·m (3.5 kgf·m, 26 lb·ft)
T.
R.

Refer to “REPLACING THE FRONT BRAKE

PADS” on page 4-39.
4. Fill: 7. Check:
• Brake master cylinder reservoir • Brake lever operation
(with the specified amount of the specified Soft or spongy feeling → Bleed the brake sys-
brake fluid) tem.
Refer to “BLEEDING THE HYDRAULIC
Specified brake fluid BRAKE SYSTEM” on page 3-12.
DOT 4
EAS30179

EWA13540 REMOVING THE FRONT BRAKE MASTER

WARNING CYLINDER
• Use only the designated brake fluid. Other TIP
brake fluids may cause the rubber seals to Before removing the front brake master cylinder,
deteriorate, causing leakage and poor drain the brake fluid from the entire brake sys-
brake performance. tem.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids 1. Remove:
may result in a harmful chemical reaction, • Brake hose union bolt “1”
leading to poor brake performance. • Brake hose gasket “2”
• When refilling, be careful that water does • Front brake hose “3”
not enter the brake master cylinder reser- TIP
voir. Water will significantly lower the boil- To collect any remaining brake fluid, place a
ing point of the brake fluid and could cause container under the master cylinder and the end
vapor lock. of the brake hose.
ECA13540

NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately. 2
5. Bleed:
• Brake system 3
Refer to “BLEEDING THE HYDRAULIC 1
BRAKE SYSTEM” on page 3-12.

4-43
 FRONT BRAKE

EAS30725 EAS30181

CHECKING THE FRONT BRAKE MASTER ASSEMBLING THE FRONT BRAKE MASTER
CYLINDER CYLINDER
1. Check: EWA13520

• Brake master cylinder WARNING

Damage/scratches/wear → Replace. • Before installation, all internal brake com-
• Brake fluid delivery passages ponents should be cleaned and lubricated
(Brake master cylinder body) with clean or new brake fluid.
Obstruction → Blow out with compressed air. • Never use solvents on internal brake com-
2. Check: ponents.
• Brake master cylinder kit
Damage/scratches/wear → Replace. Specified brake fluid
3. Check: DOT 4
• Brake master cylinder reservoir “1”
• Brake master cylinder reservoir cap “2” EAS30182

• Brake master cylinder reservoir diaphragm INSTALLING THE FRONT BRAKE MASTER
holder “3” CYLINDER
• Brake master cylinder reservoir diaphragm 1. Install:
“4” • Brake master cylinder
Damage/wear → Replace. • Brake master cylinder holder “1”

2 Front brake master cylinder hold-

1 er bolt
T.
R.

16 N·m (1.6 kgf·m, 12 lb·ft)

3
TIP
• Install the brake master cylinder holder with the
4 “UP” mark “a” facing up.
• Align the edge “b” of the brake master cylinder
holder with the edge “c” of the stay on the han-
4. Check: dlebar as shown in the illustration.
• Front brake hose • First, tighten the upper bolt, then the lower bolt.
Cracks/damage/wear → Replace.
b
c
1

4-44
 FRONT BRAKE

2. Install: EWA13540

WARNING
• Brake hose gasket “1” New
• Front brake hose “2” • Use only the designated brake fluid. Other
• Brake hose union bolt “3” brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
Front brake hose union bolt brake performance.
(master cylinder side) • Refill with the same type of brake fluid that
T.

is already in the system. Mixing brake fluids

R.

29 N·m (2.9 kgf·m, 21 lb·ft)

may result in a harmful chemical reaction,
EWA13531
leading to poor brake performance.
WARNING • When refilling, be careful that water does
Proper brake hose routing is essential to in- not enter the brake master cylinder reser-
sure safe vehicle operation. voir. Water will significantly lower the boil-
ing point of the brake fluid and could cause
TIP
vapor lock.
• Make sure that the distance “a” between the
ECA13540
brake hose and the handlebar “4” is 40–44 mm
(1.57–1.73 in) as shown in the illustration. NOTICE
• Turn the handlebar to the left and right to make Brake fluid may damage painted surfaces
sure the brake hose does not touch other parts and plastic parts. Therefore, always clean up
(e.g., wire harness, cables, leads). Correct if any spilt brake fluid immediately.
necessary. 4. Bleed:
• Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-12.
New 1 5. Check:
• Brake fluid level
3 Below the minimum level mark “a” → Add the
4 specified brake fluid to the proper level.
2 Refer to “CHECKING THE BRAKE FLUID
a
LEVEL” on page 3-11.

3. Fill: a
• Brake master cylinder reservoir
(with the specified amount of the specified
brake fluid)

Specified brake fluid

DOT 4

6. Check:
• Brake lever operation
Soft or spongy feeling → Bleed the brake sys-
tem.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-12.

4-45
 REAR BRAKE

EAS20031

REAR BRAKE
Removing the rear brake pads

35 N·m (3.5 kgf·m, 26 lb·ft)

T .R
.
4

6 N·m (0.6 kgf·m, 4.4 lb·ft)

T .R
.

Order Job/Parts to remove Q’ty Remarks

1 Rear brake caliper 1
2 Brake pad clip 2
3 Brake pad pin 1
4 Brake pad (inner) 1
5 Brake pad (outer) 1
6 Brake pad spring 1
7 Brake caliper bleed screw 1

4-46
 REAR BRAKE

Removing the rear brake master cylinder

16 N·m (1.6 kgf·m, 12 lb·ft) 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)

11

3
6 N·m (0.6 kgf·m, 4.4 lb·ft)

29 N·m (2.9 kgf·m, 21 lb·ft)

8 6
9 New

12

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

Order Job/Parts to remove Q’ty Remarks

Upper handlebar cover assembly Refer to “HANDLEBAR” on page 4-67.
Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-12.
1 Brake master cylinder reservoir cap 1
Brake master cylinder reservoir diaphragm
2 1
holder
3 Brake master cylinder reservoir diaphragm 1
4 Rear brake light switch connector 2 Disconnect.
5 Rear brake light switch 1
6 Rear brake lever pivot bolt/nut 1/1
7 Rear brake lever 1
8 Rear brake hose union bolt 1
9 Brake hose gasket 2
10 Rear brake hose 1 Disconnect.
11 Rear brake master cylinder holder 1
12 Rear brake master cylinder assembly 1

4-47
 REAR BRAKE

Disassembling the rear brake master cylinder

BF
S

2
BF

1 New

Order Job/Parts to remove Q’ty Remarks

1 Brake master cylinder kit 1
2 Brake master cylinder body 1

4-48
 REAR BRAKE

Removing the rear brake caliper

4 35 N·m (3.5 kgf·m, 26 lb·ft)

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

2 New

1
3

Order Job/Parts to remove Q’ty Remarks

Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-12.
1 Rear brake hose union bolt (brake caliper side) 1
2 Brake hose gasket 2
3 Rear brake hose 1 Disconnect.
4 Rear brake caliper 1

4-49
 REAR BRAKE

Disassembling the rear brake caliper

6
S

7 S 4
8 New BF
9 New
5
11

10

6 N·m (0.6 kgf·m, 4.4 lb·ft)

T .R

2
.

Order Job/Parts to remove Q’ty Remarks

1 Brake pad clip 2
2 Brake pad pin 1
3 Brake pad (inner) 1
4 Brake pad (outer) 1
5 Brake pad spring 1
6 Brake caliper bracket 1
7 Brake caliper piston 1
8 Brake caliper piston dust seal 1
9 Brake caliper piston seal 1
10 Brake caliper bleed screw 1
11 Brake caliper body 1

4-50
 REAR BRAKE

EAS30183 EAS30184

INTRODUCTION CHECKING THE REAR BRAKE DISC

EWA14101
1. Remove:
WARNING • Rear wheel
Disc brake components rarely require disas- Refer to “REAR WHEEL” on page 4-29.
sembly. Therefore, always follow these pre- 2. Check:
ventive measures: • Brake disc
• Never disassemble brake components un- Damage/galling → Replace.
less absolutely necessary. 3. Measure:
• If any connection on the hydraulic brake • Brake disc runout
system is disconnected, the entire brake Out of specification → Correct the brake disc
system must be disassembled, drained, runout or replace the brake disc.
cleaned, properly filled, and bled after reas- Refer to “CHECKING THE FRONT BRAKE
sembly. DISC” on page 4-38.
• Never use solvents on internal brake com-
ponents. Brake disc runout limit (as mea-
• Use only clean or new brake fluid for clean- sured on wheel)
ing brake components. 0.15 mm (0.0059 in)
• Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean 4. Measure:
up any spilt brake fluid immediately. • Brake disc thickness
• Avoid brake fluid coming into contact with Measure the brake disc thickness at a few dif-
the eyes as it can cause serious injury. ferent locations.
FIRST AID FOR BRAKE FLUID ENTERING Out of specification → Replace.
THE EYES: Refer to “CHECKING THE FRONT BRAKE
• Flush with water for 15 minutes and get im- DISC” on page 4-38.
mediate medical attention.
Brake disc thickness limit
4.0 mm (0.16 in)

5. Adjust:
• Brake disc runout
Refer to “CHECKING THE FRONT BRAKE
DISC” on page 4-38.

Rear brake disc bolt

23 N·m (2.3 kgf·m, 17 lb·ft)
T.
R.

LOCTITE®

6. Install:
• Rear wheel
Refer to “REAR WHEEL” on page 4-29.

4-51
 REAR BRAKE

EAS30185
b. Loosen the bleed screw and push the brake
REPLACING THE REAR BRAKE PADS
caliper piston into the brake caliper with
TIP your finger.
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disassem- 2
ble the brake caliper. 1

1. Measure:
• Brake pad wear limit “a”
Out of specification → Replace the brake
pads as a set.

Brake pad lining thickness limit

0.8 mm (0.03 in)
c. Tighten the bleed screw.

A Brake caliper bleed screw

6 N·m (0.6 kgf·m, 4.4 lb·ft)

T.
R.
a d. Install new brake pad spring and new brake
pads.
TIP
The longer tangs “a” of the brake pad spring
must point in the direction of the brake caliper
position.
B

a
a
a

A. Inner
B. Outer 3. Install:
• Brake pad pin
2. Install: • Brake pad clips
• Brake pad spring • Rear brake caliper
• Brake pads • Rear brake caliper bolt
TIP
Always install new brake pads and brake pad Rear brake caliper bolt
spring as a set. 35 N·m (3.5 kgf·m, 26 lb·ft)
T.
R.

a. Connect a clear plastic hose “1” tightly to

the bleed screw “2”. Put the other end of the
hose into an open container.

4-52
 REAR BRAKE

4. Check: EAS30187

DISASSEMBLING THE REAR BRAKE

• Brake fluid level
CALIPER
Below the minimum level mark “a” → Add the
1. Remove:
specified brake fluid to the proper level.
• Brake caliper piston “1”
Refer to “CHECKING THE BRAKE FLUID
• Brake caliper piston dust seal “2”
LEVEL” on page 3-11.
• Brake caliper piston seal “3”

1
a 2 3

5. Check:
• Brake lever operation a. Blow compressed air into the brake hose
Soft or spongy feeling → Bleed the brake sys- joint opening “a” to force out the piston from
tem. the brake caliper.
Refer to “BLEEDING THE HYDRAULIC EWA13550

BRAKE SYSTEM” on page 3-12. WARNING

• Cover the brake caliper piston with a rag.
EAS30186

REMOVING THE REAR BRAKE CALIPER Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
TIP
• Never try to pry out the brake caliper pis-
Before removing the brake caliper, drain the ton.
brake fluid from the entire brake system.
1. Remove:
• Rear brake hose union bolt “1”
• Brake hose gasket “2”
• Rear brake hose “3”
TIP
Put the end of the brake hose into a container a
and pump out the brake fluid carefully.

b. Remove the brake caliper piston dust seal

2 and brake caliper piston seal.

3
1

4-53
 REAR BRAKE

EAS30188 EAS30189

CHECKING THE REAR BRAKE CALIPER ASSEMBLING THE REAR BRAKE CALIPER
EWA17080

Recommended brake component WARNING

replacement schedule • Before installation, all internal brake com-
Brake pad If necessary ponents should be cleaned and lubricated
Piston seal Every two years with clean or new brake fluid.
• Never use solvents on internal brake com-
Piston dust seal Every two years ponents as they will cause the brake caliper
Brake hose Every four years piston dust seal and brake caliper piston
Every two years and seal to swell and distort.
Brake fluid whenever the brake is • Whenever a brake caliper is disassembled,
disassembled replace the brake caliper piston dust seal
and brake caliper piston seal.
1. Check:
• Brake caliper piston “1”
Specified brake fluid
Rust/scratches/wear → Replace the brake DOT 4
caliper piston.
• Brake caliper cylinder “2” EAS30190

Scratches/wear → Replace the brake caliper INSTALLING THE REAR BRAKE CALIPER
assembly. 1. Install:
• Brake caliper body “3” • Rear brake caliper “1”
Cracks/damage → Replace the brake caliper (temporarily)
assembly. • Brake hose gasket “2” New
• Brake fluid delivery passages • Rear brake hose “3”
(brake caliper body) • Brake hose union bolt “4”
Obstruction → Blow out with compressed air.
EWA17070
Rear brake hose union bolt
WARNING (brake caliper side)
T.

Whenever a brake caliper is disassembled,

R.

29 N·m (2.9 kgf·m, 21 lb·ft)

replace the brake caliper piston dust seal
EWA13531
and brake caliper piston seal.
WARNING
Proper brake hose routing is essential to in-
3 sure safe vehicle operation.
1 2 ECA19080

NOTICE
When installing the brake hose onto the
brake caliper “1”, make sure the brake pipe
“a” passes between the projections “b” on
the brake caliper.

2. Check:
• Brake caliper bracket
1
Cracks/damage → Replace.
b
2 New
a

4 3

4-54
 REAR BRAKE

2. Remove: 6. Check:
• Rear brake caliper • Brake fluid level
3. Install: Below the minimum level mark “a” → Add the
• Brake pad spring specified brake fluid to the proper level.
• Brake pads Refer to “CHECKING THE BRAKE FLUID
• Brake pad pin LEVEL” on page 3-11.
• Brake pad clips
• Rear brake caliper

Rear brake caliper bolt

35 N·m (3.5 kgf·m, 26 lb·ft) a
T.
R.

Refer to “REPLACING THE REAR BRAKE

PADS” on page 4-52.
4. Fill:
• Brake master cylinder reservoir
(with the specified amount of the specified 7. Check:
brake fluid) • Brake lever operation
Soft or spongy feeling → Bleed the brake sys-
Specified brake fluid tem.
DOT 4 Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-12.
EWA13540

WARNING EAS30193

REMOVING THE REAR BRAKE MASTER

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

4-55
 REAR BRAKE

EAS30194 EAS30196

CHECKING THE REAR BRAKE MASTER INSTALLING THE REAR BRAKE MASTER
CYLINDER CYLINDER
1. Check: 1. Install:
• Brake master cylinder • Brake master cylinder
Damage/scratches/wear → Replace. • Brake master cylinder holder “1”
• Brake fluid delivery passages
(brake master cylinder body) Rear brake master cylinder hold-
Obstruction → Blow out with compressed air. er bolt

T.
R.
2. Check: 16 N·m (1.6 kgf·m, 12 lb·ft)
• Brake master cylinder kit
Damage/scratches/wear → Replace. TIP
3. Check: • Install the brake master cylinder holder with the
• Brake master cylinder reservoir “1” “UP” mark “a” facing up.
• Brake master cylinder reservoir cap • Align the edge “b” of the brake master cylinder
• Brake master cylinder reservoir diaphragm holder with the edge “c” of the stay on the han-
holder “2” dlebar as shown in the illustration.
• Brake master cylinder reservoir diaphragm • First, tighten the upper bolt, then the lower bolt.
“3”
Damage/wear → Replace. 1
4. Check: b
• Brake hose
Cracks/damage/wear → Replace. c

2
1
a
3
2. Install:
• Brake hose gasket “1” New
• Rear brake hose “2”
• Brake hose union bolt “3”
EAS30195
Rear brake hose union bolt (mas-
ASSEMBLING THE REAR BRAKE MASTER ter cylinder side)
T.

CYLINDER
R.

EWA13520
29 N·m (2.9 kgf·m, 21 lb·ft)
WARNING EWA13531

• Before installation, all internal brake com- WARNING

ponents should be cleaned and lubricated Proper brake hose routing is essential to in-
with clean or new brake fluid. sure safe vehicle operation.
• Never use solvents on internal brake com-
ponents.

Specified brake fluid

DOT 4

4-56
 REAR BRAKE

3. Fill: 6. Check:
• Brake master cylinder reservoir • Brake lever operation
(with the specified amount of the specified Soft or spongy feeling → Bleed the brake sys-
brake fluid) tem.
Refer to “BLEEDING THE HYDRAULIC
Specified brake fluid BRAKE SYSTEM” on page 3-12.
DOT 4
EWA13540

WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake master cylinder reser-
voir. Water will significantly lower the boil-
ing point of the brake fluid and could cause
vapor lock.
ECA13540

NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
4. Bleed:
• Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-12.
5. Check:
• Brake fluid level
Below the minimum level mark “a” → Add the
specified brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-11.

4-57
 ABS (Anti-lock Brake System)

EAS20032

ABS (Anti-lock Brake System)

Removing the hydraulic unit assembly

29 N•m (2.9 kgf•m, 21 lb•ft)

T .R
.
2

4
New 5
3
7 3
2 8
4
New 4
6 New
4
New

1 9

7 N•m (0.7 kgf•m, 5.2 lb•ft)

T .R
.

Order Job/Parts to remove Q’ty Remarks

Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-12.
Refer to “GENERAL CHASSIS (2)” on
Front side cover (right) page 4-3.
Refer to “GENERAL CHASSIS (6)” on
Front upper cowling assembly page 4-15.
1 ABS ECU coupler 1 Disconnect.
Front brake hose union bolt (hydraulic unit
2 2
assembly side)
Rear brake hose union bolt (hydraulic unit
3 2
assembly side)
4 Brake hose gasket 8
Front brake hose (hydraulic unit to front brake
5 1 Disconnect.
caliper)
Front brake hose (front brake master cylinder to
6 1 Disconnect.
hydraulic unit)
Rear brake hose (rear brake master cylinder to
7 1 Disconnect.
hydraulic unit)

4-58
 ABS (Anti-lock Brake System)

Removing the hydraulic unit assembly

29 N•m (2.9 kgf•m, 21 lb•ft)

T .R
.
2

4
New 5
3
7 3
2 8
4
New 4
6 New
4
New

1 9

7 N•m (0.7 kgf•m, 5.2 lb•ft)

T .R
.

Order Job/Parts to remove Q’ty Remarks

Rear brake hose (hydraulic unit to rear brake
8 1 Disconnect.
caliper)
9 Hydraulic unit assembly 1

4-59
 ABS (Anti-lock Brake System)

EAS30197
2. Remove:
REMOVING THE HYDRAULIC UNIT
• Brake hose
ASSEMBLY
ECA21091 TIP
NOTICE Do not operate the brake levers while removing
Unless necessary, avoid removing and in- the brake hoses.
stalling the brake hoses of the hydraulic unit ECA14530

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

4-60
 ABS (Anti-lock Brake System)

EAS30200

INSTALLING THE HYDRAULIC UNIT a

ASSEMBLY
1. Install: a
4
• Hydraulic unit assembly
4 1
Hydraulic unit assembly bolt 3 2
7 N·m (0.7 kgf·m, 5.2 lb·ft) 1
T.
R.

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

Front brake hose union bolt (hy-

draulic unit assembly side)
T.
R.

29 N·m (2.9 kgf·m, 21 lb·ft)

Rear brake hose union bolt (hy-
draulic unit assembly side)
29 N·m (2.9 kgf·m, 21 lb·ft)
ECA21121

NOTICE
A. The ABS ECU coupler is connected cor-
If the brake hose union bolt does not turn rectly.
easily, replace the hydraulic unit assembly, B. The ABS ECU coupler is not connected.
brake hoses, and related parts as a set.

TIP
As shown in the picture, when the brake hose is
assembled, the steel pipe touches the convex.
After the position of edge “a”, follow the se-
quence of 1 → 2 → 3 → 4. Tighten the connect-
ing bolts to the specified torque value.

4-61
 ABS (Anti-lock Brake System)

5. Fill: EAS30201

HYDRAULIC UNIT OPERATION TESTS

• Brake master cylinder reservoir
The reaction-force pulsating action generated in
• Brake fluid reservoir
the brake levers when the ABS is activated can
(with the specified amount of the specified
be tested when the vehicle is stopped.
brake fluid)
The hydraulic unit operation can be tested using
the following two methods.
Specified brake fluid
DOT 4 • Brake line routing confirmation: this test
checks the function of the ABS after the sys-
EWA13090
tem was disassembled, adjusted, or serviced.
WARNING • ABS reaction-force confirmation: this test gen-
• Use only the designated brake fluid. Other erates the same reaction-force pulsating action
brake fluids may cause the rubber seals to that is generated in the front brake lever and
deteriorate, causing leakage and poor rear brake lever when the ABS is front activat-
brake performance. ed.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids Brake line routing confirmation
may result in a harmful chemical reaction, EWA13120

leading to poor brake performance. WARNING

• When refilling, be careful that water does Securely support the vehicle so that there is
not enter the brake fluid reservoir. Water no danger of it falling over.
will significantly lower the boiling point of
TIP
the brake fluid and could cause vapor lock.
• For the brake line routing confirmation, use the
ECA13540
diagnosis mode of the Yamaha diagnostic tool.
NOTICE • Before performing the brake line routing confir-
Brake fluid may damage painted surfaces mation, make sure that no malfunctions have
and plastic parts. Therefore, always clean up been detected in the ABS ECU and that the
any spilt brake fluid immediately. wheels are not rotating.
6. Bleed: 1. Place the vehicle on the centerstand.
• Brake system 2. Turn the main switch to “OFF”.
Refer to “BLEEDING THE HYDRAULIC 3. Open the seat.
BRAKE SYSTEM” on page 3-12. 4. Remove:
7. Check the operation of the hydraulic unit ac- • Battery cover
cording to the brake levers response. (Refer Refer to “GENERAL CHASSIS (1)” on
to “HYDRAULIC UNIT OPERATION TESTS” page 4-1.
on page 4-62.)
ECA14550

NOTICE
Always check the operation of the hydraulic
unit according to the brake lever response.
8. Delete the fault codes. (Refer to “[B-3] DE-
LETING THE FAULT CODES” on page 9-
21.)
9. Perform a trial run. (Refer to “CHECKING
THE ABS WARNING LIGHT” on page 4-66.)

4-62
 ABS (Anti-lock Brake System)

5. Check: 9. Click “Actuator Check”, and then operate the

• Battery voltage front brake lever “1” and rear brake lever “2”
Lower than 12.8 V → Charge or replace the simultaneously.
battery. TIP
• The hydraulic unit operates 1 second after the
Battery voltage front brake lever and rear brake lever are oper-
Higher than 12.8 V ated simultaneously and continues for approx-
imately 5 seconds.
TIP
• The operation of the hydraulic unit can be con-
If the battery voltage is lower than 12.8 V, charge firmed using the indicator.
the battery, and then perform brake line routing On: The hydraulic unit is operating.
confirmation. Flashing: The conditions for operating the hy-
draulic unit have not been met.
Off: The front brake lever and rear brake lever
are not being operated.

6. Disconnect the Yamaha diagnostic tool cou-

pler from the CCU (Communication Control
1 2
Unit) “1”, and then connect the Yamaha diag-
nostic tool to the coupler. 10.Check:
• Hydraulic unit operation
Yamaha diagnostic tool USB Click “Actuator Check”, a single pulse will be
90890-03267 generated in the front brake lever “1”, rear
Yamaha diagnostic tool (A/I)
brake lever “2”, and again in the front brake
90890-03264
lever “1”, in this order.
1

1 2

7. Start the Yamaha diagnostic tool and display TIP

the diagnosis mode screen. “ON” and “OFF” on the tool screen indicate
8. Select code No. 2, “Brake line routing confir- when the brakes are being applied and released
mation”. respectively.

4-63
 ABS (Anti-lock Brake System)

ECA22080
5. Check:
NOTICE • Battery voltage
• Check that the pulse is felt in the front Lower than 12.8 V → Charge or replace the
brake lever, rear brake lever, and again in battery.
the front brake lever, in this order.
• If the pulse is felt in the rear brake lever be- Battery voltage
fore it is felt in the front brake lever, check Higher than 12.8 V
that the brake hoses and brake pipes are
connected correctly to the hydraulic unit TIP
assembly. If the battery voltage is lower than 12.8 V, charge
• If the pulse is hardly felt in either the front the battery, and then perform ABS reaction-
brake lever or rear brake lever, check that force confirmation.
the brake hoses and brake pipes are con-
nected correctly to the hydraulic unit as-
sembly.
11.If the operation of the hydraulic unit is normal,
delete all of the fault codes.

ABS reaction-force confirmation

EWA13120

WARNING
Securely support the vehicle so that there is
no danger of it falling over. 6. Disconnect the Yamaha diagnostic tool cou-
pler from the CCU (Communication Control
TIP
Unit) “1”, and then connect the Yamaha diag-
• For the ABS reaction-force confirmation, use nostic tool to the coupler.
the diagnosis mode of the Yamaha diagnostic
tool. For more information, refer to the opera- Yamaha diagnostic tool USB
tion manual of the Yamaha diagnostic tool. 90890-03267
• Before performing the ABS reaction-force con- Yamaha diagnostic tool (A/I)
firmation, make sure that no malfunctions have 90890-03264
been detected in the ABS ECU and that the
wheels are not rotating. 1
1. Place the vehicle on a centerstand.
2. Turn the main switch to “OFF”.
3. Open the seat.
4. Remove:
• Battery cover
Refer to “GENERAL CHASSIS (1)” on
page 4-1.

7. Start the Yamaha diagnostic tool and display

the diagnosis mode screen.
8. Select code No. 1, “ABS reaction-force con-
firmation”.

4-64
 ABS (Anti-lock Brake System)

9. Click “Actuator Check”, and then operate the 11.After the pulsating action has stopped in the
front brake lever “1” and rear brake lever “2” front brake lever, it is generated in the rear
simultaneously. brake lever “1” and continues for a few sec-
TIP onds.
• The hydraulic unit operates 1 second after the TIP
front brake lever and rear brake lever are oper- • The reaction-force pulsating action consists of
ated simultaneously and continues for approx- quick pulses.
imately 5 seconds. • Be sure to continue operating the front brake
• The operation of the hydraulic unit can be con- lever and rear brake lever even after the pul-
firmed using the indicator. sating action has stopped.
On: The hydraulic unit is operating. • “ON” and “OFF” on the tool screen indicate
Flashing: The conditions for operating the hy- when the brakes are being applied and re-
draulic unit have not been met. leased respectively.
Off: The front brake lever and rear brake lever
are not being operated.

1
1 2 12.After the pulsating action has stopped in the
rear brake lever, it is generated in the front
10.A reaction-force pulsating action is generated brake lever and continues for a few seconds.
in the front brake lever “1” and continues for a TIP
few seconds. • The reaction-force pulsating action consists of
TIP quick pulses.
• The reaction-force pulsating action consists of • “ON” and “OFF” on the tool screen indicate
quick pulses. when the brakes are being applied and re-
• Be sure to continue operating the front brake leased respectively.
lever and rear brake lever even after the pul- ECA22080
sating action has stopped. NOTICE
• “ON” and “OFF” on the tool screen indicate • Check that the pulse is felt in the front
when the brakes are being applied and re- brake lever, rear brake lever, and again in
leased respectively. the front brake lever, in this order.
• If the pulse is felt in the rear brake lever be-
fore it is felt in the front brake lever, check
that the brake hoses and brake pipes are
connected correctly to the hydraulic unit
assembly.
• If the pulse is hardly felt in either the front
brake lever or rear brake lever, check that
the brake hoses and brake pipes are con-
nected correctly to the hydraulic unit as-
1
sembly.
13.Turn the main switch to “OFF”.
14.Remove the Yamaha diagnostic tool from the
Yamaha diagnostic tool coupler, and then in-
stall the protective cap.

4-65
 ABS (Anti-lock Brake System)

15.Turn the main switch to “ON”. EAS30202

CHECKING THE ABS WARNING LIGHT

16.Check for brake fluid leakage around the hy-
After all checks and servicing are completed, en-
draulic unit.
sure that the ABS warning light goes off by walk-
Brake fluid leakage → Replace the hydraulic
ing the vehicle at a speed of faster than 10 km/h
unit, brake hoses, and related parts as a set.
(6 mph) or performing a trial run.
17.If the operation of the hydraulic unit is normal,
delete all of the fault codes.

4-66
 HANDLEBAR

EAS20033

HANDLEBAR
Removing the rearview mirror and handlebar cover

4.0 N·m (0.40 kgf·m, 3.0 lb·ft)

T.R
.
2 1

22 N·m (2.2 kgf·m, 16 lb·ft) 3

T.R
.

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

22 N·m (2.2 kgf·m, 16 lb·ft)

T.R
.

(2)

(2)

Order Job/Parts to remove Q’ty Remarks

1 Rearview mirror 2
2 Upper handlebar cover assembly 1
3 Upper handlebar panel 1
4 Upper handlebar cover 1

4-67
 HANDLEBAR

Removing the handlebar

2.5 N·m (0.25 kgf·m, 1.8 lb·ft)

T.R
.

LS 6

1 LS
16 N·m (1.6 kgf·m, 12 lb·ft)

T.R
LS

.
8
5
LS 53 N·m (5.3 kgf·m, 39 lb·ft)

T.R
.
7 16 N·m (1.6 kgf·m, 12 lb·ft)
6

T.R
.
4 3
12
10
2
16
2.3 N·m (0.23 kgf·m, 1.7 lb·ft)
T.R
.

9 11 13 1

12
15 2.3 N·m (0.23 kgf·m, 1.7 lb·ft)
T.R
.

14
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.R
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (6)” on
Front cowling assembly page 4-15
1 Grip end (left and right) 2
2 Front brake light switch connector 2 Disconnect.
3 Front brake master cylinder holder 1
4 Front brake master cylinder 1
5 Handlebar switch coupler (right) 2 Disconnect.
6 Handlebar switch (right) 1
7 Throttle cable 2 Disconnect.
8 Throttle grip 1
9 Rear brake light switch connector 2 Disconnect.

4-68
 HANDLEBAR

Removing the handlebar

2.5 N·m (0.25 kgf·m, 1.8 lb·ft)

T.R
.

LS 6

1 LS
16 N·m (1.6 kgf·m, 12 lb·ft)

T.R
LS

.
8
5
LS 53 N·m (5.3 kgf·m, 39 lb·ft)

T.R
.
7 16 N·m (1.6 kgf·m, 12 lb·ft)
6

T.R
.
4 3
12
10
2
16
2.3 N·m (0.23 kgf·m, 1.7 lb·ft)
T.R
.

9 11 13 1

12
15 2.3 N·m (0.23 kgf·m, 1.7 lb·ft)
T.R
.

14
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.R
.

Order Job/Parts to remove Q’ty Remarks

10 Rear brake master cylinder holder 1
11 Rear brake master cylinder 1
12 Handlebar switch (left) 1
13 Handlebar grip 1
14 Clamp 1
15 Upper handlebar cover 1
16 Handlebar 1

4-69
 HANDLEBAR

EAS31622 EAS30203

REMOVING THE UPPER HANDLEBAR REMOVING THE HANDLEBAR

COVER ASSEMBLY 1. Stand the vehicle on a level surface.
1. Remove: EWA13120

• Upper handlebar cover assembly “1” WARNING

Securely support the vehicle so that there is
a. Remove the quick fastener and upper han-
no danger of it falling over.
dlebar cover assembly screws.
b. Unhook the projections “a” on the upper 2. Remove:
handlebar cover assembly from the slots • Grip end
“b” in the lower handlebar cover. 3. Remove:
• Handlebar grip “1”
1
TIP
Blow compressed air between the handlebar
and the handlebar grip, and gradually push the
a grip off the handlebar.

EAS31701

DISASSEMBLING THE UPPER HANDLEBAR

COVER ASSEMBLY
1. Disassemble:
• Upper handlebar panel “1”
• Upper handlebar panel “2”
TIP EAS30204

CHECKING THE HANDLEBAR

Unhook the projections “a” on the front handle-
1. Check:
bar cover from the slots “b” in the front handlebar
• Handlebar
cover.
Bends/cracks/damage → Replace.
EWA13690

1 WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.
b
a

4-70
 HANDLEBAR

EAS30205
4. Install:
INSTALLING THE HANDLEBAR
• Handlebar grip “1”
1. Stand the vehicle on a level surface.
EWA13120
• Grip end (left) “2”
WARNING a. Apply a thin coat of a rubber adhesive to the
Securely support the vehicle so that there is left end of the handlebar.
no danger of it falling over. b. Slide the handlebar grip over the left end of
the handlebar.
2. Install:
TIP
• Handlebar “1”
Make sure that the distance “a” between the end
Handlebar bracket nut of the left handlebar switch and the end of the
53 N·m (5.3 kgf·m, 39 lb·ft) handlebar grip is 0 mm (0 in).
T.
R.

1 a

c. Wipe off any excess rubber adhesive with a

3. Install:
clean rag.
• Handlebar switch (left) “1” EWA13700

TIP WARNING
Align the projection “a” on the left handlebar Do not touch the handlebar grip until the rub-
switch with the hole “b” in the rear handlebar ber adhesive has fully dried.
cover.
d. Install the left grip end.
TIP
1 There should be 1.0–3.0 mm (0.04–0.12 in) of
clearance “a” between the handlebar grip and
the grip end.
1
1
b a
2
1
2

4-71
 HANDLEBAR

5. Install:
b
• Handlebar switch (right) “1”
• Throttle cables “2” c
• Throttle grip “3”
• Grip end (right) 1
UP

Throttle cable holder bolt (han- a

dlebar switch side)
T.
R.

2.5 N·m (0.25 kgf·m, 1.8 lb·ft)

TIP 7. Adjust:
• Lubricate the end of the throttle cables and the • Throttle grip free play
inside of the throttle grip with a thin coat of lith- Refer to “CHECKING THE THROTTLE GRIP
ium-soap-based grease. OPERATION” on page 3-25.
• Align the projection “a” on the right handlebar
switch with the hole “b” in the rear handlebar Throttle grip free play
cover. 3.0–5.0 mm (0.12–0.20 in)
• There should be 1.0–3.0 mm (0.04–0.12 in) of
EAS31702
clearance between the throttle grip and the grip ASSEMBLING THE UPPER HANDLEBAR
end. COVER ASSEMBLY
1. Assemble:
3 LS • Upper handlebar cover “1”
LS • Upper handlebar cover “2”
1 TIP
Fit the projections “a” on the front handlebar cov-
2 er into the slots “b” in the front handlebar cover.
1 b
a 1
2
6. Install: b
• Front brake master cylinder a
• Front brake master cylinder holder “1”

Front brake master cylinder hold- 2

er bolt
T.
R.

16 N·m (1.6 kgf·m, 12 lb·ft)

TIP
• Install the brake master cylinder holder with the
“UP” mark “a” facing up.
• Align the edge “b” of the brake master cylinder
holder with the edge “c” of the stay on the han-
dlebar as shown in the illustration.
• First, tighten the upper bolt, then the lower bolt.

4-72
 HANDLEBAR

EAS31623

INSTALLING THE UPPER HANDLEBAR

COVER ASSEMBLY
1. Install:
• Upper handlebar cover assembly “1”
a. Fit the projections “a” on the upper handle-
bar cover into the slots “b” in the lower han-
dlebar cover.
1

b
b. Install the upper handlebar cover assembly
screws, and then tighten the screws to
specification.

Upper handlebar cover assembly

screw
T.
R.

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

4-73
 FRONT FORK

EAS20034

FRONT FORK
Removing the front fork legs

53 N·m (5.3 kgf·m, 39 lb·ft)

T.R
.

2
2

8 N·m (0.8 kgf·m, 5.9 lb·ft)

T.R
.

1 8 N·m (0.8 kgf·m, 5.9 lb·ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

The following procedures are applied to both
of the front fork legs.
Front wheel Refer to “FRONT WHEEL” on page 4-22.
1 Front fender 1
2 Lower bracket pinch bolt 2
3 Front fork leg 1

4-74
 FRONT FORK

Disassembling the front fork legs

9
12
New 14
LS 1 New
10
15 2
LS
3 New

11

13

LT 8 New
5 New

7
6 New
23 N·m (2.3 kgf·m, 17 lb·ft)
T .R
.

Order Job/Parts to remove Q’ty Remarks

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

4-75
 FRONT FORK

EAS30206

REMOVING THE FRONT FORK LEGS

The following procedures are applied to both of
the front fork legs. 1
1. Stand the vehicle on a level surface.
EWA13120
2
WARNING
Securely support the vehicle so that there is
no danger of it falling over.

TIP
2. Drain:
Place the vehicle on a suitable stand so that the
• Fork oil
front wheels are off ground.
TIP
2. Loosen: Stroke the outer tube several times while drain-
• Lower bracket pinch bolts “1” ing the fork oil.
EWA18000

WARNING
Before loosening the lower bracket pinch
bolts, support the front fork leg.

1
1

3. Remove:
• Dust seal “1”
• Oil seal clip “2”
(with a flathead screwdriver)
EAS30207 ECA14180

DISASSEMBLING THE FRONT FORK LEGS NOTICE

The following procedures are applied to both of Do not scratch the inner tube.
the front fork legs.
ECA19110

NOTICE 1
• The front fork leg has a very sophisticated
internal construction, which are particular-
ly sensitive to foreign material. 2
• When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
1. Remove:
• Front fork cap clip “1”
• Front fork cap “2”
TIP
Push the front fork cap in the direction of the ar-
row shown in the illustration to remove the front
fork cap clip.

4-76
 FRONT FORK

4. Remove: 3. Check:
• Front fork damper rod bolt “1” • Damper rod
• Copper washer Damage/wear → Replace.
TIP Obstruction → Blow out all of the oil passag-
While holding the damper rod with the hexagon es with compressed air.
bit socket (14 mm) “2” and T-handle “3”, loosen • Oil flow stopper
the front fork damper rod bolt. Damage → Replace.
EAS30209

ASSEMBLING THE FRONT FORK LEGS

T-handle
The following procedures are applied to both of
90890-01326
the front fork legs.
T-handle 3/8" drive 60 cm long EWA13660
YM-01326 WARNING
• Make sure the oil levels in both front fork
legs are equal.
• Uneven oil levels can result in poor han-
1 2 3 dling and a loss of stability.

TIP
• When assembling the front fork leg, be sure to
replace the following parts:
– Front fork cap clip
– Oil seal
– Oil seal clip
EAS30208

CHECKING THE FRONT FORK LEGS – Dust seal

The following procedures are applied to both of – Copper washer
the front fork legs. – O-ring
1. Check: • Before assembling the front fork leg, make
• Inner tube sure all of the components are clean.
• Outer tube 1. Install:
Bends/damage/scratches → Replace. • Damper rod ring “1”
EWA13650
• Damper rod “2”
WARNING
• Rebound spring “3”
Do not attempt to straighten a bent inner (in the inner tube “4”)
tube as this may dangerously weaken it. • Oil flow stopper “5”
ECA22740
2. Measure:
NOTICE
• Fork spring free length “a”
Out of specification → Replace. Allow the damper rod to slide slowly down
the inner tube until it protrudes from the bot-
Fork spring free length limit tom of the inner tube. Be careful not to dam-
235.6 mm (9.28 in) age the inner tube.

TIP
Fit the damper rod ring into the damper rod
groove so that the side of the ring with the pro-
a jections is facing in the direction shown in the il-
lustration.

4-77
 FRONT FORK

2
1 3

1 New

3. Lubricate:
• Inner tube’s outer surface

Recommended oil
Yamaha Suspension Oil G10

4. Install:
• Inner tube
5 4 3 1 2 (in the outer tube)
5. Install:
2. Install: • Copper washer New
• Oil seal “1” New • Front fork damper rod bolt “1”
(with the fork seal driver attachment “2” and
fork seal driver weight “3”) Front fork damper rod bolt
ECA14220 23 N·m (2.3 kgf·m, 17 lb·ft)
T.
R.

NOTICE LOCTITE®
Make sure the numbered side of the oil seal
faces up. TIP
While holding the damper rod assembly with the
TIP hexagon bit socket (14 mm) “2” and T-handle
• Lubricate the outer surface of the inner tube “3”, tighten the front fork damper rod bolt.
with fork oil.
• Before installing the oil seal, cover the top of
the front fork leg with a plastic bag to protect T-handle
the oil seal during installation. 90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
Fork seal driver weight
90890-01367
Replacement hammer
YM-A9409-7
Fork seal driver attachment (ø30) 1 2 3
90890-01400

4-78
 FRONT FORK

6. Install: ECA14230

NOTICE
• Oil seal clip “1” New
• Be sure to use the recommended fork oil.
TIP
Other oils may have an adverse effect on
Adjust the oil seal clip so that it fits into the outer front fork performance.
tube’s groove. • When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
9. After filling the front fork leg, slowly stroke the
inner tube “1” up and down (at least ten
times) to distribute the fork oil.
TIP
1 New
Be sure to stroke the inner tube slowly because
the fork oil may spurt out.

7. Install:
• Dust seal “1” New
(with the fork seal driver attachment “2” and
fork seal driver weight “3”) 1

Fork seal driver weight

90890-01367
Replacement hammer
YM-A9409-7
Fork seal driver attachment (ø30) 10.Before measuring the fork oil level, wait ten
90890-01400 minutes until the oil has settled and the air
bubbles have dispersed.
TIP
Be sure to bleed the front fork leg of any residual
3 air.

1 New

8. Fill:
• Front fork leg
(with the specified amount of the recom-
mended fork oil)

Recommended oil
Yamaha Suspension Oil G10
Quantity
89.0 cm³ (3.01 US oz, 3.14 Imp.oz)

4-79
 FRONT FORK

11.Measure: EAS30210

INSTALLING THE FRONT FORK LEGS

• Front fork leg oil level “a”
The following procedures are applied to both of
(from the top of the inner tube, with the inner
the front fork legs.
tube fully compressed and without the fork
1. Remove:
spring)
• Front side cover
Out of specification → Correct.
• Refer to “GENERAL CHASSIS (2)” on
page 4-3.
Level (left)
77 mm (3.1 in) 2. Install:
Level (right) • Front fork leg “1”
77 mm (3.1 in) Temporarily tighten the lower bracket pinch
bolts.
TIP TIP
• While filling the front fork leg, keep it upright. Make sure the inner tube end is flush with the top
• After filling, slowly pump the front fork leg up of the lower bracket.
and down to distribute the fork oil.

3. Tighten:
12.Install: • Lower bracket pinch bolts “1”
• Fork spring “1”
• O-ring New Lower bracket pinch bolt
• Front fork cap 53 N·m (5.3 kgf·m, 39 lb·ft)
T.
R.

• Front fork cap clip New TIP

TIP Tighten the lower bracket pinch bolts to specifi-
Install the fork spring with its smaller pitch down- cation twice. Tighten the upper and lower bolts
ward. alternately, starting with the upper bolts.

1 1
1

4-80
 STEERING HEAD

EAS20035

STEERING HEAD
Removing the lower bracket

1st 38 N·m (3.8 kgf·m, 28 lb·ft)

*2nd 17 N·m (1.7 kgf·m, 13 lb·ft) 75 N·m (7.5 kgf·m, 55 lb·ft)

LS 15

12
13 2
LS

14 4 3

LS 5
9 6
7
16
8 10
11

7 N·m (0.7 kgf·m, 5.2 lb·ft)

*Loosen the lower ring nut 1/4 of a turn, and then tighten it to specification.
Order Job/Parts to remove Q’ty Remarks
Refer to “GENERAL CHASSIS (2)” on
Front side cover page 4-3.
Refer to “GENERAL CHASSIS (5)” on
Center lower cover page 4-12.
Refer to “GENERAL CHASSIS (6)” on
Front upper cowling assembly page 4-15.
Front wheel Refer to “FRONT WHEEL” on page 4-22.
Handlebar Refer to “HANDLEBAR” on page 4-67.
Front fork legs Refer to “FRONT FORK” on page 4-74.
1 Front brake hose holder 1
2 Ring nut cover 1
3 Upper ring nut 1
4 Lock washer 1

4-81
 STEERING HEAD

Removing the lower bracket

1st 38 N·m (3.8 kgf·m, 28 lb·ft)

*2nd 17 N·m (1.7 kgf·m, 13 lb·ft) 75 N·m (7.5 kgf·m, 55 lb·ft)

LS 15

12
13 2
LS

14 4 3

LS 5
9 6
7
16
8 10
11

7 N·m (0.7 kgf·m, 5.2 lb·ft)

*Loosen the lower ring nut 1/4 of a turn, and then tighten it to specification.
Order Job/Parts to remove Q’ty Remarks
5 Center ring nut 1
6 Rubber washer 1
7 Lower ring nut 1
8 Lower bracket 1
9 Bearing cover 1
10 Upper bearing inner race 1
11 Upper bearing 1
12 Lower bearing 1
13 Lower bearing inner race 1
14 Dust seal 1
15 Lower bearing outer race 1
16 Upper bearing outer race 1

4-82
 STEERING HEAD

EAS30213
3. Replace:
REMOVING THE LOWER BRACKET
• Bearing
1. Stand the vehicle on a level surface.
EWA13120
• Bearing race
WARNING a. Remove the bearing races from the steer-
Securely support the vehicle so that there is ing head pipe “1” with a long rod “2” and
no danger of it falling over. hammer.
b. Remove the bearing race “3” from the lower
2. Remove: bracket with a floor chisel “4” and hammer.
• Ring nut cover c. Install a new dust seal and new bearing rac-
• Upper ring nut “1” es.
• Lock washer ECA14270

• Center ring nut NOTICE

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

Steering nut wrench

90890-01403
Exhaust flange nut wrench
YU-A9472

1
EAS30214

CHECKING THE STEERING HEAD

1. Wash: 4. Check:
• Bearing • Lower bracket
• Bearing race (along with the steering stem)
Bends/cracks/damage → Replace.
Recommended cleaning solvent
Kerosene

2. Check:
• Bearing
• Bearing race
Damage/pitting → Replace the bearings and
bearing races as a set.

4-83
 STEERING HEAD

EAS30216
3. Install:
INSTALLING THE STEERING HEAD
• Front brake hose holder “1”
1. Install:
• Upper bearing “1”
Front brake hose holder bolt
• Lower bearing 7 N·m (0.7 kgf·m, 5.2 lb·ft)

T.
• Lower bearing dust seal

R.
TIP TIP
• Apply lithium-soap-based grease to each part. While holding the front brake hose holder so that
• Be sure to install the upper bearing so that the the holder contacts the projection “a” on the low-
marks “a” on the bearing are facing upward. er bracket, tighten the bolt to specification.

a
a

1
2. Install:
• Lower ring nut “1”
• Rubber washer “2”
• Center ring nut “3”
• Lock washer “4”
• Upper ring nut “5”
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-16.

5
4 3
2
1

4-84
 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM

EAS20189

REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM

Removing the rear shock absorber assemblies and swingarm

2
4 3

7 N m (0.7 kgf m, 5.2 lb ft)

T.R
.
13

New
10 57 N m (5.7 kgf m, 42 lb ft)

T.R
.
12
New
6
11
5 9 10
7
8 1
5 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.

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

T.R
T.R

.
.

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

T.R
.
T.R
.

35 N•m (3.5 kgf•m, 26 lb•ft)

T.R

21 N•m (2.1 kgf•m, 15 lb•ft)

.
T.R
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (1)” on
Battery page 4-1.
Refer to “GENERAL CHASSIS (2)” on
Front side cover page 4-3.
Refer to “GENERAL CHASSIS (3)” on
Fuel tank cover page 4-6.
Refer to “GENERAL CHASSIS (4)” on
Storage box page 4-9.
Muffler Refer to “ENGINE REMOVAL” on page 5-4.
Radiator cover Refer to “RADIATOR” on page 6-2.
Air filter case Refer to “AIR FILTER CASE” on page 7-8.
1 Rear wheel axle nut 1
2 Rear brake hose holder (rear side) 1
3 Rear wheel sensor 1

4-85
 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM

Removing the rear shock absorber assemblies and swingarm

2
4 3

7 N m (0.7 kgf m, 5.2 lb ft)

T.R
.
13

New
10 57 N m (5.7 kgf m, 42 lb ft)

T.R
.
12
New
6
11
5 9 10
7
8 1
5 T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
21 N•m (2.1 kgf•m, 15 lb•ft) 125 N•m (12.5 kgf•m, 92 lb•ft)
T.R
T.R

.
.

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

T.R
.
T.R
.

35 N•m (3.5 kgf•m, 26 lb•ft)

T.R

21 N•m (2.1 kgf•m, 15 lb•ft)

.
T.R
.

Order Job/Parts to remove Q’ty Remarks

4 Rear brake caliper 1
5 Rear shock absorber assembly 2
6 Swingarm assembly 1
7 Rear brake hose guide 1
8 Spacer 1
9 Bearing retaining plate 1
10 Oil seal 2
11 Bearing 1
12 Swingarm 1
13 Collar 1

4-86
 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM

EAS31228 EAS31734

REMOVING THE SWINGARM MAINTENANCE OF THE REAR WHEEL

ECA22880
SENSOR
NOTICE ECA22900

Keep any type of magnets (including mag- NOTICE

netic pick-up tools, magnetic screwdrivers, • Handle the ABS components with care
etc.) away from the rear wheel sensor; other- since they have been accurately adjusted.
wise, the sensor may be damaged, resulting Keep them away from dirt and do not sub-
in improper performance of the ABS system. ject them to shocks.
• The rear wheel sensor cannot be disassem-
1. Stand the vehicle on a level surface.
EWA13120
bled. Do not attempt to disassemble it. If
WARNING faulty, replace with a new one.
Securely support the vehicle so that there is • Keep any type of magnets (including mag-
no danger of it falling over. netic pick-up tools, magnetic screwdrivers,
etc.) away from the rear wheel sensor.
TIP • Do not drop or shock the wheel sensor.
Place the vehicle on the centerstand so that the 1. Check:
rear wheel is off ground. • Rear wheel sensor
2. Remove: Refer to “MAINTENANCE OF THE FRONT
• Rear wheel axle nut “1” WHEEL SENSOR AND SENSOR ROTOR”
• Rear brake hose holder (rear side) “2” on page 4-25.
• Rear wheel sensor “3” 2. Check:
• Rear brake caliper “4” • Rear wheel sensor rotor
ECA21830 Refer to “MAINTENANCE OF THE FRONT
NOTICE WHEEL SENSOR AND SENSOR ROTOR”
Do not apply the brake lever when removing on page 4-25.
the brake caliper. EAS31229

CHECKING THE REAR SHOCK ABSORBER

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

4-87
 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM

EAS30227

CHECKING THE SWINGARM

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

Recommended lubricant 2 New

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

Bearing retaining plate bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft) c
T.
R.

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

4-88
 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM

4. Tighten: 6. Measure:
• Rear wheel axle nut “2” TIP
• Swingarm mounting bolt (upper side) “3” Measure the distance “a” only if the wheel bear-
• Swingarm mounting bolt (lower side) “4” ings, wheel sensor rotor, or both were replaced.

Rear wheel axle nut • Distance “a”

125 N·m (12.5 kgf·m, 92 lb·ft) (between the wheel sensor rotor “1” and
T.
R.

Swingarm mounting bolt swingarm “2” (edge of the wheel sensor in-
57 N·m (5.7 kgf·m, 42 lb·ft) stallation hole “b”))
Out of specification → Reinstall the bearing
TIP or replace the wheel sensor rotor.
Tighten the rear wheel axle nut “2”, then the
swingarm mounting bolts “3”, “4”. Distance “a” (between the wheel
sensor rotor and swingarm (edge
1 of the wheel sensor installation
hole))
18.92–19.60 mm (0.74–0.77 in)

2 4 b
1
5. Install:
• Rear shock absorber assembly 2
a
Rear shock absorber assembly
nut 7. Install:
T.
R.

21 N·m (2.1 kgf·m, 15 lb·ft) • Rear wheel sensor

Rear shock absorber assembly
bolt Rear wheel sensor bolt
27 N·m (2.7 kgf·m, 20 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.

ECA22910
TIP
NOTICE
Tighten the rear shock absorber assembly nuts
and bolts temporarily, and then tighten them to Make sure there are no foreign materials in
specification. the rear wheel sensor. Foreign materials
cause damage to the rear wheel sensor.

TIP
To route the rear wheel sensor lead, refer to
“CABLE ROUTING” on page 2-15.

4-89
 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM

8. Install:
• Rear brake hose holder (rear side) “1”

Rear brake hose holder bolt (rear

side)
T.
R.

7 N·m (0.7 kgf·m, 5.2 lb·ft)

TIP
Fit the projection “a” on the rear brake hose hold-
er into the hole “b” in the swingarm.

a
b

4-90
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM

4-91
 ENGINE

LUBRICATION SYSTEM CHART AND DIAGRAMS...................................... 5-1

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

ENGINE INSPECTION .................................................................................... 5-2

MEASURING THE COMPRESSION PRESSURE....................................5-2

ENGINE REMOVAL ........................................................................................5-4

INSTALLING THE ENGINE....................................................................... 5-8

CYLINDER HEAD............................................................................................ 5-9

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

CAMSHAFT ................................................................................................... 5-20

REMOVING THE CAMSHAFT ................................................................5-21
CHECKING THE CAMSHAFT.................................................................5-21
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........ 5-22
INSTALLING THE CAMSHAFT AND ROCKER ARMS .......................... 5-22
5
VALVES AND VALVE SPRINGS.................................................................. 5-24
REMOVING THE VALVES...................................................................... 5-25
CHECKING THE VALVES AND VALVE GUIDES ..................................5-26
CHECKING THE VALVE SEATS ............................................................ 5-27
CHECKING THE VALVE SPRINGS........................................................ 5-29
INSTALLING THE VALVES .................................................................... 5-29

CYLINDER AND PISTON.............................................................................. 5-31

REMOVING THE PISTON ...................................................................... 5-32
CHECKING THE CYLINDER AND PISTON ...........................................5-32
CHECKING THE PISTON RINGS........................................................... 5-33
CHECKING THE PISTON PIN ................................................................5-34
CHECKING THE TIMING CHAIN GUIDE (EXHAUST SIDE) ................. 5-35
INSTALLING THE PISTON AND CYLINDER .........................................5-35

V-BELT AUTOMATIC TRANSMISSION .......................................................5-37

REMOVING THE PRIMARY SHEAVE....................................................5-40
REMOVING THE SECONDARY SHEAVE ............................................. 5-40
DISASSEMBLING THE SECONDARY SHEAVE.................................... 5-41
CHECKING THE CLUTCH HOUSING ....................................................5-41
CHECKING THE CLUTCH SHOES ........................................................ 5-41
 CHECKING THE V-BELT........................................................................5-42
CHECKING THE PRIMARY SHEAVE ....................................................5-42
CHECKING THE PRIMARY SHEAVE WEIGHTS................................... 5-42
CHECKING THE PRIMARY SHEAVE SLIDERS .................................... 5-42
CHECKING THE SECONDARY SHEAVE .............................................. 5-43
ASSEMBLING THE PRIMARY SHEAVE ................................................ 5-43
ASSEMBLING THE SECONDARY SHEAVE..........................................5-43
INSTALLING THE PRIMARY SHEAVE, V-BELT
AND SECONDARY SHEAVE.................................................................5-44

STARTER GENERATOR .............................................................................. 5-47

REMOVING THE STARTER GENERATOR ...........................................5-48
INSTALLING THE STARTER GENERATOR..........................................5-48

OIL PUMP...................................................................................................... 5-49

CHECKING THE OIL STRAINER ........................................................... 5-51
CHECKING THE OIL PUMP ................................................................... 5-51
ASSEMBLING THE OIL PUMP...............................................................5-51

TRANSMISSION............................................................................................ 5-52
CHECKING THE TRANSMISSION ......................................................... 5-54
INSTALLING THE TRANSMISSION .......................................................5-54

CRANKSHAFT ..............................................................................................5-55
DISASSEMBLING THE CRANKCASE....................................................5-57
REMOVING THE CRANKSHAFT ASSEMBLY ....................................... 5-57
CHECKING THE CRANKSHAFT ASSEMBLY........................................ 5-58
CHECKING THE CRANKCASE ..............................................................5-58
CHECKING THE BEARING .................................................................... 5-58
CHECKING THE OIL PUMP DRIVE GEAR ............................................5-58
INSTALLING THE CRANKSHAFT .......................................................... 5-59
ASSEMBLING THE CRANKCASE.......................................................... 5-59
INSTALLING THE CENTERSTAND .......................................................5-60
 LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS20298

LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS32362

ENGINE OIL LUBRICATION CHART

Rocker arm

Camshaft Oil Nozzle

Crankshaft

Oil pump

Oil pan Oil strainer

3
Lubricant System Diagram
4

5 2 A-A
A

1. Engine oil port

2. Oil drain plug
3. Oil filter
4. Compression spring
5. O-ring
A

5-1
 ENGINE INSPECTION

EAS20041
6. Install:
ENGINE INSPECTION • Compression gauge “1”
EAS30249
• Extension “2”
MEASURING THE COMPRESSION
PRESSURE Compression gauge
TIP 90890-03081
Engine compression tester
Insufficient compression pressure will result in a YU-33223
loss of performance. Compression gauge extension
1. Measure: 122mm
• Valve clearance 90890-04136
Out of specification → Adjust. Compression gauge extension
Refer to “ADJUSTING THE VALVE CLEAR- 122mm
YM-04136
ANCE” on page 3-6.
2. Start the engine, warm it up for several min-
utes, and then turn it off. 1
3. Remove:
• Front side cover (right)
Refer to “GENERAL CHASSIS (2)” on
page 4-3.
• Footrest board assembly (right)
Refer to “GENERAL CHASSIS (5)” on
page 4-12. 2
4. Disconnect:
• Spark plug cap 7. Measure:
5. Remove: • Compression pressure
• Spark plug Out of specification → Refer to steps (c) and
ECA20470
(d).
NOTICE
Before removing the spark plug, use com- Compression pressure
pressed air to blow away any dirt accumulat- 1783–2296 kPa/1050 r/min
ed in the spark plug well to prevent it from (17.8–23.0 kgf/cm²/1050 r/min,
falling into the cylinder. 253.7–326.6 psi/1050 r/min)

a. Turn the main switch to “ON”.

b. With the throttle wide open, crank the en-
gine until the reading on the compression
gauge stabilizes.
EWA12960

WARNING
To prevent sparking, ground the spark plug
lead before cranking the engine.
c. If the compression pressure is above the
maximum specification, check the cylinder
head, valve surfaces and piston crown for
carbon deposits.
Carbon deposits → Eliminate.

5-2
 ENGINE INSPECTION

d. If the compression pressure is below the

minimum specification, pour a teaspoonful
of engine oil into the spark plug bore and
measure again.
Refer to the following table.
Compression pressure (with oil applied into
the cylinder)
Reading Diagnosis
Higher than without Piston ring(s) wear or
oil damage → Repair.
Piston, valves, cylin-
der head gasket or
Same as without oil
piston ring(s) possibly
defective → Repair.

8. Install:
• Spark plug “1”

Spark plug
13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.

TIP
When tightening the spark plug, make sure that
the inside “a” of the spark plug wrench “2” does
not contact the portion “b” of the spark plug.

b
a 2

9. Connect:
• Spark plug cap
10.Install:
• Footrest board assembly (right)
Refer to “GENERAL CHASSIS (5)” on
page 4-12.
• Front side cover (right)
Refer to “GENERAL CHASSIS (2)” on
page 4-3.

5-3
 ENGINE REMOVAL

EAS20042

ENGINE REMOVAL
Removing the muffler

25 N•m (2.5 kgf•m, 18 lb•ft)

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

53 N·m (5.3 kgf·m, 39 lb·ft)

T.R
.

1
LT

3 5

4 New

LT 2 53 N·m (5.3 kgf·m, 39 lb·ft)

T.R
.

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

T.R
.
T.R
.

53 N·m (5.3 kgf·m, 39 lb·ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

1 O2 sensor coupler 1 Disconnect.
2 Muffler protector 1
3 Muffler 1
4 Exhaust gasket 1
5 O2 sensor 1

5-4
 ENGINE REMOVAL

Disconnecting the leads

5
6

Order Job/Parts to remove Q’ty Remarks

Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-19.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-21.
Refer to “GENERAL CHASSIS (1)” on
Battery page 4-1.
Refer to “GENERAL CHASSIS (2)” on
Front cowling assembly page 4-3.
Refer to “GENERAL CHASSIS (3)” on
Side cover assembly page 4-6.
Refer to “GENERAL CHASSIS (3)” on
Storage box page 4-6.
Air filter case Refer to “AIR FILTER CASE” on page 7-8.
Refer to “V-BELT AUTOMATIC TRANSMIS-
V-belt case air duct SION” on page 5-37.
Fuel injector Refer to “FUEL INJECTOR” on page 7-6.
Throttle body Refer to “THROTTLE BODY” on page 7-11.

5-5
 ENGINE REMOVAL

Disconnecting the leads

5
6

Order Job/Parts to remove Q’ty Remarks

Muffler Refer to “ENGINE REMOVAL” on page 5-4.
Rear wheel Refer to “REAR WHEEL” on page 4-29.
1 Coolant reservoir hose 1 Disconnect.
2 Coolant temperature sensor coupler 1 Disconnect.
3 Crankshaft position sensor coupler 1 Disconnect.
4 Starter generator lead coupler 1 Disconnect.
5 Spark plug cap 1 Disconnect.
6 Engine ground lead 1 Disconnect.
7 VVA (variable valve actuator) solenoid coupler 1 Disconnect.

5-6
 ENGINE REMOVAL

Removing the engine

52 N·m (5.2 kgf·m, 38 lb·ft) 21 N·m (2.1 kgf·m, 15 lb·ft)

T.R
T.R

.
.

28 N·m (2.8 kgf·m, 21 lb·ft)

T.R

6
.

3
4 3
7

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

Order Job/Parts to remove Q’ty Remarks

1 Rear shock absorber assembly 2
2 Engine bracket nut/bolt 1
3 Engine bracket fixed nut/bolt (upper) 2/2
4 Engine mount bracket nut/bolt 2/2
5 Engine bracket 1
6 Stopper 2
7 Collar 2

5-7
 ENGINE REMOVAL

EAS30251
d. Temporarily install the engine bracket fixed
INSTALLING THE ENGINE
bolt “9” in the engine mount bracket “10”.
1. Install:
a. Temporarily put the stopper “1” and collar
“2” on the engine assembly “3”.
1
3

9
2 10
e. Tighten the engine bracket nut (front) “10”.

Engine bracket nut (front)

b. Install the engine bracket “4” to the engine 52 N·m (5.2 kgf·m, 38 lb·ft)

T.
R.
assembly, then install fixing bolt “5” and nut
(below) “6” and use the pin ø3 mm to insert
in the hole of the engine bracket and the
collar “a”, then tighten. Fix the nut to the
specified torque (first lock the right and then
the left side).
a
4

A A 10
f. After the installation is complete, confirm
2 1 that the stopper “1” will not touch the engine
assembly “3” with the main bracket upright.
6 5
4 a
A-A 1

Engine bracket nut (center)

50 N·m (5.0 kgf·m, 37 lb·ft)
T.
R.

c. Remove the ø3 pin, insert the engine mount

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

Engine mount bracket nut 3

28 N·m (2.8 kgf·m, 21 lb·ft)
T.
R.

5-8
 CYLINDER HEAD

EAS20044

CYLINDER HEAD
Removing the cylinder head

4.0 N·m (0.40 kgf·m, 3.0 lb·ft)

10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.R
.
10
T.R
.

10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.R
.
New
6 17
7 New New 18 TB1215

New 14 New
8 12
16 19
5 15
(4)
LS LT

9 7 N·m (0.7 kgf·m, 5.2 lb·ft)

T.R
.

11 26 25
M
New
13
(4) (4) (4) 24 New

10 N·m (1.0 kgf·m, 7.4 lb·ft) New

T.R

M
.

1st 10 N·m (1.0 kgf·m, 7.4 lb·ft) 25

M
2nd 24 N·m (2.4 kgf·m, 18 lb·ft) 1 2
13 N·m (1.3 kgf·m, 9.6 lb·ft) 20
T.R
.

23 22
13
3 21
10 N·m (1.0 kgf·m, 7.4 lb·ft)
30 N·m (3.0 kgf·m, 22 lb·ft)
T.R
.

T.R

4
.

New
15 N·m (1.5 kgf·m, 11 lb·ft)
T.R
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (1)” on
Battery
page 4-1.
Refer to “GENERAL CHASSIS (2)” on
Front side covers page 4-3.
Refer to “GENERAL CHASSIS (3)” on
Fuel tank cover page 4-6.
Refer to “GENERAL CHASSIS (4)” on
Storage box page 4-9.
Refer to “GENERAL CHASSIS (5)” on
Center lower cover page 4-12.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-21.

5-9
 CYLINDER HEAD

Removing the cylinder head

4.0 N·m (0.40 kgf·m, 3.0 lb·ft)

10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.R
.
10
T.R
.

10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.R
.
New
6 17
7 New New 18 TB1215

New 14 New
8 12
16 19
5 15
(4)
LS LT

9 7 N·m (0.7 kgf·m, 5.2 lb·ft)

T.R
.

11 26 25
M
New
13
(4) (4) (4) 24 New

10 N·m (1.0 kgf·m, 7.4 lb·ft) New

T.R

M
.

1st 10 N·m (1.0 kgf·m, 7.4 lb·ft) 25

M
2nd 24 N·m (2.4 kgf·m, 18 lb·ft) 1 2
13 N·m (1.3 kgf·m, 9.6 lb·ft) 20
T.R
.

23 22
13
3 21
10 N·m (1.0 kgf·m, 7.4 lb·ft)
30 N·m (3.0 kgf·m, 22 lb·ft)
T.R
.

T.R

4
.

New
15 N·m (1.5 kgf·m, 11 lb·ft)
T.R
.

Order Job/Parts to remove Q’ty Remarks

Muffler Refer to “ENGINE REMOVAL” on page 5-4.
Radiator Refer to “RADIATOR” on page 6-2.
Thermostat assembly Refer to “THERMOSTAT” on page 6-6.
Water pump Refer to “WATER PUMP” on page 6-8.

5-10
 CYLINDER HEAD

Removing the cylinder head

4.0 N·m (0.40 kgf·m, 3.0 lb·ft)

10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.R
.
10
T.R
.

10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.R
.
New
6 17
7 New New 18 TB1215

New 14 New
8 12
16 19
5 15
(4)
LS LT

9 7 N·m (0.7 kgf·m, 5.2 lb·ft)

T.R
.

11 26 25
M
New
13
(4) (4) (4) 24 New

10 N·m (1.0 kgf·m, 7.4 lb·ft) New

T.R

M
.

1st 10 N·m (1.0 kgf·m, 7.4 lb·ft) 25

M
2nd 24 N·m (2.4 kgf·m, 18 lb·ft) 1 2
13 N·m (1.3 kgf·m, 9.6 lb·ft) 20
T.R
.

23 22
13
3 21
10 N·m (1.0 kgf·m, 7.4 lb·ft)
30 N·m (3.0 kgf·m, 22 lb·ft)
T.R
.

T.R

4
.

New
15 N·m (1.5 kgf·m, 11 lb·ft)
T.R
.

Order Job/Parts to remove Q’ty Remarks

Fuel tank Refer to “FUEL TANK” on page 7-1.
Air filter case Refer to “AIR FILTER CASE” on page 7-8.
Fuel injector Refer to “FUEL INJECTOR” on page 7-6.
Intake manifold Refer to “THROTTLE BODY” on page 7-11.
1 Spark plug cap 1 Disconnect.
2 Spark plug 1
3 Coolant temperature sensor coupler 1 Disconnect.

5-11
 CYLINDER HEAD

Removing the cylinder head

4.0 N·m (0.40 kgf·m, 3.0 lb·ft)

10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.R
.
10
T.R
.

10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.R
.
New
6 17
7 New New 18 TB1215

New 14 New
8 12
16 19
5 15
(4)
LS LT

9 7 N·m (0.7 kgf·m, 5.2 lb·ft)

T.R
.

11 26 25
M
New
13
(4) (4) (4) 24 New

10 N·m (1.0 kgf·m, 7.4 lb·ft) New

T.R

M
.

1st 10 N·m (1.0 kgf·m, 7.4 lb·ft) 25

M
2nd 24 N·m (2.4 kgf·m, 18 lb·ft) 1 2
13 N·m (1.3 kgf·m, 9.6 lb·ft) 20
T.R
.

23 22
13
3 21
10 N·m (1.0 kgf·m, 7.4 lb·ft)
30 N·m (3.0 kgf·m, 22 lb·ft)
T.R
.

T.R

4
.

New
15 N·m (1.5 kgf·m, 11 lb·ft)
T.R
.

Order Job/Parts to remove Q’ty Remarks

4 Coolant temperature sensor 1
5 VVA (variable valve actuator) solenoid coupler 1 Disconnect.
6 VVA (variable valve actuator) solenoid 1
7 VVA (variable valve actuator) solenoid gasket 1
8 VVA (variable valve actuator) solenoid rod 1
9 Fuel hose holder 1
10 Cylinder head breather hose 1
11 Cylinder head cover 1
12 Cylinder head cover gasket 1
13 Dowel pin 2

5-12
 CYLINDER HEAD

Removing the cylinder head

4.0 N·m (0.40 kgf·m, 3.0 lb·ft)

10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.R
.
10
T.R
.

10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.R
.
New
6 17
7 New New 18 TB1215

New 14 New
8 12
16 19
5 15
(4)
LS LT

9 7 N·m (0.7 kgf·m, 5.2 lb·ft)

T.R
.

11 26 25
M
New
13
(4) (4) (4) 24 New

10 N·m (1.0 kgf·m, 7.4 lb·ft) New

T.R

M
.

1st 10 N·m (1.0 kgf·m, 7.4 lb·ft) 25

M
2nd 24 N·m (2.4 kgf·m, 18 lb·ft) 1 2
13 N·m (1.3 kgf·m, 9.6 lb·ft) 20
T.R
.

23 22
13
3 21
10 N·m (1.0 kgf·m, 7.4 lb·ft)
30 N·m (3.0 kgf·m, 22 lb·ft)
T.R
.

T.R

4
.

New
15 N·m (1.5 kgf·m, 11 lb·ft)
T.R
.

Order Job/Parts to remove Q’ty Remarks

14 Cylinder head cover breather plate 1
15 Cylinder head cover breather plate gasket 1
16 Oil seal 1
17 Timing chain tensioner plug 1
18 Timing chain tensioner 1
19 Timing chain tensioner gasket 1
20 Camshaft sprocket bolt 1
21 Camshaft sprocket 1
22 Decompression cam 1
23 Cylinder head 1
24 Cylinder head gasket 1
25 Dowel pin 2
26 Engine oil check bolt 1

5-13
 CYLINDER HEAD

EAS30276
3. Remove:
REMOVING THE CYLINDER HEAD
• Cylinder head
1. Align:
TIP
• “I” mark “a” on the AC magneto rotor
(with the match mark “b” on the right crank- • Loosen the bolts and nuts in the proper se-
case) quence as shown.
• Loosen each bolt and nuts 1/2 of a turn at a
a. Turn the crankshaft clockwise.
time. After all of the bolts and nuts are fully
loosened, remove them.

×
4 3 4
b
×
2
6 5
a
b. When the piston is at TDC on the compres-
1 2
sion stroke, align the “I” mark “c” on the
camshaft sprocket with the match mark “d” EAS30277
on the camshaft stopper plate. CHECKING THE CYLINDER HEAD
1. Eliminate:
• Combustion chamber carbon deposits
c d (with a rounded scraper)
TIP
Do not use a sharp instrument to avoid damag-
ing or scratching:
• Spark plug bore threads
• Valve seats

2. Loosen:
• Camshaft sprocket bolt “1”
TIP
Use the camshaft wrench “2” and loosen the
camshaft sprocket bolt.

Camshaft wrench
90890-04162
Camshaft wrench 2. Check:
YM-04162 • Cylinder head
Damage/scratches → Replace.
• Cylinder head water jacket
Mineral deposits/rust → Eliminate.
1
2

5-14
 CYLINDER HEAD

3. Measure: EAS30936

CHECKING THE CAMSHAFT SPROCKET

• Cylinder head warpage
1. Check:
Out of specification → Resurface the cylinder
• Camshaft sprocket
head.
More than 1/4 tooth wear “a” → Replace the
camshaft sprocket, timing chain and crank-
Warpage limit
0.05 mm (0.0020 in) shaft as a set.

a. Place a straightedge “1” and a thickness

gauge “2” across the cylinder head.

a. 1/4 tooth
b. Correct

1. Timing chain roller

2. Camshaft sprocket
1 2
EAS30266

CHECKING THE TIMING CHAIN TENSIONER

1. Check:
• Timing chain tensioner
Cracks/damage → Replace.
a. Remove the timing chain tensioner plug.
b. While lightly pressing the timing chain ten-
sioner rod by hand, turn the tensioner rod
b. Measure the warpage. fully clockwise with a thin screwdriver “1”.
c. If the limit is exceeded, resurface the cylin-
der head as follows.
d. Place 400–600 grit wet sandpaper on the
surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
TIP
To ensure an even surface, rotate the cylinder
head several times.
1

5-15
 CYLINDER HEAD

c. While holding the timing chain tensioner rod EAS31624

CHECKING THE VVA SOLENOID

in place with your hand, turn the screw-
1. Check:
driver counterclockwise, remove the screw-
• VVA (variable valve actuator) solenoid “1”
driver, and slowly release the timing chain
Cracks/damage → Replace.
tensioner rod.
1

d. Make sure that the timing chain tensioner EAS30282

rod comes out of the timing chain tensioner INSTALLING THE CYLINDER HEAD
housing smoothly. If there is rough move- 1. Tighten:
ment, replace the timing chain tensioner. • Cylinder head nuts “1”
e. Install the timing chain tensioner plug. • Cylinder head bolts “2”

EAS30280
Cylinder head nut
CHECKING THE DECOMPRESSION SYSTEM 24 N·m (2.4 kgf·m, 18 lb·ft)
T.

1. Check:
R.

Cylinder head bolt

• Decompression system 10 N·m (1.0 kgf·m, 7.4 lb·ft)
TIP
• Check that the decompression lever moves TIP
smoothly. • Lubricate the cylinder head nuts and thread of
• Check that the operating range “a” of the de- bolt and washers with molybdenum disulfide
compression lever is the same as the range grease.
shown in the illustration. • Tighten the cylinder head nuts and bolts in the
proper tightening sequence as shown and
a torque them in two stages.

×
3 4 4

1 1 ×
2
2 1 2 2

a. 20.88° 6 5

5-16
 CYLINDER HEAD

2. Install: 3. Install:
• Decompression cam “1” • Timing chain tensioner gasket New
• Camshaft sprocket “2” • Timing chain tensioner
• Timing chain
a. Remove the timing chain tensioner plug.
• Camshaft sprocket bolt
b. While lightly pressing the timing chain ten-
a. Turn the crankshaft clockwise. sioner rod by hand, turn the tensioner rod
b. Align the “I” mark “a” on the AC magneto ro- fully clockwise with a thin screwdriver “1”.
tor with the match mark “b” on the right TIP
crankcase.
Make sure that the tensioner rod has been fully
turned clockwise.

a
c. Install the decompression cam. 1
d. Install the timing chain onto the camshaft
sprocket, then the camshaft sprocket onto c. Install the gasket and the timing chain ten-
the camshaft, and then finger tighten the sioner “2” onto the cylinder.
camshaft sprocket bolt. EWA17620

ECA20600 WARNING
NOTICE Always use a new gasket.
Do not turn the crankshaft when installing
the camshaft sprocket to avoid damage or TIP
improper valve timing. • Install the timing chain tensioner gasket so that
the tabs “a” on the gasket are protruding in the
TIP directions shown in the illustration.
• Fit the pin on the decompression cam into the • Apply Yamaha bond No. 1215 to the threads of
slot “c” in the decompression lever on the cam- the timing chain tensioner bolts.
shaft sprocket.
• Align the “I” mark “d” on the camshaft sprocket
with the match mark “e” on the camshaft stop- Yamaha bond No. 1215
90890-85505
per plate.
Three bond No. 1215®

2 Timing chain tensioner bolt

e
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

1
d a
a
c

e. While holding the camshaft, temporarily

tighten the camshaft sprocket bolt. 2

5-17
 CYLINDER HEAD

d. Turn the timing chain tensioner rod counter- 6. Tighten:

clockwise with a thin screwdriver “1”, make • Camshaft sprocket bolt “1”
sure it releases, and then install the timing
chain tensioner plug. Camshaft sprocket bolt
30 N·m (3.0 kgf·m, 22 lb·ft)

T.
R.
1
Camshaft wrench
90890-04162
Camshaft wrench
YM-04162
ECA20610

NOTICE
Be sure to tighten the camshaft sprocket bolt
to the specified torque to avoid the possibil-
4. Turn:
ity of the bolt coming loose and damaging
• Crankshaft
the engine.
(several turns clockwise)
5. Check: TIP
• “I” mark “a”
Tighten the camshaft sprocket bolt with the cam-
Make sure the “I” mark “a” on the AC magne-
shaft wrench “2”.
to rotor is aligned with the match mark “b” on
the right crankcase.
• “I” mark “c”
Make sure the “I” mark “c” on the camshaft 1
sprocket is aligned with the match mark “d” 2
on the camshaft stopper plate.
Out of alignment → Correct.
Refer to the installation steps above.

7. Measure:
• Valve clearance
Out of specification → Adjust.
b
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-6.

c d

5-18
 CYLINDER HEAD

8. Install:
• Oil seal “1”
(into the cylinder head cover “2”)
TIP
Install the oil seal so that it is facing in the direc-
tion shown in the illustration. Press the oil seal
into the cylinder head cover using a suitable di-
ameter socket “3”.

3 2

9. Install:
• VVA (variable valve actuator) solenoid “1”

VVA (variable valve actuator) so-

lenoid bolt
T.
R.

10 N·m (1.0 kgf·m, 7.4 lb·ft)

TIP
While holding the VVA (variable valve actuator)
solenoid so that it is contacting the cylinder head
cover “2”, tighten the bolts to specification.

1
2

5-19
 CAMSHAFT

EAS20043

CAMSHAFT
Removing the rocker arms and camshaft

8 N·m (0.8 kgf·m, 5.9 lb·ft)

T .R
.

7 N·m (0.7 kgf·m, 5.2 lb·ft)

T .R
.

2
New M
11 14
14

12 10
13 9 4 New
M

M E
8
6 7
E 3
E 5
2 M

7 E
M
2 M 5
M
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T .R
.

Order Job/Parts to remove Q’ty Remarks

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

5-20
 CAMSHAFT

EAS30256 EAS30257

REMOVING THE CAMSHAFT CHECKING THE CAMSHAFT

1. Loosen: 1. Check:
• Adjusting screw (intake/exhaust) • Camshaft lobe
2. Remove: Blue discoloration/pitting/scratches → Re-
• Camshaft assembly “1” place the camshaft.
2. Measure:
Slide hammer bolt (M8) • Camshaft lobe dimensions “a”
90890-01085 Out of specification → Replace the camshaft.
Slide hammer bolt 8 mm
YU-01083-2 Camshaft lobe dimensions
Weight Lobe height limit (Intake)
90890-01084 32.111 mm (1.2642 in)
Weight Lobe height limit (Intake high
YU-01083-3 speed)
32.487 mm (1.2790 in)
a. Align the holes “a” in intake rocker arm 1 “2” Lobe height limit (Exhaust)
and intake rocker arm 2 “3”, and then push 29.320 mm (1.1543 in)
the intake rocker arm stopper pin “4” in the
direction of the arrow shown in the illustra-
a
tion.

4
a

2
3. Measure:
• Camshaft runout
b. While pushing intake rocker arm 1 “2” and Out of specification → Replace the camshaft.
intake rocker arm 2 “3” in the direction of the
arrow shown in the illustration, remove the
camshaft assembly using a slide hammer
bolt “5” and weight “6”.

3
1
5 4. Check:
• Camshaft oil passage
6
Obstruction → Blow out with compressed air.

5-21
 CAMSHAFT

EAS30259
4. Measure:
CHECKING THE ROCKER ARMS AND
• Rocker arm shaft outside diameter “a”
ROCKER ARM SHAFTS
Out of specification → Replace.
The following procedures are applied to all of the
rocker arms and rocker arm shafts.
Rocker arm shaft outside diame-
1. Check: ter limit
• Rocker arm 9.935 mm (0.3911 in)
• Rocker arm roller “1”
Damage/wear → Replace.

1 1
5. Calculate:
2. Check: • Rocker-arm-to-rocker-arm-shaft clearance
• Rocker arm shaft TIP
Blue discoloration/excessive wear/pitting/ Calculate the clearance by subtracting the rock-
scratches → Replace or check the lubrication er arm shaft outside diameter from the rocker
system. arm inside diameter.
3. Measure:
• Rocker arm inside diameter “a” Out of specification → Replace the defective
Out of specification → Replace. part(s).

Rocker arm inside diameter limit Rocker-arm-to-rocker-arm-shaft

10.015 mm (0.3943 in) clearance limit
0.080 mm (0.0032 in)

EAS30270

INSTALLING THE CAMSHAFT AND ROCKER

ARMS
a 1. Lubricate:
• Camshaft assembly

Recommended lubricant
Camshaft
Molybdenum disulfide oil
Camshaft bearing
Engine oil

5-22
 CAMSHAFT

2. Lubricate: b. While pushing intake rocker arm 1 “2” and

• Rocker arms intake rocker arm 2 “3” in the direction of the
• Rocker arm shafts arrow shown in the illustration, install the
• Spring camshaft assembly.
• Intake rocker arm stopper pin TIP
Install the camshaft with the punch mark “a” fac-
Recommended lubricant ing upward.
Rocker arm shaft
Intake rocker arm stopper pin
Molybdenum disulfide oil 2
Spring
Rocker arm roller 3
Engine oil

3. Install:
• Spring “1”
TIP a
Install the spring so that the ends “a” of the
spring are positioned at the locations shown in 5. Install:
the illustration. • Camshaft stopper plate

a 1 Camshaft stopper plate bolt (M5

× 16)
T.
R.

8 N·m (0.8 kgf·m, 5.9 lb·ft)

Camshaft stopper plate bolt (M6
× 14)
8 N·m (0.8 kgf·m, 5.9 lb·ft)

TIP
Before installing the camshaft stopper plate,
4. Install: make sure that the slots “a” in the rocker arm
• Camshaft assembly “1” shafts “2” are parallel with the edge “b” of the cyl-
inder head and that the camshaft stopper plate
a. Align the holes “a” in intake rocker arm 1 “2”
bolt holes in the cylinder head and rocker arm
and intake rocker arm 2 “3”, and then push
shafts are aligned.
the intake rocker arm stopper pin “4” in the
direction of the arrow shown in the illustra-
b
tion. 2 a

4 a
a

5-23
 VALVES AND VALVE SPRINGS

EAS20045

VALVES AND VALVE SPRINGS

Removing the valves and valve springs

1 2 3 8 New
6 New

8 New
4
7
E

7
M
M
6 New

1
E

Order Job/Parts to remove Q’ty Remarks

Cylinder head Refer to “CYLINDER HEAD” on page 5-9.
Camshaft/Rocker arm Refer to “CAMSHAFT” on page 5-20.
1 Valve cotter 8
2 Valve spring retainer 4
3 Valve spring 4
4 Intake valve 2
5 Exhaust valve 2
6 Valve stem seal 4
7 Valve spring seat 4
8 Valve guide 4

5-24
 VALVES AND VALVE SPRINGS

EAS30283

REMOVING THE VALVES 2

The following procedures are applied to all of the
valves and related components.
TIP
Before removing the internal parts of the cylinder
head (e.g., valves, valve springs, valve seats),
make sure the valves properly seal.
1. Check: 1
• Valve sealing 3. Remove:
Leakage at the valve seat → Check the valve • Valve spring retainer “1”
face, valve seat, and valve seat width. • Valve spring “2”
Refer to “CHECKING THE VALVE SEATS” • Valve “3”
on page 5-27. • Valve stem seal “4”
a. Pour a clean solvent “a” into the intake and • Valve spring seat “5”
exhaust ports. TIP
b. Check that the valves properly seal. Identify the position of each part very carefully so
TIP that it can be reinstalled in its original place.
There should be no leakage at the valve seat “1”.
1
5
2

3
4

2. Remove:
• Valve cotters “1”
TIP
Remove the valve cotters by compressing the
valve spring with the valve spring compressor
and the valve spring compressor attachment “2”.

Valve spring compressor

90890-04019
Valve spring compressor
YM-04019
Valve spring compressor attach-
ment
90890-04108
Valve spring compressor adapter
22 mm
YM-04108

5-25
 VALVES AND VALVE SPRINGS

EAS30284
2. Replace:
CHECKING THE VALVES AND VALVE
GUIDES • Valve guide New
The following procedures are applied to all of the TIP
valves and valve guides. To ease valve guide removal and installation,
1. Measure: and to maintain the correct fit, heat the cylinder
• Valve-stem-to-valve-guide clearance head to 100 °C (212 °F) in an oven.
Out of specification → Replace the valve
guide. a. Remove the valve guide with the valve
guide remover “1”.
Valve-stem-to-valve-guide clearance =
Valve guide inside diameter “a” -
Valve stem diameter “b”
1
Valve-stem-to-valve-guide clear-
ance limit (intake)
0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clear-
ance limit (exhaust)
0.100 mm (0.0039 in)
b. Install the new valve guide with the valve
guide installer “2” and valve guide remover
“1”.

Valve guide position

9.9–10.3 mm (0.39–0.41 in)

a. Valve guide position

5-26
 VALVES AND VALVE SPRINGS

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.

EAS30285

CHECKING THE VALVE SEATS

The following procedures are applied to all of the
valves and valve seats.
TIP 1. Eliminate:
After replacing the valve guide, reface the valve • Carbon deposits
seat. (from the valve face and valve seat)
2. Check:
• Valve seat
Valve guide remover (ø5) Pitting/wear → Replace the cylinder head.
90890-04097 3. Measure:
Valve guide remover (5.0 mm) • Valve seat width “a”
YM-04097
Out of specification → Replace the cylinder
Valve guide installer (ø5)
head.
90890-04098
Valve guide installer (5.0 mm)
YM-04098 Valve seat contact width limit (in-
take)
Valve guide reamer (ø5)
1.3 mm (0.05 in)
90890-04099
Valve seat contact width limit
Valve guide reamer (5.0 mm)
(exhaust)
YM-04099
1.7 mm (0.07 in)

3. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
4. Check:
• Valve face
Pitting/wear → Grind the valve face. a
• Valve stem end
Mushroom shape or diameter larger than the
body of the valve stem → Replace the valve.
5. Measure:
• Valve stem runout a. Apply blue layout fluid “b” onto the valve
Out of specification → Replace the valve. face.
TIP
• When installing a new valve, always replace
the valve guide.
• If the valve is removed or replaced, always re-
place the valve stem seal.

b
Valve stem runout
0.020 mm (0.0008 in)

5-27
 VALVES AND VALVE SPRINGS

b. Install the valve into the cylinder head.

c. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
d. Measure the valve seat width.
TIP
Where the valve seat and valve face contacted
one another, the blue layout fluid will have been
removed.
e. Apply a fine lapping compound to the valve
4. Lap:
face and repeat the above steps.
• Valve face
f. After every lapping procedure, be sure to
• Valve seat
clean off all of the lapping compound from
TIP the valve face and valve seat.
After replacing the cylinder head or replacing the g. Apply blue layout fluid “b” onto the valve
valve and valve guide, the valve seat and valve face.
face should be lapped.

a. Apply a coarse lapping compound “a” to the

valve face.
ECA13790

NOTICE
Do not let the lapping compound enter the
gap between the valve stem and the valve b
guide.

h. Install the valve into the cylinder head.

i. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
j. Measure the valve seat width again. If the
valve seat width is out of specification, re-
a
face and lap the valve seat.

b. Apply molybdenum disulfide oil onto the

valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve
seat are evenly polished, and then clean off
all of the lapping compound.
TIP
For the best lapping results, lightly tap the valve
seat while rotating the valve back and forth be-
tween your hands.

5-28
 VALVES AND VALVE SPRINGS

EAS30286

CHECKING THE VALVE SPRINGS

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

Free length limit (intake)

32.10 mm (1.26 in) 2. Install:
Free length limit (exhaust) • Valve spring seat “1”
32.10 mm (1.26 in)
• Valve stem seal “2” New
• Valve “3”
• Valve spring “4”
• Valve spring retainer “5”
(into the cylinder head)
TIP
• Make sure each valve is installed in its original
place.
• Install the valve springs with the larger pitch “a”
facing up.
a
EAS30288

INSTALLING THE VALVES 5

The following procedures are applied to all of the 1
valves and related components. 4
• Valve stem end
(with an oil stone) 3
2 New

1. Lubricate:
• Valve stem “1”

Recommended lubricant
Molybdenum disulfide oil b. Smaller pitch

• Valve stem seal “2”

(with the recommended lubricant)

Recommended lubricant
Engine oil

5-29
 VALVES AND VALVE SPRINGS

3. Install:
• Valve cotters “1”
TIP
Install the valve cotters by compressing the
valve spring with the valve spring compressor
and the valve spring compressor attachment “2”.

Valve spring compressor

90890-04019
Valve spring compressor
YM-04019
Valve spring compressor attach-
ment
90890-04108
Valve spring compressor adapter
22 mm
YM-04108

1
4. To secure the valve cotters onto the valve
stem, lightly tap the valve tip with a soft-face
hammer.
5.ECA13800

NOTICE
Hitting the valve tip with excessive force
could damage the valve.

5-30
 CYLINDER AND PISTON

EAS20046

CYLINDER AND PISTON

Removing the cylinder and piston

3 New
4
2

E
1 New
5 New 7
11
10
10 N·m (1.0 kgf·m, 7.4 lb·ft) 9
T.R
.

6
5 New

E
E

Order Job/Parts to remove Q’ty Remarks

Cylinder head Refer to “CYLINDER HEAD” on page 5-9.
1 Timing chain guide (exhaust side) 1
2 Cylinder 1
3 Cylinder gasket 1
4 Dowel pin 2
5 Piston pin clip 2
6 Piston pin 1
7 Piston 1
8 Top ring 1
9 2nd ring 1
10 Oil ring 1
11 Coolant drain bolt (cylinder side) 1

5-31
 CYLINDER AND PISTON

EAS30289
2. Remove:
REMOVING THE PISTON
• Top ring
1. Remove:
• 2nd ring
• Piston pin clips “1”
• Oil ring
• Piston pin “2”
TIP
• Piston “3”
ECA13810 When removing a piston ring, open the end gap
NOTICE with your fingers and lift the other side of the ring
Do not use a hammer to drive the piston pin over the piston crown.
out.

TIP
• Before removing the piston pin clips, cover the
crankcase opening with a clean rag to prevent
them from falling into the crankcase.
• Before removing the piston pin, deburr the pis-
ton pin clip groove and the piston pin bore ar-
ea. If both areas are deburred and the piston
pin is still difficult to remove, remove it with the
piston pin puller set “4”.
EAS30291

CHECKING THE CYLINDER AND PISTON

Piston pin puller set 1. Check:
90890-01304 • Piston wall
Piston pin puller • Cylinder wall
YU-01304 Vertical scratches → Rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
2. Measure:
• Piston-to-cylinder clearance
2 1 a. Measure cylinder bore “C” with the cylinder
bore gauge.
TIP
Measure cylinder bore “C” by taking side-to-side
and front-to-back measurements of the cylinder.
3

Bore
58.000–58.010 mm (2.2835–
2.2839 in)
Wear limit
58.060 mm (2.2858 in)

“C” = maximum of D1 - D2

5-32
 CYLINDER AND PISTON

b. If out of specification, rebore or replace the EAS30292

CHECKING THE PISTON RINGS

cylinder, and replace the piston and piston
1. Measure:
rings as a set.
• Piston ring side clearance
c. Measure piston skirt diameter P with the mi-
Out of specification → Replace the piston
crometer.
and piston rings as a set.
TIP
Before measuring the piston ring side clearance,
a eliminate any carbon deposits from the piston
ring grooves and piston rings.
P
Piston ring
Top ring
Side clearance limit
0.115 mm (0.0045 in)
a. 6.0 mm (0.24 in) from the bottom edge of 2nd ring
the piston
Side clearance limit
0.115 mm (0.0045 in)
Piston
Diameter
57.962–57.985 mm (2.2820–
2.2829 in)

d. If out of specification, replace the piston and

piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
Piston-to-cylinder clearance =
Cylinder bore - Piston skirt diameter
2. Install:
• Piston ring
(into the cylinder)
Piston-to-cylinder clearance
0.015–0.048 mm (0.0006–0.0019 TIP
in) Use the piston crown to level the piston ring near
the bottom of the cylinder where the cylinder
f. If out of specification, rebore or replace the wear is lowest.
cylinder, and replace the piston and piston
rings as a set.

5-33
 CYLINDER AND PISTON

3. Measure: EAS30293

CHECKING THE PISTON PIN

• Piston ring end gap
1. Check:
Out of specification → Replace the piston
• Piston pin
ring.
Blue discoloration/grooves → Replace the
TIP
piston pin, and then check the lubrication sys-
The oil ring expander spacer end gap cannot be tem.
measured. If the oil ring rail gap is excessive, re- 2. Measure:
place all three piston rings. • Piston pin outside diameter “a”
Out of specification → Replace the piston pin.
Piston ring
Top ring Piston pin outside diameter limit
End gap limit 13.975 mm (0.5502 in)
0.50 mm (0.0197 in)
2nd ring
End gap limit
0.85 mm (0.0335 in)

3. Measure:
• Piston pin bore diameter “b”
b Out of specification → Replace the piston.

a. Bottom of cylinder Piston pin bore inside diameter

b. Upper of cylinder limit
14.043 mm (0.5529 in)

4. Calculate:
• Piston-pin-to-piston-pin-bore clearance
Out of specification → Replace the piston pin
and piston as a set.
Piston-pin-to-piston-pin-bore clearance =
Piston pin bore diameter “b” -
Piston pin outside diameter “a”

5-34
 CYLINDER AND PISTON

EAS30290

CHECKING THE TIMING CHAIN GUIDE 3 New 2

(EXHAUST SIDE) 1
1. Check: b
• Timing chain guide (exhaust side)
Damage/wear → Replace.
EAS30294

INSTALLING THE PISTON AND CYLINDER c

1. Install:
• Lower oil ring rail “1”
• Oil ring expander “2” 3. Lubricate:
• Upper oil ring rail “3” • Piston
• 2nd ring “4” • Piston rings
• Top ring “5” • Cylinder
TIP (with the recommended lubricant)
Be sure to install the piston rings so that the
manufacturer marks face up. Recommended lubricant
Engine oil

5 4. Offset:
• Piston ring end gaps
c
4
3

2 b a
135˚
1 45˚ 45˚

2. Install: e d
• Piston “1” 45˚ 45˚
• Piston pin “2” A

• Piston pin clips “3” New a. Top ring

b. 2nd ring
TIP
c. Upper oil ring rail
• Apply engine oil to the piston pin. d. Oil ring expander
• Make sure the punch mark “a” on the piston e. Lower oil ring rail
points towards the exhaust side of the cylinder.
• Before installing the piston pin clips, cover the A. Exhaust side
crankcase opening with a clean rag to prevent
the clips from falling into the crankcase.
• When installing a piston pin clip, make sure
that the clip ends “b” are positioned away from
the cutout “c” in the piston as shown in the illus-
tration.

New 3
2

5-35
 CYLINDER AND PISTON

5. Install:
• Dowel pins
• Cylinder gasket New
• Cylinder “1”
TIP
• While holding the piston “2” with one hand, in-
stall the cylinder with the other hand.
• Pass the timing chain and timing chain guide
(intake side) through the timing chain cavity.

1 2

5-36
 V-BELT AUTOMATIC TRANSMISSION

EAS20050

V-BELT AUTOMATIC TRANSMISSION

Removing the V-belt case

10 5 10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.R
.
New 9
(10)
8
7
New 1
New 6
2
3
4
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.R
.

New

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

Order Job/Parts to remove Q’ty Remarks

Air filter case Refer to “AIR FILTER CASE” on page 7-8.
1 V-belt case air filter element cover 1
2 V-belt case air filter element 1
3 V-belt case air filter element support 1
4 O-ring 1
5 V-belt case 1
6 V-belt case gasket 1
7 Dowel pin 1
8 V-belt case check hose 1
9 Clip 1
10 Bearing 1

5-37
 V-BELT AUTOMATIC TRANSMISSION

Removing the V-belt, primary sheave and secondary sheave

45 N·m (4.5 kgf·m, 33 lb·ft)

T.R
.
13
14

12
10
10
11 8
LS 9

10

7 6
LS
4
5
3
1
2
76 N·m (7.6 kgf·m, 56 lb·ft)
T.R
.

Order Job/Parts to remove Q’ty Remarks

1 Primary fixed sheave nut 1
2 Conical spring washer 1
3 Primary fixed sheave 1
4 Washer 1
5 V-belt 1
6 Collar 1
7 Primary sliding sheave 1
8 Primary sheave weight 6
9 Cam 1
10 Slider 3
11 Washer 1
12 Clutch housing nut 1
13 Clutch housing 1
14 Secondary sheave assembly 1

5-38
 V-BELT AUTOMATIC TRANSMISSION

Disassembling the secondary sheave

7 *
6
3
4 55 N·m (5.5 kgf·m, 41 lb·ft)

T .R
.
13
14 16 5
15 New 2

8
9

12 New 10

1
12 New

* 11 New

* Apply Shell dolium grease R®.

Order Job/Parts to remove Q’ty Remarks
1 Secondary sheave nut 1
2 Clutch carrier assembly 1
3 Circlip 3
4 Clutch puller fixed plate 1
5 Clutch shoe spring 3
6 Compression spring 1
7 Spring seat 1
8 Guide pin 3
9 Collar 3
10 Secondary sliding sheave 1
11 O-ring 2
12 Oil seal 2
13 Bearing 1
14 Circlip 1
15 Bearing 1
16 Secondary fixed sheave 1

5-39
 V-BELT AUTOMATIC TRANSMISSION

EAS30310 EAS30311

REMOVING THE PRIMARY SHEAVE REMOVING THE SECONDARY SHEAVE

1. Remove: 1. Remove:
• Primary fixed sheave nut “1” • Clutch housing nut “1”
• Conical spring washer • Clutch housing “2”
• Washer TIP
• Primary fixed sheave “2” While holding the clutch housing with the rotor
TIP holding tool “3”, loosen the clutch housing nut.
While holding the primary fixed sheave with the
rotor holding tool “3”, loosen the primary fixed
Rotor holding tool
sheave nut.
90890-04166
Rotor holding tool
Rotor holding tool (including YM-04166
handle and 3 pins)
90890-04195
Rotor holding tool attachment 7 x
12 mm
90890-04197

3 3
2
1
2. Loosen:
1 • Secondary sheave nut “1”
ECA21820

2 NOTICE
Do not remove the secondary sheave nut at
this stage.

TIP
While holding the secondary sheave with the ro-
tor holding tool “2”, loosen the secondary
sheave nut one full turn with the socket wrench
“3”.

Rotor holding tool

90890-04166
Rotor holding tool
YM-04166
Socket wrench (39 mm)
90890-01493

3 2

5-40
 V-BELT AUTOMATIC TRANSMISSION

EAS31619 EAS30314

DISASSEMBLING THE SECONDARY CHECKING THE CLUTCH SHOES

SHEAVE The following procedures are applied to all of the
1. Remove: clutch shoes.
• Secondary sheave nut “1” 1. Check:
TIP • Clutch shoe
Install the sheave spring compressor “2” and Damage/wear → Replace the clutch shoes
sheave fixed block “3” onto the secondary and springs as a set.
sheave as shown. Then, compress the spring, Glazed areas → Sand with coarse sandpa-
and remove the secondary sheave nut. per.
TIP
After sanding the glazed areas, clean the clutch
Sheave spring compressor
with a cloth.
90890-04134
Sheave spring compressor 2. Measure:
YM-04134 • Clutch shoe thickness “a”
Sheave fixed block Out of specification → Replace the clutch
90890-04135 shoes and springs as a set.
Sheave fixed bracket
YM-04135 Clutch shoe thickness limit
2.1 mm (0.08 in)
2
a a
1
a
a

3
EAS30352 a a
CHECKING THE CLUTCH HOUSING
1. Check:
• Clutch housing
Damage/wear → Replace.
2. Measure:
• Clutch housing inside diameter “a”
Out of specification → Replace the clutch
housing.

Clutch housing inside diameter

limit
125.5 mm (4.94 in)

5-41
 V-BELT AUTOMATIC TRANSMISSION

EAS30315 EAS30317

CHECKING THE V-BELT CHECKING THE PRIMARY SHEAVE

1. Check: WEIGHTS
• V-belt “1” The following procedures are applied to all of the
Cracks/damage/wear → Replace. primary sheave weights.
Grease/oil → Clean the primary and second- 1. Check:
ary sheave. • Primary sheave weight
2. Measure: Cracks/damage/wear → Replace.
• V-belt width “a” 2. Measure:
Out of specification → Replace. • Primary sheave weight outside diameter “a”
Out of specification → Replace.
V-belt width limit
21.6 mm (0.85 in) Weight outside diameter limit
19.5 mm (0.77 in)
a 2 1

2. Plastic board
3. Ruler EAS31233

EAS30316
CHECKING THE PRIMARY SHEAVE
CHECKING THE PRIMARY SHEAVE SLIDERS
1. Check: 1. Check:
• Primary sliding sheave • Primary sheave slider
• Primary fixed sheave Cracks/damage/wear → Replace.
• Collar
Cracks/damage/wear → Replace the primary
sliding sheave, primary fixed sheave, and
collar as a set.

5-42
 V-BELT AUTOMATIC TRANSMISSION

EAS30319 EAS30321

CHECKING THE SECONDARY SHEAVE ASSEMBLING THE SECONDARY SHEAVE

1. Check: 1. Lubricate:
• Secondary fixed sheave • Secondary sliding sheave inner surface
• Secondary sliding sheave • Oil seal “1”
Cracks/damage/wear → Replace the sec- (with the recommended lubricant)
ondary fixed and sliding sheaves as a set.
2. Check: Recommended lubricant
• Torque cam groove “a” Shell dolium grease R®
Damage/wear → Replace the secondary
fixed and sliding sheaves as a set. TIP
3. Check: Do not apply grease to the inner surface “a” of
• Guide pin “1” the secondary fixed sheave “2”. If any grease
Damage/wear → Replace the secondary gets on the inner surface of the secondary fixed
fixed and sliding sheaves as a set. sheave, be sure to wipe it off thoroughly.

1 2 *
1

*
a
a 1

4. Check:
2. Install:
• Spring free length
Out of specification → Replace the spring. • Oil seal New
• Secondary sliding sheave “1”
Compression spring free length TIP
limit Install the secondary sliding sheave onto the
104.7 mm (4.12 in) secondary fixed sheave “2” with the oil seal
guide “3”.

Oil seal guide (37 mm)

90890-04177

3
EAS30320

ASSEMBLING THE PRIMARY SHEAVE 2

1. Clean:
• Primary fixed sheave
• Primary sliding sheave
3. Install:
• Primary sheave weight
• Guide pin “1”
• Cam

5-43
 V-BELT AUTOMATIC TRANSMISSION

4. Lubricate: EAS31234

INSTALLING THE PRIMARY SHEAVE, V-

• Guide pin grooves “a”
BELT AND SECONDARY SHEAVE
• O-rings “2” New 1. Install:
(with the recommended lubricant) • Secondary sheave assembly
TIP
Recommended lubricant
Shell dolium grease R® Before installing the secondary sheave assem-
bly, check that there is no grease on the splines
“a” of the primary drive gear. If there is any
1 grease on the splines, be sure to wipe it off thor-
New 2 oughly.
a

5. Install: a
• Spring seat
• Compression spring
• Clutch carrier assembly
2. Tighten:
• Secondary sheave nut “1”
• Secondary sheave nut “1”
TIP
• Install the sheave spring compressor “2” and Secondary sheave nut
sheave fixed block “3” onto the secondary 55 N·m (5.5 kgf·m, 41 lb·ft)
T.
R.

sheave as shown. Then, compress the spring,

and install the secondary sheave nut. TIP
• Install the secondary sheave nut “1” with its ta- While holding the secondary sheave with the ro-
pered side facing the clutch carrier. tor holding tool “2”, tighten the secondary
sheave nut with the socket wrench “3”.
Sheave spring compressor
90890-04134 Rotor holding tool
Sheave spring compressor 90890-04166
YM-04134 Rotor holding tool
Sheave fixed block YM-04166
90890-04135 Socket wrench (39 mm)
Sheave fixed bracket 90890-01493
YM-04135

2
2

3
3

5-44
 V-BELT AUTOMATIC TRANSMISSION

3. Install: 5. Install:
• Clutch housing “1” • V-belt “1”
• Clutch housing nut “2” ECA21720

NOTICE
Clutch housing nut Do not allow grease to come in contact with
45 N·m (4.5 kgf·m, 33 lb·ft) the V-belt.
T.
R.

TIP TIP
While holding the clutch housing with the rotor • Install the V-belt with the printed arrow mark on
holding tool “3”, tighten the clutch housing nut. the V-belt facing in the direction shown in the il-
lustration.
• Install the V-belt onto the primary sheave side.
Rotor holding tool
90890-04166
Rotor holding tool
YM-04166

3
1

6. Install:
• Primary fixed sheave “1”
1 • Washer
2 • Conical spring washer “2”
4. Install: • Primary fixed sheave nut
• Primary sliding sheave assembly “1” ECA21730

• Washer NOTICE
TIP Do not allow grease to contact the primary
When installing the primary sliding sheave as- sheave assembly.
sembly, hold the cam to prevent the primary TIP
sheave weights from falling out of the primary
• Apply lithium-soap-based grease to the prima-
sliding sheave.
ry fixed sheave nut side of the conical spring
washer and to the threaded portion of the
crankshaft.
• Install the conical spring washer with the mark
“a” facing outward.
1
• Install the V-belt in the primary sheave (when
the pulley is at its widest position) and in the
secondary sheave (when the pulley is at its
narrowest position), and make sure the V-belt
is tight.

5-45
 V-BELT AUTOMATIC TRANSMISSION

2
7. Tighten:
• Primary fixed sheave nut “1”

Primary fixed sheave nut

76 N·m (7.6 kgf·m, 56 lb·ft)
T.
R.

TIP
While holding the primary fixed sheave with the
rotor holding tool “2”, tighten the primary fixed
sheave nut.

Rotor holding tool (including

handle and 3 pins)
90890-04195
Rotor holding tool attachment 7 x
12 mm
90890-04197

5-46
 STARTER GENERATOR

EAS20714

STARTER GENERATOR
Removing the starter generator assembly

4
LT

10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.R
.
3

5
2

LT

70 N·m (7.0 kgf·m, 52 lb·ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-21.
Refer to “GENERAL CHASSIS (1)” on
Battery page 4-1.
Refer to “GENERAL CHASSIS (2)” on
Side cover (right) page 4-3.
Radiator fan Refer to “RADIATOR” on page 6-2.
Crankshaft position sensor coupler/Starter gen-
1 1/1 Disconnect.
erator coupler
2 Starter generator rotor nut 1
3 Starter generator rotor 1
4 Woodruff key 1
5 Starter generator/Crankshaft position sensor 1

5-47
 STARTER GENERATOR

EAS33382 EAS33383

REMOVING THE STARTER GENERATOR INSTALLING THE STARTER GENERATOR

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

1 Rotor holding tool (including

handle and 3 pins)
2. Remove: 90890-04195
• Starter generator rotor “1” Rotor holding tool attachment 7 x
(with the flywheel puller “2”) 5 mm
• Woodruff key 90890-04198
ECA21740

NOTICE
To protect the end of the crankshaft, place an
appropriate sized socket between the fly-
wheel puller center bolt and the crankshaft.
3
2
Flywheel puller
90890-01189
Flywheel puller
YM-01189 1

5-48
 OIL PUMP

EAS20054

OIL PUMP
Removing the oil pump

3 New
2
4

5 4
1 New

4.0 N·m (0.40 kgf·m, 3.0 lb·ft) LS

T.R
.

10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Refer to “V-BELT AUTOMATIC TRANSMIS-
V-belt automatic transmission
SION” on page 5-37.
1 Oil seal 1
2 Oil pump cover 1
3 Gasket 1
4 Dowel pin 2
5 Oil pump assembly 1

5-49
 OIL PUMP

Disassembling the oil pump

10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.R
.

7
5
3
6

Order Job/Parts to remove Q’ty Remarks

1 Oil pump housing cover 1
2 Pin 1
3 Oil pump driven gear 1
4 Oil pump rotor assembly 1
5 Oil pump inner rotor 1
6 Oil pump outer rotor 1
7 Oil pump housing 1

5-50
 OIL PUMP

EAS30340 EAS30342

CHECKING THE OIL STRAINER ASSEMBLING THE OIL PUMP

1. Check: 1. Lubricate:
• Oil strainer • Inner rotor
Damage → Replace. • Outer rotor
Contaminants → Clean with solvent. • Oil pump shaft
EAS30337

CHECKING THE OIL PUMP Recommended lubricant

1. Check: Engine oil
• Oil pump drive gear 2. Install:
• Oil pump driven gear • Oil pump housing “1”
• Oil pump housing • Oil pump outer rotor “2”
• Oil pump housing cover • Oil pump inner rotor “3”
Cracks/damage/wear → Replace the oil • Oil pump driven gear “4”
pump. • Pin “5”
2. Check: • Oil pump housing cover
• Oil pump operation
Rough movement → Repeat steps (1) and Oil pump housing cover screw
(2) or replace the oil pump. 1.0 N·m (0.10 kgf·m, 0.73 lb·ft)
T.
R.

TIP
When installing the inner rotor, align the pin in
the oil pump driven gear with the groove “a” in
the inner rotor.

4
5 3

a 1

3. Check:
• Oil pump operation
Refer to “CHECKING THE OIL PUMP” on
page 5-51.

5-51
 TRANSMISSION

EAS20062

TRANSMISSION
Removing the transmission

20 N·m (2.0 kgf·m, 15 lb·ft)

T.R
.

LS
New 11

New 12

10
2
12
5 12
6 E
E
E
(5)
12 13
12
E

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

Order Job/Parts to remove Q’ty Remarks

Muffler Refer to “ENGINE REMOVAL” on page 5-4.
Radiator cover Refer to “RADIATOR” on page 6-2.
Refer to “V-BELT AUTOMATIC TRANSMIS-
Secondary sheave assembly SION” on page 5-37.
Refer to “REAR SHOCK ABSORBER
Swingarm ASSEMBLIES AND SWINGARM” on
page 4-85.
Rear wheel Refer to “REAR WHEEL” on page 4-29.
1 Final transmission oil filler cap 1
2 Final transmission oil drain bolt 1
3 Transmission case cover 1
4 Transmission case cover gasket 1
5 Dowel pin 2

5-52
 TRANSMISSION

Removing the transmission

20 N·m (2.0 kgf·m, 15 lb·ft)

T.R
.

LS
New 11

New 12

10
2
12
5 12
6 E
E
E
(5)
12 13
12
E

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

Order Job/Parts to remove Q’ty Remarks

6 Main axle assembly 1
7 Drive axle 1
8 1st wheel gear 1
9 Circlip 1
10 Primary drive gear 1
11 Oil seal 2
12 Bearing 6
13 Transmission breather pipe 1

5-53
 TRANSMISSION

EAS30433
2. Install:
CHECKING THE TRANSMISSION
1. Check: • Circlip “1” New
• Transmission gears (to the drive axle “2”)
Blue discoloration/pitting/wear → Replace TIP
the defective gear(s). Install the circlip with its chamfered side facing
• Transmission gear dogs as shown.
Cracks/damage/rounded edges → Replace
the defective gear(s).
2. Check:
• Transmission gear engagement 2
1
(each pinion gear to its respective wheel New
gear)
Incorrect → Reassemble the transmission 1 New
axle assemblies.
3. Check:
2
• Transmission gear movement
Rough movement → Replace the defective 3. Install:
part(s). • Primary driven gear “1”
EAS30438 (to the main axle “2”)
INSTALLING THE TRANSMISSION
1. Install: Primary driven gear installed
• Oil seal “1” New depth “a”
(to the transmission case cover “2”) 0.5–0.9 mm (0.020–0.035 in)
• Oil seal “3” New
(to the right crankcase “4”) a

Installed depth “a” 2

21.7–21.8 mm (0.85–0.86 in)
Installed depth “b”
0.25–0.75 mm (0.01–0.03 in)
1
New 1 2
4. Install:
a • Transmission case cover “1”

Transmission case cover bolt

3 New 20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.

TIP
b 4
Tighten the transmission case cover bolts in the
proper tightening sequence as shown.

1 5
4

3 1

2 7
8

5-54
 CRANKSHAFT

EAS20061

CRANKSHAFT
Removing the crankshaft
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.R
.

1 E

LS
New

(11) 11
10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.R
.
10

10

12
LS
7

New
8 LS
New
6 2
4
5
LS
New 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.R
.

3
20 N·m (2.0 kgf·m, 15 lb·ft)
T.R
.

Order Job/Parts to remove Q’ty Remarks

Engine Refer to “ENGINE REMOVAL” on page 5-4.
Cylinder head Refer to “CYLINDER HEAD” on page 5-9.
Refer to “CYLINDER AND PISTON” on
Piston page 5-31.
Refer to “V-BELT AUTOMATIC TRANSMIS-
Secondary sheave assembly SION” on page 5-37.
Refer to “STARTER GENERATOR” on
Starter clutch page 5-47.
1 Dipstick 1
2 Engine oil drain bolt 1
3 Oil strainer cover 1
4 Spring 1

5-55
 CRANKSHAFT

Removing the crankshaft

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.R
.

1 E

LS
New

(11) 11
10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.R
.
10

10

12
LS
7

New
8 LS
New
6 2
4
5
LS
New 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.R
.

3
20 N·m (2.0 kgf·m, 15 lb·ft)
T.R
.

Order Job/Parts to remove Q’ty Remarks

5 Centerstand shaft 1
6 Centerstand 1
7 Timing chain guide (intake side) 1
8 Timing chain 1
9 Crankcase (left) 1
10 Dowel pin 2
11 Crankshaft assembly 1
12 Crankcase (right) 1

5-56
 CRANKSHAFT

EAS30389 EAS30414

DISASSEMBLING THE CRANKCASE REMOVING THE CRANKSHAFT ASSEMBLY

1. Remove: 1. Remove:
• Crankcase bolts • Crankshaft assembly “1”
TIP TIP
Loosen each bolt 1/4 of a turn at a time, in stag- • Remove the crankshaft assembly with the
es and in a crisscross pattern. After all of the crankcase separating tool “2” and M6 bolts “3”.
bolts are fully loosened, remove them. • Make sure that the crankcase separating tool
is centered over the crankshaft assembly.
ECA20630

NOTICE
• To protect the end of the crankshaft, place
an appropriate sized socket between the
crankcase separating tool bolt and the
crankshaft.
• Do not tap on the crankshaft.

2. Remove: Crankcase separating tool

90890-01135
• Crankcase (left) “1”
ECA13900 Crankcase separator
NOTICE YU-01135-B
Tap on one side of the crankcase with a soft-
face hammer. Tap only on reinforced por- 3
tions of the crankcase, not on the crankcase
mating surfaces. Work slowly and carefully
and make sure the crankcase halves sepa-
rate evenly. 2

5-57
 CRANKSHAFT

EAS31242
3. Check:
CHECKING THE CRANKSHAFT ASSEMBLY
• Crankshaft sprocket “1”
1. Measure:
Damage/wear → Replace the crankshaft as-
• Crankshaft runout
sembly.
Out of specification → Replace the crank-
• Bearing “2”
shaft assembly.
Cracks/damage/wear → Replace the crank-
TIP shaft assembly.
Turn the crankshaft slowly.
2
Runout limit
0.030 mm (0.0012 in) 1

EAS30390

CHECKING THE CRANKCASE

1. Thoroughly wash the crankcase halves in a
mild solvent.
2. Thoroughly clean all the gasket surfaces and
2. Measure: crankcase mating surfaces.
• Crankshaft width 3. Check:
Out of specification → Replace the crank- • Crankcase
shaft assembly. Cracks/damage → Replace.
EAS31244
Crank assembly width CHECKING THE BEARING
51.45–51.50 mm (2.026–2.028
1. Check:
in)
• Bearing
Clean and lubricate the bearings, and then
rotate the inner race with your finger.
Rough movement → Replace.
EAS31245

CHECKING THE OIL PUMP DRIVE GEAR

1. Check:
• Oil pump drive gear
Damage/wear → Replace.

5-58
 CRANKSHAFT

EAS30791 EAS30397

INSTALLING THE CRANKSHAFT ASSEMBLING THE CRANKCASE

1. Install: 1. Thoroughly clean all the gasket mating sur-
• Crankshaft assembly “1” faces and crankcase mating surfaces.
TIP 2. Apply:
• Install the crankshaft assembly with the crank- • Sealant
shaft installer pot “2”, crankshaft installer bolt (onto the crankcase mating surfaces)
“3”, adapter “4”, and crankshaft installer spacer
“5”. Yamaha bond No. 1215
• Hold the connecting rod at top dead center 90890-85505
(TDC) with one hand while turning the nut of Three bond No. 1215®
the crankshaft installer bolt with the other. Turn
TIP
the crankshaft installer bolt until the crankshaft
assembly bottoms against the bearing. Do not allow any sealant to come into contact
with the oil gallery.

Crankshaft installer pot

90890-01274
Installing pot
YU-90058
Crankshaft installer bolt
90890-01275
Bolt
YU-90060
Adapter (M12)
90890-01278
Adapter #3 3. Install:
YU-90063 • Crankcase (right)
Spacer (crankshaft installer) (onto the crankcase (left))
90890-04081 • Crankcase bolts
Pot spacer
YM-91044 Crankcase bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

5 TIP
• Thoroughly wipe off any sealant that protrudes
1 4
from between the left crankcase and the right
2 crankcase.
3 • Tighten the crankcase bolts in stages and in a
crisscross pattern.

5-59
 CRANKSHAFT

EAS31247

INSTALLING THE CENTERSTAND

1. Install:
• Centerstand “1”
• Spring “2”
TIP
• Make sure that the hooked end “a” of the spring
is positioned to the outside.
• Make sure that the hooked end “b” of the spring
is positioned to the outside.

1
2 b

5-60
 COOLING SYSTEM

COOLING SYSTEM DIAGRAMS .................................................................... 6-1

RADIATOR ...................................................................................................... 6-2

CHECKING THE RADIATOR.................................................................... 6-4
INSTALLING THE RADIATOR..................................................................6-4

THERMOSTAT ................................................................................................6-6
CHECKING THE THERMOSTAT ASSEMBLY ......................................... 6-7
INSTALLING THE THERMOSTAT ASSEMBLY ....................................... 6-7

WATER PUMP.................................................................................................6-8
DISASSEMBLING THE WATER PUMP.................................................. 6-10
CHECKING THE WATER PUMP ............................................................ 6-10
ASSEMBLING THE WATER PUMP........................................................ 6-10
INSTALLING THE WATER PUMP .......................................................... 6-11

6
 COOLING SYSTEM DIAGRAMS

EAS20299

COOLING SYSTEM DIAGRAMS

8
1 2 3 4 7 5

1 2 3 4 5

1. Radiator cap 5. Thermostat assembly

2. Coolant reservoir hose 6. Radiator outlet hose
3. Radiator 7. Water pump inlet hose
4. Radiator inlet hose 8. Water pump assembly

6-1
 RADIATOR

EAS20063

RADIATOR
Removing the radiator

10 N·m (1.0 kgf·m, 7.4 lb·ft)

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

4
11

5 12
(3)

(5) 9

10 N·m (1.0 kgf·m, 7.4 lb·ft) 7

T.R
.

10

(4) 8 6
LS 11 N·m (1.1 kgf·m, 8.1 lb·ft)
T.R

1 New
.

1.0 N·m (0.10 kgf·m, 0.73 lb·ft)

T.R
.

(3)

Order Job/Parts to remove Q’ty Remarks

Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-21.
Refer to “GENERAL CHASSIS (2)” on
Side cover (right) page 4-3.
Refer to “GENERAL CHASSIS (5)” on
Footrest board assembly (right)/Bottom cover page 4-12.
1 Radiator cover 1
2 Coolant reservoir breather hose 1
3 Coolant reservoir hose 1
4 Rear brake hose bracket 1
5 Rear brake hose holder (front side) 1
6 Coolant reservoir 1

6-2
 RADIATOR

Removing the radiator

10 N·m (1.0 kgf·m, 7.4 lb·ft)

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

4
11

5 12
(3)

(5) 9

10 N·m (1.0 kgf·m, 7.4 lb·ft) 7

T.R
.

10

(4) 8 6
LS 11 N·m (1.1 kgf·m, 8.1 lb·ft)
T.R

1 New
.

1.0 N·m (0.10 kgf·m, 0.73 lb·ft)

T.R
.

(3)

Order Job/Parts to remove Q’ty Remarks

7 Radiator inlet hose 1
8 Radiator outlet hose 1
9 Radiator cap 1
10 Radiator 1
11 Radiator fan case 1
12 Radiator fan 1

6-3
 RADIATOR

EAS30439

CHECKING THE RADIATOR

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

INSTALLING THE RADIATOR

1. Fill:
• Cooling system
(with the specified amount of the recom-
2. Check: mended coolant)
• Radiator hose Refer to “CHANGING THE COOLANT” on
• Coolant reservoir hose page 3-21.
Cracks/damage → Replace. 2. Check:
3. Measure: • Cooling system
• Radiator cap valve opening pressure Leaks → Repair or replace any faulty part.
Below the specified pressure → Replace the
radiator cap. a. Attach the radiator cap tester “1” to the radi-
ator.
Radiator cap valve opening pres-
sure Radiator cap tester
108.0–137.4 kPa (1.08–1.37 kgf/ 90890-01325
cm², 15.7–19.9 psi) Mityvac cooling system tester kit
YU-24460-A
a. Install the radiator cap tester “1” and radia-
tor cap tester adapter “2” to the radiator cap
“3”.

Radiator cap tester

90890-01325
Mityvac cooling system tester kit
YU-24460-A 1
Radiator cap tester adapter
31mm
90890-05375
Radiator cap tester adapter b. Apply 137.4 kPa (1.37 kgf/cm2, 19.9 psi) of
31mm pressure.
YM-05375 c. Measure the pressure to check its maintain-
ing applied pressure.

6-4
 RADIATOR

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

Rear brake hose holder bolt

(front side)
T.
R.

7 N·m (0.7 kgf·m, 5.2 lb·ft)

6-5
 THERMOSTAT

EAS20065

THERMOSTAT
Removing the thermostat assembly

* New

2 3

9 N•m (0.9 kgf•m, 6.6 lb•ft)

T .R
.

*: Apply water
Order Job/Parts to remove Q’ty Remarks
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-21.
Refer to “GENERAL CHASSIS (2)” on
Front side cover (right) page 4-3.
Refer to “GENERAL CHASSIS (5)” on
Footrest board assembly (right)/Bottom cover page 4-12.
1 Radiator inlet hose 1 Disconnect.
2 Radiator outlet hose 1 Disconnect.
3 Water pump inlet hose 1 Disconnect.
4 Thermostat assembly 1

6-6
 THERMOSTAT

EAS31248

CHECKING THE THERMOSTAT ASSEMBLY B

1. Check:
• Thermostat “1”
0.5 mm
Do not open at 74–78°C (165–172 °F) → Re- (0.02 in) 7 mm
place. (0.28 in)

A
74 – 78˚C 90˚C
(165 – 172˚F) (194˚F)
1 A. Fully closed
B. Fully open

TIP
If the accuracy of the thermostat is in doubt, re-
place it. A faulty thermostat could cause serious
a. Suspend the thermostat “1” in a container overheating or overcooling.
“2” filled with water.
b. Slowly heat the water. EAS30445

c. Place a thermometer “3” in the water. INSTALLING THE THERMOSTAT

d. While stirring the water “4”, observe the ASSEMBLY
thermostat and thermometer’s indicated 1. Fill:
temperature. • Cooling system
(with the specified amount of the recom-
mended coolant)
3 Refer to “CHANGING THE COOLANT” on
page 3-21.
2. Check:
4 • Cooling system
1 Leaks → Repair or replace any faulty part.
2 Refer to “INSTALLING THE RADIATOR” on
page 6-4.
3. Measure:
e. Check the thermostat element position “5”. • Radiator cap opening pressure
Same level for the thermostat element up- Below the specified pressure → Replace the
per end and the hole lower line “a” at 90° C radiator cap.
(194°F) Refer to “CHECKING THE RADIATOR” on
page 6-4.

6-7
 WATER PUMP

EAS20066

WATER PUMP
Removing the water pump

3
2

New 4 3

10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-21.
Refer to “GENERAL CHASSIS (2)” on
Front side cover (left) page 4-3.
Refer to “GENERAL CHASSIS (4)” on
Footrest board assembly (left)/Bottom cover page 4-9.
1 Water pump inlet hose 1 Disconnect.
2 Water pump assembly 1
3 Dowel pin 2
4 O-ring 2

6-8
 WATER PUMP

Disassembling the water pump

3 New
7 8
6 New

2 New
New 6
1
New 5 New

4
LS

10 N·m (1.0 kgf·m, 7.4 lb·ft)

Order Job/Parts to remove Q’ty Remarks

1 Water pump housing cover 1
2 Water pump housing gasket 1
3 Circlip 1
4 Impeller shaft 1
5 Water pump seal 1
6 O-ring 2
7 Bearing 2
8 Water pump housing 1

6-9
 WATER PUMP

EAS30446 EAS30448

DISASSEMBLING THE WATER PUMP ASSEMBLING THE WATER PUMP

1. Remove: 1. Install:
• Water pump seal “1” • Water pump seal “1” New
TIP (into the water pump housing “2”)
Remove the water pump seal from the inside of TIP
the water pump housing “2”. Install the water pump seal with the special tools
• Water pump bearing “3” to the specified depth as shown in the illustra-
tion.
TIP
Remove the water pump bearing from the out-
side of the water pump housing “2”. Installed depth of water pump
seal
3 0–0.5 mm (0–0.02 in)
1
2 Mechanical seal installer
90890-04145
Middle driven shaft bearing driv-
er
90890-04058
Middle drive bearing installer 40
& 50 mm
YM-04058
EAS30447

CHECKING THE WATER PUMP

1. Check: A
• Water pump housing cover
4
• Water pump housing
Cracks/damage → Replace.
3
• Impeller shaft
Cracks/damage/wear → Replace. 2 1 New
• Impeller
• Water pump seal
Cracks/damage/wear → Replace.
2. Check: A. Push down
• Bearing
3. Mechanical seal installer
Rough movement → Replace
4. Middle driven shaft bearing driver

1
a

a. Installed depth of water pump seal

• Bearing
Install the bearing as same as water pump
seal installation procedure.

6-10
 WATER PUMP

2. Lubricate: EAS30449

INSTALLING THE WATER PUMP

• Water pump seal and bearing.
1. Install:
Recommended lubricant • O-rings “1” New
Lithium-soap-based grease • Water pump assembly “2”

3. Install: Water pump assembly bolt

• Impeller shaft “1” 10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.
R.
• Circlip New
TIP
TIP
• Align the projection “a” on the impeller shaft
After installation, check that the impeller shaft ro-
with the slit “b” on the camshaft sprocket bolt.
tates smoothly.
• Lubricate the O-ring with a thin coat of lithium-
soap-based grease.

a b
2

New 1
1 LS

2. Fill:
• Cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-21.
3. Check:
• Cooling system
Leaks → Repair or replace any faulty part.
Refer to “INSTALLING THE RADIATOR” on
page 6-4.
4. Measure:
• Radiator cap opening pressure
Below the specified pressure → Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-4.

6-11
 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 ROLLOVER VALVE ......................................................7-3
INSTALLING THE FUEL PUMP................................................................7-4
INSTALLING THE FUEL TANK.................................................................7-4
CHECKING THE FUEL PRESSURE ........................................................7-5

FUEL INJECTOR............................................................................................. 7-6

REMOVING THE FUEL HOSE .................................................................7-7
CHECKING THE FUEL INJECTOR .......................................................... 7-7
INSTALLING THE FUEL INJECTOR ........................................................7-7
INSTALLING THE FUEL HOSE ................................................................7-7

AIR FILTER CASE .......................................................................................... 7-8

INSTALLING THE AIR FILTER CASE ....................................................7-10

THROTTLE BODY......................................................................................... 7-11

REMOVING THE THROTTLE BODY......................................................7-13
CHECKING THE THROTTLE BODY ......................................................7-13
CLEANING THE ISC (IDLE SPEED CONTROL) UNIT
AND THROTTLE BODY .........................................................................7-13
REPLACING THE THROTTLE BODY ....................................................7-16
INSTALLING THE THROTTLE BODY ....................................................7-16

7
 FUEL TANK

EAS20067

FUEL TANK
Removing the fuel tank

9 N·m (0.9 kgf·m, 6.6 lb·ft)

T.R
.
4

5
8
6
1 11
New
7 2

10

3
9

4.0 N·m (0.40 kgf·m, 3.0 lb·ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (2)” on
Front side cover page 4-3.
Refer to “GENERAL CHASSIS (3)” on
Fuel tank cover page 4-6.
Refer to “GENERAL CHASSIS (5)” on
Center lower cover page 4-12.
Canister Refer to “FUEL TANK” on page 7-1.
1 Fuel tank cap 1
2 Fuel tank overflow tray 1
3 Fuel tank overflow hose 1
Fuel tank breather hose (fuel tank to rollover
4 valve) 1

5 Fuel sender coupler 1 Disconnect.

6 Fuel pump coupler 1 Disconnect.
7 Fuel hose 1 Disconnect.
8 Fuel tank 1
9 Fuel pump bracket 1
10 Fuel pump 1
11 Fuel pump gasket 1

7-1
 FUEL TANK

Removing the canister

3
1
2 5

7
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.R
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (2)” on
Front side cover page 4-3.
Refer to “GENERAL CHASSIS (3)” on
Fuel tank cover page 4-6.
Refer to “GENERAL CHASSIS (5)” on
Center lower cover page 4-12.
Fuel tank breather hose (rollover valve to canis-
1 1
ter)
2 Rollover valve holder 1
3 Rollover valve 1
Fuel tank breather hose (fuel tank to rollover
4 1
valve)
5 Canister purge hose 1 Disconnect.
6 Canister 1 Disconnect.
7 Canister breather hose 1 Disconnect.

7-2
 FUEL TANK

EAS30450 EAS30451

REMOVING THE FUEL TANK REMOVING THE FUEL PUMP

1. Extract the fuel in the fuel tank through the 1. Remove:
fuel tank cap with an appropriate pump. • Fuel pump
2. Disconnect: ECA14721

• Fuel sender coupler NOTICE

• Fuel pump coupler • Do not drop the fuel pump or give it a
• Fuel hose strong shock.
EWA18020 • Do not touch the base section of the fuel
WARNING sender.
Cover the fuel hose connection with a cloth
when disconnecting it. Residual pressure in EAS30454

the fuel lines could cause fuel to spurt out CHECKING THE FUEL PUMP BODY
when removing the hose. 1. Check:
ECA20020
• Fuel pump body
NOTICE
Obstruction → Clean.
Cracks/damage → Replace the fuel pump
Although the fuel has been removed from
assembly.
the fuel tank, be careful when removing the
fuel hose, since there may be fuel remaining EAS30699

in it. CHECKING THE ROLLOVER VALVE

1. Check:
TIP • Rollover valve “1”
• To remove the fuel hose from the fuel pump, • Damage/faulty → Replace.
slide the fuel hose connector cover “1” on the TIP
end of the hose in the direction of the arrow • Check that air flows smoothly only in the direc-
shown, and then remove the hose. tion of the arrow shown in the illustration.
• Before removing the hose, place a few rags in • The rollover valve must be in an upright posi-
the area under where it will be removed. tion when checking the airflow.

1 1

3. Remove:
• Fuel tank

7-3
 FUEL TANK

EAS30456 EAS30457

INSTALLING THE FUEL PUMP INSTALLING THE FUEL TANK

1. Install: 1. Install:
• Fuel pump gasket “1” New • Fuel tank “1”
• Fuel pump a. Temporarily install the fuel tank.
• Fuel pump bracket TIP
Make sure that the flanges of the fuel tank bolts
Fuel pump bracket bolt “2” do not contact the fuel tank.
4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
T.
R.

b. Install the fuel tank overflow tray and fuel

TIP tank cover “3”. To install the fuel tank cover,
• Do not damage the installation surfaces of the refer to “GENERAL CHASSIS (3)” on
fuel tank when installing the fuel pump. page 4-6.
• Always use a new fuel pump gasket. c. Tighten the fuel tank bolts to specification.
• Face the gasket lip “a” toward the fuel pump.
• Align the projections “b” (two locations) on the Fuel tank bolt
fuel pump gasket with the slots “c” in the fuel 9 N·m (0.9 kgf·m, 6.6 lb·ft)

T.
R.
pump.
• Align the projection “d” on the fuel pump with
3
the slot in the fuel pump bracket.
• Tighten the fuel pump bolts in the proper tight-
ening sequence as shown.
2

1
a 2. Install:
c
• Fuel hose
1 New ECA17500

b NOTICE
When installing the fuel hose, make sure that
it is securely connected, and that the fuel
1 hose connector cover on the fuel hose is in
d
the correct position, otherwise the fuel hose
will not be properly installed.
4
TIP
3 • Install the fuel hose securely onto the fuel
pump until a distinct “click” is heard.
• To install the fuel hose, slide the fuel hose con-
2 nector cover “1” on each end of the hose in the
direction of the arrow shown.

7-4
 FUEL TANK

EAS30703
d. Measure the fuel pressure.
CHECKING THE FUEL PRESSURE
1. Remove:
Fuel line pressure (at idle)
• Front side cover assembly (left) 220–300 kPa (2.2–3.0 kgf/cm²,
Refer to “GENERAL CHASSIS (2)” on 31.9–43.5 psi)
page 4-3.
• Footrest board (left) Faulty → Replace the fuel pump.
Refer to “GENERAL CHASSIS (5)” on e. Connect the fuel hose.
page 4-12. Refer to “INSTALLING THE FUEL TANK”
2. Check: on page 7-4.
• Pressure regulator operation
3. Install:
a. Disconnect the fuel hose from the fuel • Footrest board (left)
pump. Refer to “GENERAL CHASSIS (5)” on
EWA18020
page 4-12.
WARNING
• Front side cover assembly (left)
Cover the fuel hose connection with a cloth
Refer to “GENERAL CHASSIS (2)” on
when disconnecting it. Residual pressure in
page 4-3.
the fuel lines could cause fuel to spurt out
when removing the hose.
ECA20020

NOTICE
Although the fuel has been removed from
the fuel tank, be careful when removing the
fuel hose, since there may be fuel remaining
in it.

TIP
Before removing the hose, place a few rags in
the area under where it will be removed.
b. Connect the pressure gauge “1” and fuel
pressure adapter “2” to the fuel hose “3”.

Pressure gauge
90890-03153
Pressure gauge
YU-03153
Fuel pressure adapter 6.3mm
90890-03227

1
YAMA
H

2 3

c. Start the engine.

7-5
 FUEL INJECTOR

EAS20191

FUEL INJECTOR
Removing the fuel injector

10 N·m (1.0 kgf·m, 7.4 lb·ft)

T .R
.
5
1
3
New 8 E

2 6

New 7

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (1)” on
Battery page 4-1.
Refer to “GENERAL CHASSIS (2)” on
Front side cover page 4-3.
Refer to “GENERAL CHASSIS (3)” on
Fuel tank cover page 4-6.
Refer to “GENERAL CHASSIS (4)” on
Storage box page 4-9.
1 Fuel hose 1
2 Fuel injector coupler 1 Disconnect.
3 Fuel injector connector 1
4 Fuel injector gasket 1
5 Clamp ring 1
6 Fuel injector 1
7 O-ring 1
8 O-ring 1

7-6
 FUEL INJECTOR

EAS31250

REMOVING THE FUEL HOSE

Fuel injector bolt
1. Disconnect: 10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.
• Fuel hose

R.
EWA17610
TIP
WARNING
Cover fuel hose connections with a cloth • Lubricate the O-ring with engine oil.
when disconnecting them. Residual pres- • Align the projection “a” on the fuel injector
sure in the fuel lines could cause fuel to adapter with the hole “b” in the intake manifold.
spurt out when removing the hoses. • Align the projection “c” on the fuel injector with
the hole “d” in the fuel injector adapter.
ECA20020

NOTICE
Although the fuel has been removed from 3
the fuel tank, be careful when removing the New 2
fuel hose, since there may be fuel remaining c
a
in it.
b 1
TIP
• To remove the fuel hose from the fuel injector, d
slide the fuel hose connector cover “1” on the
end of the hose in the direction of the arrow
shown, and then remove the hose. EAS31253

• Before removing the hose, place a few rags in INSTALLING THE FUEL HOSE
the area under where it will be removed. 1. Install:
• Fuel hose
ECA17500

NOTICE
When installing the fuel hose, make sure that
it is securely connected, and that the fuel
hose connector cover on the fuel hose is in
1 the correct position, otherwise the fuel hose
will not be properly installed.

TIP
• Install the fuel hose securely onto the fuel in-
EAS31251 jector until a distinct “click” is heard.
CHECKING THE FUEL INJECTOR • To install the fuel hose onto the fuel injector,
1. Check: slide the fuel hose connector cover “1” on the
• Injector end of the hose in the direction of the arrow
Obstruction → Replace and check the fuel shown.
pump/fuel supply system.
Deposit → Replace.
Damage → Replace.
2. Check:
• Injector resistance
Refer to “INSTALLING THE FUEL INJEC- 1
TOR” on page 7-7.
EAS31617

INSTALLING THE FUEL INJECTOR

1. Install:
• Fuel injector adaptor “1”
• O-ring “2” New
(to the fuel injector)
• Fuel injector “3”

7-7
 AIR FILTER CASE

EAS20068

AIR FILTER CASE

Removing the air filter case

4
7

8
New
3
New

9 1

5
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.R
.

2.5 N·m (0.25 kgf·m, 1.8 lb·ft) 2

T.R
.

1.2 N·m (0.12 kgf·m, 0.88 lb·ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (1)” on
Battery page 4-1.
Refer to “GENERAL CHASSIS (2)” on
Front side cover page 4-3.
Refer to “GENERAL CHASSIS (3)” on
Fuel tank cover page 4-6.
Refer to “GENERAL CHASSIS (4)” on
Storage box page 4-9.
1 Air filter case cover 1
2 Air filter case duct 1
3 Air filter element 1
4 Transmission case breather hose 1

7-8
 AIR FILTER CASE

Removing the air filter case

4
7

8
New
3
New

9 1

5
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.R
.

2.5 N·m (0.25 kgf·m, 1.8 lb·ft) 2

T.R
.

1.2 N·m (0.12 kgf·m, 0.88 lb·ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

5 Cylinder head breather hose 1 Disconnect.
6 Air filter case joint clamp screw 1 Loosen.
7 Air filter case 1
8 Air filter check hose 1
9 Air filter case joint 1

7-9
 AIR FILTER CASE

EAS31618
3. Install:
INSTALLING THE AIR FILTER CASE
• Air filter case duct “1”
1. Install:
TIP
• Hose “1”
(to the air filter case joint “2”) Fit the projection “a” on the air filter case duct be-
TIP
tween the projections “b” on the air filter case
cover “2”.
• Apply Three bond 1521 “3” onto the mating
surfaces of the hose and air filter case joint.
• Align the slot “b” on the air filter case joint with
the projection “a” in the hose.

2 b
b
a
1 2 1 a

3
2. Install:
• Air filter case joint clamp “1”
(to the air filter case joint “2”)

Air filter case joint clamp screw

2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
T.
R.

TIP
Align the projection “a” on the air filter case joint
with the slot “b” in the air filter case joint clamp.

1 2

b a

7-10
 THROTTLE BODY

EAS20070

THROTTLE BODY
Removing the throttle body
8
5 N·m (0.5 kgf·m, 3.7 lb·ft)
T.R
.

10 N·m (1.0 kgf·m, 7.4 lb·ft) 1 3

T.R
.

7 9 10 N·m (1.0 kgf·m, 7.4 lb·ft)

2

T.R
.
New

6
5
4

New

4.5 N·m (0.45 kgf·m, 3.3 lb·ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (1)” on
Battery page 4-1.
Refer to “GENERAL CHASSIS (2)” on
Side covers page 4-3.
Refer to “GENERAL CHASSIS (3)” on
Storage box page 4-6.
Air filter case joint Refer to “AIR FILTER CASE” on page 7-8.
Fuel injector Refer to “FUEL INJECTOR” on page 7-6.
1 ISC (Idle Speed Control) unit coupler 1 Disconnect.
2 Throttle body sensor assembly coupler 1 Disconnect.

7-11
 THROTTLE BODY

Removing the throttle body

8
5 N·m (0.5 kgf·m, 3.7 lb·ft)
T.R
.

10 N·m (1.0 kgf·m, 7.4 lb·ft) 1 3

T.R
.

7 9 10 N·m (1.0 kgf·m, 7.4 lb·ft)

2

T.R
.
New

6
5
4

New

4.5 N·m (0.45 kgf·m, 3.3 lb·ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

3 Canister purge hose 1 Disconnect.
4 Throttle cable holder 1
5 Throttle body 1 Loosen.
6 Intake manifold 1
7 ISC (Idle Speed Control) unit holder 1
8 ISC (Idle Speed Control) unit 1
9 Spring 1

7-12
 THROTTLE BODY

EAS30979 EAS31254

REMOVING THE THROTTLE BODY CLEANING THE ISC (IDLE SPEED

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

NOTICE
Do not adjust the stop screw “1”. 1
2

7-13
 THROTTLE BODY

4. Check: a. Use a rag soaked in the recommended

• ISC (Idle Speed Control) unit cleaning agent to wipe off any deposits and
Plunger “1” does not rotate smoothly/plunger foreign materials.
rotates together with the motor shaft “2” →
Replace. Recommended cleaning agent
Yamaha oil & brake cleaner
ECA21790

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

7. Adjust the ISC unit plunger to the specified

distance “a” from the motor assembly body.

Distance “a”
0.0–3.0 mm (0.0–0.12 in)

a
b

7-14
 THROTTLE BODY

8. Install: 9. Install:
• Spring • ISC (Idle Speed Control) unit holder “1”
• O-ring “1” New • Screw
• ISC (Idle Speed Control) unit “2”
ECA21800 ISC (Idle Speed Control) unit
NOTICE holder screw

T.
R.
• Do not use the ISC unit if it was dropped. 5 N·m (0.5 kgf·m, 3.7 lb·ft)
• Do not allow water to enter the ISC unit and
do not allow foreign materials to adhere to TIP
the assembly. Align the slot “a” in the ISC unit holder with the
• Do not touch the terminals of the coupler projection “b” on the ISC unit “2”.
directly.
• Because the force of the spring may push 1
out the ISC unit unexpectedly, be sure to 2
hold the motor assembly when installing
the components.

TIP a
• Install the new O-ring until it contacts the raised
portion of the ISC unit body. b
• When installing the ISC unit, be sure to align
the oval portion “a” of the ISC unit with the oval 10.Install the throttle body to the vehicle.
hole “b” in the throttle body. 11.Reset:
• ISC learning valves
Use the diagnostic code number “67”.
Refer to “SELF-DIAGNOSTIC FUNCTION
2 1 New AND DIAGNOSTIC CODE TABLE” on
page 9-37.
• ISC valve position
Use the diagnostic code number “54”.
Refer to “SELF-DIAGNOSTIC FUNCTION
AND DIAGNOSTIC CODE TABLE” on
page 9-37.

Yamaha diagnostic tool USB

90890-03267
Yamaha diagnostic tool (A/I)
90890-03264
b 12.Place the vehicle on the centerstand so that
the rear wheel is off ground.
a 13.Check:
• Engine idling speed
Start the engine, warm it up, and then mea-
sure the engine idling speed. Within specifi-
cation → Service is finished.
Out of specification → Replace the throttle
body.
Refer to “REPLACING THE THROTTLE
BODY” on page 7-16.

Engine idling speed

1500–1700 r/min

7-15
 THROTTLE BODY

EAS31160 EAS30980

REPLACING THE THROTTLE BODY INSTALLING THE THROTTLE BODY

1. Remove the throttle body from the vehicle. 1. Install:
2. Install a new throttle body to the vehicle. • Throttle body
3. Reset:
• ISC learning valves Throttle body bolt
Use the diagnostic code number “67”. 10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.
R.
Refer to “SELF-DIAGNOSTIC FUNCTION
AND DIAGNOSTIC CODE TABLE” on TIP
page 9-37. • Align the projection “a” on the O-ring with the
• ISC valve position slot “b” in the throttle body.
Use the diagnostic code number “54”
Refer to “SELF-DIAGNOSTIC FUNCTION
AND DIAGNOSTIC CODE TABLE” on
page 9-37.

Yamaha diagnostic tool USB

90890-03267 b a
Yamaha diagnostic tool (A/I)
90890-03264

4. Place the vehicle on the centerstand so that

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

Engine idling speed

1500–1700 r/min

7-16
 THROTTLE BODY

7-17
 ELECTRICAL SYSTEM

IGNITION SYSTEM ......................................................................................... 8-1

CIRCUIT DIAGRAM .................................................................................. 8-1
TROUBLESHOOTING ..............................................................................8-3

ELECTRIC STARTING SYSTEM .................................................................... 8-5

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

STOP AND START SYSTEM........................................................................8-11

CIRCUIT DIAGRAM ................................................................................ 8-11
STOP AND START SYSTEM OPERATION ...........................................8-13
TROUBLESHOOTING ............................................................................8-14

CHARGING SYSTEM....................................................................................8-17
CIRCUIT DIAGRAM ................................................................................ 8-17
TROUBLESHOOTING ............................................................................8-19

LIGHTING SYSTEM ......................................................................................8-21

CIRCUIT DIAGRAM ................................................................................ 8-21
TROUBLESHOOTING ............................................................................8-23

SIGNALING SYSTEM ...................................................................................8-25

CIRCUIT DIAGRAM ................................................................................ 8-25
TROUBLESHOOTING ............................................................................8-27

FUEL PUMP SYSTEM...................................................................................8-31

CIRCUIT DIAGRAM ................................................................................ 8-31
TROUBLESHOOTING ............................................................................8-33

ELECTRICAL COMPONENTS...................................................................... 8-34

CHECKING THE SWITCHES .................................................................8-35
CHECKING THE FUSES ........................................................................8-36
REPLACING THE SGCU (starter generator control unit)........................ 8-36
CHECKING AND CHARGING THE BATTERY....................................... 8-37
CHECKING THE RELAYS ...................................................................... 8-38
CHECKING THE SPARK PLUG CAP .....................................................8-39
8
CHECKING THE IGNITION COIL ........................................................... 8-39
CHECKING THE IGNITION SPARK GAP............................................... 8-40
CHECKING THE STARTER GENERATOR............................................8-40
CHECKING THE FUEL SENDER ........................................................... 8-41
CHECKING THE COOLANT TEMPERATURE SENSOR.......................8-41
CHECKING THE FUEL INJECTOR ........................................................ 8-42
CHECKING THE VVA SOLENOID.......................................................... 8-42
CHECKING THE SMART KEY BATTERY .............................................. 8-43
CHECKING THE BUZZER ...................................................................... 8-43
CHECKING THE MAIN SWITCH SOLENOID.........................................8-43
 EAS30490
EAS20072

RR

R
R
Br Br
9 Br
Br Br
CIRCUIT DIAGRAM

10
R R 13
R
ON Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
R/Y R/Y OPEN
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
Br Br/R OFF
IGNITION SYSTEM

LOCK L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Br Br/R
(B)

Br

O O
44
45
Br
Br

Br

W/R W/R G
W/L W/L G W/R W/R B/L
W/B W/B L/Y Br/B W/L W/L Br/B
W/Y W/Y 51
Br/B Br/B L/Y W/B W/B W/Y
43 B/L B/L
(B)
(B)

8-1
B B L/Y L/Y L/Y L/Y

R
L/Y B 36
B B
(L) (L)
1

B
B

B
B B
B B
B B
B B
B
B

BB

B
72
72
IGNITION SYSTEM
 IGNITION SYSTEM

1. Battery
9. Main fuse
10. Ignition fuse
13. Main switch
36. Sidestand switch
43. SGCU (starter generator control unit)
44. Ignition coil
45. Spark plug
51. Crankshaft position sensor
72. Frame ground

8-2
 IGNITION SYSTEM

EAS30492

TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP
• Before troubleshooting, remove the following part(s):
1. Battery cover
2. Front side cover
3. Fuel tank cover
4. Storage box
5. Footrest board assembly
6. Front cowling assembly

1. Check the fuse.

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

OK↓

2. Check the battery.

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

OK↓

3. Check the spark plug.

Refer to “CHECKING THE SPARK NG→ Re-gap or replace the spark plug.
PLUG” on page 3-5.

OK↓

4. Check the ignition spark gap.

Refer to “CHECKING THE IGNI- OK→ Ignition system is OK.
TION SPARK GAP” on page 8-40.

NG↓

5. Check the spark plug cap.

Refer to “CHECKING THE SPARK NG→ Replace the spark plug cap.
PLUG CAP” on page 8-39.

OK↓

6. Check the ignition coil.

Refer to “CHECKING THE IGNI- NG→ Replace the ignition coil.
TION COIL” on page 8-39.

OK↓

7. Check the main switch.

Refer to “CHECKING THE NG→ Replace the main switch.
SWITCHES” on page 8-35.

OK↓

8-3
 IGNITION SYSTEM

8. Check the sidestand switch.

Refer to “CHECKING THE NG→ Replace the sidestand switch.
SWITCHES” on page 8-35.

OK↓

9. Check the entire ignition system

wiring. Properly connect or replace the wire har-
NG→
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-1.

OK↓

Replace the starter generator assem-

bly or the SGCU. Refer to “REPLAC-
ING THE SGCU (starter generator
control unit)” on page 8-36.

8-4
 EAS30493
EAS20073

R
RR

6
Br/R Br

7
R
R
Br
9
CIRCUIT DIAGRAM
Br Br
Br Br

10
R R 13
R R W G
ON Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
R/Y R/Y OPEN
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
Br Br/R OFF
LOCK Y/R Y/B B L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Br Br/R
(B)

Br/R R
Br/R
Br/R Br B

(B)
31
R
Br/R Br
B Br
R

Br
ELECTRIC STARTING SYSTEM

27 L/W
Br 33 L/W
Br Br B/Y B/Y
28 Br W/R W/R G
G W/R W/R B/L
L/W W/L W/L
PUSH B/Y W/B W/B L/Y Br/B W/L W/L Br/B
FREE 34 W/Y W/Y 51
Br/B Br/B L/Y W/B W/B W/Y
B Br B/Y L/B
B 40 43 B/L B/L
(B)
(B)
L/B L/B L/B
L/W
Y/R
L/B R 35
R/B Br/R Br Y/R Y/R

8-5
R
Br R/B R/B

B B L/Y L/Y L/Y L/Y

B
R
R L/Y B 36
B B
(L) (L)
1

B B
B
B
G G R/L
R R R/Y 55
W W R/W

R/Y R/W R/L

R W G

B
B B
B B
B B
B B
B
B

B BB BB

B B B
73 72 72
72 72
ELECTRIC STARTING SYSTEM
 ELECTRIC STARTING SYSTEM

1. Battery
6. Signaling system fuse
7. Fuel injection system fuse
9. Main fuse
10. Ignition fuse
13. Main switch
27. Handlebar switch (right)
28. Start switch
31. Main relay
33. Front brake light switch
34. Rear brake light switch
35. Starter charge relay
36. Sidestand switch
40. Joint 3
43. SGCU (starter generator control unit)
51. Crankshaft position sensor
55. Starter generator
72. Frame ground
73. Engine ground

8-6
 ELECTRIC STARTING SYSTEM

EAS30494

STARTING CIRCUIT CUT-OFF SYSTEM OPERATION

If the main switch is turned to “ON” and the start switch “ ” is pushed, the starter generator can only op-
erate if at least one of the following conditions is met:
• The front brake lever is pulled to the handlebar (the front brake light switch is closed) and the side-
stand is up (the sidestand switch is closed).
• The rear brake lever is pulled to the handlebar (the rear brake light switch is closed) and the sidestand
is up (the sidestand switch is closed).

7
14

1 13 15
2
5
6

3 8

4 9 10 11 12

1. Battery
2. Main fuse
3. Main switch
4. Ignition fuse
5. Fuel injection system fuse
6. Main relay
7. Starter charge relay
8. Signaling system fuse
9. Rear brake light switch
10. Front brake light switch
11. Start switch
12. Sidestand switch
13. SGCU (starter generator control unit)
14. Starter generator
15. Crankshaft position sensor

8-7
 ELECTRIC STARTING SYSTEM

EAS30495

TROUBLESHOOTING
The starter generator fails to turn.
TIP
• Before troubleshooting, remove the following part(s):
1. Battery cover
2. Center cover
3. Side cover
4. Storage box

1. Check the fuses.

(Main, ignition, fuel injection sys-
tem, and signaling system) NG→ Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 8-36.

OK↓

2. Check the battery.

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

OK↓

3. Check the starter generator.

Refer to “CHECKING THE START- NG→ Replace the starter generator assembly.
ER GENERATOR” on page 8-40.

OK↓

4. Check the main relay.

Refer to “CHECKING THE RE- NG→ Replace the main relay.
LAYS” on page 8-38.

OK↓

5. Check the starter charge relay.

Refer to “CHECKING THE RE- NG→ Replace the starter charge relay.
LAYS” on page 8-38.

OK↓

6. Check the main switch.

Refer to “CHECKING THE NG→ Replace the main switch.
SWITCHES” on page 8-35.

OK↓

7. Check the sidestand switch.

Refer to “CHECKING THE NG→ Replace the sidestand switch.
SWITCHES” on page 8-35.

OK↓

8-8
 ELECTRIC STARTING SYSTEM

8. Check the start switch.

The start switch is faulty. Replace the right
Refer to “CHECKING THE NG→
handlebar switch.
SWITCHES” on page 8-35.

OK↓

9. Check the brake light switches.

(Front and rear)
NG→ Replace the brake light switch(es).
Refer to “CHECKING THE
SWITCHES” on page 8-35.

OK↓

10.Check the entire starting system

wiring. Properly connect or replace the wire har-
NG→
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-5.

OK↓

Replace the starter generator assem-

bly or SGCU. Refer to “REPLACING
THE SGCU (starter generator control
unit)” on page 8-36.

8-9
 ELECTRIC STARTING SYSTEM

8-10
 RR

EAS33384
EAS20715

7
R
R
Br
9 Br
Br Br
Br Br

10
R R 13
12 R R W G
Br ON Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
R/Y R/Y OPEN
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
Br Br/R OFF
LOCK Y/R Y/B B L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br
CIRCUIT DIAGRAM

Br Br/R
(B)

Br
Br
R

Br

47 48
49 B/L Y L P/W Br/W
B/L B/L
Y Y
L L
50 (B)
Y/W 39 W/G
27 Y/W
W/G
STOP AND START SYSTEM

29 W/R W/R G
G W/R W/R B/L
Y/W W/L W/L
ON W/B W/B L/Y Br/B W/L W/L Br/B
OFF W/Y W/Y 51
Br/B Br/B L/Y W/B W/B W/Y
B/W 43 B/L B/L
(B)
(B)
B/W
Y/W
Y/R
G/R G/R G/R B/L
B/W R 35 B/L B/L 52
R/B Br/R Br Y/R Y/R (B)
(B)

B/W R
Br R/B R/B
B

B B L/Y L/Y L/Y L/Y

B
R
R L/Y B 36
B B
(L) (L)

8-11
1

B B
B
B
G G R/L
R R R/Y 55
W W R/W

W/B R/Y R/W R/L

W
R W G

W
Br W/B
Br Br B
Y Y W 56 W B Br Y

59
B B B/W
B
B 60
B R Br Y G L W W/L W/B B/W

B Br R/L Y L/G L/G Br Lg/L Lg/W B/W B

B B
B B
B B (B)
B B B/W 61
B B B
B
B

B BB BB
B
B B
73 72 72
72

68
R/W L/W Br/W Y/W Dg Ch Br R
L/R G/B W/L Br/R W/R G B R

(Gy)
STOP AND START SYSTEM
 STOP AND START SYSTEM

1. Battery
7. Fuel injection system fuse
9. Main fuse
10. Ignition fuse
12. ABS control unit fuse
13. Main switch
27. Handlebar switch (right)
29. Stop and Start System switch
35. Starter charge relay
36. Sidestand switch
39. Joint 2
43. SGCU (starter generator control unit)
47. Throttle body sensor assembly
48. Intake air pressure sensor
49. Intake air temperature sensor
50. Throttle position sensor
51. Crankshaft position sensor
52. Coolant temperature sensor
55. Starter generator
56. Front wheel sensor
59. ABS ECU
60. Meter assembly
61. Multi-function meter
68. Stop and Start System indicator light
72. Frame ground
73. Engine ground

8-12
 STOP AND START SYSTEM

EAS33385

STOP AND START SYSTEM OPERATION

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

12
7
13
11
1 2 14
6
15

8 16
3 17
18 19
9
4 5 10

1. Battery 15. Throttle position sensor

2. Main fuse 16. Front wheel sensor
3. Main switch 17. ABS ECU
4. ABS control unit fuse 18. Sidestand switch
5. Ignition fuse 19. Stop and Start System switch
6. Fuel injection system fuse
7. Starter charge relay
8. Yamaha diagnostic tool coupler
9. Multi-function meter
10. Stop and Start System indicator light
11. SGCU (starter generator control unit)
12. Starter generator
13. Crankshaft position sensor
14. Coolant temperature sensor

8-13
 STOP AND START SYSTEM

EAS33386

TROUBLESHOOTING
• The engine stop function does not operate.
• The engine start function does not operate.
• The Stop and Start System indicator light fails to come on.
TIP
• Before troubleshooting, remove the following part(s):
1. Battery cover
2. Center cover
3. Side cover
4. Storage box

1. Check the fuses.

(Main, ignition, fuel injection sys-
tem, and ABS control unit) NG→ Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 8-36.

OK↓

2. Check the battery.

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

OK↓

3. Check the main switch.

Refer to “CHECKING THE NG→ Replace the main switch.
SWITCHES” on page 8-35.

OK↓

4. Check the Stop and Start System

switch. The Stop and Start System switch is
NG→
Refer to “CHECKING THE faulty. Replace the right handlebar switch.
SWITCHES” on page 8-35.

OK↓

5. Check the entire starting system

wiring. Properly connect or replace the wire har-
NG→
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-11.

OK↓

Check the condition of each of the

Stop and Start System circuits. Refer
to “Checking the Stop and Start Sys-
tem” on page 8-15.

8-14
 STOP AND START SYSTEM

Checking the Stop and Start System

The engine stop function does not operate.

1. Check the coolant temperature

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

OK↓

The throttle position sensor is faulty. Re-

2. Check the throttle position sensor. NG→
place the throttle body assembly.

OK↓

3. Check the front wheel sensor. NG→ Replace the front wheel sensor.

OK↓

4. Check the entire wiring. Properly connect or replace the wiring har-
NG→
Refer to TIP. ness.

OK↓

Replace the SGCU. Refer to “RE-

PLACING THE SGCU (starter gener-
ator control unit)” on page 8-36.
TIP
Replace the wire harness if there is an open or short circuit.

The engine start function does not operate.

1. Check the sidestand switch.

Refer to “CHECKING THE NG→ Replace the sidestand switch.
SWITCHES” on page 8-35.

OK↓

2. Check the starter generator.

Refer to “CHECKING THE START- NG→ Replace the starter generator assembly.
ER GENERATOR” on page 8-40.

OK↓

3. Check the start charge relay.

Refer to “CHECKING THE RE- NG→ Replace the start charge relay.
LAYS” on page 8-38.

OK↓

The throttle position sensor is faulty. Re-

4. Check the throttle position sensor. NG→
place the throttle body assembly.

OK↓

8-15
 STOP AND START SYSTEM

5. Check the entire Stop and Start

System wiring. Properly connect or replace the wiring har-
NG→
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-11.

OK↓

Replace the starter generator assem-

bly or the SGCU. Refer to “REPLAC-
ING THE SGCU (starter generator
control unit)” on page 8-36.

The Stop and Start System indicator light fails to come on.

1. Check the entire wiring. Properly connect or replace the wiring har-
NG→
Refer to TIP. ness.

OK↓

Replace the SGCU or meter assem-

bly. Refer to “REPLACING THE
SGCU (starter generator control unit)”
on page 8-36.
TIP
Replace the wire harness if there is an open or short circuit.
• Between SGCU coupler and meter assembly coupler.
(Blue/Red–Blue/Red)

8-16
 EAS30496
EAS20074

R
RR

R
R
Br
9 Br Br
Br Br
CIRCUIT DIAGRAM

10
R R 13
R R W G
ON Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
R/Y R/Y OPEN
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
Br Br/R OFF
LOCK Y/R Y/B B L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Br Br/R
(B)
CHARGING SYSTEM

R
Br/R Br/R
Br/R Br B

(B)
31
R
Br/R Br
B Br

Br

43

Y/R
R 35
R/B Br/R Br

R Br/R
Br R/B R/B

8-17
B
R
R

B B
B
B
G G R/L
R R R/Y 55
W W R/W

R/Y R/W R/L

R W G

B
B B
B B
B
B

B BB BB

B B
73 72 72
72 72
CHARGING SYSTEM
 CHARGING SYSTEM

1. Battery
9. Main fuse
10. Ignition fuse
13. Main switch
31. Main relay
35. Starter charge relay
43. SGCU (starter generator control unit)
55. Starter generator
72. Frame ground
73. Engine ground

8-18
 CHARGING SYSTEM

EAS30497

TROUBLESHOOTING
The battery is not being charged.
TIP
• Before troubleshooting, remove the following part(s):
1. Battery cover
2. Center cover
3. Side cover
4. Storage box
5. Front side cover

1. Check the fuses.

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

OK↓

2. Check the battery.

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

OK↓

3. Check the starter generator.

Refer to “CHECKING THE START- NG→ Replace the starter generator assembly.
ER GENERATOR” on page 8-40.

OK↓

4. Check the main relay.

Refer to “CHECKING THE RE- NG→ Replace the main relay.
LAYS” on page 8-38.

OK↓

5. Check the starter charge relay.

Refer to “CHECKING THE RE- NG→ Replace the starter charge relay.
LAYS” on page 8-38.

OK↓

6. Check the main switch.

Refer to “CHECKING THE NG→ Replace the main switch.
SWITCHES” on page 8-35.

OK↓

8-19
 CHARGING SYSTEM

7. Check the entire charging system

wiring. Properly connect or replace the wire har-
NG→
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-17.

OK↓

Replace the starter generator assem-

bly or the SGCU. Refer to “REPLAC-
ING THE SGCU (starter generator
control unit)” on page 8-36.

8-20
 RR

EAS30498
EAS20075

8
R R
R
Br
9 Br
Br
Br Br

10
Br R R 13
Br
11 R R W G
ON Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
R/Y R/Y OPEN
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
Br Br/R OFF
LOCK Y/R Y/B B L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br
R
Br Br/R
R (B)
CIRCUIT DIAGRAM

Br
LIGHTING SYSTEM

B Br
Br Br B
L/B Br

22 L/B

L/B P
25
Y Y
Y/W
B B 43
Ch Dg
L/W B
(B)

Y
P L/B
Y/W
R/W L/W
(B)

R Y/B

Br
Br

8-21
1 Br

B
75 Br Br B

L
82 Y Br 76 74
B Y L
84 Br B
85 86 Br Y Y Br
G B B Y/B B Br B
Y B
Gy Br/R B
Br

83 85
G Y/B
Gy Br/R

B B
B
B
B B 60
B
B

B Br
B Br/R
B B
R
B B R R 61
B B B
B
B

B BB BB
B
B B B 62
73 72 72
72 72

R/W L/W Br/W Y/W Dg Ch Br R

L/R G/B W/L Br/R W/R G B R

(Gy)
LIGHTING SYSTEM
 LIGHTING SYSTEM

1. Battery
8. Backup fuse
9. Main fuse
10. Ignition fuse
11. Headlight fuse
13. Main switch
22. Handlebar switch (left)
25. Dimmer switch
43. SGCU (starter generator control unit)
60. Meter assembly
61. Multi-function meter
62. ABS warning light
72. Frame ground
73. Engine ground
74. License plate light
75. Tail/brake light assembly
76. Taillight
82. Headlight assembly
83. Headlight control unit
84. High beam
85. Low beam
86. Auxiliary light

8-22
 LIGHTING SYSTEM

EAS30499

TROUBLESHOOTING
Any of the following fail to light: headlight, high beam indicator light, taillight, auxiliary lights or meter
light.
TIP
• Before troubleshooting, remove the following part(s):
1. Battery cover
2. Front side cover
3. Footrest board assembly
4. Front cowling assembly
5. Leg shield
6. Upper handlebar cover assembly

1. Check the condition of each bulb

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

OK↓

2. Check the fuses.

(Main, ignition, and headlight)
NG→ Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 8-36.

OK↓

3. Check the battery.

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

OK↓

4. Check the main switch.

Refer to “CHECKING THE NG→ Replace the main switch.
SWITCHES” on page 8-35.

OK↓

5. Check the dimmer switch.

The dimmer switch is faulty. Replace the
Refer to “CHECKING THE NG→
left handlebar switch.
SWITCHES” on page 8-35.

OK↓

8-23
 LIGHTING SYSTEM

6. Check the entire lighting system

wiring. Properly connect or replace the wire har-
NG→
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-21.

OK↓

Replace the SGCU, meter assembly,

tail/brake light assembly or headlight
unit. Refer to “REPLACING THE
SGCU (starter generator control unit)”
on page 8-36.

8-24
 R

EAS30500
EAS20076
RR

6
Br/R Br
Br

8
R R
R
Br
9 Br
Br
Br Br

10
R R 13
12 R
Br ON Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
R/Y R/Y OPEN
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
Br Br/R OFF
CIRCUIT DIAGRAM

LOCK L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br
R
Br Br/R
R (B)

Br/R R
Br/R
Br/R Br B

(B)
31
R
Br/R Br
Br
SIGNALING SYSTEM

Br
20 Br
P Br Br
P 21
P P Br

27 Br/W
22 P L/W R/W Br 33
Dg Br Br B/Y B/Y
Ch Dg
30 Br B/Y
Dg Br/W
24 26 OFF B/Y
L/B P Br/W
Y Y 34 37
Y/W FREE
PUSH PUSH B B Ch B Br B/Y B/Y
Ch 43
Ch Dg (R)
L/W B Y
(B) B
L/W

B B L/R L/R
P L/B G/R G/R G/R B/L
L/R B/L B/L 52
Y/W (B)
R/W L/W B
B
(B) B
B

Ch Ch
Ch
R
Dg Dg
Dg

8-25
1
B
G 42 B G

B (Gy)
Ch Dg Ch Dg B
B
75 Y B
G
81 80 79 78
B
B B Ch 76 77
W/B
Ch Dg G
(Br) (G) (Br) B Y
W
Br
B B B B B
B
Ch Dg Ch B
Y B
(Br) (G) Dg Br W
(Br) Br W/B
Br Br B
Y Y W 56 W B Br Y

59
B B B B/W
W/L
B
B
B B B 60
B
W/L
B G
B R Br Y G L W W/L W/B B/W

B Br R/L Y L/G L/G Br Lg/L Lg/W B/W B

B B

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

66

R/W L/W Br/W Y/W Dg Ch Br R

L/R G/B W/L Br/R W/R G B R

(Gy)
SIGNALING SYSTEM
 SIGNALING SYSTEM

1. Battery
6. Signaling system fuse
8. Backup fuse
9. Main fuse
10. Ignition fuse
12. ABS control unit fuse
13. Main switch
20. Horn
21. Diode
22. Handlebar switch (left)
24. Horn switch
26. Turn signal switch
27. Handlebar switch (right)
30. Hazard switch
31. Main relay
33. Front brake light switch
34. Rear brake light switch
37. Joint 1
42. Fuel sender
43. SGCU (starter generator control unit)
52. Coolant temperature sensor
56. Front wheel sensor
59. ABS ECU
60. Meter assembly
61. Multi-function meter
65. Turn signal indicator light (left)
66. Turn signal indicator light (right)
72. Frame ground
73. Engine ground
75. Tail/brake light assembly
76. Taillight
77. Brake light
78. Front turn signal light (left)
79. Front turn signal light (right)
80. Rear turn signal light (left)
81. Rear turn signal light (right)

8-26
 SIGNALING SYSTEM

EAS30501

TROUBLESHOOTING
• Any of the following fail to light: turn signal lights, brake light, warning lights or indicator lights.
• The horn fails to sound.
• The fuel meter fails to come on.
• The speedometer fails to operate.
• The instantaneous fuel consumption meter fails to operation.
TIP
• Before troubleshooting, remove the following part(s):
1. Battery cover
2. Front side cover
3. Fuel tank cover
4. Storage box
5. Center lower cover
6. Upper handlebar cover assembly

1. Check the fuses.

(Main, ignition, signaling system
ABS control unit) NG→ Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 8-36.

OK↓

2. Check the battery.

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

OK↓

3. Check the main switch.

Refer to “CHECKING THE NG→ Replace the main switch.
SWITCHES” on page 8-35.

OK↓

4. Check the entire signaling system

wiring. Properly connect or replace the wire har-
NG→
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-25.

OK↓

Check the condition of each of the sig-

naling system circuits. Refer to
“Checking the signaling system”.

8-27
 SIGNALING SYSTEM

Checking the signaling system

The horn fails to sound.

1. Check the horn switch.

The horn switch is faulty. Replace the left
Refer to “CHECKING THE NG→
handlebar switch.
SWITCHES” on page 8-35.

OK↓

2. Check the entire signaling system

wiring. Properly connect or replace the wire har-
NG→
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-25.

OK↓

Replace the horn.

The brake light fails to come on.

1. Check the front brake light switch.

Refer to “CHECKING THE NG→ Replace the front brake light switch.
SWITCHES” on page 8-35.

OK↓

2. Check the rear brake light switch.

Refer to “CHECKING THE NG→ Replace the rear brake light switch.
SWITCHES” on page 8-35.

OK↓

3. Check the entire signaling system

wiring. Properly connect or replace the wire har-
NG→
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-25.

OK↓

Replace the tail/brake light assembly.

The turn signal light, turn signal indicator light or both fail to blink.

1. Check the turn signal light bulbs

and sockets.
Refer to “CHECKING THE BULBS Replace the turn signal light bulb, socket
NG→
AND BULB SOCKETS” in “BASIC or both.
INFORMATION” (separate vol-
ume).

OK↓

2. Check the turn signal switch.

The turn signal switch is faulty. Replace
Refer to “CHECKING THE NG→
the left handlebar switch.
SWITCHES” on page 8-35.

OK↓

8-28
 SIGNALING SYSTEM

3. Check the entire signaling system

wiring. Properly connect or replace the wire har-
NG→
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-25.

OK↓

Replace the meter assembly.

The coolant temperature warning light fails to come on.

1. Check the coolant temperature

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

OK↓

2. Check the entire signaling system

wiring. Properly connect or replace the wire har-
NG→
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-25.

OK↓

Replace the meter assembly or

SGCU. Refer to “REPLACING THE
SGCU (starter generator control unit)”
on page 8-36.

The fuel meter, fuel level warning light, or both fails to come on.

1. Check the fuel sender.

Refer to “CHECKING THE FUEL NG→ Replace the fuel pump.
SENDER” on page 8-41.

OK↓

2. Check the entire signaling system

wiring. Properly connect or replace the wire har-
NG→
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-25.

OK↓

Replace the meter assembly.

8-29
 SIGNALING SYSTEM

The speedometer, V-belt replacement indicator, engine oil change indicator, instantaneous fuel
consumption meter fails to operate.

1. Check the front wheel sensor.

Refer to “MAINTENANCE OF THE
NG→ Replace the front wheel sensor.
FRONT WHEEL SENSOR AND
SENSOR ROTOR” on page 4-25.

OK↓

2. Check the entire wiring. Properly connect or replace the wiring har-
NG→
Refer to TIP. ness.

OK↓

Replace the SGCU, or meter assem-

bly. Refer to “REPLACING THE
SGCU (starter generator control unit)”
on page 8-36.
TIP
Replace the wire harness if there is an open or short circuit.
• Between front speed sensor coupler and SGCU coupler.
(Brown–Brown)
(Yellow–Yellow)
• Between SGCU coupler and meter assembly coupler.
(Blue/Red–Blue/Red)

8-30
 EAS30513
RR EAS20081

7
R
R
Br
9 Br
Br Br

10
R R 13
CIRCUIT DIAGRAM

R
ON Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
R/Y R/Y OPEN
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
Br Br/R OFF
LOCK L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Br Br/R
(B)
FUEL PUMP SYSTEM

Br
Br

Br

43

8-31
R

B/Y R
41 (B)
1 R B/Y B/Y

B
B

B
B B
B B
B
B

BB

72
FUEL PUMP SYSTEM
 FUEL PUMP SYSTEM

1. Battery
7. Fuel injection system fuse
9. Main fuse
10. Ignition fuse
13. Main switch
41. Fuel pump
43. SGCU (starter generator control unit)
72. Frame ground

8-32
 FUEL PUMP SYSTEM

EAS30514

TROUBLESHOOTING
If the fuel pump fails to operate.
TIP
• Before troubleshooting, remove the following part(s):
1. Battery cover
2. Front side cover
3. Footrest board assembly
4. Fuel tank

1. Check the fuses.

(Main, ignition and fuel injection)
NG→ Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 8-36.

OK↓

2. Check the battery.

Refer to “CHECKING AND • Clean the battery terminals.
NG→
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 8-37.

OK↓

3. Check the main switch.

Refer to “CHECKING THE NG→ Replace the main switch.
SWITCHES” on page 8-35.

OK↓

4. Check the fuel pump.

Refer to “CHECKING THE FUEL NG→ Replace the fuel pump.
PRESSURE” on page 7-5.

OK↓

5. Check the entire fuel pump system

wiring. Properly connect or replace the wiring har-
NG→
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-31.

OK↓

Replace the SGCU. Refer to “RE-

PLACING THE SGCU (starter gener-
ator control unit)” on page 8-36.

8-33
 ELECTRICAL COMPONENTS

EAS20089

ELECTRICAL COMPONENTS
2
1
3 4
5
32
6
31
7
30
10
8
29
9
28 11

24,25,26,27

23 12

13

22 14
21 20

15
19 18 17 16
1. Battery 19. Spark plug
2. Main switch 20. Coolant temperature sensor
3. Front brake light switch 21. Starter generator
4. Rear brake light switch 22. Crankshaft position sensor
5. Auxiliary DC jack 23. Rear wheel sensor
6. Buzzer 24. Throttle body sensor assembly
7. SGCU (starter generator control unit) 25. Intake air pressure sensor
8. Main relay 26. Intake air temperature sensor
9. Starter charge relay 27. Throttle position sensor
10. Fuse box 28. ISC (Idle Speed Control) unit
11. ABS ECU 29. Fuel injector
12. Horn 30. Ignition coil
13. Front wheel sensor 31. CCU (Communication Control Unit)
14. Fuel pump 32. Smart key unit
15. Fuel sender
16. Sidestand switch
17. VVA (variable valve actuator) solenoid
18. O2 sensor

8-34
 ELECTRICAL COMPONENTS

EAS30549

CHECKING THE SWITCHES

11 1
R R R/Y Br/R
B Y/W ON
L/B P
FREE OPEN
PUSH Y/W OFF
R/Y LOCK
Ch Dg
10 Br/R
Y L/B
Y
B
2
9 L/W
L/W B L/W
P B
PUSH
FREE
B
8
Ch B/W Dg 3
Y/W B/W
Y/W
ON
OFF
B/W

7
4
Dg Dg Br/W Ch

Br/W
Ch

6
B
B
B

1. Main switch
2. Start switch
3. Start and Stop System switch
4. Hazard switch
5. Front brake light switch
6. Sidestand switch
7. Rear brake light switch
8. Turn signal light switch
9. Horn switch
10. Dimmer switch
11. Menu switch

8-35
 ELECTRICAL COMPONENTS

EAS30551

CHECKING THE FUSES Amper-

Fuses Q’ty
The following procedures are applied to all of the age rating
fuses. Spare 30 A 1
ECA20520

NOTICE Spare 7.5 A 1

To avoid a short circuit, always turn the main Spare 5A 1
switch to “OFF” when checking or replacing
EWA13310
a fuse.
WARNING
1. Remove: Never use a fuse with an amperage rating
• Battery cover other than that specified. Improvising or us-
Refer to “GENERAL CHASSIS (1)” on ing a fuse with the wrong amperage rating
page 4-1. may cause extensive damage to the electri-
2. Check: cal system, cause the lighting and ignition
• Fuse systems to malfunction and could possibly
a. Connect the digital circuit tester to the fuse cause a fire.
and check the continuity.
4. Install:
Digital circuit tester (CD732) • Battery cover
90890-03243 Refer to “GENERAL CHASSIS (1)” on
Model 88 Multimeter with ta- page 4-1.
chometer
EAS33388
YU-A1927
REPLACING THE SGCU (starter generator
b. If the digital circuit tester indicates “∞”, re- control unit)
place the fuse. 1. Turn the main switch to “OFF”.
2. Replace the SGCU (starter generator control
3. Replace: unit).
• Blown fuse 3. Clean the throttle body.
a. Turn the main switch to “OFF”. Refer to “CLEANING THE ISC (IDLE SPEED
b. Install a new fuse of the correct amperage CONTROL) UNIT AND THROTTLE BODY”
rating. on page 7-13.
c. Set on the switches to verify if the electrical 4. Check:
circuit is operational. • Engine idling speed
d. If the fuse immediately blows again, check Start the engine, warm it up, and then mea-
the electrical circuit. sure the engine idling speed.
Amper-
Fuses Q’ty Engine idling speed
age rating
1500–1700 r/min
Main fuse 30 A 1
Headlight fuse 7.5 A 1
Backup fuse 7.5 A 1
Ignition fuse 7.5 A 1
Fuel injection system 7.5 A 1
fuse
Signaling system fuse 7.5 A 1
Terminal fuse 5A 1
ABS motor fuse 30.0 A 1
ABS solenoid fuse 15.0 A 1
ABS control unit fuse 2.0 A 1
Smart key system fuse 2.0 A 1

8-36
 ELECTRICAL COMPONENTS

EAS30552
6. Connect:
CHECKING AND CHARGING THE BATTERY
• Battery leads
TIP (to the battery terminals)
Refer to “CHECKING AND CHARGING THE ECA13630

BATTERY” in “BASIC INFORMATION” (sepa- NOTICE

rate volume). First, connect the positive battery lead “1”,
and then the negative battery lead “2”.
1. Remove:
• Battery cover
Refer to “GENERAL CHASSIS (1)” on
page 4-1.
2. Disconnect:
• Battery lead
(from the battery terminals) 2
ECA13640

NOTICE
First, disconnect the negative battery lead 1
“1”, and then positive battery lead “2”.
7. Check:
• Battery terminals
Dirt → Clean with a wire brush.
Loose connection → Connect properly.
8. Lubricate:
• Battery terminals
1
Recommended lubricant
Dielectric grease
2
9. Install:
3. Remove: • Battery cover
• Battery Refer to “GENERAL CHASSIS (1)” on
4. Check: page 4-1.
• Battery charge
a. Connect a digital circuit tester to the battery
terminals.
• Positive tester probe →
positive battery terminal
• Negative tester probe →
negative battery terminal

5. Install:
• Battery

8-37
 ELECTRICAL COMPONENTS

EAS30553
Starter charge relay
CHECKING THE RELAYS
Check each switch for continuity with the digital First step:
circuit tester. If the continuity reading is incor-
rect, replace the relay. 1
3
Digital circuit tester (CD732)
2
90890-03243
Model 88 Multimeter with ta- Br Br/R R/B
chometer
R
YU-A1927
Y/R

1. Disconnect the relay from the wire harness.

2. Connect the digital circuit tester and battery 1. Positive tester probe
(12 V) to the relay terminals as shown. 2. Negative tester probe
Check the relay operation. 3. Negative tester probe
Out of specification → Replace.
Result
3 1 Continuity
4
+ (between “1” and “2”)
2 No continuity
(between “1” and “3”)
B Br Second step:
Br/R
R
3 2
5 +
1. Positive battery terminal 4
2. Negative battery terminal
1
3. Positive tester probe
4. Negative tester probe Br Br/R R/B
R
Y/R
Result
Continuity 1. Positive battery terminal
(between “3” and “4”) 2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
5. Negative tester probe

Result
No continuity
(between “3” and “4”)
Continuity
(between “3” and “5”)

8-38
 ELECTRICAL COMPONENTS

EAS30557

CHECKING THE SPARK PLUG CAP • Positive tester probe →

1. Check: Brown “1”
• Negative tester probe →
• Spark plug cap resistance
Orange “2”
Out of specification → Replace.

Resistance
3.75–6.25 kΩ

a. Remove the spark plug cap from the spark 2

plug lead.
b. Connect the digital circuit tester to the spark
plug cap as shown.

Digital circuit tester (CD732) 1

90890-03243
c. Measure the primary coil resistance.
Model 88 Multimeter with ta-
chometer 2. Check:
YU-A1927 • Secondary coil resistance
Out of specification → Replace.

Secondary coil resistance

8.64–12.96 kΩ

a. Connect the digital circuit tester to the igni-

tion coil as shown.

Digital circuit tester (CD732)

90890-03243
Model 88 Multimeter with ta-
c. Measure the spark plug cap resistance. chometer
EAS30558 YU-A1927
CHECKING THE IGNITION COIL
1. Check: • Positive tester probe →
• Primary coil resistance Orange “1”
Out of specification → Replace. • Negative tester probe →
High tension cord “2”
Primary coil resistance
2.16–2.64 Ω
2
a. Disconnect the ignition coil connectors from
the ignition coil terminals.
b. Connect the digital circuit tester to the igni-
tion coil as shown.

Digital circuit tester (CD732)

90890-03243 1
Model 88 Multimeter with ta-
chometer b. Measure the secondary coil resistance.
YU-A1927

8-39
 ELECTRICAL COMPONENTS

EAS30556 EAS33389

CHECKING THE IGNITION SPARK GAP CHECKING THE STARTER GENERATOR

1. Check: 1. Disconnect:
• Ignition spark gap • Starter generator coupler
Out of specification → Perform the ignition (from the wire harness)
system troubleshooting, starting with step 5. 2. Check:
Refer to “TROUBLESHOOTING” on page 8- • Starter generator resistance
3. Out of specification → Replace the starter
generator assembly.
Minimum ignition spark gap
6.0 mm (0.24 in) Starter generator resistance
0.048–0.072 Ω
TIP
If the ignition spark gap is within specification, a. Connect the digital circuit tester to the start-
the ignition system circuit is operating normally. er generator coupler as shown.

a. Disconnect the spark plug cap from the Digital circuit tester (CD732)
spark plug. 90890-03243
b. Connect the ignition checker “1” as shown. Model 88 Multimeter with ta-
chometer
Ignition checker YU-A1927
90890-06754
Oppama pet–4000 spark checker • Positive tester probe →
YM-34487 Red/Yellow “1”
• Negative tester probe →
Red/Blue “3”

• Positive tester probe →

Red/Yellow “1”
• Negative tester probe →
Red/White “2”

• Positive tester probe →

Red/Blue “3”
• Negative tester probe →
2. Ignition coil Red/White “2”
c. Turn the main switch to “ON”.
d. Measure the ignition spark gap “a”.
e. Crank the engine by pushing the “ ” of the
start switch and gradually increase the
spark gap until a misfire occurs.

R/Y R/W R/L

1 2 3
b. Measure the starter generator resistance.

8-40
 ELECTRICAL COMPONENTS

EAS30573 EAS30578

CHECKING THE FUEL SENDER CHECKING THE COOLANT TEMPERATURE

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

Out of specification → Replace the fuel pump WARNING

assembly. • Handle the coolant temperature sensor
with special care.
Fuel sender • Never subject the coolant temperature sen-
Sender unit resistance (full) sor to strong shocks. If the coolant tem-
10.0–14.0 Ω perature sensor is dropped, replace it.
Sender unit resistance (empty)
2. Check:
267.0–273.0 Ω
• Coolant temperature sensor resistance
Out of specification → Replace.
a. Connect the digital circuit tester to the fuel
sender terminals as shown.
Coolant temperature sensor re-
sistance
Digital circuit tester (CD732) 2513–2777 Ω at 20 °C (2513–
90890-03243 2777 Ω at 68 °F)
Model 88 Multimeter with ta- Coolant temperature sensor re-
chometer sistance
YU-A1927 210–221 Ω at 100 °C (210–221 Ω
at 212 °F)
• Positive tester probe →
Green “1” a. Connect the digital circuit tester to the cool-
• Negative tester probe →
ant temperature sensor terminals as
Black “2”
shown.

Digital circuit tester (CD732)

2 90890-03243
Model 88 Multimeter with ta-
chometer
B/Y B YU-A1927
R G
b. Immerse the coolant temperature sensor
“1” in a container filled with coolant “2”.
1
TIP
Make sure that the coolant temperature sensor
b. Move the fuel sender float to minimum “3”
terminals do not get wet.
and maximum “4” level position.
c. Place a thermometer “3” in the coolant.
4
3
1
3

2
c. Measure the fuel sender resistance.
d. Heat the coolant or let it cool down to the
specified temperatures.

8-41
 ELECTRICAL COMPONENTS

e. Measure the coolant temperature sensor EAS31612

CHECKING THE VVA SOLENOID

resistance.
1. Check:
3. Install: • VVA solenoid resistance
• Coolant temperature sensor Out of specification → Replace.

Coolant temperature sensor Resistance

15 N·m (1.5 kgf·m, 11 lb·ft) 1.8–2.2 Ω at 20 °C (1.8–2.2 Ω at 68
T.
R.

°F)
EAS30681

CHECKING THE FUEL INJECTOR

a. Disconnect the VVA solenoid coupler from
1. Check:
the VVA solenoid.
• Fuel injector resistance
b. Connect the digital circuit tester to the VVA
Out of specification → Replace the fuel injec-
solenoid terminal as shown.
tor.
Digital circuit tester (CD732)
Resistance 90890-03243
12.2 Ω
Model 88 Multimeter with ta-
chometer
a. Disconnect the fuel injector coupler from YU-A1927
fuel injector.
b. Connect the digital circuit tester to the fuel • Positive tester probe
injector terminals as shown. Solenoid terminal “1”
• Negative tester probe
Digital circuit tester (CD732) Solenoid terminal “2”
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927 1 2

• Positive tester probe →

Injector terminal “1”
• Negative tester probe →
Injector terminal “2”

2 1
c. Measure the VVA solenoid resistance.

c. Measure the fuel injector resistance.

8-42
 ELECTRICAL COMPONENTS

EAS31553

CHECKING THE SMART KEY BATTERY 2 1

1. Check:
• Smart key battery voltage B R
Out of specification → Replace the smart key
battery.

Smart key battery voltage

2.7–3.2 V

a. Remove the smart key battery from the c. Check that the buzzer sounds.
smart key.
b. Connect the digital circuit tester to the smart EAS31257

key battery as shown. CHECKING THE MAIN SWITCH SOLENOID

1. Check:
Digital circuit tester (CD732) • Main switch solenoid
90890-03243 a. Disconnect the main switch solenoid cou-
Model 88 Multimeter with ta- pler from the wire harness.
chometer b. Connect the digital circuit tester to the main
YU-A1927 switch solenoid as shown.

• Positive tester probe → Digital circuit tester (CD732)

Positive battery terminal “1” 90890-03243
• Negative tester probe → Model 88 Multimeter with ta-
Negative battery terminal “2” chometer
YU-A1927

• Positive tester probe →

Red/White “1”
1 • Negative tester probe →
Black “2”
2

1 2
R/W B
c. Measure the smart key battery voltage.
EAS31555

CHECKING THE BUZZER

1. Check:
• Buzzer operation
Buzzer does not sound → Replace.
c. Check the main switch solenoid continuity.
a. Disconnect the buzzer coupler from the d. If there is no continuity, replace the main
wire harness. switch assembly.
b. Connect the battery (12 V) to the buzzer
coupler as shown.
• Positive battery lead →
Red “1”
• Negative battery lead →
Black “2”

8-43
 SELF DIAGNOSTIC

SELF-DIAGNOSTIC FUNCTION..................................................................... 9-1

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

SYSTEM DIAGRAM ........................................................................................9-5

ECU CIRCUIT DIAGRAM..........................................................................9-5
ECU COUPLER LAYOUT ......................................................................... 9-6

FUEL INJECTION SYSTEM............................................................................9-9

CIRCUIT DIAGRAM .................................................................................. 9-9
BASIC PROCESS FOR TROUBLESHOOTING ..................................... 9-11
[A] THE MIL COMES ON/FLASHES
AND ENGINE OPERATION IS NOT NORMAL...................................... 9-12
[B] THE MIL DOES NOT COME ON,
BUT THE ENGINE OPERATION IS NOT NORMAL ..............................9-12

ABS (Anti-lock Brake System) .................................................................... 9-13

CIRCUIT DIAGRAM ................................................................................ 9-13
ABS COUPLER LOCATION CHART ......................................................9-15
MAINTENANCE OF THE ABS ECU .......................................................9-16
ABS TROUBLESHOOTING OUTLINE....................................................9-16
BASIC INSTRUCTIONS FOR TROUBLESHOOTING ............................ 9-17
BASIC PROCESS FOR TROUBLESHOOTING ..................................... 9-18
[A] CHECKING THE ABS WARNING LIGHT..........................................9-19
[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON............. 9-19
[A-2] ALL INDICATOR LIGHTS FAIL TO COME ON ..............................9-19
[A-3] THE ABS WARNING LIGHT COMES ON ...................................... 9-19
[B-1] MALFUNCTION ARE CURRENTLY DETECTED .......................... 9-20
[B-2] DIAGNOSIS USING THE FAULT CODES ..................................... 9-20
[B-3] DELETING THE FAULT CODES....................................................9-21
[C-1] FINAL CHECK ................................................................................ 9-21

SMART KEY SYSTEM .................................................................................. 9-23

CIRCUIT DIAGRAM ................................................................................ 9-23
TROUBLESHOOTING ............................................................................9-25
SMART KEY SYSTEM SELF-DIAGNOSIS............................................. 9-29
SMART KEY SYSTEM EMERGENCY MODE ........................................ 9-31
REGISTERING A SMART KEY...............................................................9-32
DISABLING A SMART KEY .................................................................... 9-34
DISABLING THE POWER-ON ALARM...................................................9-35
9
REPLACEMENT PARTS LIST ................................................................9-36
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE..........9-37
DTC TABLE............................................................................................. 9-37
COMMUNICATION ERROR
WITH THE YAMAHA DIAGNOSTIC TOOL ............................................9-39
SELF-DIAGNOSTIC FUNCTION TABLE ................................................ 9-40
SELF-DIAGNOSTIC FUNCTION TABLE
(FOR ABS (Anti-lock Brake System)) .....................................................9-51
DIAGNOSTIC CODE: SENSOR OPERATION TABLE ........................... 9-56
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE ......................9-58

EVENT CODE TABLE...................................................................................9-59

P0030............................................................................................................. 9-61
TROUBLESHOOTING ............................................................................9-61

P00D1, P2195................................................................................................9-65
TROUBLESHOOTING ............................................................................9-65

P0106............................................................................................................. 9-69
TROUBLESHOOTING ............................................................................9-69

P0107, P0108 ................................................................................................9-71

TROUBLESHOOTING ............................................................................9-71

P0112, P0113 ................................................................................................9-75

TROUBLESHOOTING ............................................................................9-75

P0117, P0118 ................................................................................................9-79

TROUBLESHOOTING ............................................................................9-79

P0122, P0123 ................................................................................................9-83

TROUBLESHOOTING ............................................................................9-83

P0132............................................................................................................. 9-87
TROUBLESHOOTING ............................................................................9-87

P0201............................................................................................................. 9-90
TROUBLESHOOTING ............................................................................9-90

P0335............................................................................................................. 9-93
TROUBLESHOOTING ............................................................................9-93

P0351............................................................................................................. 9-97
TROUBLESHOOTING ............................................................................9-97
P0500...........................................................................................................9-101
TROUBLESHOOTING ..........................................................................9-101

P0507...........................................................................................................9-105
TROUBLESHOOTING ..........................................................................9-105

P0511...........................................................................................................9-112
TROUBLESHOOTING ..........................................................................9-112

P0560, P0563 ..............................................................................................9-116

TROUBLESHOOTING ..........................................................................9-116

P0601...........................................................................................................9-117
TROUBLESHOOTING ..........................................................................9-117

P062F ..........................................................................................................9-118
TROUBLESHOOTING ..........................................................................9-118

P1602...........................................................................................................9-120
TROUBLESHOOTING ..........................................................................9-120

P2158...........................................................................................................9-125
TROUBLESHOOTING ..........................................................................9-125

P2645...........................................................................................................9-130
TROUBLESHOOTING ..........................................................................9-130

Er-1, Er-2, Er-3, Er-4 ...................................................................................9-134

TROUBLESHOOTING ..........................................................................9-134

11, 25_ABS .................................................................................................9-138

TROUBLESHOOTING ..........................................................................9-138

12_ABS .......................................................................................................9-139
TROUBLESHOOTING ..........................................................................9-139

13, 26_ABS .................................................................................................9-140

TROUBLESHOOTING ..........................................................................9-140

14, 27_ABS .................................................................................................9-141

TROUBLESHOOTING ..........................................................................9-141

15_ABS .......................................................................................................9-142
 TROUBLESHOOTING ..........................................................................9-142

16_ABS .......................................................................................................9-144
TROUBLESHOOTING ..........................................................................9-144

17, 45_ABS ................................................................................................. 9-146

TROUBLESHOOTING ..........................................................................9-146

18, 46_ABS ................................................................................................. 9-147

TROUBLESHOOTING ..........................................................................9-147

21_ABS .......................................................................................................9-148
TROUBLESHOOTING ..........................................................................9-148

31_ABS .......................................................................................................9-149
TROUBLESHOOTING ..........................................................................9-149

32_ABS .......................................................................................................9-151
TROUBLESHOOTING ..........................................................................9-151

33_ABS .......................................................................................................9-152
TROUBLESHOOTING ..........................................................................9-152

34_ABS .......................................................................................................9-154
TROUBLESHOOTING ..........................................................................9-154

41_ABS .......................................................................................................9-155
TROUBLESHOOTING ..........................................................................9-155

42, 47_ABS ................................................................................................. 9-156

TROUBLESHOOTING ..........................................................................9-156

43_ABS .......................................................................................................9-157
TROUBLESHOOTING ..........................................................................9-157

44_ABS .......................................................................................................9-158
TROUBLESHOOTING ..........................................................................9-158

51, 52_ABS ................................................................................................. 9-159

TROUBLESHOOTING ..........................................................................9-159

53_ABS .......................................................................................................9-160
TROUBLESHOOTING ..........................................................................9-160
54_ABS .......................................................................................................9-162
TROUBLESHOOTING ..........................................................................9-162

55_ABS .......................................................................................................9-164
TROUBLESHOOTING ..........................................................................9-164

56_ABS .......................................................................................................9-165
TROUBLESHOOTING ..........................................................................9-165

63_ABS .......................................................................................................9-166
TROUBLESHOOTING ..........................................................................9-166

64_ABS .......................................................................................................9-168
TROUBLESHOOTING ..........................................................................9-168
 SELF-DIAGNOSTIC FUNCTION

EAS20437

SELF-DIAGNOSTIC FUNCTION
EAS33142

GLOSSARY
Word Description
MIL
MIL is an indicator light that comes on when a control unit determines a
(Malfunction indica-
malfunction.
tor light)
DTC
DTC is a code that is saved within a control unit’s memory when the control
(Diagnostic trouble
unit determines a malfunction.
code)
Pending DTC Pending DTC is a code that is saved within a control unit’s memory when
(Pending diagnostic the control unit detects an abnormal condition. If the abnormal condition
trouble code) continues, a malfunction may be determined.
Driving cycle is the duration from the main switch is turned to ON, OBD re-
Driving cycle
quirements are met, and until the main switch is turned to OFF.
FFD FFD is the data of all signal sensors saved at the moment a malfunction is
(Freeze frame data) determined.
Current malfunction A DTC for an unrecovered, current malfunction.
Recovered malfunc-
A DTC for a previously determined but now recovered malfunction.
tion
Abnormal condition that is detected but not yet determined to be a malfunc-
Pending abnormality
tion.
Threshold is a point set to detect if the output from sensors are abnormal or
Threshold
not.
OBD
Self-diagnostic system is equipped in a control unit for the emission control
(On-board diagnos-
system.
tics)
GST
Generic diagnostic tool that complies with OBD standards.
(Generic scan tool)
YDT
(Yamaha diagnostic Diagnostic tool developed especially for Yamaha vehicles.
tool)

EAS32858

OUTLINE
The control unit is equipped with a self-diagnostic function in order to ensure that the system is operat-
ing normally. If this function detects a malfunction in the system, it immediately operates the system un-
der substitute characteristics and illuminates the warning light to alert the rider that a malfunction has
occurred in the system. Once a malfunction has been detected, a DTC is stored in the memory of the
control unit.

9-1
 SELF-DIAGNOSTIC FUNCTION

EAS32859

CHECKING THE WARNING LIGHT

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

1 2

System Lighting up warning light Lighting time

FUEL INJECTION SYSTEM MIL “2” 2.0 seconds
ABS (Anti-lock Brake Sys-
ABS warning light “1” *1
tem)

TIP
*1: The ABS warning light goes off when the vehicle is judged to normal with running.

9-2
 SELF-DIAGNOSTIC FUNCTION

EAS32806

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

Yamaha diagnostic tool USB

90890-03267
Yamaha diagnostic tool (A/I)
90890-03264

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

EAS33550

PARTS CONNECTED TO THE SGCU

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

9-3
 SELF-DIAGNOSTIC FUNCTION

EAS32918

PARTS CONNECTED TO THE ABS ECU

The following parts are connected to the hydraulic unit assembly (ABS ECU).
When checking for a power short circuit, the couplers must be disconnected from all of the following
parts beforehand.
• ABS solenoid fuse • Rear wheel sensor
• ABS motor fuse • Meter assembly
• ABS ECU fuse • SGCU (Starter Generator Control Unit)
• Front wheel sensor

9-4
 SYSTEM DIAGRAM

EAS20387

SYSTEM DIAGRAM
EAS32920

ECU CIRCUIT DIAGRAM

METER ASSEMBLY
EFI FUSE BACKUP FUSE
IGNITION COIL
40

47 1

33
IGNITION
LOW BEAM FUEL INJECTOR
FUSE
43 5
FUEL PUMP
FRONT WHEEL
DIMMER HIGH BEAM SENSOR 3
SWITCH O2 SENSOR HEATER

25
ABS ECU
HEADLIGHT
SWITCH 38
MAIN OS SENSOR
REAR WHEEL
RELAY
SENSOR
8
HEADLIGHT
FUSE
48
START SWITCH
13
44
SSS SWITCH
MAIN
SWITCH
SGCU 15
(STARTER ISC (IDLE SPEED CONTROL)
GENERATOR
CONTROL
UNIT)
29
MAIN FUSE
SIDESTAND SWITCH

SIGNALING FUSE BRAKE LIGHT 42 31

SWITCH

TERMINAL FUSE
7 THROTTLE BODY SENSOR ASSEMBLY

23
35
THROTTLE POSITION S
20
17
STARTER CHARGER RELAY
34 INTAKE AIR TEMPERAT
50
36
51 INTAKE AIR PRESSURE
BATTERY

21
49
52 46
COOLANT TEMPERATURE SENSOR

STARTER GENERATOR 54 45
53
9
VVA (VARIABLE VALVE ACTUATION)
18
11
4
39
CRANKSHAFT 12
POSITION
SENSOR
24 16
YAMAHA DIAGNOSTIC TOOL
26 32
19

9-5
 SYSTEM DIAGRAM

EAS33369

ECU COUPLER LAYOUT

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 5354

Wire harness Wire harness

No. Connected parts No. Connected parts
color color
Yamaha diagnostic Crankshaft position
1 Lg/L 23 W/Y
tool sensor
ISC (Idle Speed 24 O2 sensor P/B
2 G/Y
Control)
Crankshaft position
3 — — 25 W/B
sensor
ISC (Idle Speed Throttle body sen-
4 Ch 26 L
Control) sor assemblies
Crankshaft position 27 — —
5 W/L
sensor
Throttle body sen-
VVA (Variable valve 28 B/L
6 Ch sor assemblies
actuation) solenoid
Throttle body sen-
7 — — 29 Y
sor assemblies
VVA (Variable valve Crankshaft position
8 G 30 B/L
actuation) solenoid sensor
9 O2 sensor B/L Crankshaft position
31 Br/B
10 Ground B sensor

11 — — 32 Starter charge relay R/B

12 Fuel injector O/B 33 Starter switch L/B

Crankshaft position Fuel injection sys-

13 W/R 34 R
sensor tem fuse

14 Fuel pump B/Y Coolant tempera-

35 G/R
ture sensor
15 — —
Coolant tempera-
16 Ignition coil O 36 B/L
ture sensor
Yamaha diagnostic Stop Start System
17 Lg/W 37 W/G
tool switch
ISC (Idle Speed 38 ABS ECU W
18 Sb
Control)
39 Sidestand switch L/Y
19 — —
40 — —
ISC (Idle Speed
20 Gy 41 Meter assembly L/R
Control)
21 — — 42 Ground B

22 — — 43 O2 sensor Gy/R
44 ABS ECU W/B

9-6
 SYSTEM DIAGRAM

Wire harness
No. Connected parts
color
Throttle body sen-
45 Br/W
sor assemblies
46 Ground B
Throttle body sen-
47 P/W
sor assemblies
48 Main relay Br
49 Starter charge relay Y/R
50 Headlight unit Y/B
51 Battery B
52 Starter generator R
53 Starter generator W
54 Starter generator G

9-7
 SYSTEM DIAGRAM

9-8
 RR

EAS32871
EAS20440

R
R

7 8 R
R
R Br Br
Br Br
9 Br Br/R Br
Br
Br Br

10
R R 13 R
R
12 R
Br ON Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
R/Y R/Y OPEN
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
Br Br/R OFF
LOCK L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br
CIRCUIT DIAGRAM

Br Br/R
(B)

Br
38 O O
44
Br O/B O/B
45
O/B Br
Br (B)
Br P P
R G/Y G/Y P G/Y Sb Gy
Gy Gy 46
Lg/L B Sb Sb
Br (B)
R Lg/W

Lg/W
(R) R Lg/L
Lg/W
47 48
Lg/L 32 B P/W P/W
Br/W Br/W 49 B/L Y L P/W Br/W
B/L B/L
Y Y
L L
50 (B)
FUEL INJECTION SYSTEM

W/R W/R G
W/L W/L G W/R W/R B/L
W/B W/B L/Y Br/B W/L W/L Br/B
W/Y W/Y 51
Br/B Br/B L/Y W/B W/B W/Y
43 B/L B/L
(B)
(B)

L/R L/R G/R G/R G/R B/L

L/R B/L B/L 52
(B)

G G G Ch
Ch Ch 53
B B L/Y L/Y L/Y L/Y (Gy)

B
R
L/Y B 36 Gy/R Br/R B B P/B
B B
B/Y R B/L B/L W L Gy/R
(L) (L)

9-9
41 P/B
(B)
1 R B/Y B/Y
B B Br/R P/B
54 W L Gy/R B/L
(B) (B)
B B
B
B
B

W/B

W
Br W/B
Br Br B
Y Y W 56 W B Br Y

59
Lg/W
B B B/W
Lg/W W/L
B
B 60
Lg/L W/L
B Lg/L R Br Y G L W W/L W/B B/W

B Br R/L Y L/G L/G Br Lg/L Lg/W B/W B

B
B B
B B B (B)
B B B/W 61
B B B
B
B

L/R
B BB BB
B
B B B
73 72 72
72 72

67

R/W L/W Br/W Y/W Dg Ch Br R

L/R G/B W/L Br/R W/R G B R

(Gy)
FUEL INJECTION SYSTEM
 FUEL INJECTION SYSTEM

1. Battery
7. Fuel injection system fuse
8. Backup fuse
9. Main fuse
10. Ignition fuse
12. ABS control unit fuse
13. Main switch
32. Yamaha diagnostic tool coupler
36. Sidestand switch
38. Injector
41. Fuel pump
43. SGCU (starter generator control unit)
44. Ignition coil
45. Spark plug
46. ISC (Idle Speed Control) unit
47. Throttle body sensor assembly
48. Intake air pressure sensor
49. Intake air temperature sensor
50. Throttle position sensor
51. Crankshaft position sensor
52. Coolant temperature sensor
53. VVA (variable valve actuator) solenoid
54. O2 sensor
56. Front wheel sensor
59. ABS ECU
60. Meter assembly
61. Multi-function meter
67. Engine trouble warning light
72. Frame ground
73. Engine ground

9-10
 FUEL INJECTION SYSTEM

EAS32917

BASIC PROCESS FOR TROUBLESHOOTING

This section describes the basic process about fuel injection system troubleshooting.
But because a work procedure varies depending to symptom and DTC, check and repair it according
to applicable troubleshooting.

When turning the main switch No Does the MIL (LED) work No
Check the MIL (LED).
to ON, does the MIL come on? properly?

Yes Yes

Yes [B] Perform the checking with the

The MIL goes off after 2 seconds?
diagnostic mode.

No

Still on/flash.
[A] Check the DTC.

Do the troubleshooting according

to the DTCs of "malfunction".

Check the DTCs of "malfunction"

are not displayed on the screen.

Finished.

9-11
 FUEL INJECTION SYSTEM

EAS33147

[A] THE MIL COMES ON/FLASHES AND ENGINE OPERATION IS NOT NORMAL
1. Check the DTC of “malfunction” using the YDT.
2. Delete the DTC using the YDT. (Only for *1)
3. Check and repair the malfunction according to applicable DTC troubleshooting.
4. Turn the main switch to OFF, and then turn the main switch to ON, and then check the DTC of “mal-
function” is not displayed.
TIP
• If another DTC is displayed, repeat steps (1) to (4) until no DTC is displayed.
• Turn the main switch to OFF will not erase the malfunction history.

EAS33148

[B] THE MIL DOES NOT COME ON, BUT THE ENGINE OPERATION IS NOT NORMAL
1. Monitor the operation of these sensors and actuators by using the YDT in the diagnostic mode.
Refer to “DIAGNOSTIC CODE: SENSOR OPERATION TABLE” on page 9-56 and “DIAGNOSTIC
CODE: ACTUATOR OPERATION TABLE” on page 9-58.
D01: Throttle position sensor signal
D30: Ignition coil
D36: Injector

If a malfunction is detected in the sensors or actuators, repair or replace all faulty parts.
If no malfunction is detected in the sensors and actuators, check and repair the inner parts of the en-
gine.

9-12
 R R

2 3 R

EAS32890
EAS20443
R/L
RR

6
Br/R Br

8 R
R
R
Br
9 Br
Br
Br Br

10
R R 13 R
R
12 R
Br ON Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
R/Y R/Y OPEN
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
Br Br/R OFF
CIRCUIT DIAGRAM

LOCK L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Br Br/R
(B)

Br/R R
Br/R
Br/R Br B

(B)
31
R
Br/R Br
B Br

Lg/L B Br
R Lg/W

Lg/W
(R) R Lg/L
Lg/W
Lg/L 32 B

Br 33
Br Br B/Y B/Y
Br B/Y
B/Y
ABS (Anti-lock Brake System)

34 37
Br B/Y B/Y Y 43
Y

R
R

9-13
1

B
B

B
75 Y B

77
W/B

B Y
W
Br

B
Y B
Br R W
Br W/B
R/L
Y Br Br B
Lg/W Y Y W 56 W B Br Y
Lg/L
B
59
L/G G G B
L/G L L W 57 W B G L
Lg/W
B B B/W B/W
Lg/W W/L B/W
B
B Lg/W
B B 60
Lg/L W/L 58 B/W
B
B Lg/L R Br Y G L W W/L W/B B/W
B/W
Lg/L
Br R/L Y L/G L/G Br Lg/L Lg/W B/W B
B

B (B)
B B B/W 61
B B B
B
B

B BB BB
B
B B B 62
73 72 72
72 72

R/W L/W Br/W Y/W Dg Ch Br R

L/R G/B W/L Br/R W/R G B R

(Gy)
ABS (Anti-lock Brake System)
 ABS (Anti-lock Brake System)

1. Battery
2. ABS solenoid fuse
3. ABS motor fuse
6. Signaling system fuse
8. Backup fuse
9. Main fuse
10. Ignition fuse
12. ABS control unit fuse
13. Main switch
31. Main relay
32. Yamaha diagnostic tool coupler
33. Front brake light switch
34. Rear brake light switch
37. Joint 1
43. SGCU (starter generator control unit)
56. Front wheel sensor
57. Rear wheel sensor
58. Joint 4
59. ABS ECU
60. Meter assembly
61. Multi-function meter
62. ABS warning light
72. Frame ground
73. Engine ground
75. Tail/brake light assembly
77. Brake light

9-14
 ABS (Anti-lock Brake System)

EAS32892

ABS COUPLER LOCATION CHART

R Br Y G L W W/L B/W
R/L Y Br L/R L/B B/W B

(B)

Br Y W B

G L W B

3
Lg/L B
R Lg/W
4

R/W L/W Br/W Y/W Dg Ch Br R

L/R G/B W/L Br/R W/R G B R

(Gy)

1. ABS ECU coupler

2. Rear wheel sensor coupler
3. Yamaha diagnostic tool coupler
4. Meter assembly coupler
5. Front wheel sensor coupler

9-15
 ABS (Anti-lock Brake System)

EAS32893

MAINTENANCE OF THE ABS ECU

Checking the ABS ECU

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

1
2

EAS33284

ABS TROUBLESHOOTING OUTLINE

This section describes the troubleshooting for the ABS in detail. Read this service manual carefully and
make sure you fully understand the information provided before repairing any malfunctions or perform-
ing service.
The ABS ECU (electronic control unit) has a self-diagnosis function. When failures occur in the system,
the ABS warning light on the meter assembly indicates a malfunction.
The following troubleshooting describes the problem identification and service method using the Yama-
ha diagnostic tool. For information about using the Yamaha diagnostic tool, refer to “[B-2] DIAGNOSIS
USING THE FAULT CODES” on page 9-20. For troubleshooting items other than the following items,
follow the normal service method.
EWA16710

WARNING
When maintenance or checks have been performed on components related to the ABS, be sure
to perform a final check before delivering the vehicle to the customer.

TIP
To final check, refer to “[C-1] FINAL CHECK” on page 9-21.

ABS operation when the ABS warning light comes on

1. The ABS warning light remains on → ABS operates as a normal brake system.
• A malfunction was detected using the ABS self-diagnosis function.
• The ABS self-diagnosis has not been completed.
The ABS self-diagnosis starts when the main switch is turned to “ON” and finishes when the vehicle
has traveled at a speed of approximately 10 km/h (6 mi/h).
2. The ABS warning light comes on after the engine starts, and then goes off when the vehicle starts
moving (traveling at a speed of approximately 10 km/h (6 mi/h)). → ABS operation is normal.
3. The ABS warning light flashes → ABS operation is normal.
• Refer to “BASIC INSTRUCTIONS FOR TROUBLESHOOTING” on page 9-17.

9-16
 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 9-21.
By deleting the fault codes stored in the ABS ECU memory, it is possible to pursue the cause correctly
if another malfunction occurs.
TIP
The ABS performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the
main switch was turned to “ON”. During this test, a “clicking” noise can be heard from front side, and if
the front brake lever or rear brake lever are even slightly applied, a vibration can be felt at the levers, but
these do not indicate a malfunction.

Self-diagnosis using the ABS ECU

The ABS ECU performs a static check of the entire system when the main switch is turned to “ON”.
It also checks for malfunctions while the vehicle is ridden. Since all malfunctions are recorded after
they are detected, it is possible to check the recorded malfunction data by utilizing the Yamaha di-
agnostic tool when the ABS ECU has entered the self-diagnosis mode.

Special precautions for handling and servicing a vehicle equipped with ABS
ECA17620

NOTICE
Care should be taken not to damage components by subjecting them to shocks or pulling on
them with too much force since the ABS components are precisely adjusted.
• The ABS ECU and hydraulic unit are united assemblies and cannot be disassembled.
• The malfunction history is stored in the memory of the ABS ECU. Delete the fault codes when the ser-
vice is finished. (This is because the past fault codes will be displayed again if another malfunction oc-
curs.)
EAS32895

BASIC INSTRUCTIONS FOR TROUBLESHOOTING

EWA17420

WARNING
• Perform the troubleshooting [A]→[B]→[C] in order. Be sure to follow the order since a wrong
diagnosis could result if the steps are followed in a different order or omitted.
• Use sufficiently charged regular batteries only.
[A] Malfunction check using the ABS warning light
[B] Use the Yamaha diagnostic tool and determine the location of the malfunction and the cause from
the recorded fault code.
Determine the cause of the malfunction from the condition and place where the malfunction occurred.
[C] Servicing the ABS
Execute the final check after disassembly and assembly.

9-17
 ABS (Anti-lock Brake System)

EAS32878

BASIC PROCESS FOR TROUBLESHOOTING

Fails to
[A] Turn the main switch to “ON”, [A-1] Does only the ABS • The ABS warning light (LED) is
come on Yes
and check the ABS warning warning light fail to defective. Return to [A].
light. come on? • The wire harness is grounded
between the ABS ECU and the
Comes on meter assembly.
• The meter assembly circuit is
defective.
• The hydraulic unit assembly is
defective.

No
• The main switch is defective.
Yes • The battery voltage is low.
[A-2] Do all indicator lights
• The taillight fuse is blown. Return to [A].
fail to come on?
• The meter assembly circuit is
defective.

[A-3] The ABS warning light comes Cannot communicate • The connection with the Yamaha
on. diagnostic tool is defective. Return to [A].
Connect the Yamaha • The ABS control unit fuse is blown.
diagnostic tool, and then • The ABS ECU coupler is
execute functional diagnosis. disconnected.
Can the tool communicate • The wire harness is defective.
with the ABS ECU? • The hydraulic unit assembly
is defective.
Can communicate • The ABS solenoid fuse is blown.
Refer to “ Troubleshooting details
of fault code No. 31 ”.

[B-1] Check for ABS fault Yes [B-2] Diagnose by the fault [B-3] Delete the fault codes.
codes in the screen for the Return to [A].
code.
Yamaha diagnostic tool.
Execute fault diagnosis.
Are fault codes displayed on
the screen?
The reaction force generated
No during brake line routing
confirmation is incorrect.
• The brake hoses and brake
[C-1] Perform the final checks. pipes are not connected
No
Were all of the final checks correctly. Return to [A].
completed normally? The ABS warning light does
not go off when the light is
Yes checked.
(Check that the ABS warning • The malfunction is not
light goes off during the ABS corrected.
warning light check.) • There is a break in the wire
harness between the ABS ECU
and the meter assembly.
• The meter assembly circuit is
defective.
• The ABS warning light circuit in
the hydraulic unit assembly is
defective.

Finished.

9-18
 ABS (Anti-lock Brake System)

EWA16710

WARNING
When maintenance or checks have been performed on components related to the ABS, be sure
to perform a final check before delivering the vehicle to the customer.

TIP
To final check, refer to “[C-1] FINAL CHECK” on page 9-21.

EAS32897

[A] CHECKING THE ABS WARNING LIGHT

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

[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON

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

[A-2] ALL INDICATOR LIGHTS FAIL TO COME ON

1. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES” on page 8-35.
• If there is no continuity, replace the main switch.
2. Battery
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-37.
• If the battery is defective, clean the battery terminals and recharge it, or replace the battery.
3. Taillight fuse
• Check the fuse for continuity.
Refer to “CHECKING THE FUSES” on page 8-36.
• If the taillight fuse is blown, replace the fuse.
4. Circuit
• Check the meter assembly circuit.
Refer to “CIRCUIT DIAGRAM” on page 9-13.
• If the meter assembly circuit is open, replace the wire harness.
EAS32900

[A-3] THE ABS WARNING LIGHT COMES ON

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

9-19
 ABS (Anti-lock Brake System)

EAS32903

[B-1] MALFUNCTION ARE CURRENTLY DETECTED

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

[B-2] DIAGNOSIS USING THE FAULT CODES

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

Yamaha diagnostic tool USB

90890-03267
Yamaha diagnostic tool (A/I)
90890-03264

Connecting the Yamaha diagnostic tool

Removing the battery cover. Refer to “GENERAL CHASSIS (1)” on page 4-1.
Disconnect the Yamaha diagnostic tool coupler from the CCU (Communication Control Unit) “1”, and
then connect the Yamaha diagnostic tool to the coupler.
1

Details about the displayed fault codes are shown in the following chart. Refer to this chart and check
the vehicle.
Once all the work is complete, delete the fault codes. [B-3]
TIP
Check the inspection points after terminating the connection with the Yamaha diagnostic tool and turn-
ing the main switch off.

9-20
 ABS (Anti-lock Brake System)

EAS33339

[B-3] DELETING THE FAULT CODES

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

Yamaha diagnostic tool USB

90890-03267
Yamaha diagnostic tool (A/I)
90890-03264

Connecting the Yamaha diagnostic tool

Disconnect the YDT coupler from the CCU (Communication Control Unit) “1”, and then connect the
YDT to the coupler.
1

EAS32905

[C-1] FINAL CHECK

Check all the following items to complete the inspection.
If the process is not completed properly, start again from the beginning.

Checking procedures
1. Check the brake fluid level in the front brake master cylinder reservoir and the rear brake master cyl-
inder reservoir.
Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-11.
2. Check the wheel sensors for proper installation.
Refer to “INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC)” on page 4-27 and “INSTALL-
ING THE REAR WHEEL (REAR BRAKE DISC)” on page 4-31.
3. Perform brake line routing confirmation.
Refer to “HYDRAULIC UNIT OPERATION TESTS” on page 4-62.
If it does not have reaction-force properly, the brake hose is not properly routed or connected.
4. Delete the fault codes.
Refer to “[B-3] DELETING THE FAULT CODES” on page 9-21.
5. Checking the ABS warning light.
Check that the ABS warning light goes off.
If the ABS warning light does not come on or if it does not go off, refer to “CHECKING THE ABS
WARNING LIGHT” on page 4-66.
If the ABS warning light does not turn off, the possible causes are following:
• The problem is not solved.
• Open circuit between the ABS ECU and the meter assembly.
Check for continuity between White/Blue terminal of the ABS ECU coupler and White/Blue terminal
of the meter assembly coupler.
• Malfunction in the meter assembly circuit.
• Malfunction in the ABS warning light circuit in the hydraulic unit assembly.

9-21
 ABS (Anti-lock Brake System)

9-22
 EAS33403
EAS20717
R/Y G/W RR

8 R
R R
R Br
Br Br
9 Br Br/R Br
Br
Br Br

10
R R 13 R
G/W R R
R Br
ON Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
R/Y R/Y R/W B B R/W
OPEN
B R/B Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
OFF
CIRCUIT DIAGRAM
Br Br/R (B) (B) G/W L/R R/B L/Y B/W G/B 19
LOCK R R L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br
R/Y R L W/R Br R/W R
Br Br/R B L
18 R/B B R R
L B (B)
B (B) R
L/R
14 15 L L W/R
B R/W R/W L/Y
G/B
B/W

Br
Br
SMART KEY SYSTEM

Br

43
L/R
L/R L/R
L/R

L/Y
Ch Ch B B L/Y L/Y L/Y L/Y
Ch
R
L/Y B 36
Dg Dg
Dg B B

9-23
(L) (L)
1

B
Ch Dg Ch Dg
B
B
81 80 79 78 G
B
B B Ch
Ch Dg G
(Br) (G) (Br)

B B B B B
B
Ch Dg Ch
(Br) (G) Dg
(Br)

B B
B
B B 60
B
B
B/W B G/B
B
B B B B Br
B B
B W/R
B R
B B R R 61
B B B
B Ch
B Dg
L/R
B BB BB
B
B B B B
73 72 72
72 72
65 64

66

R/W L/W Br/W Y/W Dg Ch Br R

L/R G/B W/L Br/R W/R G B R

(Gy)
SMART KEY SYSTEM
 SMART KEY SYSTEM

1. Battery
4. Smart key system fuse
8. Backup fuse
9. Main fuse
10. Ignition fuse
13. Main switch
14. Request switch
15. Main switch solenoid
18. Smart key unit
19. Buzzer
36. Sidestand switch
43. SGCU (starter generator control unit)
60. Meter assembly
61. Multi-function meter
64. Smart key system indicator light
65. Turn signal indicator light (left)
66. Turn signal indicator light (right)
72. Frame ground
73. Engine ground
78. Front turn signal light (left)
79. Front turn signal light (right)
80. Rear turn signal light (left)
81. Rear turn signal light (right)

9-24
 SMART KEY SYSTEM

EAS33404

TROUBLESHOOTING
Vehicle power does not turn on. (Meter light and tail/brake light do not come on.)
Engine does not start even though vehicle power is turned on.
Seat does not open. (Vehicle power is turned on.)
Left front storage box does not open. (Vehicle power is turned on.)
Fuel tank cap lid does not open.
Answer back function does not operate.
TIP
Before troubleshooting, remove the following part(s):
1. Battery cover
2. Windshield
3. Front panel
4. Front cowling assembly

Checking the vehicle power

1. Check the smart key.

→ The smart key indicator light
comes on when the smart key but-
Replace the button cell battery of the
ton is pushed. NG→
smart key. Standard battery: CR2032
→ Check the button cell battery.
Refer to “CHECKING THE SMART
KEY BATTERY” on page 8-43.

OK↓

2. Check the fuses.

(Main, backup, ignition, and smart
key system) NG→ Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 8-36.

OK↓

3. Check the battery.

Refer to “CHECKING AND • Clean the battery terminals.
NG→
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 8-37.

OK↓

4. Check the main switch and request

switch.
NG→ Replace the main switch.
Refer to “CHECKING THE
SWITCHES” on page 8-35.

OK↓

5. Check the main switch solenoid.

Refer to “CHECKING THE MAIN
NG→ Replace the main switch.
SWITCH SOLENOID” on page 8-
43.

OK↓

9-25
 SMART KEY SYSTEM

6. Check the entire smart key sys-

tem’s wiring. Properly connect or replace the wire har-
NG→
Refer to “CIRCUIT DIAGRAM” on ness.
page 9-23.

OK↓

Replace the smart key unit.

Checking the smart key system

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

1. Check the vehicle power.

Refer to “Checking the vehicle NG→ Repair or replace any defective parts.
power” on page 9-25.

OK↓

• There are sources of strong electro-

magnetic waves in the vicinity →
Move the vehicle.
• Smart key malfunction → Register
and use a different smart key.
• Smart key unit malfunction → Re-
place the smart key unit.

Engine does not start even though vehicle power is turned on.

1. When the vehicle power is turned

on, the smart key indicator light “ ” Check and repair the electric starting sys-
flashes 4 times. NO→ tem. Refer to “ELECTRIC STARTING
Refer to “SMART KEY SYSTEM SYSTEM” on page 8-5.
SELF-DIAGNOSIS” on page 9-29.

YES↓

2. Turn the main switch to “OFF”, and

Repair or replace any defective parts. Re-
then push the main switch and
NG→ fer to “Checking the vehicle power” on
check that it can be turned back to
page 9-25.
“ON”.

OK↓

9-26
 SMART KEY SYSTEM

3. Check for continuity in the commu-

nication line between the SGCU
NG→ Replace the wire harness.
and the smart key unit (blue/red –
blue/red).

OK↓

• Replace the SGCU.

Refer to “REPLACING THE SGCU
(starter generator control unit)” on
page 8-36.
• Replace the smart key unit.

Seat does not open. (Vehicle power is turned on.)

1. Check the vehicle power.

Refer to “Checking the vehicle NG→ Repair or replace any defective parts.
power” on page 9-25.

OK↓

• Check the mechanical components

of the lock for malfunctions. Repair
or replace any defective parts.
• Adjust or replace the seat lock cable.

Left front storage box does not open. (Vehicle power is turned on.)

1. Check the vehicle power.

Refer to “Checking the vehicle NG→ Repair or replace any defective parts.
power” on page 9-25.

OK↓

• Check the mechanical components

of the lock for malfunctions. Repair
or replace any defective parts.
• Adjust or replace the left front stor-
age box lock cable.

Fuel tank cap lid does not open.

1. Check that the main switch can be

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

OK↓

• Check the mechanical components

of the lock for malfunctions. Repair
or replace any defective parts.
• Adjust or replace the fuel tank cap lid
lock cable.

9-27
 SMART KEY SYSTEM

Answer back function does not operate.

1. Check the vehicle power.

Refer to “Checking the vehicle NG→ Repair or replace any defective parts.
power” on page 9-25.

OK↓

2. Check the buzzer operation.

Refer to “CHECKING THE BUZZ- NG→ Replace the buzzer.
ER” on page 8-43.

OK↓

3. Check the turn signal light bulbs

and sockets.
Refer to “CHECKING THE BULBS Replace the turn signal light bulb, socket
NG→
AND BULB SOCKETS” in “BASIC or both.
INFORMATION” (separate vol-
ume).

OK↓

Replace the smart key unit.

9-28
 SMART KEY SYSTEM

EAS33405

SMART KEY SYSTEM SELF-DIAGNOSIS

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

Flashing time/num- Malfunction and

Item Flash pattern
ber of flashes check point

0.5 (s) Replace the button

a cell battery of the
Low voltage of smart b smart key.
0.5 (s)
20 (seconds)
key button cell battery Refer to “SMART
KEY SYSTEM” on
a.LED on page 9-23.
b.LED off
The smart key cannot
be recognized.
0.15 (s)
Check that there are
a
no sources of strong
Vehicle power off ver- b
0.15 (s)
30 (seconds) electromagnetic
ification error
waves in the vicinity,
a.LED on the smart key is not
b.LED off lost, and the battery is
not discharged.
The smart key cannot
be recognized.
0.15 (s)
Check that there are
a
Flashes continuously no sources of strong
Running detection er- b
0.15 (s)
until the error is re- electromagnetic
ror*
solved. waves in the vicinity,
a.LED on the smart key is not
b.LED off lost, and the battery is
not discharged.

0.3 (s) Flashes continuously Check the wire har-

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

* The running detection error

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

9-29
 SMART KEY SYSTEM

SMART KEY SYSTEM SELF-DIAGNOSIS

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

Device that de-

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

9-30
 SMART KEY SYSTEM

EAS33406

SMART KEY SYSTEM EMERGENCY MODE

If the smart key is lost or if it cannot be used due a discharged battery or malfunction, this mode can be
used to turn on the smart key system.
TIP
The emergency mode operation will be canceled if the respective steps are not carried out within the
time set for each operation.
1. Stop the vehicle in a safe place and turn the main switch to “OFF”.
2. Push the main switch for 5 seconds until the smart key indicator light flashes once, then release it.
Repeat two more times. The smart key indicator light “1” will come on for 3 seconds to indicate the
transition to emergency mode.

3. After the smart key indicator light “ ” goes off, use the main switch to enter the identification number
“1” located on the identification number card. (Refer to the following procedure on how to input the
identification number.)

868588

4. The input identification number is indicated by the number of flashes of the smart key indicator light
“ ” while the main switch is pushed.
For example, if the smart key identification number is 123456:
Push and hold the main switch. →
The smart key indicator light “ ” will start to flash. →

Release the main switch after the smart key indicator light “ ” flashes 1 time. →
The first digit of the identification number has been set as 1. →
Push and hold the main switch again. →

9-31
 SMART KEY SYSTEM

Release the main switch after the smart key indicator light “ ” flashes 2 times. →
The second digit of the identification number has been set as 2. →
Repeat the above procedure until all 6 digits of the identification number have been set.
5. The smart key indicator light “ ” will come on for 10 seconds if the correct 6-digit identification num-
ber was entered.
TIP
When one of the following situations applies, emergency mode will be terminated and the smart key in-
dicator light will flash quickly for 3 seconds. In this case, start over again from step 2.
• When there are no main switch operations for 10 seconds during the identification number input pro-
cess.
• When the smart key indicator light is allowed to flash nine or more times.
• The identification number is not entered correctly.
6. While the smart key indicator light is on, push the main switch once more to complete emergency
mode access. The smart key indicator light will go off and then come back on for approximately 4
seconds.
7. While the smart key indicator light is on, turn the main switch to “ON”. The vehicle can now be oper-
ated normally.
EAS33407

REGISTERING A SMART KEY

The following procedure can be used to register additional smart keys or a new smart key in case the
original smart key is lost.
TIP
• A maximum of 6 smart keys can be registered to the smart key unit.
• Be sure to register the smart keys one at a time. Do not register multiple smart keys at the same time.
1. Place the smart key “1” that will be registered within 80 cm (31.5 in) “a” of the main switch.

1
2. Perform steps 1–5 in “SMART KEY SYSTEM EMERGENCY MODE” on page 9-31.

9-32
 SMART KEY SYSTEM

3. While the smart key indicator light “ ” is on for 10 seconds, push the main switch “1” for 5 seconds
until buzzer sounds once.

4. The smart key indicator light (red) “1” on the new smart key comes on for 10 seconds.
TIP
While the smart key indicator light on the smart key is on, the smart key indicator light “ ” flashes ac-
cording to the number of currently registered smart keys. (For example, if 5 smart keys are registered,
the indicator light flashes 5 times.)

5. While the smart key indicator light is on for 10 seconds, push the button on the smart key to transmit
a signal from the smart key to the smart key unit.
6. If the smart key is registered successfully, the smart key indicator light “ ” will come on for 3 sec-
onds, and then the smart key system will turn off.
If the smart key was not registered successfully, the smart key indicator light “ ” will flash for 3 sec-
onds, and then the smart key system will turn off.
TIP
If this registration procedure is performed for a smart key that is already registered, the smart key indi-
cator light “ ” will flash for 7 seconds (on for 0.2 second and off for 0.8 second).

9-33
 SMART KEY SYSTEM

EAS33408

DISABLING A SMART KEY

If a smart key is lost or stolen, the smart key can be disabled.
1. Place all of the smart keys “1” 300 cm (118.1 in) “a” or more away from the vehicle or lock the com-
munication.

1
2. Perform steps 1–5 in “SMART KEY SYSTEM EMERGENCY MODE” on page 9-31.
3. While the smart key indicator light “ ” is on for 10 seconds, perform the following procedure.
a. Push the main switch “1” 5 times or more until buzzer sounds 3 times.

4. Check that the smart key indicator light “ ” goes off (the smart key disable mode is activated).
5. Turn on (unlocked setting) the smart keys that you want to enable and place them within 80 cm (31.5
in) of the smart key unit.
6. Push the main switch for 5 seconds or more to start the communication between the smart key unit
and the smart keys that are located within 80 cm (31.5 in) of the unit.
TIP
The number of smart keys that currently can be used will be indicated.
Number of flashes = Number of verified smart keys. (1 cycle of on for 0.3 second and off for 0.3 second
= 1 smart key)
7. Push the main switch for 5 seconds or more. The use of only the verified smart keys will be enabled.
The use of all other smart keys will be disabled.
TIP
• If the procedure was not completed successfully, repeat the procedure from step 1.
• To enable a smart key after its use has been disabled, perform this procedure again.

9-34
 SMART KEY SYSTEM

EAS33409

DISABLING THE POWER-ON ALARM

1. Place the smart key “1” that will be registered within 80 cm (31.5 in) “a” of the main switch.

1
2. Push the main switch and the smart key indicator light will come on for approximately 4 seconds.
3. While the smart key indicator light is on, turn the main switch to “ON”.
4. Extend and retract the sidestand by hand for 10 times or more within 15 seconds from vehicle power
on.
5. When the buzzer sounds, the setting is complete.
• If the buzzer sounds 2 times: The power-on alarm is turned off.
• If the buzzer sounds 1 times: The power-on alarm is turned on.

9-35
 SMART KEY SYSTEM

EAS33410

REPLACEMENT PARTS LIST

TIP
When replacing the parts, refer to the following sections.
• Refer to “SMART KEY SYSTEM EMERGENCY MODE” on page 9-31.
• Refer to “REGISTERING A SMART KEY” on page 9-32.
• Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36.

Required item Replacement parts

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

9-36
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EAS20551

SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EAS33149

DTC TABLE
Fail-safe system
Diagnos-
DTC Symptom Starting the Driving the tic code
engine vehicle
“11, Front wheel sensor (intermittent pulses
— — —
25_ABS” or no pulses)
Rear wheel sensor (intermittent pulses or
“12_ABS” — — —
no pulses)
“13, Front wheel sensor (abnormal pulse pe-
— — —
26_ABS” riod)
“14, Rear wheel sensor (abnormal pulse peri-
— — —
27_ABS” od)
“15_ABS” Front wheel sensor (open or short circuit) — — —
“16_ABS” Rear wheel sensor (open or short circuit) — — —
“17,
Front wheel sensor (missing pulses) — — —
45_ABS”
“18,
Rear wheel sensor (missing pulses) — — —
46_ABS”
Hydraulic unit assembly (defective sole-
“21_ABS” — — —
noid drive circuit)
Hydraulic unit assembly (abnormal ABS
“31_ABS” — — —
solenoid power supply)
Hydraulic unit assembly (short circuit in
“32_ABS” — — —
ABS solenoid power supply circuit)
Hydraulic unit assembly (abnormal ABS
“33_ABS” — — —
motor power supply)
Hydraulic unit assembly (short circuit in
“34_ABS” — — —
ABS motor power supply circuit)
Front wheel ABS (intermittent wheel
“41_ABS” speed pulses or incorrect depressuriza- — — —
tion)
Rear wheel ABS (intermittent wheel
“42,
speed pulses or incorrect depressuriza- — — —
47_ABS”
tion)
“43_ABS” Front wheel sensor (missing pulses) — — —
“44_ABS” Rear wheel sensor (missing pulses) — — —
• Vehicle system power supply (voltage
of ABS ECU power supply is high)
“51, (DTC No. 51)
— — —
52_ABS” • Vehicle system power supply (voltage
of wheel sensor power supply is high)
(DTC No. 52)
Vehicle system power supply (voltage of
“53_ABS” — — —
ABS ECU power supply is low)

9-37
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Fail-safe system
Diagnos-
DTC Symptom Starting the Driving the tic code
engine vehicle
Hydraulic unit assembly (defective ABS
“54_ABS” solenoid and ABS motor power supply — — —
circuits)
Hydraulic unit assembly (defective ABS
“55_ABS” — — —
ECU)
Hydraulic unit assembly (abnormal pow-
“56_ABS” — — —
er supply)
Front wheel sensor power supply (volt-
“63_ABS” — — —
age of power supply is low)
Rear wheel sensor power supply (volt-
“64_ABS” — — —
age of power supply is low)
O2 sensor heater: defective heater or
“P0030” heater driver ON / OFF command and er- Able Able —
ror signal is mismatching.
• [P00D1] O2 sensor: heater perfor-
mance deteriorated. Normal signal is
“P00D1, not received from the O2 sensor while
Able Able —
P2195” driving the O2 sensor.
• [P2195] O2 sensor: open circuit is de-
tected.
• [P0106] Intake air pressure sensor:
“P0106” clogging hole or sensor installation im- Able Able D03
properly.
• [P0107] Intake air pressure sensor:
short to ground circuit is detected.
“P0107,
• [P0108] Intake air pressure sensor: Able Able D03
P0108”
open or short to power circuit is detect-
ed.
• [P0112] Intake air temperature sensor:
short to ground circuit is detected.
“P0112,
• [P0113] Intake air temperature sensor: Able Able D05
P0113”
open or short to power circuit is detect-
ed.
• [P0117] Coolant temperature sensor:
short to ground circuit is detected.
“P0117,
• [P0118] Coolant temperature sensor: Able Able D06
P0118”
open or short to power circuit is detect-
ed.
• [P0122] Throttle position sensor: open
“P0122, or short to ground circuit is detected.
Able Able D01
P0123” • [P0123] Throttle position sensor: short
to power circuit is detected.
O2 sensor: short to power circuit is de-
“P0132” Able Able —
tected.
“P0201” Fuel injector: malfunction in fuel injector. Unable Unable D36

9-38
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Fail-safe system
Diagnos-
DTC Symptom Starting the Driving the tic code
engine vehicle
Crankshaft position sensor: normal sig-
“P0335” nal is not received from the crankshaft Unable Unable —
position sensor.
Ignition coil: open or short circuit is de-
“P0351” tected in the primary lead of the ignition Unable Unable D30
coil.
Front wheel sensor: normal signal is not
“P0500” received from the front wheel speed sen- Able Able D07
sor.
“P0507” Engine idling speed is too high. Able Able D54
“P0511” ISC valve malfunction is detected. Able Able —
Charging voltage is abnormal.
“P0560,
[P0560] Discharged condition / [P0563] Able Able —
P0563”
Overcharged condition.
Internal malfunction in SGCU. (When this
malfunction is detected in the SGCU, the
“P0601” Unable Unable —
DTC might not appear on the tool dis-
play.)
EEPROM DTC: an error is detected
“P062F” Able Able D60
while reading or writing on EEPROM.
Malfunction in SGCU internal circuit
“P1602” (malfunction of SGCU power cut-off func- Able Able —
tion).
Rear wheel sensor: normal signal is not
“P2158” received from the rear wheel speed sen- Able Able —
sor.
Normal signal is not received from the
“P2645” VVA solenoid circuit while driving the Able Able D45
VVA solenoid.

EAS33030

COMMUNICATION ERROR WITH THE YAMAHA DIAGNOSTIC TOOL

Fail-safe system
Diagnos-
DTC Symptom Starting the Driving the tic code
engine vehicle
SGCU internal malfunction (Output sig-
Er-1 Able Able —
nal error)
SGCU internal malfunction (Output sig-
Er-2 Able Able —
nal error)
SGCU internal malfunction (Output sig-
Er-3 Able Able —
nal error)
SGCU internal malfunction (Input signal
Er-4 Able Able —
error)

9-39
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EAS33028

SELF-DIAGNOSTIC FUNCTION TABLE

TIP
For details of the fault code, refer to “TROUBLESHOOTING” on page 8-33.

Probable cause of Fail-safe system

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

9-40
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system

DTC Item Vehicle symptom
malfunction operation
P0106 Intake air pressure • Detached throttle Engine idling speed Intake air pressure
sensor (clogged body sensor as- is high. difference is fixed to
hole or loose) sembly. Engine idling speed 0 [kPa].
• Improperly in- is unstable. Load is detected ac-
stalled throttle Engine response is cording to the throt-
body. poor. tle opening.
• Clogged intake air Loss of engine pow- Intake manifold
pressure sensor er. pressure is calculat-
hole. Increased exhaust ed using the throttle
emissions. position sensor.
Stop and start sys- Transient control
tem is not operated. according to the in-
Idling does not stop. take air pressure is
not carried out.
Intake air pressure
is fixed to 101.3
[kPa].
O2 feedback is not
carried out.
Stop and start sys-
tem is not carried
out.
P0107 [P0107] Intake air [P0107] Low voltage Engine idling speed Intake air pressure
P0108 pressure sensor of the intake air is high. difference is fixed to
(short to ground cir- pressure sensor cir- Engine idling speed 0 [kPa].
cuit is detected) cuit (0.2 V or less) is unstable. Load is detected ac-
[P0108] Intake air [P0108] High volt- Engine response is cording to the throt-
pressure sensor age of the intake air poor. tle opening.
(open or short to pressure sensor cir- Loss of engine pow- Intake manifold
power circuit is de- cuit (4.9 V or more) er. pressure is calculat-
tected) • Defective coupler Increased exhaust ed using the throttle
between throttle emissions. position sensor.
body sensor as- Stop and start sys- Transient control
sembly and tem is not operated. according to the in-
SGCU. Idling does not stop. take air pressure is
• Open or short cir- not carried out.
cuit in wire har- Intake air pressure
ness between is fixed to 101.3
throttle body sen- [kPa].
sor assembly and O2 feedback is not
SGCU. carried out.
• Defective intake Stop and start sys-
air pressure sen- tem is not carried
sor. out.
• Malfunction in
SGCU.

9-41
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system

DTC Item Vehicle symptom
malfunction operation
P0112 [P0112] Intake air [P0112] Low voltage Engine is difficult to The intake air tem-
P0113 temperature sensor of the intake air tem- start. perature is fixed to
(short to ground cir- perature sensor cir- Increased exhaust 20 [°C].
cuit is detected) cuit (0.2 V or less) emissions. O2 feedback is not
[P0113] Intake air [P0113] High volt- Engine idling speed carried out.
temperature sensor age of the intake air is unstable. Stop and start sys-
(open or short to temperature sensor Stop and start sys- tem is not carried
power circuit is de- circuit (4.8 V or tem is not operated. out.
tected) more) Idling does not stop.
• Defective coupler
between throttle
body sensor as-
sembly and
SGCU.
• Open or short cir-
cuit in wire har-
ness between
throttle body sen-
sor assembly and
SGCU.
• Improperly in-
stalled throttle
body sensor as-
sembly.
• Defective intake
air temperature
sensor.
• Malfunction in
SGCU.

9-42
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system

DTC Item Vehicle symptom
malfunction operation
P0117 [P0117] Coolant [P0117] Low voltage Engine is difficult to O2 feedback is not
P0118 temperature sensor of the coolant tem- start. carried out.
(short to ground cir- perature sensor cir- Increased exhaust The coolant tem-
cuit is detected) cuit (0.1 V or less) emissions. perature is fixed to
[P0118] Coolant [P0118] High volt- Engine idling speed 30 [°C] (when key is
temperature sensor age of the coolant is unstable. ON) or 80 [°C]
(open or short to temperature sensor Stop and start sys- (when riding).
power circuit is de- circuit (4.8 V or tem is not operated. Stop and start sys-
tected) more) Idling does not stop. tem is not carried
• Defective coupler out.
between coolant
temperature sen-
sor and SGCU.
• Open or short cir-
cuit in wire har-
ness between
coolant tempera-
ture sensor and
SGCU.
• Improperly in-
stalled coolant
temperature sen-
sor.
• Defective coolant
temperature sen-
sor.
• Malfunction in
SGCU.

9-43
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system

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

9-44
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system

DTC Item Vehicle symptom
malfunction operation
P0201 Fuel injector (Nor- • Defective coupler Loss of engine pow- When engine is run-
mal signal is not re- between fuel injec- er. ning: Engine is
ceived from the fuel tor and SGCU. Engine is difficult to forcefully stopped.
injector circuit) • Open or short cir- start. When engine is
cuit in wire har- Engine cannot be stopped: Engine
ness between fuel started. cannot be started.
injector and Engine stops. Injection is not car-
SGCU. ried out.
• Defective fuel in-
jector.
• Malfunction in
SGCU.
• Improperly in-
stalled fuel injec-
tor.
P0335 Crankshaft position • Defective coupler Engine cannot be Does not operate.
sensor (no normal between crank- started.
signals are received shaft position sen-
from the crankshaft sor and SGCU.
position sensor) • Open or short cir-
cuit in wire har-
ness between
crankshaft position
sensor and SGCU.
• Improperly in-
stalled crankshaft
position sensor.
• Defective starter
generator rotor.
• Defective crank-
shaft position sen-
sor.
• Malfunction in
SGCU.
P0351 Ignition system • Defective coupler Engine stops. When engine is run-
(Normal signal is not between ignition Loss of engine pow- ning: Engine is
received from the ig- coil and SGCU. er. forcefully stopped.
nition circuit) • Open or short cir- Engine is difficult to When engine is
cuit in wire har- start. stopped: Engine
ness between Engine cannot be cannot be started.
ignition coil and started. Injection is not car-
SGCU. ried out.
• Improperly in-
stalled ignition coil.
• Defective ignition
coil.
• Malfunction in
SGCU.

9-45
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system

DTC Item Vehicle symptom
malfunction operation
P0500 Front wheel sensor • Open or short cir- Vehicle speed is not O2 feedback is not
(Normal signal is not cuit in wire har- displayed on the carried out.
received from the ness between meter. Stop and start sys-
front wheel sensor) front wheel sensor Engine stalls when tem is not carried
and ABS unit. the vehicle is decel- out.
• Open or short cir- erating to a stop.
cuit in wire har- Engine idling speed
ness between is high.
ABS unit and Engine idling speed
SGCU. is unstable.
• Defective front Increased exhaust
wheel sensor. emissions.
• Malfunction in Stop and start sys-
SGCU. tem is not operated.
Idling does not stop.
P0507 ISC valve (stuck ful- • Defective front Engine idling speed ISC is stopped.
ly open) wheel sensor. is high. Stop and start sys-
• Defective coupler Stop and start sys- tem is not carried
between ISC unit tem is not operated. out.
and SGCU. Idling does not stop.
• Open or short cir-
cuit in wire har-
ness between ISC
unit and SGCU.
• Improperly in-
stalled ISC unit.
• Air sucking from
intake air passage.
• Defective throttle
valve or throttle ca-
bles.
• Defective ISC unit
(ISC valve stuck
fully open).
• Malfunction in
SGCU.
P0511 ISC valve (ISC • Defective coupler Engine is difficult to Power is not sup-
valve malfunction is between ISC valve start. plied to the ISC unit.
detected. ISC valve and SGCU. Engine idling speed Stop and start sys-
does not operate) • Open or short cir- is unstable. tem is not carried
cuit in wire har- Engine idling speed out.
ness between ISC is high.
valve and SGCU. Stop and start sys-
• Defective ISC tem is not operated.
stepping motor. Idling does not stop.
• Malfunction in
SGCU.

9-46
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system

DTC Item Vehicle symptom
malfunction operation
P0560 Vehicle system • Battery discharg- Engine is difficult to O2 feedback learn-
power voltage per- ing. start. ing is not carried
formance: Charging • Battery discharg- Increased exhaust out.
voltage is abnormal. ing (broken rectifi- emissions. Stop and start sys-
(Discharged condi- er / regulator or Battery perfor- tem is not carried
tion) disconnected lead mance has deterio- out.
in rectifier / regula- rated or battery is
tor system). defective.
Stop and start sys-
tem is not operated.
Idling does not stop.
P0563 Vehicle system • Battery overcharg- Engine is difficult to O2 feedback learn-
power voltage out of ing. start. ing is not carried
range: charging • Battery overcharg- Increased exhaust out.
voltage is abnormal. ing (broken rectifi- emissions. Stop and start sys-
(Overcharged con- er / regulator or Battery perfor- tem is not carried
dition) disconnected lead mance has deterio- out.
in rectifier / regula- rated or battery is
tor system). defective.
Stop and start sys-
tem is not operated.
Idling does not stop.
P0601 Faulty SGCU mem- • Malfunction in Engine cannot be Engine cannot be
ory. (When this mal- SGCU. started. started.
function is detected Ignition and injec-
in the SGCU, the tion are not carried
DTC might not ap- out.
pear on the tool dis- Judgment for other
play.) DTCs are not car-
ried out.
Writing to EEPROM
is not carried out.
P062F EEPROM fault code • Malfunction in Increased exhaust O2 feedback learn-
number (an error is SGCU. emissions. ing value is initial-
detected while read- • O2 feedback learn- Engine cannot be ized.
ing or writing on EE- ing value is not started or is difficult CO adjustment val-
PROM) properly written. to start. ue is initialized.
• CO adjustment Engine idling speed OBD memory value
value is not prop- is unstable. is initialized.
erly written. OBD memory value Stop and start sys-
• OBD memory val- is not correct. tem is not carried
ue is not properly Stop and start sys- out.
written. tem is not operated.

9-47
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system

DTC Item Vehicle symptom
malfunction operation
P1602 Malfunction in • Improperly con- Engine idling speed —
SGCU internal cir- nected battery is high.
cuit (normal backup lead. Engine idling speed
voltage is not sup- • Defective coupler is unstable.
plied to the SGCU) between main Increased exhaust
switch and SGCU. emissions.
• Open circuit in wire Engine is difficult to
harness between start.
main switch and
SGCU.
• Malfunction in
SGCU.
P2158 Rear wheel sensor: • Open or short cir- Traction control Traction control
normal signals are cuit in wire har- does not work. does not work.
not received from ness between rear Traction control sys-
the rear wheel sen- wheel sensor and tem indicator on the
sor. ABS ECU. meter comes on.
• Open or short cir- Traction control sys-
cuit in wire har- tem switch is dis-
ness between able.
ABS ECU and Traction control sys-
SGCU. tem indicator on the
• Defective rear meter goes OFF.
wheel sensor.
• Malfunction ABS
ECU.
• Malfunction in
SGCU.
P2195 O2 sensor (open cir- • Improperly in- Increased exhaust O2 feedback is not
cuit is detected) stalled O2 sensor. emissions. carried out.
• Defective coupler
between O2 sen-
sor and SGCU.
• Open or short cir-
cuit in wire har-
ness between O2
sensor and SGCU.
• Defective O2 sen-
sor.
• Malfunction in
SGCU.
• Normal signal is
not received from
O2 sensor.
EU3 specified volt-
age:
(0.25 V or more to
0.53 V or less)
EU4/5 specified
voltage:
(0.25 V or more to
0.40 V or less)

9-48
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system

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

9-49
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system

DTC Item Vehicle symptom
malfunction operation
Er-4 SGCU internal mal- • Open or short cir- Registered data is Normally operated
function (Input sig- cuit in wire har- not received from except for the me-
nal error) ness between the meter. ter.
meter and SGCU. Normal signals are
• Defective coupler not received from
between meter the YDT (Yamaha
and SGCU. Diagnostic Tool).
• Defective meter Meter operation is
unit. impossible.
• Malfunction in
SGCU.

9-50
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EAS33286

SELF-DIAGNOSTIC FUNCTION TABLE (FOR ABS (Anti-lock Brake System))

TIP
For details of the DTC, refer to “BASIC INSTRUCTIONS FOR TROUBLESHOOTING” on page 9-17.

DTC Item Symptom Check point

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

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SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

DTC Item Symptom Check point

15 Front wheel sensor (open Open or short circuit is de- • Defective coupler be-
or short circuit) tected in the front wheel tween the front wheel
sensor. sensor and the hydraulic
unit assembly
• Open or short circuit in
the wire harness be-
tween the front wheel
sensor and the hydraulic
unit assembly
• Defective front wheel
sensor or hydraulic unit
assembly
16 Rear wheel sensor (open Open or short circuit is de- • Defective coupler be-
or short circuit) tected in the rear wheel tween the rear wheel
sensor. sensor and the hydraulic
unit assembly
• Open or short circuit in
the wire harness be-
tween the rear wheel
sensor and the hydraulic
unit assembly
• Defective rear wheel
sensor or hydraulic unit
assembly
17* Front wheel sensor (miss- Front wheel sensor signal • Foreign material ad-
45* ing pulses) is not received properly. hered around the front
(Missing pulses are de- wheel sensor
tected in the signal while • Incorrect installation of
the vehicle is traveling.) the front wheel
• Defective sensor rotor or
incorrect installation of
the rotor
• Defective front wheel
sensor or incorrect in-
stallation of the sensor
18* Rear wheel sensor (miss- Rear wheel sensor signal • Foreign material ad-
46* ing pulses) is not received properly. hered around the rear
(Missing pulses are de- wheel sensor
tected in the signal while • Incorrect installation of
the vehicle is traveling.) the rear wheel
• Defective sensor rotor or
incorrect installation of
the rotor
• Defective rear wheel
sensor or incorrect in-
stallation of the sensor
21 Hydraulic unit assembly Solenoid drive circuit in • Defective hydraulic unit
(defective solenoid drive the hydraulic unit assem- assembly
circuit) bly is open or short-circuit-
ed.

9-52
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

DTC Item Symptom Check point

24 Brake light switch or tail/ Brake light signal is not re- • Defective signaling sys-
brake light ceived properly while the tem (tail/brake light or
vehicle is traveling. (Brake brake light switch)
light circuit, or front or rear • Defective coupler be-
brake light switch circuit.) tween the signaling sys-
tem (tail/brake light or
brake light switch) and
the hydraulic unit assem-
bly
• Open or short circuit in
the wire harness be-
tween the signaling sys-
tem (tail/brake light or
brake light switch) and
the hydraulic unit assem-
bly
• Defective hydraulic unit
assembly
31 Hydraulic unit assembly Power is not supplied to • Blown ABS solenoid fuse
(abnormal ABS solenoid the solenoid circuit in the • Defective coupler be-
power supply) hydraulic unit assembly. tween the battery and the
hydraulic unit assembly
• Open or short circuit in
the wire harness be-
tween the battery and the
hydraulic unit assembly
• Defective hydraulic unit
assembly
32 Hydraulic unit assembly Short circuit is detected in • Defective hydraulic unit
(short circuit in ABS sole- the solenoid power supply assembly
noid power supply circuit) circuit in the hydraulic unit
assembly.
33 Hydraulic unit assembly Power is not supplied to • Blown ABS motor fuse
(abnormal ABS motor the motor circuit in the hy- • Defective coupler be-
power supply) draulic unit assembly. tween the battery and the
hydraulic unit assembly
• Open or short circuit in
the wire harness be-
tween the battery and the
hydraulic unit assembly
• Defective hydraulic unit
assembly
34 Hydraulic unit assembly Short circuit is detected in • Defective hydraulic unit
(short circuit in ABS motor the motor power supply assembly
power supply circuit) circuit in the hydraulic unit
assembly.

9-53
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

DTC Item Symptom Check point

41 Front wheel ABS (intermit- • Pulses from the front • Incorrect installation of
tent wheel speed pulses or wheel sensor are re- the front wheel sensor
incorrect depressuriza- ceived intermittently • Incorrect rotation of the
tion) while the vehicle is trav- front wheel
eling. • Front brake dragging
• Front wheel will not re- • Defective hydraulic unit
cover from the locking assembly
tendency even though
the signal is transmitted
from the ABS ECU to re-
duce the hydraulic pres-
sure.
42 Rear wheel ABS (intermit- • Pulses from the rear • Incorrect installation of
47 tent wheel speed pulses or wheel sensor are re- the rear wheel sensor
incorrect depressuriza- ceived intermittently (for DTC No. 42)
tion) while the vehicle is trav- • Incorrect rotation of the
eling. (for DTC No. 42) rear wheel
• Rear wheel will not re- • Rear brake dragging
cover from the locking • Defective hydraulic unit
tendency even though assembly
the signal is transmitted
from the ABS ECU to re-
duce the hydraulic pres-
sure.
43 Front wheel sensor (miss- Front wheel sensor signal • Foreign material ad-
ing pulses) is not received properly. hered around the front
(Missing pulses are de- wheel sensor
tected in the signal while • Incorrect installation of
the vehicle is traveling.) the front wheel
• Defective sensor rotor or
incorrect installation of
the rotor
• Defective front wheel
sensor or incorrect in-
stallation of the sensor
44 Rear wheel sensor (miss- Rear wheel sensor signal • Foreign material ad-
ing pulses) is not received properly. hered around the rear
(Missing pulses are de- wheel sensor
tected in the signal while • Incorrect installation of
the vehicle is traveling.) the rear wheel
• Defective sensor rotor or
incorrect installation of
the rotor
• Defective rear wheel
sensor or incorrect in-
stallation of the sensor
51 • Vehicle system power • Power voltage supplied • Defective battery
52 supply (voltage of ABS to the ABS ECU in the • Disconnected battery
ECU power supply is hydraulic unit assembly terminal
high) (for DTC No. 51) is too high. (for DTC No. • Defective charging sys-
• Vehicle system power 51) tem
supply (voltage of wheel • Power voltage supplied
sensor power supply is to the wheel sensor is too
high) (for DTC No. 52) high. (for DTC No. 52)

9-54
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

DTC Item Symptom Check point

53 Vehicle system power Power voltage supplied to • Defective battery
supply (voltage of ABS the ABS ECU in the hy- • Defective coupler be-
ECU power supply is low) draulic unit assembly is tween the battery and the
too low. hydraulic unit assembly
• Open or short circuit in
the wire harness be-
tween the battery and the
hydraulic unit assembly
• Defective charging sys-
tem
54 Hydraulic unit assembly Abnormality is detected in • Defective battery
(defective ABS solenoid the solenoid or motor pow- • Defective coupler be-
and ABS motor power er supply circuit in the hy- tween the battery and the
supply circuits) draulic unit assembly. hydraulic unit assembly
• Open or short circuit in
the wire harness be-
tween the battery and the
hydraulic unit assembly
• Defective charging sys-
tem
• Defective hydraulic unit
assembly
55 Hydraulic unit assembly Abnormal data is detected • Defective hydraulic unit
(defective ABS ECU) in the hydraulic unit as- assembly
sembly.
56 Hydraulic unit assembly Abnormality is detected in • Defective hydraulic unit
(abnormal internal power the power supply circuit in assembly
supply) the hydraulic unit assem-
bly.
63 Front wheel sensor power Power voltage supplied • Short circuit in the wire
supply (voltage of power from the ABS ECU to the harness between the
supply is low) front wheel sensor is too front wheel sensor and
low. the hydraulic unit assem-
bly
• Defective front wheel
sensor
• Defective hydraulic unit
assembly
64 Rear wheel sensor power Power voltage supplied • Short circuit in the wire
supply (voltage of power from the ABS ECU to the harness between the
supply is low) rear wheel sensor is too rear wheel sensor and
low. the hydraulic unit assem-
bly
• Defective rear wheel
sensor
• Defective hydraulic unit
assembly

* The DTC No. varies according to the vehicle conditions.

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SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EAS33031

DIAGNOSTIC CODE: SENSOR OPERATION TABLE

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

9-56
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Diagnostic
Item Tool display Procedure
code No.
20 Sidestand switch Check the sidestand
• Stand retracted ON switch condition.

• Stand extended OFF

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

9-57
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EAS33032

DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE

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

9-58
 EVENT CODE TABLE

EAS20707

EVENT CODE TABLE

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

9-59
 EVENT CODE TABLE

No. Item Symptom Possible cause Remarks

242 ISC During idling, the Idling engine speed is • Implement diagnosis
(Stuck at the up- adjustment is main- slow mode D67, and check
per limit for ad- tained at the upper • Clogged throttle body the ISC maintenance
justment) limit • Poorly adjusted throt- request.
tle cable • If a DTC is indicated,
• Poorly adjusted perform to that first.
clutch cable * Event code number 242
• Malfunction in the may be indicated even if
fuel injection system the system is normal.
• Dirty or worn spark
plug
• Malfunction in the
battery
• Malfunction in SGCU
243 ISC During idling, the Idling engine speed is • If a DTC is indicated,
(Stuck at the adjustment is main- fast perform to that first.
lower limit for tained at the lower • Poorly adjusted throt- * Event code number 243
adjustment) limit tle cable may be indicated even if
• Poorly adjusted the system is normal.
clutch cable
• Malfunction in the
fuel injection system
• Dirty or worn spark
plug
• Malfunction in the
battery
• Malfunction in SGCU
244 Difficult/unable Engine starting diffi- • Empty fuel tank • If a DTC is indicated,
to start engine cult/unable condi- • Defective fuel injec- perform the checks and
tion detected tion system maintenance jobs for
• Dirty or worn spark the DTC first.
plug * Event code number 244
• Defective battery may be indicated even if
• Defective SGCU the system is normal.
245 Engine stall Engine stall detect- • Empty fuel tank • If a DTC is indicated,
ed • Improperly adjusted perform the checks and
throttle cable maintenance jobs for
• Improperly adjusted the DTC first.
clutch cable * Event code number 245
• Defective fuel injec- may be indicated even if
tion system the system is normal.
• Dirty or worn spark
plug
• Defective battery
• Defective SGCU

9-60
 P0030

EAS20397

P0030
EAS33134

TROUBLESHOOTING
Item
O2 sensor heater: defective heater or heater driver ON/OFF command and error signal is mismatching.
Fail-safe system
• Able to start engine
• Able to drive vehicle

Procedure
1. Connection of O2 sensor coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 2.
2. Connection of SGCU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 3.

9-61
 P0030

3. Wire harness continuity.

• Disconnect the O2 sensor coupler, SGCU coupler and ignition fuse.
• Open circuit check
Between O2 sensor coupler “1” and SGCU cou-
pink/black–pink/black
pler “2”
Between O2 sensor coupler “1” and ignition fuse
brown/red–brown
holder “3”

3
2
1
Br/R P/B Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
Gy/R B/L Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Start the engine, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to “Short circuit check”.

9-62
 P0030

• Short circuit check

TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3.
Ground short circuit check “A”
pink/black–ground
Between O2 sensor coupler “1” and ground
brown/red–ground

Lines short circuit check “B”

pink/black–any other coupler terminal
O2 sensor coupler “1”
brown/red–any other coupler terminal
SGCU coupler “2” pink/black–any other coupler terminal
Ignition fuse holder “3” brown–any other coupler terminal

A B
1 1 2
Br/R P/B
Gy/R B/L
Br/R P/B
Gy/R B/L Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance ∞ Ω?
YES
→ Go to step 4.
NO
a. Replace the wire harness.
b. Start the engine, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 4.

9-63
 P0030

4. Defective O2 sensor heater.

• Replace the O2 sensor.
Refer to “ENGINE REMOVAL” on page 5-4.
• Start the engine, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 5.
5. Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36.
6. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-64
 P00D1, P2195

EAS20660

P00D1, P2195
EAS33115

TROUBLESHOOTING
Item
• [P00D1] O2 sensor: heater performance deteriorated. Normal signal is not received from the O2 sen-
sor while driving the O2 sensor.
• [P2195] O2 sensor: open circuit is detected.
Fail-safe system
• Able to start engine
• Able to drive vehicle

Procedure
1. Installed condition of O2 sensor.
• Check for looseness or pinching.

Is check result OK?

YES
→ Go to step 2.
NO
a. Reinstall the O2 sensor.
Refer to “ENGINE REMOVAL” on page 5-4.
b. Start the engine and warm up it. And then, racing the engine.
c. Check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 8, and complete the service.
NO
→ Delete the DTC, and then go to step 2.
2. Connection of O2 sensor coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and warm up it. And then, racing the engine.
c. Check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 8, and complete the service.
NO
→ Delete the DTC, and then go to step 3.

9-65
 P00D1, P2195

3. Connection of SGCU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and warm up it. And then, racing the engine.
c. Check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 8, and complete the service.
NO
→ Delete the DTC, and then go to step 4.
4. Wire harness continuity.
• Disconnect the O2 sensor coupler, SGCU coupler and ignition fuse coupler.
• Open circuit check
pink/black–pink/black
Between O2 sensor coupler “1” and SGCU cou-
gray/red–gray/red
pler “2” black/blue–black/blue
Between O2 sensor coupler “1” and ignition fuse
brown/red–brown
holder “3”

3
2
1
Br/R P/B Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
Gy/R B/L Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance 0 Ω?
YES
[P00D1]
→ Go to “Short circuit check”.
[P2195]
→ Go to step 5.
NO
a. Replace the wire harness.
b. Start the engine and warm up it. And then, racing the engine.
c. Check the DTC using the malfunction mode of the YDT.

9-66
 P00D1, P2195

Is it in the “Recovered” condition?

YES
→ Go to step 8, and complete the service.
NO
→ Go to “Short circuit check”.
• Short circuit check
TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3.
Ground short circuit check “A”
pink/black–ground
brown/red–ground
Between O2 sensor coupler “1” and ground
gray/red–ground
black/blue–ground

Lines short circuit check “B”

pink/black–any other coupler terminal
brown/red–any other coupler terminal
O2 sensor coupler “1”
gray/red–any other coupler terminal
black/blue–any other coupler terminal
pink/black–any other coupler terminal
SGCU coupler “2” gray/red–any other coupler terminal
black/blue–any other coupler terminal
Ignition fuse holder “3” brown/red–any other coupler terminal

A B

1 2 3
1
Br/R P/B Br/R P/B
Gy/R B/L Gy/R B/L Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance ∞ Ω?
YES
→ Go to step 5.
NO
a. Replace the wire harness.
b. Start the engine and warm up it. And then, racing the engine.
c. Check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 8, and complete the service.
NO
→ Go to step 5.

9-67
 P00D1, P2195

5. Defective fuel pressure.

• Check the fuel pressure.
Refer to “CHECKING THE FUEL PRESSURE” on page 7-5.

Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the fuel pump.
Refer to “REMOVING THE FUEL PUMP” on page 7-3.
b. Start the engine and warm up it. And then, racing the engine.
c. Check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 8, and complete the service.
NO
→ Go to step 6.
6. Defective O2 sensor.
• Check the O2 sensor.

Is check result OK?

YES
→ Go to step 7.
NO
a. Replace the O2 sensor.
Refer to “ENGINE REMOVAL” on page 5-4.
b. Start the engine and warm up it. And then, racing the engine.
c. Check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 8, and complete the service.
NO
→ Go to step 7.
7. Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36.
8. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-68
 P0106

EAS20421

P0106
EAS32840

TROUBLESHOOTING
Item
Intake air pressure sensor: clogging of hole or sensor installation improperly.
Fail-safe system
• Able to start engine
• Able to drive vehicle

Procedure
ECA20500

NOTICE
Do not remove the throttle body sensor assembly from the throttle body.

TIP
If the DTC “P0107/P0108” or “P0106” are detected at the same time, perform the check and service for
DTC listed below first.
• P0107, P0108
1. Installed condition of throttle body sensor assembly.
• Check for detached or clogged.
Refer to “THROTTLE BODY” on page 7-11.

Is check result OK?

YES
→ Go to step 2.
NO
a. Reinstall the throttle body.
Refer to “THROTTLE BODY” on page 7-11.
b. Start the engine and let it idle for approximately 5 seconds with the throttle fully closed, and then
check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 3, and complete the service.
NO
→ Go to step 2.

9-69
 P0106

2. Defective intake air pressure sensor.

• Execute the diagnostic mode. (Code 03)
• When engine is stopped: Atmospheric pressure at the current altitude and weather conditions is in-
dicated.
101 kPa (757.6 mmHg, 29.8 inHg), approx. 3.99
At sea level
V
Approx. 90 kPa (675.1 mmHg, 26.6 inHg), ap-
1000 m (3300 ft) above sea level
prox. 3.55 V
Approx. 80 kPa (600.0 mmHg, 23.6 inHg), ap-
2000 m (6700 ft) above sea level
prox. 3.16 V
Approx. 70 kPa (525.0 mmHg, 20.7 inHg), ap-
3000 m (9800 ft) above sea level
prox. 2.76 V

• When engine is cranking: Make sure that the indication value changes.

Is check result OK?

YES
→ Go to step 3, and complete the service.
NO
a. Replace the throttle body.
Refer to “THROTTLE BODY” on page 7-11.
b. Start the engine and let it idle for approximately 5 seconds with the throttle fully closed, and then
check the DTC using the malfunction mode of the YDT.
c. Confirm the “Recovered” condition, then go to step 3.
3. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-70
 P0107, P0108

EAS20567

P0107, P0108
EAS33047

TROUBLESHOOTING
Item
• [P0107] Intake air pressure sensor: open or short to ground circuit is detected.
• [P0108] Intake air pressure sensor: short to power circuit is detected.
Fail-safe system
• Able to start engine
• Able to drive vehicle

Procedure
ECA20500

NOTICE
Do not remove the throttle body sensor assembly from the throttle body.

TIP
If the DTC “P0107/P0108” or “P0106” are detected at the same time, perform the check and service for
DTC listed below first.
• P0107, P0108
1. Connection of throttle body sensor 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).

Is the coupler condition normal?

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 2.
2. Connection of SGCU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

9-71
 P0107, P0108

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 3.
3. Wire harness continuity.
• Disconnect the throttle body sensor assembly coupler and SGCU coupler.
• Open circuit check
[P0108] black/blue–black/blue
Between throttle body sensor assembly coupler
[P0107] pink/white–pink/white
“1” and SGCU coupler “2”
[P0107] blue–blue

2
1 Lg/L G/Y
Lg/W Sb
P W/L Ch
Gy
G B/L B
W/Y P/B W/B L
O/B W/R B/Y O
B/L Y B/L Br/B R/B
B/L Y L P/W Br/W L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to “Short circuit check”.

9-72
 P0107, P0108

• Short circuit check

TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3.
Ground short circuit check “A”
Between throttle body sensor assembly coupler
[P0107] pink/white–ground
“1” and ground

Lines short circuit check “B”

Throttle body sensor assembly coupler “1” [P0108] pink/white–any other coupler terminal
SGCU coupler “2” [P0108] pink/white–any other coupler terminal

A B

1 1 2
B/L Y L P/W Br/W
B/L Y L P/W Br/W
Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance ∞ Ω?
YES
→ Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 4.
4. Installed condition of throttle body sensor assembly.
• Check for looseness or pinching.

Is check result OK?

YES
→ Go to step 5.
NO
a. Reinstall the throttle body sensor assembly.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 5.

9-73
 P0107, P0108

5. Defective intake air pressure sensor.

• Execute the diagnostic mode. (Code 03)
• When engine is stopped: Atmospheric pressure at the current altitude and weather conditions is in-
dicated.
Approx. 101 kPa (757.6 mmHg, 29.8 inHg), ap-
At sea level
prox. 3.99 V
Approx. 90 kPa (675.1 mmHg, 26.6 inHg), ap-
1000 m (3300 ft) above sea level
prox. 3.55 V
Approx. 80 kPa (600.0 mmHg, 23.6 inHg), ap-
2000 m (6700 ft) above sea level
prox. 3.16 V
Approx. 70 kPa (525.0 mmHg, 20.7 inHg), ap-
3000 m (9800 ft) above sea level
prox. 2.76 V

• When engine is cranking: Make sure that the indication value changes.

Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the throttle body.
Refer to “THROTTLE BODY” on page 7-11.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 6.
6. Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36.
7. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-74
 P0112, P0113

EAS20568

P0112, P0113
EAS33048

TROUBLESHOOTING
Item
• [P0112] Intake air temperature sensor: short to ground circuit is detected.
• [P0113] Intake air temperature sensor: open or short to power circuit is detected.
Fail-safe system
• Able to start engine
• Able to drive vehicle

Procedure
ECA20500

NOTICE
Do not remove the throttle body sensor assembly from the throttle body.

TIP
Perform this procedure when the engine is cold.
1. Connection of throttle body sensor 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).

Is the coupler condition normal?

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness and/or sub-wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 2.
2. Connection of SGCU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 3.

9-75
 P0112, P0113

3. Wire harness continuity.

• Disconnect the throttle body sensor assembly coupler and SGCU coupler.

Is DTC P0112 displayed?

YES
→ Go to “Short circuit check”.
NO
→ Go to “Open circuit check”.
• Open circuit check
Between throttle body sensor assembly coupler [P0113] brown/white–brown/white
“1” and SGCU coupler “2” [P0113] black/blue–black/blue

2
1 Lg/L G/Y
Lg/W Sb
P W/L Ch
Gy
G B/L B
W/Y P/B W/B L
O/B W/R B/Y O
B/L Y B/L Br/B R/B
B/L Y L P/W Br/W L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to “Short circuit check”.

9-76
 P0112, P0113

• Short circuit check

TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3.
Ground short circuit check “A”
Between throttle body sensor assembly coupler
[P0112] brown/white–ground
“1” and ground

Lines short circuit check “B”

SGCU coupler “2” [P0113] brown/white–any other coupler terminal

A B
2
1
B/L Y L P/W Br/W Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance ∞ Ω?
YES
→ Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 4.
4. Installed condition of throttle body sensor assembly.
• Check for looseness.
Refer to “THROTTLE BODY” on page 7-11.

Is check result OK?

YES
→ Go to step 5.
NO
a. Reinstall the throttle body sensor assembly.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 5.

9-77
 P0112, P0113

5. Defective intake air temperature sensor.

• Execute the diagnostic mode. (Code 05)
• When engine is cold: Displayed temperature is close to the ambient temperature.

Is check result OK?

YES
→ Go to step 6.
NO
a. The displayed temperature is not close to the ambient temperature → Replace the throttle body.
Refer to “THROTTLE BODY” on page 7-11.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 6.
6. Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36.
7. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-78
 P0117, P0118

EAS20569

P0117, P0118
EAS33049

TROUBLESHOOTING
Item
• [P0117] Coolant temperature sensor: short to ground circuit is detected.
• [P0118] Coolant temperature sensor: open or short to power circuit is detected.
Fail-safe system
• Able to start engine
• Able to drive vehicle

Procedure
TIP
Perform this procedure when the engine is cold.
1. Connection of coolant temperature sensor coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 2.
2. Connection of SGCU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 3.

9-79
 P0117, P0118

3. Wire harness continuity.

• Disconnect the coolant temperature sensor coupler and SGCU coupler.

Is DTC P0117 displayed?

YES
→ Go to “Short circuit check”.
NO
→ Go to “Open circuit check”.
• Open circuit check
Between coolant temperature sensor coupler [P0118] green/red–green/red
“1” and SGCU coupler “2” [P0118] black/blue–black/blue

1 2
Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
G/R B/L
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance 0 Ω?
YES
→ Go to step “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step “Short circuit check”.

9-80
 P0117, P0118

• Short circuit check

TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3.
Ground short circuit check “A”
Between coolant temperature sensor coupler
[P0117] green/red–ground
“1” and ground

Lines short circuit check “B”

Coolant temperature sensor coupler “1” [P0118] green/red–any other coupler terminal
SGCU coupler “2” [P0118] green/red–any other coupler terminal

A B

1 1 2
G/R B/L
Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
G/R B/L Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance ∞ Ω?
YES
→ Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 4.
4. Installed condition of coolant temperature sensor.
• Check for looseness or pinching.
Refer to “CYLINDER HEAD” on page 5-9.

Is check result OK?

YES
→ Go to step 5.
NO
a. Reinstall the sensor.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 5.

9-81
 P0117, P0118

5. Defective coolant temperature sensor.

• Execute the diagnostic mode. (Code 06)
• When engine is cold: Displayed temperature is close to the ambient temperature.
• The displayed temperature is not close to the ambient temperature → Check the coolant tempera-
ture sensor.
Refer to “CHECKING THE COOLANT TEMPERATURE SENSOR” on page 8-41.

Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the coolant temperature sensor.
Refer to “CYLINDER HEAD” on page 5-9.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 6.
6. Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36.
7. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-82
 P0122, P0123

EAS20757

P0122, P0123
EAS33050

TROUBLESHOOTING
Item
• [P0122] Throttle position sensor: open or short to ground circuit is detected.
• [P0123] Throttle position sensor: short to power circuit is detected.
Fail-safe system
• Able to start engine
• Able to drive vehicle

Procedure
ECA20500

NOTICE
Do not remove the throttle body sensor assembly from the throttle body.
1. Connection of throttle body sensor 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).

Is the coupler condition normal?

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 2.
2. Connection of SGCU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 3.

9-83
 P0122, P0123

3. Wire harness continuity.

• Disconnect the throttle body sensor assembly coupler and SGCU coupler.
• Open circuit check
[P0122] blue–blue
Between throttle body sensor assembly coupler
[P0122] yellow–yellow
“1” and SGCU coupler “2”
[P0123] black/blue–black/blue

2
1 Lg/L G/Y
Lg/W Sb
P W/L Ch
Gy
G B/L B
W/Y P/B W/B L
O/B W/R B/Y O
B/L Y B/L Br/B R/B
B/L Y L P/W Br/W L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 9, and complete the service.
NO
→ Go to “Short circuit check”.

9-84
 P0122, P0123

• Short circuit check

TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3.
Ground short circuit check “A”
Between throttle body sensor assembly coupler
[P0122] yellow–ground
“1” and ground

Lines short circuit check “B”

Throttle body sensor assembly coupler “1” [P0123] yellow–any other coupler terminal
SGCU coupler “2” [P0123] yellow–any other coupler terminal

A B
1 1 2

Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O

B/L Y L P/W Br/W B/L Y L P/W Br/W
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance ∞ Ω?
YES
→ Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 4.
4. Installed condition of throttle body sensor assembly.
• Check for looseness or pinching.

Is check result OK?

YES
→ Go to step 5.
NO
a. Reinstall the throttle body.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 5.

9-85
 P0122, P0123

5. Defective throttle position sensor.

• Check throttle position sensor signal 1.
• Execute the diagnostic mode. (Code 01)
When the throttle valves are fully closed 12–22
When throttle valves are fully open 94–110

Is check result OK?

YES
→ Go to step 7.
NO
a. Replace the throttle body assembly.
Refer to “REPLACING THE THROTTLE BODY” on page 7-16.
b. Start the engine, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 6.
6. Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36.
7. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-86
 P0132

EAS20571

P0132
EAS33051

TROUBLESHOOTING
Item
O2 sensor: short to power circuit is detected.
Fail-safe system
• Able to start engine
• Able to drive vehicle

Procedure
1. Installed condition of O2 sensor.
• Check for looseness or pinching.
Refer to “ENGINE REMOVAL” on page 5-4.

Is check result OK?

YES
→ Go to step 2.
NO
a. Reinstall or replace the sensor.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 2.
2. Connection of O2 sensor coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 3.

9-87
 P0132

3. Connection of SGCU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 4.
4. Wire harness continuity.
• Disconnect the O2 sensor coupler and SGCU coupler.
• Short circuit check
TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3.
Lines short circuit check
SGCU coupler “1” gray/red–any other coupler terminal

Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O

Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance ∞ Ω?
YES
→ Go to step 5.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 5.

9-88
 P0132

5. Defective O2 sensor.
• Check the O2 sensor.
Refer to “ENGINE REMOVAL” on page 5-4.

Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the O2 sensor.
Refer to “ENGINE REMOVAL” on page 5-4.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 6.
6. Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36.
7. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-89
 P0201

EAS20574

P0201
EAS33054

TROUBLESHOOTING
Item
Fuel injector: malfunction in fuel injector.
Fail-safe system
• Unable to start engine
• Unable to drive vehicle

Procedure
1. Connection of fuel injector coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code 36)

Is operating sound heard?

YES
→ Go to step 6.
NO
→ Go to step 2.
2. Defective fuel injector.
• Measure the injector resistance.
Refer to “CHECKING THE FUEL INJECTOR” on page 8-42.

Is check result OK?

YES
→ Go to step 3.
NO
a. Replace the fuel injector.
Refer to “THROTTLE BODY” on page 7-11.
b. Execute the diagnostic mode. (Code 36)

Is operating sound heard?

YES
→ Go to step 6.
NO
→ Go to step 3.

9-90
 P0201

3. Connection of SGCU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code 36)

Is operating sound heard?

YES
→ Go to step 6.
NO
→ Go to step 4.
4. Wire harness continuity.
• Disconnect the ignition fuse, fuel injector coupler and SGCU coupler
• Open circuit check
Between ignition fuse holder “1” and fuel injec-
brown–brown
tor coupler “2”
Between fuel injector coupler “2” and SGCU
orange/black–orange/black
coupler “3”

1
3
2
Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
O/B Br Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code 36)

Is operating sound heard?

YES
→ Go to step 6.
NO
→ Go to “Short circuit check”.

9-91
 P0201

• Short circuit check

TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3.
Ground short circuit check “A”
orange/black–ground
Between fuel injector coupler “2” and ground
brown–ground

Lines short circuit check “B”

orange/black–any other coupler terminal
Fuel injector coupler “2”
brown–any other coupler terminal
SGCU coupler “1” orange/black–any other coupler terminal

A B

2 2 1
O/B Br
O/B Br
Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance ∞ Ω?
YES
→ Go to step 5.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code 36)

Is operating sound heard?

YES
→ Go to step 6.
NO
→ Go to step 5.
5. Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36.
6. Delete the DTC and check that the MIL goes off.
• Start the engine and let it idle for approximately 5 seconds.
• Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT, and
then delete the DTC.

9-92
 P0335

EAS20578

P0335
EAS33058

TROUBLESHOOTING
Item
Crankshaft position sensor: normal signals are not received from the crankshaft position sensor.
Fail-safe system
• Unable to start engine
• Unable to drive vehicle

Procedure
1. Connection of crankshaft position sensor coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Crank the engine, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 2.
2. Connection of wire harness SGCU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Crank the engine, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 3.

9-93
 P0335

3. Wire harness continuity.

• Disconnect the crankshaft position sensor coupler and SGCU coupler.
• Open circuit check
white/red–white/red
white/blue–white/blue
Between crankshaft position sensor coupler “1” white/black–white/black
and SGCU coupler “2” white/yellow–white/yellow
brown/black–brown/black
black/blue–black//blue

1
W/R B/L
2
W/L Br/B Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
W/B W/Y Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Crank the engine, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to “Short circuit check”.

9-94
 P0335

• Short circuit check

TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3.
Ground short circuit check “A”
white/red–ground
white/blue–ground
Between crankshaft position sensor coupler “1” white/black–ground
and ground white/yellow–ground
brown/black–ground
black/blue–ground

Lines short circuit check “B”

white/red–any other coupler terminal
white/blue–any other coupler terminal
white/black–any other coupler terminal
Crankshaft position sensor coupler “1”
white/yellow–any other coupler terminal
brown/black–any other coupler terminal
black/blue–any other coupler terminal
white/red–any other coupler terminal
white/blue–any other coupler terminal
white/black–any other coupler terminal
SGCU coupler “2”
white/yellow–any other coupler terminal
brown/black–any other coupler terminal
black/blue–any other coupler terminal

A B
1 1 2

W/R B/L W/R B/L

W/L Br/B W/L Br/B
Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
W/B W/Y W/B W/Y Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance ∞ Ω?
YES
→ Go to step 4.
NO
a. Replace the wire harness.
b. Crank the engine, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 4.

9-95
 P0335

4. Installed condition of crankshaft position sensor.

• Check for looseness or pinching.
• Check the gap (1.15 mm (0.05 in)) between the crankshaft position sensor and the generator rotor.

Is check result OK?

YES
→ Go to step 5.
NO
a. Reinstall or replace the sensor.
b. Crank the engine, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 5.
5. Defective crankshaft position sensor.
a. Replace the crankshaft position sensor.
b. Crank the engine, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 6.
6. Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36.
7. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-96
 P0351

EAS20580

P0351
EAS33060

TROUBLESHOOTING
Item
Ignition coil: open or short circuit is detected in the primary lead of the ignition coil.
Fail-safe system
• Unable to start engine
• Unable to drive vehicle

Procedure
1. Connection of ignition 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).

Is the coupler condition normal?

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 2.
2. Connection of SGCU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 3.

9-97
 P0351

3. Wire harness continuity.

• Disconnect the ignition coil coupler and SGCU coupler.
• Open circuit check
Between ignition coil coupler “1” and SGCU
orange–orange
coupler “2”

2 1

Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O

Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to “Short circuit check”.

9-98
 P0351

• Short circuit check

TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3.
Ground short circuit check “A”
Between ignition coil coupler “1” and ground orange–ground

Lines short circuit check “B”

Ignition coil coupler “1” orange–any other coupler terminal
SGCU coupler “2” orange–any other coupler terminal

A B
1 2 1

Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O

Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance ∞ Ω?
YES
→ Go to step 4.
NO
a. Replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 4.
4. Installed condition of ignition coil.
• Check for looseness or pinching.

Is check result OK?

YES
→ Go to step 5.
NO
a. Reinstall.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 5.

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 P0351

5. Defective ignition coil.

• Measure the primary coil resistance of the ignition coil.
Refer to “CHECKING THE IGNITION COIL” on page 8-39.

Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the ignition coil.
Refer to “GENERAL CHASSIS (3)” on page 4-6.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 6.
6. Malfunction in SGCU.
• Execute the diagnostic mode. (Code 30)
• Confirm that spark plug does not spark.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36.
7. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-100
 P0500

EAS20674

P0500
EAS33303

TROUBLESHOOTING
Item
Front wheel sensor: normal signal is not received from the front wheel sensor.
Fail-safe system
• Able to start engine
• Able to drive vehicle

Procedure
1. Connection of front wheel sensor coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code 07)
c. Rotate the front wheel by hand and check that the indicated value increases.

Is that value increased?

YES
→ Go to step 8.
NO
→ Go to step 2.
2. Connection of ABS ECU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code 07)
c. Rotate the front wheel by hand and check that the indicated value increases.

Is that value increased?

YES
→ Go to step 8.
NO
→ Go to step 3.

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 P0500

3. Connection of SGCU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code 07)
c. Rotate the front wheel by hand and check that the indicated value increases.

Is that value increased?

YES
→ Go to step 7.
NO
→ Go to step 4.
4. Wire harness continuity.
• Disconnect the front wheel sensor coupler, ABS ECU coupler and SGCU coupler.
• Open circuit check
Between front wheel sensor coupler “1” and brown–brown
ABS ECU coupler “2” yellow–yellow
Between ABS ECU coupler “2” and SGCU cou-
white–white
pler “3”

1 2 3
Br Y G L W W/L W/B B/W Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
R
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
Br Y R/L Y L/G L/G Br Lg/L Lg/W B/W B L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code 07)
c. Rotate the front wheel by hand and check that the indicated value increases.

Is that value increased?

YES
→ Go to step 8.
NO
→ Go to “Short circuit check”.

9-102
 P0500

• Short circuit check

TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3.
Ground short circuit check “A”
brown–ground
Between ABS ECU coupler “2” and ground
yellow–ground

Lines short circuit check “B”

brown–any other coupler terminal
Front wheel sensor coupler “1”
yellow–any other coupler terminal
brown–any other coupler terminal
ABS ECU coupler “2”
yellow–any other coupler terminal
SGCU coupler “3” white–any other coupler terminal

A B

2 1
R Br Y G L W W/L W/B B/W Br Y
R/L Y L/G L/G Br Lg/L Lg/W B/W B

2 3

R Br Y G L W W/L W/B B/W Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
R/L Y L/G L/G Br Lg/L Lg/W B/W B L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance ∞ Ω?
YES
→ Go to step 5.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code 07)
c. Rotate the front wheel by hand and check that the indicated value increases.

Is that value increased?

YES
→ Go to step 8.
NO
→ Go to step 5.

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 P0500

5. Defective front wheel sensor.

• Check the installed condition of front wheel sensor.

Is check result OK?

YES
→ Go to step 8.
NO
a. Reinstall or replace the front wheel sensor.
Refer to “FRONT WHEEL” on page 4-22.
b. Execute the diagnostic mode. (Code 07)
c. Rotate the front wheel by hand and check that the indicated value increases.

Is that value increased?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 8.
6. Malfunction in SGCU.
• Replace the SGCU.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36
• Execute the diagnostic mode. (Code 07)
• Rotate the front wheel by hand and check that the indicated value increases.

Is that value increased?

YES
→ Go to step 8.
NO
→ Go to step 7.
7. Malfunction in ABS ECU.
• Replace the ABS ECU and go to step 8.
8. Delete the DTC and check that the MIL goes off.
• Turn the main switch to “ON”, and then rotate the front wheel by hand.
• Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT, and
then delete the DTC. Delete this DTC even if it has a condition of “Detected”.

9-104
 P0507

EAS20589

P0507
EAS33069

TROUBLESHOOTING
Item
Engine idling speed is too high.
A. Component other than ISC unit is defective (ISC unit operating sound is heard).
B. Defective ISC unit (ISC unit operating sound is not heard).
Fail-safe system
• Able to start engine
• Able to drive vehicle
TIP
If the DTCs P0507, P0560 are detected at the same time, perform the checked service for DTC listed
below first.
• P0560
If the DTCs P0507, P0500 are detected at the same time, perform the checked service for DTC listed
below first.
• P0500
If the DTCs P0507, P0511 are detected at the same time, perform the checked service for DTC listed
below first.
• P0511

Procedure
1. Locate the malfunction.
• Execute the diagnostic mode. (Code 54)
• Fully close the ISC valve, and then open the valve to the standby opening position.
• This operation takes approximately 3 seconds.

Is ISC operating sound heard?

YES
→ Go to step 2.
NO
→ Go to step 10.
2. Incorrect front wheel sensor signal.
• Execute the diagnostic mode. (Code 07)
• Front wheel stopped: Check that the cumulative pulse value does not increase.
• Front wheel is rotated several turns by hand: Check that the cumulative pulse value increases

Is check result OK?

YES
→ Go to step 3.
NO
a. Go to DTC P0500.
b. Start the engine and let it idle for approximately 10 seconds.
c. Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 9, and complete the service.
NO
→ Go to step 3.

9-105
 P0507

3. Throttle valve does not fully close due to malfunction in throttle cables.
• Check the throttle grip free play.
Refer to “CHECKING THE THROTTLE GRIP OPERATION” on page 3-25.

Is check result OK?

YES
→ Go to step 4.
NO
a. Replace the throttle bodies.
b. Start the engine and let it idle for approximately 10 seconds.
c. Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 9, and complete the service.
NO
→ Go to step 4.
4. Air sucking from the throttle body.
• Check the throttle body.
Refer to “THROTTLE BODY” on page 7-11.

Is check result OK?

YES
→ Go to step 5.
NO
a. Reinstall the throttle body.
b. Start the engine and let it idle for approximately 10 seconds.
c. Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 9, and complete the service.
NO
→ Go to step 5.
5. Air sucking from the ISC unit.
• Check for looseness or pinching.
• Check the intake air passages for air sucking.

Is check result OK?

YES
→ Go to step 6.
NO
a. Reinstall the ISC unit.
b. Start the engine and let it idle for approximately 10 seconds.
c. Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 9, and complete the service.
NO
→ Go to step 6.

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 P0507

6. The air volume for the throttle body and ISC unit is excessive.
• Clean the throttle body and ISC unit.
Refer to “CLEANING THE ISC (IDLE SPEED CONTROL) UNIT AND THROTTLE BODY” on
page 7-13.

Is check result OK?

YES
→ Go to step 7.
NO
a. Start the engine and let it idle for approximately 10 seconds.
b. Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 9, and complete the service.
NO
→ Go to step 7.
7. The ISC valve is not moving correctly.
• Replace the ISC unit.
• Start the engine and let it idle for approximately 10 seconds.
• Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 9, and complete the service.
NO
→ Go to step 8.
8. Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36.
• Execute the diagnostic mode. (Code 54)
• Return the ISC valve to the initial opening position.
9. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.
10.Connection of ISC unit coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is check result OK?

YES
→ Go to step 11.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code 54)

Is check result OK?

YES
→ Go to step 17.
NO
→ Go to step 11, and complete the service.

9-107
 P0507

11.Connection of SGCU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 12.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code 54)

Is ISC operating sound heard ?

YES
→ Go to step 17, and complete the service.
NO
→ Go to step 12.
12.Wire harness continuity.
• Disconnect the ISC unit coupler and SGCU coupler.
• Open circuit check
pink–pink
Between ISC unit coupler “1” and SGCU cou- green/yellow–green/yellow
pler “2” gray–gray
sky blue–sky blue

2
1 Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
P G/Y Sb Gy L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code 54)

Is hear operating sound?

YES
→ Go to step 17, and complete the service.
NO
→ Go to step “Short circuit check”.

9-108
 P0507

• Short circuit check

TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3.
Ground short circuit check “A”
pink–ground
green/yellow–ground
Between ISC unit coupler “1” and ground
gray–ground
sky blue–ground

Lines short circuit check “B”

pink–any other coupler terminal
green/yellow–any other coupler terminal
ISC unit coupler “1”
gray–any other coupler terminal
sky blue–any other coupler terminal
pink–any other coupler terminal
green/yellow–any other coupler terminal
SGCU coupler “2”
gray–any other coupler terminal
sky blue–any other coupler terminal

A B

1 1 2

P G/Y Sb Gy P G/Y Sb Gy
Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance ∞ Ω?
YES
→ Go to step 13.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code 54)

Is hear operating sound?

YES
→ Go to step 17.
NO
→ Go to step 13.

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 P0507

13.Installed condition of ISC unit.

• Check for looseness or pinching.

Is check result OK?

YES
→ Go to step 14.
NO
a. Reinstall the ISC unit.
b. Execute the diagnostic mode. (Code 54)

Is ISC operating sound heard?

YES
→ Go to step 17, and complete the service.
NO
→ Go to step 14.
14.Battery malfunction.
• Check the battery voltage.
Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-37.

Is check result OK?

YES
→ Go to step 15.
NO
→ Execute the diagnostic mode. (Code 54)

Is ISC operating sound heard?

YES
→ Go to step 17, and complete the service.
NO
→ Go to step 15.
15.ISC valve is not moving correctly.
• Replace the ISC unit.
Refer to “CLEANING THE ISC (IDLE SPEED CONTROL) UNIT AND THROTTLE BODY” on
page 7-13.

Is check result OK?

YES
→ Go to step 16.
NO
→ Execute the diagnostic mode. (Code 54)

Is ISC operating sound heard?

YES
→ Go to step 17, and complete the service.
NO
→ Go to step 16.

9-110
 P0507

16.Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36.
• Execute the diagnostic mode. (Code 54)
• Return the ISC valve to the standby opening position.
17.Delete the DTC and check that the MIL goes off.
• Start the engine and let it idle for approximately 10 seconds.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-111
 P0511

EAS20590

P0511
EAS33070

TROUBLESHOOTING
Item
ISC unit: ISC valve malfunction is detected. (Open or short circuit is detected between ISC valve and
SGCU.)
Fail-safe system
• Able to start engine
• Able to drive vehicle

Procedure
1. Connection of ISC unit coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 2.
2. Connection of SGCU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 3.

9-112
 P0511

3. Wire harness continuity.

• Disconnect the ISC unit coupler and SGCU coupler.
• Open circuit check
pink–pink
Between ISC unit coupler “1” and SGCU cou- green/yellow–green/yellow
pler “2” gray–gray
sky blue–sky blue

2
1 Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
P G/Y Sb Gy L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to “Short circuit check”.

9-113
 P0511

• Short circuit check

TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3.
Ground short circuit check “A”
pink–ground
green/yellow–ground
Between ISC unit coupler “1” and ground
gray–ground
sky blue–ground

Lines short circuit check “B”

pink–any other coupler terminal
green/yellow–any other coupler terminal
ISC unit coupler “1”
gray–any other coupler terminal
sky blue–any other coupler terminal
pink–any other coupler terminal
green/yellow–any other coupler terminal
SGCU coupler “2”
gray–any other coupler terminal
sky blue–any other coupler terminal

A B

1 1 2

P G/Y Sb Gy
P G/Y Sb Gy
Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance ∞ Ω?
YES
→ Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 4.

9-114
 P0511

4. Faulty the ISC unit operation

• Execute the diagnostic mode. (Code 54)
• Check the operating sound of the ISC valve.

Is ISC operating sound heard?

YES
→ Go to step 5.
NO
a. Replace the ISC unit.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 5.
5. Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36.
6. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-115
 P0560, P0563

EAS20434

P0560, P0563
EAS33138

TROUBLESHOOTING
Item
• [P0560] Battery charging voltage is abnormal. (Discharged condition)
• [P0563] Battery charging voltage is abnormal. (Overcharged condition)
Fail-safe system
• Able to start engine
• Able to drive vehicle

Procedure
1. Malfunction in charging system.
• Check the charging system.
Refer to “CHARGING SYSTEM” on page 8-17.

Is check result OK?

YES
→ Repeat step 1.
NO
a. Defective connection in the charging system circuit → Properly connect or replace the wire har-
ness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 2, and complete the service.
NO
→ Repeat step 1.
2. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-116
 P0601

EAS20676

P0601
EAS33305

TROUBLESHOOTING
Item
Internal malfunction in SGCU. (When this malfunction is detected in the SGCU, the DTC might not ap-
pear on the tool display.)
Fail-safe system
• Unable to start engine
• Unable to drive vehicle

Procedure
1. Malfunction in SGCU.
• Replace the SGCU.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36.
• Turn the main switch to “ON”.
• Check that the MIL does not come on.

9-117
 P062F

EAS20598

P062F
EAS33078

TROUBLESHOOTING
Item
EEPROM DTC: an error is detected while reading or writing on EEPROM.
Fail-safe system
• Able/Unable to start engine
• Able/Unable to drive vehicle

Procedure
1. Locate the malfunction.
• Execute the diagnostic mode (Code 60)
00
Go to step 5.
01
Go to step 2.
11
Go to step 3.
12
Go to step 3.
14
Go to step 4.
2. “01” is indicated in diagnostic mode (Code 60). EEPROM data error for adjustment of CO adjust-
ment value.
• Activate the CO volume adjustment mode using the YDT.
• Click the “Step up” or “Step down” button 1 time. (Clicking the “Step up” or “Step down” button during
this procedure does not change the CO volume.)
• After this adjustment is made, turn the main switch to “OFF”.
• Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
a. Repeat step 1.
b. If the same number is indicated, go to step 5.
3. “11” is indicated in diagnostic mode (Code 60). EEPROM data error for ISC learning value and/or
“12” is indicated in the diagnostic mode (Code 60). EEPROM data error for A/F learning values.
• After this adjustment is made, turn the main switch to “OFF”.
• Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
a. Repeat step 1.
b. If the same number is indicated, go to step 5.

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 P062F

4. “14” is indicated in the diagnostic mode (Code 60). EEPROM data error for outside diameter of tire
learning value.
• Turn the main switch to “OFF”.
• Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
a. Execute the diagnostic mode (Code 87)
b. Repeat step 1.
c. If the same number is indicated, go to step 5.
5. Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36.
6. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-119
 P1602

EAS20615

P1602
EAS33095

TROUBLESHOOTING
Item
Malfunction in SGCU internal circuit (malfunction of SGCU power cut-off function).
Fail-safe system
• Able/Unable to start engine
• Able/Unable to drive vehicle

Procedure
1. Installed condition of battery leads.
• Check the installed condition of the battery and battery leads (loose bolts).

Is check result OK?

YES
→ Go to step 2.
NO
a. Reinstall or replace the battery leads.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 2.
2. Connection of starter charge coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 3.

9-120
 P1602

3. Wire harness continuity.

• Disconnect the main fuse, fuel injection system fuse and SGCU coupler.
• Open circuit check
Between battery “1” and main fuse holder “2” red–red
Between fuel injection system fuse holder “2”
red–red
and SGCU coupler “3”

2 3
1
Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to “Short circuit check”.

9-121
 P1602

• Short circuit check

TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3.
Ground short circuit check “A”
Between SGCU coupler “3” and ground red–ground

Lines short circuit check “B”

SGCU coupler “3” red–any other coupler terminal

A B
3 3

Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance ∞ Ω?
YES
→ Go to step 5.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 5.

9-122
 P1602

4. Wire harness continuity.

• Disconnect the main switch coupler, ignition fuse, starter charge relay coupler and SGCU coupler.
• Open circuit check
Between main switch coupler “1” and ignition
brown–brown
fuse holder “2”
Between ignition fuse holder “2” and starter
brown–brown
charger relay coupler “3”
Between starter charge relay “3” and SGCU red/black–red/black
coupler “4”

4
1 3
Y/R
R/Y R Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
Br R/B Br/R Br Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/RW/B Br/W B P/W Br

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to “Short circuit check”.

9-123
 P1602

• Short circuit check

TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3.
Ground short circuit check “A”
Between starter charge relay coupler “3” and
red/black–ground
ground

Lines short circuit check “B”

Starter charge relay coupler “3” red/black–any other coupler terminal
SGCU coupler “4” red/black–any other coupler terminal

A B 3 4
3
Y/R Y/R
R R
Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
R/B Br/R Br R/B Br/R Br
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/RW/B Br/W B P/W Br

Is resistance ∞ Ω?
YES
→ Go to step 5.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 5.
5. Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36.
6. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-124
 P2158

EAS20633

P2158
EAS33113

TROUBLESHOOTING
Item
Rear wheel sensor: normal signals are not received from the rear wheel sensor.
Fail-safe system
• Able to start engine
• Able to drive vehicle

Procedure
1. Locate the malfunction.
• Check the ABS warning light.

Is the ABS warning light on?

YES
→ Refer to “ABS TROUBLESHOOTING OUTLINE” on page 9-16.
NO
→ Go to step 2.
2. Connection of rear wheel sensor coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Check the rear wheel speed with YDT monitor item.
c. Rotate the rear wheel by hand and check that the indicated value increases.

Is that value increased?

YES
→ Go to step 9, and complete the service.
NO
→ Go to step 3.

9-125
 P2158

3. Connection of ABS 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).

Is the coupler condition normal?

YES
→ Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Check the rear wheel speed with YDT monitor item.
c. Rotate the rear wheel by hand and check that the indicated value increases.

Is that value increased?

YES
→ Go to step 9, and complete the service.
NO
→ Go to step 4.
4. Connection of SGCU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 5.
NO
a. Connect the coupler securely or replace the wire harness.
b. Check the rear wheel speed by YDT monitor item.
c. Rotate the rear wheel by hand and check that the indicated value increases.

Is that value increased?

YES
→ Go to step 9, and complete the service.
NO
→ Go to step 5.

9-126
 P2158

5. Wire harness continuity.

• Disconnect the rear wheel sensor coupler, ABS ECU coupler and SGCU coupler.
• Open circuit check
Between rear wheel sensor coupler “1” and green–green
ABS ECU coupler “2” blue–blue
Between ABS ECU coupler “2” and SGCU cou-
white/black–white/black
pler “3”

1 2 3
Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
R Br Y G L W W/L W/B B/W
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
G L R/L Y L/G L/G Br Lg/L Lg/W B/W B L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Check the rear wheel speed with YDT monitor item.
c. Rotate the rear wheel by hand and check that the indicated value increases.

Is that value increased?

YES
→ Go to step 9, and complete the service.
NO
→ Go to “Short circuit check”.

9-127
 P2158

• Short circuit check

TIP
Disconnect the SGCU and ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3 and “PARTS CONNECTED TO THE
ABS ECU” on page 9-4.
Ground short circuit check “A”
green–ground
Between ABS ECU coupler “2” and ground blue–ground
white/black–ground

Lines short circuit check “B”

green–any other coupler terminal
Rear wheel sensor coupler “1”
blue–any other coupler terminal
green–any other coupler terminal
ABS ECU coupler “2” blue–any other coupler terminal
white/black–any other coupler terminal
ECU coupler “3” white/black–any other coupler terminal

A B
1 3
2
G L
Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
R Br Y G L W W/L W/B B/W Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
R/L B L/B R G/R B/L W/G W L/Y L/R B Gy/RW/B Br/W B P/W Br
Y L/G L/G Br Lg/L Lg/W B/W

R Br Y G L W W/L W/B B/W

R/L Y L/G L/G Br Lg/L Lg/W B/W B

Is resistance ∞ Ω?
YES
→ Go to step 5.
NO
a. Replace the wire harness.
b. Check the rear wheel speed with YDT monitor item.
c. Rotate the rear wheel by hand and check that the indicated value increases.

Is that value increased?

YES
→ Go to step 9, and complete the service.
NO
→ Go to step 6.

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 P2158

6. Defective rear wheel sensor.

• Check the installed condition of rear wheel sensor.

Is check result OK?

YES
→ Go to step 7.
NO
a. Reinstall or replace the rear wheel sensor.
Refer to “REAR WHEEL” on page 4-29.
b. Check the rear wheel speed with YDT monitor item.
c. Rotate the rear wheel by hand and check that the indicated value increases.

Is that value increased?

YES
→ Go to step 9, and complete the service.
NO
→ Go to step 7.
7. Malfunction in SGCU.
• Replace the SGCU.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36.
• Check the rear wheel speed with YDT monitor item.
• Rotate the rear wheel by hand and check that the indicated value increases.

Is that value increased?

YES
→ Go to step 9, and complete the service.
NO
→ Go to step 8.
8. Malfunction in ABS ECU.
• Replace the ABS ECU.
Refer to “REMOVING THE HYDRAULIC UNIT ASSEMBLY” on page 4-60.
• Go to step 9, and complete the service.
9. Delete the DTC and check that the MIL goes off.
• Turn the main switch to “ON”, and then rotate the rear wheel by hand.
• Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT, and
then delete the DTC.
• Delete this DTC even if it has a condition of “Detected”.

9-129
 P2645

EAS20642

P2645
EAS33122

TROUBLESHOOTING
Item
VVA solenoid: Normal signal is not received from the VVA solenoid circuit while driving the VVA sole-
noid.
Fail-safe system
• Able to start engine
• Able to drive vehicle

Procedure
1. Connection of VVA solenoid coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and accelerate to 6000 r/min and then check the DTC using the malfunction
mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 2.
2. Connection of SGCU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and accelerate to 6000 r/min and then check the DTC using the malfunction
mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 3.

9-130
 P2645

3. Wire harness continuity.

• Disconnect the VVA solenoid coupler and SGCU coupler.
• Open circuit check
Between VVA solenoid coupler “1” and SGCU green–green
coupler “2” chocolate–chocolate
Between SGCU coupler “2” and ground black–ground

2
1 Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br
G Ch

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to “Short circuit check”.

9-131
 P2645

• Short circuit check

TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3.
Ground short circuit check “A”
green–ground
Between VVA solenoid coupler “1” and ground
chocolate–ground

Lines short circuit check “B”

green–any other coupler terminal
VVA solenoid coupler “1”
chocolate–any other coupler terminal
green–any other coupler terminal
SGCU coupler “2”
chocolate–any other coupler terminal

A B

1 1 2

G Ch
G Ch
Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance ∞ Ω?
YES
→ Go to step 4.
NO
a. Replace the wire harness.
b. Start the engine and accelerate to 6000 r/min and then check the DTC using the malfunction
mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 4.

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 P2645

4. Faulty the VVA solenoid operation

• Check the VVA solenoid resistance.
Refer to “CHECKING THE VVA SOLENOID” on page 8-42.

Is check result OK?

YES
→ Go to step 5.
NO
a. Replace the VVA solenoid.
b. Start the engine and accelerate to 6000 r/min and then check the DTC using the malfunction
mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 5.
5. Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36.
6. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-133
 Er-1, Er-2, Er-3, Er-4

EAS20776

Er-1, Er-2, Er-3, Er-4

EAS33508

TROUBLESHOOTING
Item
• [Er-1] SGCU internal malfunction (output signal error): signals cannot be transmitted between the
SGCU and the multi-function meter.
• [Er-2] SGCU internal malfunction (output signal error): signals are not received from the SGCU within
the specified duration
• [Er-3] SGCU internal malfunction (output signal error): data from the SGCU cannot be received cor-
rectly.
• [Er-4] SGCU internal malfunction (input signal error): registered data is not received from the meter.
• Able to start engine
• Able to drive vehicle

Procedure
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).

Is the coupler condition normal?

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 2
2. Connection of SGCU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 3

9-134
 Er-1, Er-2, Er-3, Er-4

3. Meter assembly wire harness continuity.

• Disconnect the meter assembly coupler and SGCU coupler.
• Open circuit check
Between meter assembly coupler “1” and
blue/red–blue/red
SGCU coupler “2”

1 2

Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O

R/W L/W Br/W Y/W Dg Ch Br R Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/R G/B W/L Br/R W/R G B R L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to “Short circuit check”

9-135
 Er-1, Er-2, Er-3, Er-4

• Short circuit check

TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3.
Ground short circuit check “A”
Between meter assembly coupler “1” and
blue/red –ground
ground

Lines short circuit check “B”

Meter assembly coupler “1” blue/red –any other coupler terminal
SGCU coupler “2” blue/red–any other coupler terminal

A B

1 1 2
R/W L/W Br/W Y/W Dg Ch Br R R/W L/W Br/W Y/W Dg Ch Br R Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
L/R G/B W/L Br/R W/R G B R L/R G/B W/L Br/R W/R G B R Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance ∞ Ω?
YES
→ Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 4.
4. Defective meter assembly
• Check that the installed condition of meter assembly.
• Check for looseness or pinching.

Is check result OK?

YES
→ Go to step 6, and complete the service.
NO
a. Replace the meter assembly.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.
Is it in the “Recovered” condition?
YES
→ Go to step 6, and complete the service.
NO
→ Go to step 5.

9-136
 Er-1, Er-2, Er-3, Er-4

5. Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36.
6. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-137
 11, 25_ABS

EAS20685

11, 25_ABS
EAS33314

TROUBLESHOOTING
Item
Front wheel sensor (intermittent pulses or no pulses)

Procedure
TIP
With the front wheel stopped, the rear wheel was rotated for longer than about 20 seconds (DTC No.
11) or for longer than about 2 seconds (DTC No. 25).
1. Foreign material adhered around the front wheel sensor
• Check the surface of the sensor rotor and wheel sensor for foreign material, such as metal particles.

Is check result OK?

YES
→ Go to step 2.
NO
→ Clean the sensor rotor and wheel sensor.
2. Incorrect installation of the front wheel
• Check the components for looseness, distortion, and bends.
Refer to “CHECKING THE FRONT WHEEL” on page 4-25.

Is check result OK?

YES
→ Go to step 3.
NO
→ Replace the wheel axle, tire, front wheel, wheel bearings or oil seals.
3. Defective sensor rotor or incorrect installation of the rotor
• Check the surface of the sensor rotor for damage.
Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page 4-
25.

Is check result OK?

YES
→ Go to step 4.
NO
→ Replace the sensor rotor.
4. Defective front wheel sensor or incorrect installation of the sensor
• Check the wheel sensor for damage and the installed condition of the sensor.
Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page 4-
25.

Is check result OK?

YES
→ Replace the hydraulic unit assembly (ABS ECU).
NO
→ Repair or replace the wheel sensor.

9-138
 12_ABS

EAS20686

12_ABS
EAS33315

TROUBLESHOOTING
Item
Rear wheel sensor (intermittent pulses or no pulses)

Procedure
1. Foreign material adhered around the rear wheel sensor
• Check the surface of the sensor rotor and wheel sensor for foreign material, such as metal particles.

Is check result OK?

YES
→ Go to step 2.
NO
→ Clean the sensor rotor and wheel sensor.
2. Incorrect installation of the rear wheel
• Check the components for looseness, distortion, and bends.
Refer to “CHECKING THE REAR WHEEL” on page 4-30.

Is check result OK?

YES
→ Go to step 3.
NO
→ Replace the wheel axle, tire, rear wheel, wheel bearings or oil seals.
3. Defective sensor rotor or incorrect installation of the rotor
• Check the surface of the sensor rotor for damage.
Refer to “MAINTENANCE OF THE REAR WHEEL SENSOR ROTOR” on page 4-30.

Is check result OK?

YES
→ Go to step 4.
NO
→ Replace the sensor rotor.
4. Defective rear wheel sensor or incorrect installation of the sensor
• Check the wheel sensor for damage and the installed condition of the sensor.
Refer to “MAINTENANCE OF THE REAR WHEEL SENSOR ROTOR” on page 4-30.

Is check result OK?

YES
→ Replace the hydraulic unit assembly (ABS ECU).
NO
→ Repair or replace the wheel sensor.

9-139
 13, 26_ABS

EAS20687

13, 26_ABS
EAS33316

TROUBLESHOOTING
Item
Front wheel sensor (abnormal pulse period)

Procedure
TIP
• If the front brake ABS operates continuously for 20 seconds or more, DTC No. 26 will be recorded. If
the front brake ABS operates continuously for 36 seconds or more, DTC No. 13 will be recorded.
• Vehicle possibly ridden on uneven roads.
1. Foreign material adhered around the front wheel sensor
• Check the surface of the sensor rotor and wheel sensor for foreign material, such as metal particles.

Is check result OK?

YES
→ Go to step 2.
NO
→ Clean the sensor rotor and wheel sensor.
2. Incorrect installation of the front wheel
• Check the components for looseness, distortion, and bends.
Refer to “CHECKING THE FRONT WHEEL” on page 4-25.

Is check result OK?

YES
→ Go to step 3.
NO
→ Replace the wheel axle, tire, front wheel, wheel bearings or oil seals.
3. Defective sensor rotor or incorrect installation of the rotor
• Check the surface of the sensor rotor for damage.
Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page 4-
25.

Is check result OK?

YES
→ Go to step 4.
NO
→ Replace the sensor rotor.
4. Defective front wheel sensor or incorrect installation of the sensor
• Check the wheel sensor for damage and the installed condition of the sensor.
Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page 4-
25.

Is check result OK?

YES
→ Replace the hydraulic unit assembly (ABS ECU).
NO
→ Repair or replace the wheel sensor.

9-140
 14, 27_ABS

EAS20688

14, 27_ABS
EAS33317

TROUBLESHOOTING
Item
Rear wheel sensor (abnormal pulse period)

Procedure
TIP
• If the rear brake ABS operates continuously for 20 seconds or more, DTC No. 27 will be recorded. If
the rear brake ABS operates continuously for 36 seconds or more, DTC No. 14 will be recorded.
• Vehicle possibly ridden on uneven roads.
1. Foreign material adhered around the rear wheel sensor
• Check the surface of the sensor rotor and wheel sensor for foreign material, such as metal particles.

Is check result OK?

YES
→ Go to step 2.
NO
→ Clean the sensor rotor and rear sensor.
2. Incorrect installation of the rear wheel
• Check the components for looseness, distortion, and bends.
Refer to “CHECKING THE REAR WHEEL” on page 4-30.

Is check result OK?

YES
→ Go to step 3.
NO
→ Replace the wheel axle, tire, rear wheel, wheel bearings or oil seals.
3. Defective sensor rotor or incorrect installation of the rotor
• Check the surface of the sensor rotor for damage.
Refer to “MAINTENANCE OF THE REAR WHEEL SENSOR ROTOR” on page 4-30.

Is check result OK?

YES
→ Go to step 4.
NO
→ Replace the sensor rotor.
4. Defective rear wheel sensor or incorrect installation of the sensor
• Check the wheel sensor for damage and the installed condition of the sensor.
Refer to “MAINTENANCE OF THE REAR WHEEL SENSOR ROTOR” on page 4-30.

Is check result OK?

YES
→ Replace the hydraulic unit assembly (ABS ECU).
NO
→ Repair or replace the wheel sensor.

9-141
 15_ABS

EAS20662

15_ABS
EAS33040

TROUBLESHOOTING
Item
Front wheel sensor (open or short circuit)

Procedure
1. Defective coupler between the front wheel sensor and the hydraulic unit assembly
• Check the coupler for any pins that may be pulled out.
• Check the locking condition of the coupler.
TIP
Turn the main switch to OFF before disconnecting or connecting a coupler.

Is check result OK?

YES
→ Go to step 2.
NO
→ If there is a malfunction, repair it and connect the coupler securely.
2. Wire harness continuity
• Disconnect the ABS ECU coupler and front wheel sensor coupler.
• Open circuit check
Between ABS ECU coupler “1” and front wheel brown–brown
sensor coupler “2” yellow–yellow

1
R Br Y G L W W/L W/B B/W
2
R/L Y L/G L/G Br Lg/L Lg/W B/W B Br Y

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
→ Replace the wire harness.

9-142
 15_ABS

• Short circuit check

TIP
Disconnect the ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4.
Ground short circuit check “A”
brown–ground
Between ABS ECU coupler “1” and ground
yellow–ground

Lines short circuit check “B”

brown–any other coupler terminal
ABS ECU coupler “1”
yellow–any other coupler terminal
brown–any other coupler terminal
Front wheel sensor “2”
yellow–any other coupler terminal

A B

1 1 2
R Br Y G L W W/L W/B B/W

R/L Y L/G L/G Br Lg/L Lg/W B/W B

Br Y
R Br Y G L W W/L W/B B/W

R/L Y L/G L/G Br Lg/L Lg/W B/W B

Is resistance ∞ Ω?
YES
→ Go to step 3.
NO
→ Replace the wire harness.
3. Defective front wheel sensor or hydraulic unit assembly
• If the above items were performed and no malfunctions were found, the wheel sensor or hydraulic
unit assembly is defective.
• Replace the wheel sensor or hydraulic unit assembly.
Refer to “FRONT WHEEL” on page 4-22 and “ABS (Anti-lock Brake System)” on page 4-58.

9-143
 16_ABS

EAS20663

16_ABS
EAS33285

TROUBLESHOOTING
Item
Rear wheel sensor (open or short circuit)

Procedure
1. Defective coupler between the rear wheel sensor and the hydraulic unit assembly
• Check the coupler for any pins that may be pulled out.
• Check the locking condition of the coupler.
TIP
Turn the main switch to OFF before disconnecting or connecting a coupler.

Is check result OK?

YES
→ Go to step 2.
NO
→ If there is a malfunction, repair it and connect the coupler securely.
2. Wire harness continuity
• Disconnect the ABS ECU coupler and rear wheel sensor coupler.
• Open circuit check
Between ABS ECU coupler “1” and rear wheel green–green
sensor coupler “2” blue–blue

1
R Br Y G L W W/L W/B B/W
2
R/L Y L/G L/G Br Lg/L Lg/W B/W B G L

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
→ Replace the wire harness.

9-144
 16_ABS

• Short circuit check

TIP
Disconnect the ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4.
Ground short circuit check “A”
green–ground
Between ABS ECU coupler “1” and ground
blue–ground

Lines short circuit check “B”

green–any other coupler terminal
ABS ECU coupler “1”
blue–any other coupler terminal
green–any other coupler terminal
Rear wheel sensor “2”
blue–any other coupler terminal

A B

1 1 2
R Br Y G L W W/L W/B B/W

R/L Y L/G L/G Br Lg/L Lg/W B/W B

G L
R Br Y G L W W/L W/B B/W

R/L Y L/G L/G Br Lg/L Lg/W B/W B

Is resistance ∞ Ω?
YES
→ Go to step 3.
NO
→ Replace the wire harness.
3. Defective rear wheel sensor or hydraulic unit assembly
• If the above items were performed and no malfunctions were found, the wheel sensor or hydraulic
unit assembly is defective.
• Replace the wheel sensor or hydraulic unit assembly.
Refer to “REAR WHEEL” on page 4-29 and “ABS (Anti-lock Brake System)” on page 4-58.

9-145
 17, 45_ABS

EAS20708

17, 45_ABS
EAS33372

TROUBLESHOOTING
Item
Front wheel sensor (missing pulses)

Procedure
TIP
If pulse gaps are detected when the vehicle is traveling at a speed of 30 km/h (19 mi/h) or more, DTC
No. 17 will be recorded. If the vehicle is traveling at a speed of 29 km/h (18 mi/h) or less, DTC No. 45
will be recorded first and DTC No. 17 will be recorded if the condition continues.
1. Foreign material adhered around the front wheel sensor
• Check the surface of the sensor rotor and wheel sensor for foreign material, such as metal particles.

Is check result OK?

YES
→ Go to step 2.
NO
→ Clean the sensor rotor and wheel sensor.
2. Incorrect installation of the front wheel
• Check the components for looseness, distortion, and bends.
Refer to “CHECKING THE FRONT WHEEL” on page 4-25.

Is check result OK?

YES
→ Go to step 3.
NO
→ Replace the wheel axle, tire, front wheel, wheel bearings or oil seals.
3. Defective sensor rotor or incorrect installation of the rotor
• Check the surface of the sensor rotor for damage.
Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page 4-
25.

Is check result OK?

YES
→ Go to step 4.
NO
→ Replace the sensor rotor.
4. Defective front wheel sensor or incorrect installation of the sensor
• Check the wheel sensor for damage and the installed condition of the sensor.
Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page 4-
25.

Is check result OK?

YES
→ Replace the hydraulic unit assembly (ABS ECU).
NO
→ Repair or replace the wheel sensor.

9-146
 18, 46_ABS

EAS20709

18, 46_ABS
EAS33373

TROUBLESHOOTING
Item
Rear wheel sensor (missing pulses)

Procedure
TIP
If pulse gaps are detected when the vehicle is traveling at a speed of 30 km/h (19 mi/h) or more, DTC
No. 18 will be recorded. If the vehicle is traveling at a speed of 29 km/h (18 mi/h) or less, DTC No. 46
will be recorded first and DTC No. 18 will be recorded if the condition continues.
1. Foreign material adhered around the rear wheel sensor
• Check the surface of the sensor rotor and wheel sensor for foreign material, such as metal particles.

Is check result OK?

YES
→ Go to step 2.
NO
→ Clean the sensor rotor and wheel sensor.
2. Incorrect installation of the rear wheel
• Check the components for looseness, distortion, and bends.
Refer to “CHECKING THE REAR WHEEL” on page 4-30.

Is check result OK?

YES
→ Go to step 3.
NO
→ Replace the wheel axle, tire, rear wheel, wheel bearings or oil seals.
3. Defective sensor rotor or incorrect installation of the rotor
• Check the surface of the sensor rotor for damage.
Refer to “MAINTENANCE OF THE REAR WHEEL SENSOR ROTOR” on page 4-30.

Is check result OK?

YES
→ Go to step 4.
NO
→ Replace the sensor rotor.
4. Defective rear wheel sensor or incorrect installation of the sensor
• Check the wheel sensor for damage and the installed condition of the sensor.
Refer to “MAINTENANCE OF THE REAR WHEEL SENSOR ROTOR” on page 4-30.

Is check result OK?

YES
→ Replace the hydraulic unit assembly (ABS ECU).
NO
→ Repair or replace the wheel sensor.

9-147
 21_ABS

EAS20690

21_ABS
EAS33320

TROUBLESHOOTING
Item
Hydraulic unit assembly (defective solenoid drive circuit)

Procedure
1. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to “ABS (Anti-lock Brake System)” on page 4-58.

9-148
 31_ABS

EAS20691

31_ABS
EAS33321

TROUBLESHOOTING
Hydraulic unit assembly (defective ABS solenoid power supply)

Procedure
1. Blown ABS solenoid fuse
• Check the ABS solenoid fuse.
Refer to “CHECKING THE FUSES” on page 8-36.

Is check result OK?

YES
→ Go to step 2.
NO
→ Replace the fuse and check the wire harness.
2. Defective coupler between the battery and the hydraulic unit assembly
• Check the coupler for any pins that may be pulled out.
• Check the locking condition of the coupler.
TIP
Turn the main switch to OFF before disconnecting or connecting a coupler.

Is check result OK?

YES
→ Go to step 3.
NO
→ If there is a malfunction, repair it and connect the coupler securely.
3. Wire harness continuity
• Disconnect the ABS solenoid fuse and ABS ECU coupler.
• Open circuit check
Between ABS solenoid fuse holder “1” and ABS
red–red
ECU coupler “2”

2
1
R Br Y G L W W/L W/B B/W

R/L Y L/G L/G Br Lg/L Lg/W B/W B

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
→ Replace the wire harness.

9-149
 31_ABS

• Short circuit check

TIP
Disconnect the ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4.
Ground short circuit check “A”
Between ABS ECU coupler “2” and ground red–ground

Lines short circuit check “B”

ABS ECU coupler “2” red–any other coupler terminal

A B

2 2
R Br Y G L W W/L W/B B/W Br Y G L W W/L W/B B/W
R
R/L Y L/G L/G Br Lg/L Lg/W B/W B R/L B
Y L/G L/G Br Lg/L Lg/W B/W

Is resistance ∞ Ω?
YES
→ Go to step 4.
NO
→ Replace the wire harness.
4. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to “ABS (Anti-lock Brake System)” on page 4-58.

9-150
 32_ABS

EAS20712

32_ABS
EAS33376

TROUBLESHOOTING
Item
Hydraulic unit assembly (short circuit in ABS solenoid power supply circuit)

Procedure
1. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to “ABS (Anti-lock Brake System)” on page 4-58.

9-151
 33_ABS

EAS20692

33_ABS
EAS33322

TROUBLESHOOTING
Item
Hydraulic unit assembly (abnormal ABS motor power supply)

Procedure
1. Blown ABS motor fuse
• Check the ABS motor fuse.
Refer to “CHECKING THE FUSES” on page 8-36.

Is check result OK?

YES
→ Go to step 2.
NO
→ Replace the fuse and check the wire harness.
2. Defective coupler between the battery and the hydraulic unit assembly
• Check the coupler for any pins that may be pulled out.
• Check the locking condition of the coupler.
TIP
Turn the main switch to OFF before disconnecting or connecting a coupler.

Is check result OK?

YES
→ Go to step 3.
NO
→ If there is a malfunction, repair it and connect the coupler securely.
3. Wire harness continuity
• Disconnect the ABS motor fuse and ABS ECU coupler.
• Open circuit check
Between ABS motor fuse holder “1” and ABS
red/blue–red/blue
ECU coupler “2”

2
1
R Br Y G L W W/L W/B B/W

R/L Y L/G L/G Br Lg/L Lg/W B/W B

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
→ Replace the wire harness.

9-152
 33_ABS

• Short circuit check

TIP
Disconnect the ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4.
Ground short circuit check “A”
Between ABS ECU coupler “2” and ground red/blue–ground

Lines short circuit check “B”

ABS ECU coupler “2” red/blue–any other coupler terminal

A B

2 2
R Br Y G L W W/L W/B B/W
R Br Y G L W W/L W/B B/W
R/L Y L/G L/G Br Lg/L Lg/W B/W B
R/L Y L/G L/G Br Lg/L Lg/W B/W B

Is resistance ∞ Ω?
YES
→ Go to step 4.
NO
→ Replace the wire harness.
4. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to “ABS (Anti-lock Brake System)” on page 4-58.

9-153
 34_ABS

EAS20693

34_ABS
EAS33323

TROUBLESHOOTING
Item
Hydraulic unit assembly (short circuit in ABS motor power supply circuit)

Procedure
1. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to “ABS (Anti-lock Brake System)” on page 4-58.

9-154
 41_ABS

EAS20694

41_ABS
EAS33331

TROUBLESHOOTING
Item
Front wheel ABS (intermittent wheel speed pulses or incorrect depressurization)

Procedure
1. Incorrect installation of the front wheel sensor
• Check the components for looseness, distortion, and bends.
Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page 4-
25.

Is check result OK?

YES
→ Go to step 2.
NO
→ Repair or replace the defective part.
2. Incorrect rotation of the front wheel
• Check that there is no brake disc drag on the wheel and make sure that it rotates smoothly.
Refer to “CHECKING THE FRONT WHEEL” on page 4-25 and “CHECKING THE FRONT BRAKE
DISC” on page 4-38.

Is check result OK?

YES
→ Go to step 3.
NO
→ Repair or replace the defective part.
3. Front brake dragging
• Check that the brake fluid pressure is correctly transmitted to the brake caliper when the brake lever
is operated and that the pressure decreases when the lever is released.
Refer to “CHECKING THE FRONT BRAKE DISC” on page 4-38.

Is check result OK?

YES
→ Go to step 4.
NO
→ Repair or replace the defective part.
4. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to “ABS (Anti-lock Brake System)” on page 4-58.

9-155
 42, 47_ABS

EAS20695

42, 47_ABS
EAS33324

TROUBLESHOOTING
Item
Rear wheel ABS (intermittent wheel speed pulses or incorrect depressurization)

Procedure
1. Incorrect installation of the rear wheel sensor (DTC No. 42)
• Check the components for looseness, distortion, and bends.
Refer to “MAINTENANCE OF THE REAR WHEEL SENSOR ROTOR” on page 4-30.

Is check result OK?

YES
→ Go to step 2.
NO
→ Repair or replace the defective part.
2. Incorrect rotation of the rear wheel
• Check that there is no brake disc drag on the rear wheel and make sure that it rotates smoothly.
Refer to “CHECKING THE REAR WHEEL” on page 4-30 and “CHECKING THE REAR BRAKE
DISC” on page 4-51.

Is check result OK?

YES
→ Go to step 3.
NO
→ Repair or replace the defective part.
3. Rear brake dragging
• Check that the brake fluid pressure is correctly transmitted to the brake caliper when the rear brake
lever is operated and that the pressure decreases when the lever is released.
Refer to “CHECKING THE REAR BRAKE DISC” on page 4-51.

Is check result OK?

YES
→ Go to step 4.
NO
→ Repair or replace the defective part.
4. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to “ABS (Anti-lock Brake System)” on page 4-58.

9-156
 43_ABS

EAS20696

43_ABS
EAS33330

TROUBLESHOOTING
Item
Front wheel sensor (missing pulses)

Procedure
1. Foreign material adhered around the front wheel sensor
• Check the surface of the sensor rotor and wheel sensor for foreign material, such as metal particles.

Is check result OK?

YES
→ Go to step 2.
NO
→ Clean the sensor rotor and wheel sensor.
2. Incorrect installation of the front wheel
• Check the components for looseness, distortion, and bends.
Refer to “CHECKING THE FRONT WHEEL” on page 4-25.

Is check result OK?

YES
→ Go to step 3.
NO
→ Replace the wheel axle, tire, front wheel, wheel bearings or oil seals.
3. Defective sensor rotor or incorrect installation of the rotor
• Check the surface of the sensor rotor for damage.
Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page 4-
25.

Is check result OK?

YES
→ Go to step 4.
NO
→ Replace the sensor rotor.
4. Defective front wheel sensor or incorrect installation of the sensor
• Check the wheel sensor for damage and the installed condition of the sensor.
Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page 4-
25.

Is check result OK?

YES
→ Replace the hydraulic unit assembly (ABS ECU).
NO
→ Repair or replace the wheel sensor.

9-157
 44_ABS

EAS20697

44_ABS
EAS33325

TROUBLESHOOTING
Item
Rear wheel sensor (missing pulses)

Procedure
1. Foreign material adhered around the rear wheel sensor
• Check the surface of the sensor rotor and wheel sensor for foreign material, such as metal particles.

Is check result OK?

YES
→ Go to step 2.
NO
→ Clean the sensor rotor and wheel sensor.
2. Incorrect installation of the rear wheel
• Check the components for looseness, distortion, and bends.
Refer to “CHECKING THE REAR WHEEL” on page 4-30.

Is check result OK?

YES
→ Go to step 3.
NO
→ Replace the wheel axle, tire, rear wheel, wheel bearings or oil seals.
3. Defective sensor rotor or incorrect installation of the rotor
• Check the surface of the sensor rotor for damage.
Refer to “MAINTENANCE OF THE REAR WHEEL SENSOR ROTOR” on page 4-30.

Is check result OK?

YES
→ Go to step 4.
NO
→ Replace the sensor rotor.
4. Defective rear wheel sensor or incorrect installation of the sensor
• Check the wheel sensor for damage and the installed condition of the sensor.
Refer to “MAINTENANCE OF THE REAR WHEEL SENSOR ROTOR” on page 4-30.

Is check result OK?

YES
→ Replace the hydraulic unit assembly (ABS ECU).
NO
→ Repair or replace the wheel sensor.

9-158
 51, 52_ABS

EAS20698

51, 52_ABS
EAS33326

TROUBLESHOOTING
Item
• Vehicle system power supply (voltage of ABS ECU power supply is high) (DTC No. 51)
• Vehicle system power supply (voltage of wheel sensor power supply is high) (DTC No. 52)

Procedure
1. Defective battery
• Recharge or replace the battery, and check again.
Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-37.
2. Disconnected battery terminal
• Check the connection.

Is check result OK?

YES
→ Go to step 3.
NO
→ Replace or reconnect the terminal.
3. Defective charging system
• Check the charging system.
Refer to “CHARGING SYSTEM” on page 8-17.

Is check result OK?

YES
→ Replace the hydraulic unit assembly (ABS ECU).
NO
→ Confirm the cause of the problem and repair it, and check again.

9-159
 53_ABS

EAS20699

53_ABS
EAS33327

TROUBLESHOOTING
Item
Vehicle system power supply (voltage of ABS ECU power supply is low)

Procedure
1. Defective battery
• Recharge or replace the battery, and check again.
Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-37.
2. Defective coupler between the battery and the hydraulic unit assembly
• Check the coupler for any pins that may be pulled out.
• Check the locking condition of the coupler.
TIP
Turn the main switch to OFF before disconnecting or connecting a coupler.

Is check result OK?

YES
→ Go to step 3.
NO
→ If there is a malfunction, repair it and connect the coupler securely.
3. Wire harness continuity
• Disconnect the ABS ECU fuse and ABS ECU coupler.
• Open circuit check
Between ABS ECU fuse holder “1” and ABS
brown
ECU coupler “2”

1 2
R Br Y G L W W/L W/B B/W

R/L Y L/G L/G Br Lg/L Lg/W B/W B

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
→ Replace the wire harness.

9-160
 53_ABS

• Short circuit check

TIP
Disconnect the ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4.
Ground short circuit check “A”
Between ABS ECU coupler “2” and ground brown–ground

Lines short circuit check “B”

ABS ECU coupler “2” brown–any other coupler terminal

A B

2
2

R Br Y G L W W/L W/B B/W R Br Y G L W W/L W/B B/W

R/L Y L/G L/G Br Lg/L Lg/W B/W B R/L B
Y L/G L/G Br Lg/L Lg/W B/W

Is resistance ∞ Ω?
YES
→ Go to step 4.
NO
→ Replace the wire harness.
4. Defective charging system
• Check the charging system.
Refer to “CHARGING SYSTEM” on page 8-17.

Is check result OK?

YES
→ Replace the hydraulic unit assembly (ABS ECU).
NO
→ Confirm the cause of the problem and repair it, and check again.

9-161
 54_ABS

EAS20711

54_ABS
EAS33375

TROUBLESHOOTING
Item
Hydraulic unit assembly (defective ABS solenoid and ABS motor power supply circuits)

Procedure
1. Defective battery
• Recharge or replace the battery, and check again.
Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-37.
2. Defective coupler between the battery and the hydraulic unit assembly
• Check the coupler for any pins that may be pulled out.
• Check the locking condition of the coupler.
TIP
Turn the main switch to OFF before disconnecting or connecting a coupler.

Is check result OK?

YES
→ Go to step 3.
NO
→ If there is a malfunction, repair it and connect the coupler securely.
3. Wire harness continuity
• Disconnect the ABS ECU fuse, ABS motor fuse and ABS ECU coupler.
• Open circuit check
Between ABS ECU fuse holder “1” and ABS
brown
ECU coupler “3”
Between ABS motor fuse holder “2” and ABS
red/blue–red/blue
ECU coupler “3”

3
R Br Y G L W W/L W/B B/W

R/L Y L/G L/G Br Lg/L Lg/W B/W B

2

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
→ Replace the wire harness.

9-162
 54_ABS

• Short circuit check

TIP
Disconnect the ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4.
Ground short circuit check “A”
brown–ground
Between ABS ECU coupler “3” and ground
red/blue–ground

Lines short circuit check “B”

brown–any other coupler terminal
ABS ECU coupler “3”
red/blue–any other coupler terminal

A B

3 3

R Br Y G L W W/L W/B B/W R Br Y G L W W/L W/B B/W

R/L Y L/G L/G Br Lg/L Lg/W B/W B R/L Y L/G L/G Br Lg/L Lg/W B/W B

Is resistance ∞ Ω?
YES
→ Go to step 4.
NO
→ Replace the wire harness.
4. Defective charging system
• Check the charging system.
Refer to “CHARGING SYSTEM” on page 8-17.

Is check result OK?

YES
→ Go to step 5.
NO
→ Confirm the cause of the problem and repair it, and check again.
5. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to “ABS (Anti-lock Brake System)” on page 4-58.

9-163
 55_ABS

EAS20700

55_ABS
EAS33328

TROUBLESHOOTING
Item
Hydraulic unit assembly (defective ABS ECU)

Procedure
1. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to “ABS (Anti-lock Brake System)” on page 4-58.

9-164
 56_ABS

EAS20701

56_ABS
EAS33329

TROUBLESHOOTING
Item
Hydraulic unit assembly (abnormal internal power supply)

Procedure
1. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to “ABS (Anti-lock Brake System)” on page 4-58.

9-165
 63_ABS

EAS20703

63_ABS
EAS33334

TROUBLESHOOTING
Item
Front wheel sensor power supply (voltage of power supply is low)

Procedure
1. Wire harness continuity.
TIP
Disconnect the ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4.
Ground short circuit check “A”
Between front wheel sensor coupler “1” and brown–ground
ground yellow–ground

Lines short circuit check “B”

brown–any other coupler terminal
Front wheel sensor coupler “1”
yellow–any other coupler terminal
brown–any other coupler terminal
ABS ECU coupler “2”
yellow–any other coupler terminal

A B

1 1 2
Br Y Br Y
R Br Y G L W W/L W/B B/W

R/L Y L/G L/G Br Lg/L Lg/W B/W B

Is resistance ∞ Ω?
YES
→ Go to step 2.
NO
→ Replace the wire harness.

9-166
 63_ABS

2. Defective front wheel sensor

Ground short circuit check “A”
white–ground
Between front wheel sensor “1” and ground
black–ground

Lines short circuit check “B”

white–any other coupler terminal
Front wheel sensor “1”
black–any other coupler terminal

A B

1 1
W B W B

Is resistance ∞ Ω?
YES
→ Go to step 3.
NO
→ Replace the wire harness.
3. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to “ABS (Anti-lock Brake System)” on page 4-58.

9-167
 64_ABS

EAS20704

64_ABS
EAS33335

TROUBLESHOOTING
Item
Rear wheel sensor power supply (voltage of power supply is low)

Procedure
1. Wire harness continuity.
TIP
Disconnect the ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4.
Ground short circuit check “A”
Between rear wheel sensor coupler “1” and green–ground
ground blue–ground

Lines short circuit check “B”

green–any other coupler terminal
Rear wheel sensor coupler “1”
blue–any other coupler terminal
green–any other coupler terminal
ABS ECU coupler “2”
blue–any other coupler terminal

A B

1 1 2
G L G L
R Br Y G L W W/L W/B B/W

R/L Y L/G L/G Br Lg/L Lg/W B/W B

Is resistance ∞ Ω?
YES
→ Go to step 2.
NO
→ Replace the wire harness.

9-168
 64_ABS

2. Defective rear wheel sensor

Ground short circuit check “A”
Between rear wheel sensor coupler “1” and white–ground
ground black–ground

Lines short circuit check “B”

white–any other coupler terminal
Rear wheel sensor coupler “1”
black–any other coupler terminal

A B

1 1
W B W B

Is resistance ∞ Ω?
YES
→ Go to step 3.
NO
→ Replace the wire harness.
3. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to “ABS (Anti-lock Brake System)” on page 4-58.

9-169
EAS20091
55. Starter generator EAS30613

WIRING DIAGRAM 56. Front wheel sensor COLOR CODE

57. Rear wheel sensor B Black
GPD155-A 2022 Br Brown
58. Joint 4
1. Battery Ch Chocolate
59. ABS ECU
2. ABS solenoid fuse Dg Dark green
60. Meter assembly
3. ABS motor fuse G Green
61. Multi-function meter
4. Smart key system fuse Gy Gray
62. ABS warning light
5. Terminal fuse L Blue
63. High beam indicator light
6. Signaling system fuse O Orange
64. Smart key system indicator
7. Fuel injection system fuse P Pink
light
8. Backup fuse R Red
65. Turn signal indicator light (left)
9. Main fuse Sb Sky blue
66. Turn signal indicator light (right)
10. Ignition fuse W White
67. Engine trouble warning light Y Yellow
11. Headlight fuse
68. Stop and Start System indica- B/L Black/Blue
12. ABS control unit fuse
tor light B/R Black/Red
13. Main switch
69. Traction control system indica- B/W Black/White
14. Request switch
tor light B/Y Black/Yellow
15. Main switch solenoid
70. Notification indicator light 1 Br/R Brown/Red
16. Auxiliary DC jack
71. Notification indicator light 2 Br/W Brown/White
17. DC outlet
72. Frame ground G/B Green/Black
18. Smart unit
73. Engine ground G/R Green/Red
19. Buzzer
74. License plate light G/W Green/White
20. Horn
75. Tail/brake light assembly G/Y Green/Yellow
21. Diode
76. Taillight Gy/G Gray/Green
22. Handlebar switch (left) Gy/R Gray/Red
77. Brake light
23. Menu switch L/B Blue/Black
78. Front turn signal light (left)
24. Horn switch L/R Blue/Red
79. Front turn signal light (right)
25. Dimmer switch L/W Blue/White
80. Rear turn signal light (left)
26. Turn signal switch L/Y Blue/Yellow
81. Rear turn signal light (right)
27. Handlebar switch (right) P/B Pink/Black
82. Headlight assembly
28. Start switch P/L Pink/Blue
83. Headlight control unit
29. Stop and Start System switch P/W Pink/White
84. High beam
30. Hazard switch R/B Red/Black
85. Low beam
31. Main relay R/G Red/Green
86. Auxiliary light
32. Yamaha diagnostic tool cou- R/L Red/Blue
pler R/W Red/White
33. Front brake light switch R/Y Red/Yellow
34. Rear brake light switch Sb/W Sky blue/White
35. Starter charge relay W/R White/Red
36. Sidestand switch W/Y White/Yellow
37. Joint 1 Y/B Yellow/Black
38. Injector Y/G Yellow/Green
39. Joint 2 Y/L Yellow/Blue
Y/R Yellow/Red
40. Joint 3
Y/W Yellow/White
41. Fuel pump
42. Fuel sender
43. SGCU (starter generator con-
trol unit)
44. Ignition coil
45. Spark plug
46. ISC (idle speed control) unit
47. Throttle body sensor assembly
48. Intake air pressure sensor
49. Intake air temperature sensor
50. Throttle position sensor
51. Crankshaft position sensor
52. Coolant temperature sensor
53. VVA (variable valve actuator)
solenoid
54. O2 sensor
GPD155-A 2022
WIRING DIAGRAM

R R

2 3 R
R/L
R/Y G/W RR W/R Br B

4 5 17 Br W/R
W/R
W/R
6 W/R
B 16 B B
Br/R Br
Br W/R B
R
R

7 8 R
R R
R Br Br
Br Br
9 Br
Br
Br/R Br Br
Br
Br Br

10
Br R R 13 R

11 12 Br
R
G/W
Br
R R R
R W G
Br ON Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
R/Y R/Y R/W B B R/W
OPEN
Br Br/R OFF
LOCK
(B) (B) G/W L/R R/B L/Y B/W G/B 19 B
R
R/B
R Y/R Y/B B
Lg/W Sb Gy W/Y P/B W/B L
L/B R G/R B/L W/G W L/Y
B/L Y B/L Br/B R/B
L/R B Gy/R W/B Br/W B P/W Br
R/Y
Br Br/R
L B B L
R L W/R Br R/W
18 R/B B R R
R

(B)
B (B) R
14 15 L/R
Br
Br/R B
L
R/W
L
R/W
W/R
L/Y
G/B
R 38 O O
44
Br/R Br/R
Br/R
B/W
Br B
31
Br O/B O/B
45
(B) O/B Br
R
Br/R Br (B)
B Br P P
46
R G/Y G/Y P G/Y Sb Gy
Br Br B Gy Gy
Lg/L B Sb Sb
L/B Br (B)
20 Br R Lg/W

47
P Br Br Lg/W
21
(R) R Lg/L
48
P Lg/W
Lg/L 32
P P Br B P/W
Br/W
P/W
Br/W 49 B/L Y L P/W Br/W
B/L B/L
Y Y 50 (B)
Y/W 39 W/G
L L

27 L/W Y/W Br/W

22 Y/W P L/B L/W R/W Br 33 L/W
W/G

28 29 30 Dg Br Br B/Y B/Y
W/R W/R G
23 24 25 26 Ch Dg
L/W Y/W Dg Br/W Br B/Y W/L W/L G W/R W/R B/L
37
PUSH ON OFF
L/B P
FREE FREE Y Y FREE OFF Br/W 34 B/Y W/B
W/Y
W/B
W/Y
L/Y
51 Br/B W/L W/L Br/B

Ch Dg
Y/W
PUSH PUSH PUSH B B B B B/W Ch
Ch B
(R)
Br B/Y B/Y Y L/B 40 43 Br/B
B/L
Br/B
B/L
L/Y W/B W/B W/Y

L/W B Y (B)
(B) (B)
L/W L/B B/W B L/B L/B
L/W Y/W
L/R
B Y B Y/R
35 52
L/R L/R G/R G/R
P L/B R G/R B/L
L/B B/W L/R B/L B/L
Y/W R/B Br/R Br (B)
(B) Y/R Y/R
R/W L/W B
B
B/W R Br/R
(B)
B B Br R/B
L/Y
R/B G
Ch
G
Ch 53 G Ch

B B L/Y L/Y L/Y L/Y (Gy)

Ch Ch
Ch
R
R
R L/Y B 36 B
Y/B Gy/R Br/R B B P/B
Dg Dg
Dg B B
Br B/Y R B/L B/L W L Gy/R
Br (L) (L) 41 P/B
1 Br
R B/Y
(B)
B/Y
B B Br/R P/B
54
42
B W L Gy/R B/L
G B G
(B) (B)
B
B B (Gy)
Ch Dg Ch Dg B
75 Br Y Br
B
B
81 80 79 78 G G
R
G
R
R/L
R/Y 55
82 Y Br B B
B
Ch 76 77 74 L W W R/W

W/B R/Y R/W R/L

Ch Dg G

84 (Br) (G) (Br) B Y L

85
W
Br B R W G
86 Br Y Y Br B B B B
B
B

G B B Y/B Ch Dg Ch B Br B
Y B
Gy Br/R (Br) (G) Dg B
Br R W

83 85 (Br) Br
R/L
W/B
G
Gy
Y/B
Br/R
Y
Lg/W
Lg/L
Br
Y
Br
Y
B
W 56 W B Br Y

B B
59
L/G
L/G
G
L
G
L
B
W 57 W B G L
Lg/W
B B B B/W B/W
Lg/W W/L B/W
B
B B
B
B
Lg/W
60
B
B
B Lg/L
Lg/L
W/L
G
58 B/W
B/W B R Br Y G L W W/L W/B B/W
B G/B B/W
B Lg/L Y/W
B B Br R/L Y L/G L/G Br Lg/L Lg/W B/W B
B B B
B B B Br/R
B W/R
B
B B
B
B/W R
R
R
L/W
61 (B)

B B B
R/W
B Ch
B Dg
Br/W
L/R
B BB BB

B B B B
B
62 63
73 72 72
72 72
65 64

66 67

68 69
R/W L/W Br/W Y/W Dg Ch Br R
71 70 L/R G/B W/L Br/R W/R G B R

(Gy)
GPD155-A 2022
WIRING DIAGRAM

2 3
B

4 5 17
6 16

7 8

9
10
13
11 12
ON
OPEN
OFF
LOCK
(B) (B) 19
18 (B)
(B)
14 15
38 44
31 45
(B)

(B)

46
(B)
20
21
(R)
47 48
32
49
50 (B)
39
27
22 33
28 29 30
23 24 25 26 /

37
PUSH ON OFF
FREE FREE
FREE OFF 34 /
51
PUSH PUSH PUSH B
(R)
40 43 (B)
(B) (B)
/

B B
35 52
(B) (B)

(B)
53
(Gy)

36
(L) (L) 41
1 (B)

42 54
(B) (B)
(Gy)

75
81 80 79 78 G
74 55
82 76 77
84 (Br) (G) (Br)
85 86 B B B

(Br) (G)

83 85 (Br)

56
59
57
/

60
58 B/W

B/W

61 (B)

62 63
73 72 72
72 72
65 64

66 67

68 69

71 70
(Gy)