Мануал ямаха р1 2007 на русском

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• Page 1
  2020 SERVICE MANUAL YZF-R1 YZF-R1M YZFR1L YZFR1LC YZFR1ML YZF1MLC LIT-11616-33-33 B3L-28197-10…
• Page 3
  If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from their vehicle and to conform to federal environmental quality objectives.
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  EAS20004 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •…
• Page 5
  EAS20005 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque…

• Page 7: Table Of Contents

  EAS10003 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM SELF DIAGNOSTIC…

• Page 9: General Information

  GENERAL INFORMATION IDENTIFICATION ……………….. 1-1 VEHICLE IDENTIFICATION NUMBER ………….1-1 MODEL LABEL………………1-1 FEATURES…………………. 1-2 GLOSSARY………………..1-2 DISPLAY ………………..1-2 MENU SCREEN ………………1-6 BASIC SERVICE INFORMATION…………..1-20 ELECTRICAL SYSTEM…………….1-20 SPECIAL TOOLS ………………1-21…

• Page 10: Identification

  IDENTIFICATION EAS20007 IDENTIFICATION EAS30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS30003 MODEL LABEL The model label “1” is affixed to the frame under the passenger seat. This information will be needed to order spare parts.

• Page 11: Glossary

  3. GPS indicator (CCU-equipped models) SCU — Suspension Control Unit 4. Logging indicator (CCU-equipped models) TCS — Traction Control System 5. Clock YRC — Yamaha Ride Control 6. Revolution peak hold indicator EAS31707 7. Front brake pressure indicator DISPLAY 8. Acceleration indicator The display has two different main screen dis- 9.

• Page 12
  FEATURES 9. YRC items MODE/PWR/TCS/SCS/EBM 10. Speedometer • ODO will lock at 999999 and cannot be reset. 11. Tachometer • TRIP-1 and TRIP-2 will reset to 0 and begin counting again after 9999.9 has been reached. EWA18210 WARNING • When the fuel tank reserve level has been Stop the vehicle before making any setting reached, F-TRIP appears automatically and changes.
• Page 13
  FEATURES YRC items MODE/PWR/TCS/SCS/EBM • When a YRC item is highlighted but cannot be The current MODE (YRC mode) and its related adjusted, the YRC item box will return to black. PWR, TCS, SCS, and EBM settings are shown here. The individual settings for YRC items PWR, TCS, SCS, LCS, QSS, LIF, EBM, and BC can 10 : 00…
• Page 14
  FEATURES • If the ERS indicator does not return to normal. [To use the lap timer] (Refer to “ELECTRONICALLY ADJUSTABLE 1. Short push the wheel switch. The information SUSPENSION SYSTEM (for YZF-R1M)” on display item will flash for five seconds. page 9-29.) 2.

• Page 15: Menu Screen

  FEATURES Coolant temperature warning EAS31708 MENU SCREEN This icon appears if the coolant temperature reaches 117 °C (242 °F) or higher. Stop the ve- 10 : 00 MENU hicle and turn off the engine. Allow the engine to cool. Display Mode ECA10022 YRC Setting NOTICE…

• Page 16
  FEATURES Select — rotate the wheel switch up or down to 3. Long push the wheel switch to exit the MENU highlight the desired module or setting item and screen or use the wheel switch to select an- then short push the wheel switch (briefly press other module.
• Page 17
  FEATURES 1 applies the least amount of overall system in- tion from the selected YRC mode (the LCS icon tervention, while setting level 9 applies the great- will not appear and the launch control function est amount of overall traction control. cannot be activated).
• Page 18
  FEATURES 2. The “YRC Setting” screen is displayed, and The engine brake management system reduces the YRC mode box “YRC” is highlighted. engine torque when decelerating. The fuel injec- Short push the wheel switch to enter the box tion, ignition timing, and electronic throttle valve and then select the YRC mode A, B, C or D are electronically adjusted by the ECU.
• Page 19
  FEATURES the far left to return to the MENU screen, or for YZF-R1M select the “ ” mark to fine tune YRC Setting 10 : 00 the ERS mode settings. T — 1 T — 2 ERS (YZF-R1M) R — 1 10 : 00 YRC Setting BRAKE…
• Page 20
  FEATURES 3. Select the suspension item that you want to adjust, and then rotate the wheel switch to • M-1 is preset for track use with racing slick adjust the setting level. tires. • M-2 is preset for track use with street tires. •…
• Page 21
  FEATURES 1. Select “Display”. “Logging” (for CCU-equipped models) Vehicle and riding information can be recorded (logged) and this data can be accessed with a 10 : 00 Lap Time smart device. (Refer to “CONNECTING TO THE Display CCU (for YZF-R1M)” on page 4-8.) Reset [To start and stop logging] 1.
• Page 22
  FEATURES When using kilometers, the fuel consumption units can be changed between km/L or L/ The logging function will also start automatically 100km. When using miles, MPG will be avail- when you start off. able. “Maintenance” [To set the distance or fuel consumption This module allows you to record distance trav- units] eled between engine oil changes (use the OIL…
• Page 23
  FEATURES and night settings. A photo sensor equipped in 3. Select the background color (select “BLACK” the instrument panel detects lighting conditions for a black background or “WHITE” for a and will automatically change the display be- white background). tween its day and night settings. The photo sen- sor also controls a subtle automatic brightness 10 : 00 Wallpaper…
• Page 24
  FEATURES [To make setting changes] 5. Rotate the wheel switch to adjust the r/min at 1. Select “Shift IND Setting”. which the shift timing indicator light will come on. “IND Start” operational range is 8000– 14800 r/min. 10 : 00 Shift Indicator GP GPS Shift IND Setting…
• Page 25
  FEATURES “Tach IND Setting” 4. Select “Tach IND 1st” to set the green zone This module allows you to turn the tachometer starting r/min. color display on or off. When turned off, the ta- chometer will display all r/min levels below the 10 : 00 Shift Indicator red zone in black or white (depending on wallpa-…
• Page 26
  FEATURES 10 : 00 Shift Indicator 10 : 00 LCS QS 1000 r/min 1000 r/min Tach IND Setting IND Mode Tach IND 1st 8000 r/min 123.4 1  2 TRIP-1 mile 123456 Tach IND 2nd 11000 mile r/min MODE- 8. Select the triangle symbol to exit. 1.
• Page 27
  FEATURES 3. For example, let’s select “DISPLAY-1”. 7. Select the triangle symbol to exit. To set the 4. Select “STREET MODE 1-1”. other display groups, repeat from step 3. “Brightness” 10 : 00 Display Setting This module allows you to adjust the general DISPLAY-1 brightness level of the display screen.
• Page 28
  FEATURES 2. When “Clock” is selected, the hours figure will 6. Short push the wheel switch again to exit and be highlighted. go back to the MENU screen. “All Reset” 10 : 00 Clock This module resets everything, except the odometer and clock, to its factory preset or de- : 34 fault setting.

• Page 29: Basic Service Information

  BASIC SERVICE INFORMATION EAS20010 BASIC SERVICE INFORMATION EAS30014 ELECTRICAL SYSTEM Electrical parts handling ECA22611 NOTICE • Do not perform angle adjustment of the IMU and battery box by pinching the washer and related parts. • When installing the IMU, apply a thin coat of silicone grease onto the washer where con- tacting the IMU grommet.

• Page 30: Special Tools

  • 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 (US) 3-4, 4-80, 4-81, 90890-03269 9-2, 9-23, 9-24 Yamaha diagnostic tool (A/I) 3-4, 4-80, 4-81,…

• Page 31
  SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Oil filter wrench 3-29 90890-01426 Oil filter wrench YU-38411 Oil pressure gauge joint 18 mm 3-30 90890-04176 YU-04176 ø18 Oil pressure gauge set 3-30 90890-03120 Vacuum/pressure pump gauge set 4-30 90890-06945 Pressure/ vacuum tester YB-35956-B Wheel bearing ring nut tool 4-46, 4-48…
• Page 32
  SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Fork seal driver 4-95, 4-95, 4-96, 90890-01442 4-105, 4-105 Adjustable fork seal driver (36–46 mm) YM-01442 Rod puller 4-96, 4-97 90890-01437 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Rod puller attachment (M10) 4-96, 4-97 90890-01436 Universal damping rod bleeding tool set…
• Page 33
  SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Drive chain cut & rivet tool 4-126, 4-128 90890-01550 Drive chain cut & rivet tool YM-01550 Compression gauge 90890-03081 90890-03081 Engine compression tester YU-33223 YU-33223 Pivot shaft wrench 5-16, 5-16 90890-01485 Frame mount insert wrench YM-01485 Valve spring compressor 5-27, 5-30, 5-38,…
• Page 34
  Crankshaft protector 5-46 90890-01382 Crankshaft protector YM-01382 Flywheel puller 5-46 90890-01404 Flywheel puller YM-01404 Yamaha bond No. 1215 5-47, 5-74 90890-85505 (Three bond No.1215®) Sheave holder 5-49, 5-49 90890-01701 Primary clutch holder YS-01880-A Digital circuit tester (CD732) 5-52, 8-41, 8-42,…
• Page 35
  SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Universal clutch holder 5-64, 5-67 90890-04086 Universal clutch holder YM-91042 Piston pin clip rotation tool 5-79 90890-04175 YM-04175 Piston pin puller set 5-80 90890-01304 Piston pin puller YU-01304 YU-01304 Connecting rod big end bearing installer 5-83, 5-86 ø9.1 ø8.1…
• Page 36
  SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Radiator cap tester 6-5, 6-6 90890-01325 Mityvac cooling system tester kit YU-24460-A YU-24460-A Radiator cap tester adapter 6-5, 6-6 90890-01352 Pressure tester adapter YU-33984 YU-33984 Mechanical seal installer (ø33) 6-16 90890-04132 Water pump seal installer (ø33) YM-33221-A Middle driven shaft bearing driver 6-16…
• Page 37
  Test harness– speed sensor (3P) YU-03208 Yamaha diagnostic tool (A/I) 90890-03264 This special tool includes the YDT sub harness (6P) (90890-03266). 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. 1-28…
• Page 38
  SPECIAL TOOLS 1-29…

• Page 39: Specifications

  SPECIFICATIONS GENERAL SPECIFICATIONS ……………. 2-1 ENGINE SPECIFICATIONS …………….2-2 CHASSIS SPECIFICATIONS …………….2-7 ELECTRICAL SPECIFICATIONS …………..2-10 TIGHTENING TORQUES …………….2-12 ENGINE TIGHTENING TORQUES…………2-12 CHASSIS TIGHTENING TORQUES…………2-14 CABLE ROUTING ………………2-17…

• Page 40: General Specifications

  GENERAL SPECIFICATIONS EAS20013 GENERAL SPECIFICATIONS Model Model B3L2 (YZFR1L_except for California) B3L3 (YZFR1LC_for California) B4S2 (YZFR1ML_except for California) B4S3 (YZFR1MLC_for California) Dimensions Overall length 2055 mm (80.9 in) Overall width 690 mm (27.2 in) Overall height 1165 mm (45.9 in) Wheelbase 1405 mm (55.3 in) Ground clearance…

• Page 41: Engine Specifications

  ENGINE SPECIFICATIONS EAS20014 ENGINE SPECIFICATIONS Engine Combustion cycle 4-stroke Cooling system Liquid cooled Valve train DOHC Displacement 998 cm³ Cylinder arrangement Inline Number of cylinders 4-cylinder Bore × stroke 79.0 × 50.9 mm (3.11 × 2.00 in) Compression ratio 13.0 : 1 Compression pressure 1261–1624 kPa/210 r/min (12.6–16.2 kgf/cm²/ 210 r/min, 179.4–231.0 psi/210 r/min)

• Page 42
  ENGINE SPECIFICATIONS Spark plug(s) Manufacturer/model NGK/LMAR9E-J Spark plug gap 0.6–0.7 mm (0.024–0.028 in) Cylinder head Warpage limit 0.10 mm (0.0039 in) Camshaft Camshaft cap inside diameter 25.500–25.521 mm (1.0039–1.0048 in) Camshaft journal diameter 25.459–25.472 mm (1.0023–1.0028 in) Camshaft-journal-to-camshaft-cap clearance 0.028–0.062 mm (0.0011–0.0024 in) Limit 0.080 mm (0.0032 in) Camshaft lobe dimensions…
• Page 43
  ENGINE SPECIFICATIONS Limit 35.09 mm (1.38 in) Outer spring Free length (intake) 35.72 mm (1.41 in) Limit 33.93 mm (1.34 in) Free length (exhaust) 36.85 mm (1.45 in) Limit 35.01 mm (1.38 in) Cylinder Bore 79.000–79.010 mm (3.1102–3.1106 in) Wear limit 79.060 mm (3.1126 in) Piston Diameter…
• Page 44
  ENGINE SPECIFICATIONS Balancer Balancer shaft runout limit 0.030 mm (0.0012 in) Bearing color code Code 0 White Code 1 Blue Code 2 Black Code 3 Brown Code 4 Green Code 5 Yellow Code 6 Pink Balancer shaft journal to balancer shaft bearing clearance 0.028–0.046 mm (0.0011–0.0018 in) Clutch…
• Page 45
  ENGINE SPECIFICATIONS Air filter Air filter element Oil-coated paper element Fuel pump Pump type Electrical Maximum consumption amperage 5.2 A Fuel injector 12.0 Ω Resistance Throttle body ID mark B3L2 10 (except for California) B3L3 20 (for California) Idling condition Engine idling speed 1200–1400 r/min AI system…

• Page 46: Chassis Specifications

  CHASSIS SPECIFICATIONS EAS20015 CHASSIS SPECIFICATIONS Chassis Frame type Diamond Caster angle 24.0 ° Trail 102 mm (4.0 in) Front wheel Wheel type Cast wheel Rim size 17M/C X MT3.50 Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 1.0 mm (0.04 in) Wheel axle bending limit 0.25 mm (0.01 in)

• Page 47
  260.0 mm (10.24 in) (YZF-R1M) Limit 215.1 mm (8.47 in) (YZF-R1) 254.8 mm (10.03 in) (YZF-R1M) Recommended oil Yamaha Suspension Oil 01 (YZF-R1) Öhlins R&T 43 (YZF-R1M) Inner tube bending limit 0.2 mm (0.01 in) Quantity (left) 470.0 cm³ (15.89 US oz, 16.58 Imp.oz) (YZF-R1) 263.0 cm³…
• Page 48
  CHASSIS SPECIFICATIONS Rear suspension Type Swingarm (link suspension) Spring Coil spring Shock absorber Gas-hydraulic damper Wheel travel 120 mm (4.7 in) Spring preload Adjusting system Mechanical adjustable type Adjustment value (Soft) 77.5 mm (3.05 in) (YZF-R1) 0.0 mm (0.00 in) (YZF-R1M) Adjustment value (STD) 78.5 mm (3.09 in) (YZF-R1) 4.0 mm (0.16 in) (YZF-R1M)

• Page 49: Electrical Specifications

  ELECTRICAL SPECIFICATIONS EAS20016 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Ignition timing (B.T.D.C.) 3.0–7.0 °s/1300 r/min Engine control unit Model TBDF3K Ignition coil 0.85–1.15 Ω Primary coil resistance Secondary coil resistance 8.50–11.50 kΩ Charging system Charging system AC magneto Standard output 14.0 V, 26.3 A at 5000 r/min…

• Page 50
  ELECTRICAL SPECIFICATIONS Starter motor Brush overall length limit 5.5 mm (0.22 in) Brush spring force 4.80–7.20 N (489–734 gf, 17.28–25.92 oz) Mica undercut (depth) 2.40 mm (0.09 in) Solenoid 49.82–56.18 Ω Steering damper solenoid resistance 42.0–48.0 Ω Intake solenoid resistance Fuel injection sensor 189–231 Ω…

• Page 51: Tightening Torques

  TIGHTENING TORQUES EAS20017 TIGHTENING TORQUES EAS30016 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Exhaust pipe nut 20 N·m (2.0 kgf·m, 15 lb·ft) Muffler protector bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) EXUP valve pulley cover bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Spark plug 13 N·m (1.3 kgf·m, 9.6 lb·ft) Spark plug (new)
• Page 52
  TIGHTENING TORQUES Clutch cover bolt 1. Tighten the bolts to 6 N·m (0.6 kgf·m, 4.4 lb·ft) with a torque wrench following the tightening order. 2. Perform the following procedure to all the bolts one by one in the tightening sequence as shown in the illustration.

• Page 53: Chassis Tightening Torques

  TIGHTENING TORQUES EAS30017 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front wheel axle nut 115 N·m (11.5 kgf·m, 85 lb·ft) Front wheel axle pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) See TIP. Rear wheel sprocket nut 100 N·m (10 kgf·m, 74 lb·ft) Rear wheel axle nut 190 N·m (19 kgf·m, 140 lb·ft)

• Page 54
  TIGHTENING TORQUES Lower bracket pinch bolt Tighten each bolt to 23 N·m (2.3 kgf·m, 17 lb·ft) in the order pinch bolt “1” → pinch bolt “2” → pinch bolt “1” → pinch bolt “2”. 2-15…
• Page 55
  TIGHTENING TORQUES 2-16…

• Page 56: Cable Routing

  CABLE ROUTING EAS20021 CABLE ROUTING Handlebar (front view) 2-17…

• Page 57
  CABLE ROUTING 1. Handlebar switch lead (right) 2. Clutch cable 3. Handlebar switch lead (left) 4. Clutch switch connector 5. Main switch lead 6. Horn lead Radiator bracket (left) 8. Intake solenoid vacuum hose 9. Horn 10. Steering damper solenoid lead 11.
• Page 58
  CABLE ROUTING Frame (front right side view) 2-19…
• Page 59
  CABLE ROUTING 1. Clutch cable 2. Front brake hose (front brake master cylinder to hydraulic unit) 3. Steering damper solenoid lead 4. Front fork stepping motor sub-wire harness (for YZF-R1M) 5. Coolant reservoir breather hose 6. Side cover (right) 7. Damper 8.
• Page 60
  CABLE ROUTING Frame (rear right side view) 2-21…
• Page 61
  CABLE ROUTING 1. Muffler protector bracket (right) 2. O sensor lead 3. Rear wheel sensor lead 4. Rear brake light switch lead 5. EXUP cable 6. Frame 7. Clutch cover A. Route the O sensor lead over the muffler protector bracket (right). B.
• Page 62
  CABLE ROUTING Electrical components tray (left side view) 30 31 32 30 31 32 2-23…
• Page 63
  CABLE ROUTING 1. Intake funnel servo motor lead D. Fasten the right handlebar switch leads, left handlebar switch leads and radiator fan motor 2. Main switch coupler leads with a plastic locking tie. The leads may be 3. Handlebar switch coupler (right) (non-waterproof fastened in any order.
• Page 64
  CABLE ROUTING Frame (left side view) K 11 K 11 2-25…
• Page 65
  CABLE ROUTING 1. Secondary injector lead N. Fasten the sidestand switch lead, O sensor lead 2. Throttle position sensor (left), and oil pressure switch lead with the holder. The catch of the holder may be facing in any 3. Wire harness direction.
• Page 66
  CABLE ROUTING Frame (top view) 2-27…
• Page 67
  CABLE ROUTING 1. Auxiliary light lead 2. Steering damper solenoid coupler 3. Intake solenoid lead (sub-wire harness) 4. Steering damper solenoid lead 5. Front turn signal/position light lead (right) 6. Meter assembly 7. Meter assembly coupler 8. Intake solenoid vacuum hose 9.
• Page 68
  CABLE ROUTING Frame (top view) (for YZF-R1M) 2-29…
• Page 69
  CABLE ROUTING 1. Steering damper solenoid coupler (Öhlins: OPTION) 2. Steering damper solenoid coupler 3. Intake solenoid lead 4. Front turn signal/position light lead (right) 5. Sub-wire harness (front fork stepping motor) 6. Sub-wire harness (SCU, steering damper solenoid, sub-wire harness) 7.
• Page 70
  CABLE ROUTING Frame (top view) 2-31…
• Page 71
  CABLE ROUTING 1. Horn lead N. Route the intake solenoid vacuum hose over the guide and to the outside of the projection on the 2. Main switch lead guide. 3. Handlebar switch lead (left) O. Fasten the main switch lead and wire harness to 4.
• Page 72
  CABLE ROUTING Frame (top view) 2-33…
• Page 73
  CABLE ROUTING 1. Primary injector #1 2. Primary injector #2 3. Primary injector #3 4. Primary injector #4 5. Coolant temperature sensor coupler (sub-wire harness) 6. O sensor lead 7. Neutral switch coupler 8. Fuel pump lead 9. Engine ground lead 10.
• Page 74
  CABLE ROUTING Rear fender (top view) 15 16 20 33 34 35 15 16 23 24 25 2-35…
• Page 75
  J. Route the EXUP cables to the front of the rear 5. Joint coupler shock absorber assembly gas cylinder. 6. Yamaha diagnostic tool coupler K. Route the Yamaha diagnostic tool coupler lead 7. Tail/brake light lead under the joint coupler. 8. Rear turn signal light coupler L.
• Page 76
  CABLE ROUTING Rear fender (left side view) 2-37…
• Page 77
  CABLE ROUTING 1. Rear fender 2. Mudguard assembly 3. License plate light lead 4. License plate light coupler 5. Rear turn signal light coupler (left) 6. Rear turn signal light coupler (right) 7. EXUP cable 2 8. EXUP cable 1 9.
• Page 78
  CABLE ROUTING Rear brake hose (right side view) 2-39…
• Page 79
  CABLE ROUTING 1. Hydraulic unit 2. Rear frame 3. Brake fluid reservoir 4. Frame 5. Brake hose (rear brake master cylinder to hydraulic unit) 6. Rear wheel sensor lead 7. Rear brake master cylinder 8. Swingarm assembly 9. Rear wheel sensor lead cover 10.
• Page 80
  CABLE ROUTING Front brake hose (left side view) 2-41…
• Page 81
  CABLE ROUTING 1. Brake hose (front brake master cylinder to hydraulic unit) 2. Brake hose (hydraulic unit to front brake calipers) 3. Front wheel sensor lead 4. Front brake caliper 5. Front wheel sensor 6. Front fork leg 7. Collar 8.
• Page 82
  CABLE ROUTING Front brake hose (left side view) 2-43…
• Page 83
  CABLE ROUTING 1. Brake hose bracket 2. Frame 3. Brake hose (hydraulic unit to front brake calipers) 4. Brake hose (front brake master cylinder to hydraulic unit) A. Install the brake hose (front brake master cylinder to hydraulic unit) so that it is on the inside relative to the brake hose (hydraulic unit to front brake calipers).
• Page 84
  CABLE ROUTING Hydraulic unit assembly (top and left side view) 2-45…
• Page 85
  CABLE ROUTING 1. Brake hose (front brake master cylinder to brake hose joint) 2. Brake hose (front brake calipers to brake hose joint) 3. Brake hose (front brake caliper side brake hose joint to hydraulic unit) 4. Brake hose (front brake master cylinder side brake hose joint to hydraulic unit) 5.
• Page 86
  CABLE ROUTING Fuel tank (top and left side view) 2-47…
• Page 87
  CABLE ROUTING 1. Fuel tank 2. Fuel pump 3. Fuel tank breather hose 4. Fuel tank drain hose 5. Fuel hose 1 (fuel tank to fuel hose 2) A. Point the end of the hose clamp outward. B. Install the fuel tank drain hose with its white paint mark facing outward.
• Page 88
  CABLE ROUTING Canister (for California) 2-49…
• Page 89
  CABLE ROUTING 1. Fuel hose 1 (fuel tank to fuel hose 2) 2. Canister 3. Canister holder 4. O sensor coupler 5. Neutral switch coupler 6. Fuel pump lead 7. Fuel tank breather hose (fuel tank to canister) 8. Fuel tank drain hose 9.
• Page 90
  CABLE ROUTING Air filter case and throttle bodies (top and left side view) 2-51…
• Page 91
  CABLE ROUTING 1. Air filter case 2. Secondary injector 3. Fuel hose (fuel rail to fuel rail) 4. Crankcase breather hose 5. Fuel hose 2 (secondary injector fuel rail side) 6. Canister purge hose (for California) 7. Throttle body position sensor 8.
• Page 92
  CABLE ROUTING Air cut-off valve (right side view) 2-53…
• Page 93
  CABLE ROUTING 1. Air filter case 2. Air cut-off valve 3. Air induction system hose (air filter case to air cut-off valve) 4. Cylinder head cover 5. Air induction system hose (air cut-off valve to reed valve cover) 6. Cylinder identification sensor 7.
• Page 94
  CABLE ROUTING Air duct (left and right side view) 2-55…
• Page 95
  CABLE ROUTING 1. Air intake duct valve 2. Air intake duct 3. Surge tank 4. Surge tank hose 5. One-way valve 6. Intake solenoid vacuum hose (one-way valve to intake solenoid) 7. Intake solenoid vacuum hose (intake solenoid to air intake duct valve) 8.
• Page 96
  CABLE ROUTING Radiator (left side view) 2-57…
• Page 97
  CABLE ROUTING 1. Cooling system air bleed hose 2. Thermostat assembly 3. Hose clamp 4. Radiator inlet hose 5. Cylinder 6. Crankcase 7. Generator cover 8. Water pump outlet pipe 9. Radiator outlet hose A. Align the white paint mark on the radiator inlet hose, projection on the radiator pipe, and crimped section of the hose clamp.
• Page 98
  CABLE ROUTING Radiator (right side view) 2-59…
• Page 99
  CABLE ROUTING 1. Air induction system hose U. 3 mm (0.12 in) or more 2. Cooling system air bleed hose V. Make sure not to install the hose clamp on the raised portion of the hose fitting of the water pump 3.
• Page 100
  CABLE ROUTING Muffler (top and left side view) 2-61…
• Page 101
  CABLE ROUTING 1. Exhaust chamber 2. EXUP valve pulley cover 3. Muffler 4. EXUP servo motor 5. EXUP cable 2 6. EXUP cable 1 A. Route EXUP cable 1 and EXUP cable 2 through the guide. Route EXUP cable 1 above EXUP cable 2.
• Page 102
  CABLE ROUTING CCU (top and right side view) (for YZF-R1M) 2-63…
• Page 103
  2. GPS unit lead 3. GPS unit coupler 4. Wire harness coupler cap 5. Wire harness coupler (to sub-wire harness) 6. Yamaha diagnostic tool coupler 7. CCU (Communication Control Unit) lead (sub-wire harness) 8. Passenger seat cover 9. GPS unit 10.
• Page 104
  CABLE ROUTING 2-65…

• Page 105: Periodic Checks And Adjustments

  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 (Primary injector)……..3-4 CHECKING THE FUEL LINE (Secondary injector) ……..3-4 CHECKING THE SPARK PLUGS ………….

• Page 106
  ADJUSTING THE PRELOAD OF THE FRONT FORK LEGS (for YZF-R1M) ………………3-23 ADJUSTING THE DAMPING FORCE OF THE FRONT FORK LEGS AND REAR SHOCK ABSORBER ASSEMBLY (for YZF-R1M)….3-23 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ….3-25 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY (for YZF-R1) ……………….

• Page 108: Periodic Maintenance

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

• Page 109
  • Perform dynamic inspection 1 * Diagnostic sys- √ √ √ √ √ √ using Yamaha diagnostic tool. tem check • Check the error codes. 2 * Air filter element • Replace. Every 24000 mi (37000 km) • Check operation. √…
• Page 110
  29 * Front and rear √ √ √ √ √ √ • Check operation. brake switches • Apply Yamaha cable lubricant √ √ √ √ √ √ 30 * Control cables or other suitable cable lubri- cant thoroughly.

• Page 111: Checking The Vehicle Using The Yamaha Diagnostic Tool

  Make sure the fuel tank breather hose is rout- cludes YDT sub harness (6P) (90890-03266). ed correctly. • If you already have Yamaha diagnostic tool (A/ I) (90890-03262), YDT sub harness (6P) Before removing the fuel hoses, place a few (90890-03266) is separately required.

• Page 112: Checking The Spark Plugs

  PERIODIC MAINTENANCE 2. Check: Manufacturer/model • Fuel hose “1” NGK/LMAR9E-J Cracks/damage → Replace. Loose connection → Connect properly. 4. Check: • Electrode “1” Before removing the fuel hose, place a few rags Damage/wear → Replace the spark plug. in the area under where it will be removed. •…

• Page 113: Adjusting The Valve Clearance

  PERIODIC MAINTENANCE • Rider seat 4. Measure: Refer to “GENERAL CHASSIS (1)” on page • Valve clearance Out of specification → Adjust. 4-1. Valve clearance (cold) EAS30622 ADJUSTING THE VALVE CLEARANCE Intake The following procedure applies to all of the 0.09–0.17 mm (0.0035–0.0067 in) valves.
• Page 114
  PERIODIC MAINTENANCE • If the valve clearance is incorrect, record the measured reading. • Measure the valve clearance in the following sequence. Valve clearance measuring sequence Cylinder #1 → #3 → #2 → #4 i. Measure the valve clearance #2 with a thickness gauge.
• Page 115
  PERIODIC MAINTENANCE d. Calculate the sum of the values obtained in steps (b) and (c) to determine the re- quired valve pad thickness and the valve pad number. Example: 1.60 mm (0.063 in) + 0.03 mm (0.001 in) = 1.63 mm (0.064 in) The valve pad number is A63.

• Page 116: Checking The Engine Idling Speed

  Refer to “CHECKING AND CLEANING THE Camshaft cap bolt THROTTLE BODIES” on page 7-15. 8 N·m (0.8 kgf·m, 5.9 lb·ft) a. Connect the Yamaha diagnostic tool. Camshaft cap bolt (new) Use the diagnostic code number “67”. 10 N·m (1.0 kgf·m, 7.4 lb·ft) Refer to “SELF-DIAGNOSTIC FUNC-…

• Page 117
  PERIODIC MAINTENANCE ECA21300 NOTICE Vacuum gauge 90890-03094 Do not turn the bypass air screw (white paint Vacuummate mark) of the throttle body that is the stan- YU-44456 dard. Otherwise, the engine may run roughly at idle and the throttle bodies may not oper- ate properly.

• Page 118: Checking The Throttle Body Joints

  PERIODIC MAINTENANCE • Exhaust chamber “2” EAS31318 CHECKING THE THROTTLE BODY JOINTS • Muffler “3” 1. Remove: Cracks/damage → Replace. • Throttle bodies • Gasket “4” Refer to “THROTTLE BODIES” on page Exhaust gas leaks → Replace. 7-11. 2. Check: 2.

• Page 119: Checking The Air Induction System

  PERIODIC MAINTENANCE 2. Check: 4. Install: • Canister “1” • Air filter element • Canister purge hose • Upper air filter case • Fuel tank breather hose ECA20710 NOTICE Cracks/damage → Replace. Loose connection → Connect properly. Never operate the engine without the air filter element installed.

• Page 120: Checking The Brake Operation

  PERIODIC MAINTENANCE e. Install the front side cowling (right). Refer to “GENERAL CHASSIS (5)” on page 4-16. EAS30801 CHECKING THE BRAKE OPERATION 1. Check: • Brake operation Brake not working properly → Check the brake system. G088887 Refer to “FRONT BRAKE” on page 4-52 and 2.

• Page 121: Adjusting The Front Disc Brake

  PERIODIC MAINTENANCE erably reduce brake performance resulting ECA13540 NOTICE in loss of control and possibly cause an ac- Brake fluid may damage painted surfaces cident. Therefore, check and if necessary, and plastic parts. Therefore, always clean up bleed the brake system. any spilt brake fluid immediately.

• Page 122: Checking The Rear Brake Pads

  PERIODIC MAINTENANCE air must be removed by bleeding the brake 2. Check: system. Air in the brake system will consid- • Brake hose surface erably reduce braking performance. Partly blackened surface on the brake hose → Replace. ECA13510 3. Check: NOTICE •…

• Page 123: Bleeding The Hydraulic Brake System (Abs)

  PERIODIC MAINTENANCE EAS30893 BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS) EWA14000 WARNING Always bleed the brake system when the brake related parts are removed. ECA22640 NOTICE • Bleed the brake system in the following or- der. • 1st step: Front brake master cylinder •…

• Page 124: Checking The Wheels

  The following procedure applies to both of the en if a tire combination other than one tires. approved by Yamaha is used on this vehicle. 1. Check: • Tire pressure Front tire Out of specification → Regulate.

• Page 125: Checking The Wheel Bearings

  PERIODIC MAINTENANCE Refer to “INSTALLING THE SWINGARM” on EWA13210 WARNING page 4-123. New tires have a relatively low grip on the EAS31923 road surface until they have been slightly DRIVE CHAIN SLACK worn. Therefore, approximately 100 km should be traveled at normal speed before Checking the drive chain slack any high-speed riding is done.

• Page 126: Lubricating The Drive Chain

  PERIODIC MAINTENANCE Adjusting the drive chain slack that is suitable for O-ring chains. Do not use any EWA13120 other lubricants on the drive chain since they WARNING may contain solvents that could damage the O- Securely support the vehicle so that there is rings.

• Page 127: Lubricating The Steering Head

  PERIODIC MAINTENANCE G088893 G088894 5. Install: Steering nut wrench • Upper bracket 90890-01403 Refer to “HANDLEBARS” on page 4-83. Exhaust flange nut wrench YU-A9472 EAS30646 LUBRICATING THE STEERING HEAD 1. Lubricate: Lower ring nut (initial tightening • Upper bearing torque) •…

• Page 128: Checking The Sidestand

  PERIODIC MAINTENANCE EAS30806 ADJUSTING THE FRONT FORK LEGS (for Recommended lubricant YZF-R1) Molybdenum disulfide grease The following procedure applies to both of the front fork legs. EAS30650 CHECKING THE SIDESTAND EWA13120 WARNING 1. Check: • Sidestand operation Securely support the vehicle so that there is Check that the sidestand moves smoothly.

• Page 129
  PERIODIC MAINTENANCE Rebound damping Compression damping ECA13590 ECA13590 NOTICE NOTICE Never go beyond the maximum or minimum Never go beyond the maximum or minimum adjustment positions. adjustment positions. 1. Adjust: 1. Adjust: • Rebound damping • Compression damping a. Turn the adjusting bolt “1” in direction “a” a.

• Page 130: Adjusting The Preload Of The Front Fork Legs (For Yzf-R1M)

  PERIODIC MAINTENANCE EAS31635 ADJUSTING THE PRELOAD OF THE FRONT Spring preload FORK LEGS (for YZF-R1M) Minimum (soft) The following procedure applies to both of the 0 turn(s) in direction “a” front fork legs. Standard EWA13120 3 turn(s) in direction “a” WARNING Maximum (hard) Securely support the vehicle so that there is…

• Page 131
  PERIODIC MAINTENANCE based on running conditions. For all modes and models, spring preload is physically adjusted by 10 : 00 YRC Setting hand. M — 1 For track modes T-1 and T-2, the following set- M — 2 tings can be adjusted: M — 3 BRAKE SUPPORT: reduces nosedive (front- end pitch from braking)

• Page 132: Checking The Rear Shock Absorber Assembly

  PERIODIC MAINTENANCE f. Select the suspension item that you want to adjust, and then rotate the wheel switch 10 : 00 MENU to adjust the setting level. Display Mode YRC Setting All ERS modes regardless of type are indepen- Lap Time dent.
• Page 133
  PERIODIC MAINTENANCE Direction “a” Rebound damping is increased (sus- pension is harder). Direction “b” Rebound damping is decreased (sus- pension is softer). Rebound damping Minimum (soft) 23 click(s) in direction “b” Standard The spring preload setting is determined by 12 click(s) in direction “b” measuring distance “c”.

• Page 134: Adjusting The Preload Of The Rear Shock Absorber Assembly (For Yzf-R1M)

  PERIODIC MAINTENANCE Direction “a” Direction “a” Compression damping is increased Compression damping is increased (suspension is harder). (suspension is harder). Direction “b” Direction “b” Compression damping is decreased Compression damping is decreased (suspension is softer). (suspension is softer). Fast compression damping Slow compression damping Minimum (soft) Minimum (soft)

• Page 135: Checking The Connecting Arm And Relay Arm

  PERIODIC MAINTENANCE Spring preload Spring preload ECA13590 NOTICE Minimum 0 mm (0.00 in) Never go beyond the maximum or minimum Standard adjustment positions. 4 mm (0.16 in) 1. Adjust: Maximum • Spring preload 9 mm (0.35 in) a. Loosen the locknut “1”. d.

• Page 136: Changing The Engine Oil

  PERIODIC MAINTENANCE Recommended brand YAMALUBE Type Full synthetic SAE viscosity grades 10W-40, 15W-50 Recommended engine oil grade API service SG type or higher, JASO standard MA ECA13361 NOTICE 4. Drain: • Engine oil • Engine oil also lubricates the clutch and the (completely from the crankcase) wrong oil types or additives could cause 5.

• Page 137: Measuring The Engine Oil Pressure

  PERIODIC MAINTENANCE 6. Install: • Oil pressure switch joint (with the oil pressure • Engine oil drain bolt switch) “2” EWA12980 (along with the gasket WARNING The engine, muffler and engine oil are ex- Engine oil drain bolt tremely hot. 23 N·m (2.3 kgf·m, 17 lb·ft) 7.

• Page 138: Checking The Coolant Level

  PERIODIC MAINTENANCE EAS30811 6. Start the engine, warm it up for several min- CHECKING THE COOLANT LEVEL utes. 1. Stand the vehicle on a level surface. ECA13410 NOTICE • Place the vehicle on a maintenance stand. When the engine is cold, the engine oil will •…

• Page 139: Checking The Cooling System

  PERIODIC MAINTENANCE sidual pressure to escape. When the hissing EAS30812 CHECKING THE COOLING SYSTEM sound has stopped, press down on the radi- 1. Check: ator cap and turn it counterclockwise to re- • Radiator “1” move. • Radiator inlet hose “2” •…

• Page 140
  PERIODIC MAINTENANCE ECA21291 NOTICE • Adding water instead of coolant dilutes the antifreeze concentration of the coolant. If water is used instead of coolant; check, and if necessary, correct the antifreeze concentration of the coolant. • Use only distilled water. However, if dis- tilled water is not available, soft water may be used.

• Page 141: Adjusting The Exup Cables

  PERIODIC MAINTENANCE 14.Pour the specified coolant into the radiator until it is full. 15.Install: • Radiator cap 16.Start the engine, warm it up for several min- utes, and then turn it off. 17.Check: • Coolant level Refer to “CHECKING THE COOLANT LEV- EL”…

• Page 142: Checking The Front Brake Light Switch

  PERIODIC MAINTENANCE EAS31147 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the in- ner and outer cables. EWA13270 WARNING Damaged outer cable may cause the cable to corrode and interfere with its movement. Re- place damaged outer cable and inner cables as soon as possible.

• Page 143: Adjusting The Headlight Beams

  PERIODIC MAINTENANCE EAS30664 ADJUSTING THE HEADLIGHT BEAMS 1. Adjust: • Headlight beam (vertically) To adjust the headlight beam (vertically), insert a crosshead screwdriver into the holes “a” in the headlight cover and turn the adjusting screw. a. Turn the adjusting screws “1”. a.

• Page 144
  PERIODIC MAINTENANCE 3-37…

• Page 145: Chassis

  CHASSIS GENERAL CHASSIS (1) …………….. 4-1 REMOVING THE TAIL COVER …………..4-5 REMOVING THE REAR SIDE COVER………….4-5 INSTALLING THE IMU…………….4-5 INSTALLING THE REAR SIDE COVER ……….. 4-6 INSTALLING THE TAIL COVER …………… 4-6 GENERAL CHASSIS (2) …………….. 4-7 REMOVING THE TAIL COVER …………..4-8 INSTALLING THE CCU (for YZF-R1M) …………

• Page 146
  GENERAL CHASSIS (7) …………….4-28 CHECKING THE AIR INTAKE DUCT VALVE………4-30 CHECKING THE VACUUM LINE…………4-30 ASSEMBLING THE AIR INTAKE DUCT ASSEMBLY……4-30 INSTALLING THE AIR INTAKE DUCT VALVE……..4-31 GENERAL CHASSIS (8) …………….4-32 REMOVING THE ECU (engine control unit) ………..4-33 INSTALLING THE ECU (engine control unit) ……….4-33 GENERAL CHASSIS (9) …………….
• Page 147
  REAR BRAKE ………………..4-63 INTRODUCTION ………………4-68 CHECKING THE REAR BRAKE DISC…………4-68 REPLACING THE REAR BRAKE PADS……….4-68 REMOVING THE REAR BRAKE CALIPER ……….4-69 DISASSEMBLING THE REAR BRAKE CALIPER ……..4-69 CHECKING THE REAR BRAKE CALIPER……….4-70 ASSEMBLING THE REAR BRAKE CALIPER ……..4-70 INSTALLING THE REAR BRAKE CALIPER………..4-70 REMOVING THE REAR BRAKE MASTER CYLINDER ……
• Page 148
  REAR SHOCK ABSORBER ASSEMBLY ……….4-112 HANDLING THE REAR SHOCK ABSORBER ……..4-116 DISPOSING OF A REAR SHOCK ABSORBER ……..4-116 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY….4-116 DISASSEMBLING THE REAR SHOCK ABSORBER ASSEMBLY..4-117 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ….4-117 CHECKING THE CONNECTING ARM AND RELAY ARM….4-117 ASSEMBLING THE REAR SHOCK ABSORBER ASSEMBLY…..4-118 INSTALLING THE RELAY ARM…………4-118 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ….4-119…
• Page 150
  GENERAL CHASSIS (1) EAS20026 GENERAL CHASSIS (1) Removing the seats and battery 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 2.0 N ・…

• Page 151: General Chassis (1)

  GENERAL CHASSIS (1) Removing the rear side covers and rear fender (for YZF-R1) m (0.7 kgf m, 5.2 lb • • • m (0.9 kgf m, 6.6 lb • • • 10 9 m (0.9 kgf m, 6.6 lb • •…

• Page 152
  GENERAL CHASSIS (1) Removing the rear side covers and rear fender (for YZF-R1M) m (0.9 kgf m, 6.6 lb m (0.7 kgf m, 5.2 lb • • • • • • m (0.9 kgf m, 6.6 lb • • • m (0.9 kgf m, 6.6 lb •…
• Page 153
  GENERAL CHASSIS (1) Disassembling the mudguard assembly 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 1.8 N ・ m (0.18 kgf ・ m, 1.3 lb ・ ft) ’ Order Job/Parts to remove Remarks Mudguard assembly cover Clamp Stay Rear turn signal light…

• Page 154: Removing The Tail Cover

  GENERAL CHASSIS (1) EAS33139 REMOVING THE TAIL COVER 1. Remove: • Tail cover “1” EAS31636 INSTALLING THE IMU ECA22611 NOTICE a. Remove the quick fasteners. • Do not perform angle adjustment of the IMU b. Unhook the projections “a” on the tail cov- and battery box by pinching the washer er “1”…

• Page 155: Installing The Rear Side Cover

  GENERAL CHASSIS (1) EAS33140 INSTALLING THE TAIL COVER Recommended lubricant 1. Install: Silicone grease • Tail cover “1” IMU bolt 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) a. Fit the projections “a” on the tail cover “1” into the holes “b” in the rear fender, and then install the quick fasteners.

• Page 156
  Rider seat/Passenger seat/Battery cover 4-1. Passenger seat cover GPS unit coupler Disconnect. Cushion GPS unit Tail cover CCU coupler (sub-wire harness) Disconnect. Band CCU (Communication Control Unit) CCU bracket 1 CCU bracket 2 Wire harness coupler Disconnect. Yamaha diagnostic tool coupler Sub-wire harness…

• Page 157: Removing The Tail Cover

  Contact your local authori- proach the vehicle with a wireless capable ties. smartphone or tablet. d. Connect to the wireless network “Yamaha EAS31676 CONNECTING TO THE CCU (for YZF-R1M) Motor Network” by inputting the CCU seri- The CCU (Communication Control Unit) con- al number as the password.
• Page 158
  GENERAL CHASSIS (3) EAS20156 GENERAL CHASSIS (3) Removing the front panel covers 3.8 N m (0.38 kgf m, 2.8 lb • • • 3.8 N m (0.38 kgf m, 2.8 lb • • • 3.5 N m (0.35 kgf m, 2.6 lb •…

• Page 159: Removing The Front Panel (Left)

  GENERAL CHASSIS (3) c. Unhook the projections “e” on the front EAS31352 REMOVING THE FRONT PANEL (LEFT) panel cover (left) from the holes “f” on the 1. Remove: front cowling. • Front panel (left) “1” d. Unhook the projections “g” on the front panel cover (left) from the holes “h”…

• Page 160: Removing The Front Panel Cover (Right)

  GENERAL CHASSIS (3) a. Fit the projections “a” on the front panel EAS33348 REMOVING THE FRONT PANEL COVER cover (left) into the holes “b” on the front (RIGHT) upper cowling. 1. Remove: b. Insert the projections “c” on the front panel •…

• Page 161: Installing The Front Panel Cover (Right)

  GENERAL CHASSIS (3) a. Fit the projections “a” on the front panel EAS33350 INSTALLING THE FRONT PANEL COVER (right) “1” into the holes “b” in the front pan- (RIGHT) el cover (right). Slide the front panel (right) 1. Install: rearward. •…

• Page 162
  GENERAL CHASSIS (4) EAS20157 GENERAL CHASSIS (4) Removing the Rearview mirrors and windshield 0.4 N m (0.04 kgf m, 0.30 lb • • • 4.0 N m (0.40 kgf m, 3.0 lb • • • m (0.7 kgf m, 5.2 lb •…

• Page 163: Removing The Front Upper Cowling

  GENERAL CHASSIS (4) d. Remove the front upper cowling bolts “7”. EAS31362 REMOVING THE FRONT UPPER COWLING 1. Remove: • Front upper cowling “1” e. Remove the front upper cowling “1”. f. Unhook the projections “a” on the front up- per cowling from the holes “b”…

• Page 164: General Chassis (5)

  GENERAL CHASSIS (4) on the front upper cowling into the grom- mets “d” in the front cowling assembly. Fit the projections “e” on the front upper cowl- ing into the holes “f” on the front cowling assembly. Fit the projections “g” on the front upper cowling into the holes “h”…

• Page 165
  GENERAL CHASSIS (5) EAS20158 GENERAL CHASSIS (5) Removing the front side cowlings (for YZF-R1) m (0.9 kgf m, 6.6 lb m (0.9 kgf m, 6.6 lb • • • • • • m (0.7 kgf m, 5.2 lb • • •…
• Page 166
  GENERAL CHASSIS (5) Removing the front side cowlings (for YZF-R1M) m (0.9 kgf m, 6.6 lb m (0.9 kgf m, 6.6 lb • • • • • • m (0.7 kgf m, 5.2 lb • • • m (0.9 kgf m, 6.6 lb m (0.7 kgf m, 5.2 lb…

• Page 167: Removing The Front Muffler Protector (Left)

  GENERAL CHASSIS (5) EAS33365 REMOVING THE FRONT MUFFLER PROTECTOR (LEFT) 1. Remove: • Front muffler protector (left) “1” EAS31696 REMOVING THE FRONT SIDE COWLING (LEFT) (for YZF-R1) 1. Remove: • Front side cowling (left) “1” a. Remove the front muffler protector bolts (left).

• Page 168: Removing The Front Side Cowling (Right) (For Yzf-R1)

  GENERAL CHASSIS (5) a. Remove the front side cowling bolts, quick EAS33340 REMOVING THE FRONT SIDE COWLING fastener screws and quick fasteners. (RIGHT) (for YZF-R1) b. Pull the front side cowling (left) “1” for- 1. Remove: ward, and then unhook the projection “a” •…

• Page 169: Installing The Front Side Cowling (Right) (For Yzf-R1)

  GENERAL CHASSIS (5) a. Fit the projection “a” on the front side cowl- EAS33341 INSTALLING THE FRONT SIDE COWLING ing (left) “1” into the hole “b” on the front (RIGHT) (for YZF-R1) cowling. 1. Install: b. Fit the projection “c” on the front side cowl- •…

• Page 170: Installing The Front Side Cowling (Left) (For Yzf-R1M)

  GENERAL CHASSIS (5) EAS33367 INSTALLING THE FRONT MUFFLER PROTECTOR (LEFT) 1. Install: • Front muffler protector (left) “1” c. Install the front side cowling bolts, quick fastener screws and quick fasteners. Front side cowling bolt 9 N·m (0.9 kgf·m, 6.6 lb·ft) a.

• Page 171: General Chassis (6)

  GENERAL CHASSIS (5) Front muffler protector bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) 4-22…

• Page 172
  GENERAL CHASSIS (6) EAS20159 GENERAL CHASSIS (6) Removing the side covers and front cowling assembly m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb • •…
• Page 173
  GENERAL CHASSIS (6) Removing the side covers and front cowling assembly m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb •…
• Page 174
  GENERAL CHASSIS (6) Disassembling the front cowling assembly 1.5 N m (0.15 kgf m, 1.1 lb • • • 1.5 N m (0.15 kgf m, 1.1 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.5 kgf m, 3.7 lb •…

• Page 175: Removing The Side Cover (Left)

  GENERAL CHASSIS (6) EAS33354 REMOVING THE SIDE COVER (LEFT) 1. Remove: • Side cover (left) “1” EAS33356 INSTALLING THE SIDE COVER (LEFT) 1. Install: • Side cover (left) “1” a. Remove the side cover bolt (right) and quick fastener. b. Pull the side cover (left) “1” rearward and unhook the projections “a”…

• Page 176: Installing The Side Cover (Right)

  GENERAL CHASSIS (6) • Insert the projection “a” on the side cover bracket (right) “1” in the hole of the frame. • Hook the projection “b” on the side cover bracket (right) “1” to the frame. • Push the projection “b” on the side cover brack- et (right) “1”…

• Page 177
  GENERAL CHASSIS (7) EAS20193 GENERAL CHASSIS (7) Removing the air intake duct 11 N m (1.1 kgf m, 8.1 lb • • • 3.0 N m (0.30 kgf m, 2.2 lb • • • 11 N m (1.1 kgf m, 8.1 lb •…
• Page 178
  GENERAL CHASSIS (7) Removing the air intake duct 11 N m (1.1 kgf m, 8.1 lb • • • 3.0 N m (0.30 kgf m, 2.2 lb • • • 11 N m (1.1 kgf m, 8.1 lb • • •…

• Page 179: Checking The Air Intake Duct Valve

  GENERAL CHASSIS (7) EAS31645 CHECKING THE AIR INTAKE DUCT VALVE 1. Check: • Air intake duct valve operation a. Connect the vacuum/pressure pump gauge set “1” to the air intake duct valve “2”. Vacuum/pressure pump gauge 90890-06945 4. Check: Pressure/ vacuum tester YB-35956-B •…

• Page 180: Installing The Air Intake Duct Valve

  GENERAL CHASSIS (7) EAS31647 INSTALLING THE AIR INTAKE DUCT VALVE 1. Install: • Air intake duct valve a. Hook the end of the shaft “a” onto the plate “1” as shown. b. Align the tabs “b” on the air intake duct valve “2”…

• Page 181
  GENERAL CHASSIS (8) EAS20194 GENERAL CHASSIS (8) Removing the ECU and side cover bracket m (0.7 kgf m, 5.2 lb • • • ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (3)” on page Front panel cover (left) 4-9.

• Page 182: Removing The Ecu (Engine Control Unit)

  GENERAL CHASSIS (8) EAS31641 REMOVING THE ECU (engine control unit) 1. Disconnect: • ECU coupler “1” While pushing the portion “a” of the ECU cou- pler, move the lock lever “b” in the direction of the arrow shown to disconnect the coupler. EAS31642 INSTALLING THE ECU (engine control unit) 1.

• Page 183
  GENERAL CHASSIS (9) EAS20195 GENERAL CHASSIS (9) Removing the electrical components tray m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb • • • ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (3)” on page Front panel cover (left) 4-9.

• Page 184: Front Wheel

  FRONT WHEEL EAS20028 FRONT WHEEL Removing the front wheel and brake discs (for YZF-R1) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 2.5 N m (0.25 kgf m, 1.8 lb • • • 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 35 N ・…
• Page 185
  FRONT WHEEL Removing the front wheel and brake discs (for YZF-R1M) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 2.5 N m (0.25 kgf m, 1.8 lb • • • 35 N ・ m (3.5 kgf ・ m, 26 lb ・ ft) 6 N ・…
• Page 186
  FRONT WHEEL Disassembling the front wheel 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) ’ Order Job/Parts to remove Remarks Front wheel sensor rotor Oil seal Wheel ring Wheel bearing Spacer 4-37…

• Page 187: Removing The Front Wheel

  FRONT WHEEL • Wheel bearings EAS30145 REMOVING THE FRONT WHEEL a. Clean the surface of the front wheel hub. ECA20981 b. Remove the oil seals “1” with a flat-head NOTICE screwdriver. • Keep any type of magnets (including mag- netic pick-up tools, magnetic screwdrivers, To prevent damaging the wheel, place a rag “2”…

• Page 188: Assembling The Front Wheel

  FRONT WHEEL Place a suitable washer “1” between the socket “2” and the bearing so that both the inner race “3” and outer race “4” are pressed at the same time, and then press the bearing until the inner race makes contact with the spacer “5”. G088897 4.

• Page 189: Maintenance Of The Front Wheel Sensor And Sensor Rotor

  FRONT WHEEL a. Hold the dial gauge at a right angle against EAS30155 MAINTENANCE OF THE FRONT WHEEL the wheel sensor rotor surface. SENSOR AND SENSOR ROTOR b. Measure the wheel sensor rotor runout. ECA21070 NOTICE • Handle the ABS components with care since they have been accurately adjusted.

• Page 190
  FRONT WHEEL Front brake disc bolt Apply lithium soap-based grease onto the mat- 17 N·m (1.7 kgf·m, 13 lb·ft) ing surface of the front wheel axle nut. LOCTITE® 6. Tighten: ECA19150 • Front wheel axle nut NOTICE Replace the brake disc bolts with new ones. Front wheel axle nut 115 N·m (11.5 kgf·m, 85 lb·ft) Tighten the brake disc bolts in stages and in a…
• Page 191
  FRONT WHEEL Distance “a” (between the front wheel sensor rotor and front wheel sensor) 0.9–1.7 mm (0.035–0.067 in) (for YZF-R1) 1.1–1.9 mm (0.043–0.075 in) (for YZF-R1M) Measure the distance between the front wheel 8. Install: sensor rotor and front wheel sensor in several •…

• Page 192: Rear Wheel

  REAR WHEEL EAS20029 REAR WHEEL Removing the rear wheel 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 190 N ・ m (19 kgf ・ m, 140 lb ・ ft) 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) 16 N ・…

• Page 193
  REAR WHEEL Removing the brake disc and rear wheel sprocket 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 30 N m (3.0 kgf m, 22 lb • • • 105 N ・ m (10.5 kgf ・ m, 77 lb ・ ft) 28 N ・…
• Page 194
  REAR WHEEL Disassembling the rear wheel 80 N ・ m (8.0 kgf ・ m, 59 lb ・ ft) ’ Order Job/Parts to remove Remarks Collar Oil seal Wheel bearing Spacer Oil seal Wheel bearing ring nut Wheel bearing 4-45…

• Page 195: Removing The Rear Wheel

  REAR WHEEL EAS30910 ECA21040 REMOVING THE REAR WHEEL NOTICE ECA21030 • Do not depress the brake pedal when re- NOTICE moving the brake caliper. • Keep any type of magnets (including mag- • Be sure not to contact the sensor electrode netic pick-up tools, magnetic screwdrivers, to any metal part when removing the rear etc.) away from the rear wheel sensor or…

• Page 196: Checking The Rear Wheel

  REAR WHEEL • Rear wheel drive hub dampers Damage/wear → Replace. EAS30161 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1. Check: • Rear wheel sprocket More than 1/4 tooth “a” wear → Replace the drive sprocket, the rear wheel sprocket and the drive chain as a set.

• Page 197: Assembling The Rear Wheel

  REAR WHEEL EAS30163 ASSEMBLING THE REAR WHEEL Wheel bearing ring nut tool ECA21340 90890-01574 NOTICE YM-01574 • Do not drop the wheel sensor rotor or sub- ject it to shocks. Wheel bearing ring nut • If any solvent gets on the wheel sensor ro- 80 N·m (8.0 kgf·m, 59 lb·ft) tor, wipe it off immediately.

• Page 198: Maintenance Of The Rear Wheel Sensor And Sensor Rotor

  REAR WHEEL • Be sure to use stick-on type balancing weights. 1. Adjust: • Rear wheel static balance Refer to “ADJUSTING THE FRONT WHEEL STATIC BALANCE” on page 4-40. EAS30165 INSTALLING THE REAR WHEEL (DISC BRAKE) 1. Install: • Rear brake disc •…

• Page 199
  REAR WHEEL 4. Install: 6. Tighten: • Collars • Rear wheel axle nut • Brake caliper bracket • Rear brake caliper bolts • Rear wheel Rear wheel axle nut • Adjusting blocks 190 N·m (19 kgf·m, 140 lb·ft) • Rear wheel axle Rear brake caliper bolt (front) •…
• Page 200
  REAR WHEEL 8. Measure: • Distance “a” (between the rear wheel sensor rotor “1” and rear wheel sensor “2”) Out of specification → Check the wheel bear- ing for looseness, and the rear wheel sensor and sensor rotor installation conditions (warpage caused by overtorque, wrong in- stallation direction, rotor decentering, LOC- TITE®…

• Page 201: Front Brake

  FRONT BRAKE EAS20030 FRONT BRAKE Removing the front brake pads 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) 35 N ・ m (3.5 kgf ・ m, 26 lb ・ ft) ’…

• Page 202
  FRONT BRAKE Removing the front brake master cylinder 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) 1.2 N ・ m (0.12 kgf ・ m, 0.88 lb ・ ft) 32 N ・ m (3.2 kgf ・ m, 24 lb ・ ft) 1.0 N ・…
• Page 203
  FRONT BRAKE Disassembling the front brake master cylinder 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) ’ Order Job/Parts to remove Remarks Brake master cylinder kit Bleed screw Brake master cylinder body 4-54…
• Page 204
  FRONT BRAKE Removing the front brake calipers 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 32 N ・ m (3.2 kgf ・ m, 24 lb ・ ft) 35 N ・ m (3.5 kgf ・ m, 26 lb ・ ft) ’…
• Page 205
  FRONT BRAKE Disassembling the front brake calipers 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) ’ Order Job/Parts to remove Remarks The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston…

• Page 206: Introduction

  FRONT BRAKE EAS30168 INTRODUCTION EWA14101 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • Never disassemble brake components un- less absolutely necessary. • If any connection on the hydraulic brake G098641 system is disconnected, the entire brake 3.

• Page 207
  FRONT BRAKE • Brake pad pin “2” a. Connect a clear plastic hose “1” tightly to • Brake pad spring “3” the bleed screw “2”. Put the other end of the hose into an open container. b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger.

• Page 208: Removing The Front Brake Calipers

  FRONT BRAKE 8. Check: c. Remove the brake caliper piston dust • Brake lever operation seals and brake caliper piston seals. Soft or spongy feeling → Bleed the brake sys- d. Repeat the previous steps to force out the tem. right side pistons from the brake caliper.

• Page 209: Installing The Front Brake Calipers

  FRONT BRAKE • Brake pad spring Specified brake fluid • Brake pad pin DOT 4 • Brake pad clips • Front brake caliper EAS30175 INSTALLING THE FRONT BRAKE CALIPERS Front brake caliper bolt The following procedure applies to both of the 35 N·m (3.5 kgf·m, 26 lb·ft) brake calipers.

• Page 210: Removing The Front Brake Master Cylinder

  FRONT BRAKE EAS30179 REMOVING THE FRONT BRAKE MASTER Specified brake fluid CYLINDER DOT 4 Before removing the front brake master cylinder, EAS30182 INSTALLING THE FRONT BRAKE MASTER drain the brake fluid from the entire brake sys- CYLINDER tem. 1. Install: 1.

• Page 211
  FRONT BRAKE • Turn the handlebars to the left and right to 6. Check: make sure the brake hose does not touch other • Brake lever operation Soft or spongy feeling → Bleed the brake sys- parts (e.g., wire harness, cables, leads). Cor- rect if necessary.

• Page 212: Rear Brake

  REAR BRAKE EAS20031 REAR BRAKE Removing the rear brake pads 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) 27 N ・ m (2.7 kgf ・ m, 20 lb ・ ft) 17 N ・ m (1.7 kgf ・ m, 13 lb ・ ft) 2.5 N ・…
• Page 213
  REAR BRAKE Removing the rear brake master cylinder 32 N ・ m (3.2 kgf ・ m, 24 lb ・ ft) 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 7 N ・…
• Page 214
  REAR BRAKE Removing the rear brake master cylinder 32 N ・ m (3.2 kgf ・ m, 24 lb ・ ft) 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 7 N ・…
• Page 215
  REAR BRAKE Removing the rear brake caliper 32 N ・ m (3.2 kgf ・ m, 24 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 27 N ・ m (2.7 kgf ・ m, 20 lb ・ ft) ’…
• Page 216
  REAR BRAKE Disassembling the rear brake caliper 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) 17 N ・ m (1.7 kgf ・ m, 13 lb ・ ft) 2.5 N ・ m (0.25 kgf ・ m, 1.8 lb ・ ft) ’…

• Page 217: Introduction

  REAR BRAKE 4. Adjust: EAS30183 INTRODUCTION • Brake disc runout EWA14101 Refer to “CHECKING THE FRONT BRAKE WARNING DISCS” on page 4-57. Disc brake components rarely require disas- sembly. Therefore, always follow these pre- Rear brake disc bolt ventive measures: 27 N·m (2.7 kgf·m, 20 lb·ft) •…

• Page 218: Removing The Rear Brake Caliper

  REAR BRAKE • Remove any excess grease. 4. Install: • Rear brake caliper • Brake pad retaining bolts • Screw plug Rear brake caliper bolt (front) 27 N·m (2.7 kgf·m, 20 lb·ft) Rear brake caliper bolt (rear) 12 N·m (1.2 kgf·m, 8.9 lb·ft) LOCTITE®…

• Page 219: Checking The Rear Brake Caliper

  REAR BRAKE 2. Check: EWA13550 WARNING • Rear brake caliper bracket Cracks/damage → Replace. • Cover the brake caliper piston with a rag. Be careful not to get injured when the pis- Refer to “REAR WHEEL” on page 4-43. ton is expelled from the brake caliper. EAS30189 •…

• Page 220: Removing The Rear Brake Master Cylinder

  REAR BRAKE • When refilling, be careful that water does not enter the brake fluid reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. ECA13540 NOTICE Brake fluid may damage painted surfaces and plastic parts.

• Page 221: Checking The Rear Brake Master Cylinder

  REAR BRAKE EAS30194 CHECKING THE REAR BRAKE MASTER CYLINDER 1. Check: • Brake master cylinder Damage/scratches/wear → Replace. • Brake fluid delivery passages (brake master cylinder body) Obstruction → Blow out with compressed air. 2. Check: • Brake fluid reservoir 2.

• Page 222
  REAR BRAKE 6. Adjust: • Rear brake light operation timing Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH” on page 3-35. 4-73…

• Page 223: Abs (Anti-Lock Brake System)

  ABS (Anti-lock Brake System) EAS20032 ABS (Anti-lock Brake System) Removing the hydraulic unit assembly m (0.7 kgf m, 5.2 lb m (0.7 kgf m, 5.2 lb • • • • • • 32 N m (3.2 kgf m, 24 lb •…

• Page 224
  ABS (Anti-lock Brake System) Removing the hydraulic unit assembly m (0.7 kgf m, 5.2 lb m (0.7 kgf m, 5.2 lb • • • • • • 32 N m (3.2 kgf m, 24 lb • • • 16 N m (1.6 kgf m, 12 lb •…

• Page 225: Abs Components Chart

  ABS (Anti-lock Brake System) EAS30728 ABS COMPONENTS CHART 15,16 1. Meter assembly 2. Hydraulic unit assembly 3. Fuse box 1 4. ABS solenoid fuse 5. YDT coupler 6. Starter relay 7. ABS motor fuse 8. Rear brake caliper 9. Rear wheel sensor rotor 10.

• Page 226: Removing The Hydraulic Unit Assembly

  ABS (Anti-lock Brake System) EAS30197 REMOVING THE HYDRAULIC UNIT ASSEMBLY ECA18230 NOTICE Unless necessary, avoid removing and in- stalling the brake pipes of the hydraulic unit assembly. EWA13930 WARNING Refill with the same type of brake fluid that is 2. Remove: already in the system.

• Page 227: Checking The Hydraulic Unit Assembly

  ABS (Anti-lock Brake System) Hydraulic unit assembly bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) LOCTITE® EAS30198 CHECKING THE HYDRAULIC UNIT ASSEMBLY 1. Check: • Hydraulic unit assembly 2. Remove: Cracks/damage → Replace the hydraulic unit • Rubber plugs or bolts (M10 × 1.0) assembly and the brake pipes that are con- 3.

• Page 228: Hydraulic Unit Operation Test

  ABS (Anti-lock Brake System) • When refilling, be careful that water does not enter the brake master cylinder reser- There is an identifying white paint mark “c” on voir or brake fluid reservoir. Water will sig- the upper surface of the pipe of the brake hose nificantly lower the boiling point of the (front brake master cylinder to the hydraulic brake fluid and could cause vapor lock.

• Page 229
  “2”, and again in the brake lever “1”, in this or- der. • Yamaha diagnostic tool (A/I) (90890-03264) in- cludes 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. Refer to “YDT” on page 9-2.
• Page 230
  YDT sub harness (6P) (90890-03266). hoses and brake pipes are connected cor- • If you already have Yamaha diagnostic tool (A/ rectly to the hydraulic unit assembly. I) (90890-03262), YDT sub harness (6P) 10.If the operation of the hydraulic unit is normal,…

• Page 231: Checking The Abs Warning Light

  12.Turn the main switch to “OFF”. 13.Remove the Yamaha diagnostic tool from the Yamaha diagnostic tool coupler, and then in- G088913 stall the protective cap.

• Page 232: Handlebars

  HANDLEBARS EAS20033 HANDLEBARS Removing the handlebars 3.8 N m (0.38 kgf m, 2.8 lb m (0.7 kgf m, 5.2 lb 115 N m (11.5 kgf m, 85 lb • • • • • • • • • 16 N m (1.6 kgf m, 12 lb m (0.7 kgf m, 5.2 lb…

• Page 233
  HANDLEBARS Removing the handlebars 3.8 N m (0.38 kgf m, 2.8 lb m (0.7 kgf m, 5.2 lb 115 N m (11.5 kgf m, 85 lb • • • • • • • • • 16 N m (1.6 kgf m, 12 lb m (0.7 kgf m, 5.2 lb…
• Page 234
  HANDLEBARS Removing the handlebars 3.8 N m (0.38 kgf m, 2.8 lb m (0.7 kgf m, 5.2 lb 115 N m (11.5 kgf m, 85 lb • • • • • • • • • 16 N m (1.6 kgf m, 12 lb m (0.7 kgf m, 5.2 lb…

• Page 235: Removing The Handlebars

  HANDLEBARS EAS30203 REMOVING THE HANDLEBARS Steering stem nut 1. Stand the vehicle on a level surface. 115 N·m (11.5 kgf·m, 85 lb·ft) EWA13120 Upper bracket pinch bolt WARNING 26 N·m (2.6 kgf·m, 19 lb·ft) Securely support the vehicle so that there is Handlebar bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) no danger of it falling over.

• Page 236
  HANDLEBARS b. Make sure that the throttle grip “1” turns 5. Install: smoothly. • Front brake master cylinder assembly Refer to “INSTALLING THE FRONT BRAKE MASTER CYLINDER” on page 4-61. 6. Install: • Clutch lever holder “1” • Clutch cable Clutch lever holder pinch bolt 11 N·m (1.1 kgf·m, 8.1 lb·ft) Align the center of slit on the clutch lever holder…
• Page 237
  HANDLEBARS 8. Install: • Handlebar grip “1” • Grip end (left) “2” Grip end bolt 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) a. Apply a thin coat of rubber adhesive onto the end of the left handlebar. b. Side the handlebar grip over the end of the left handlebar.

• Page 238: Front Fork (For Yzf-R1)

  FRONT FORK (for YZF-R1) EAS20034 FRONT FORK (for YZF-R1) Removing the front fork legs (for YZF-R1) 32 N ・ m (3.2 kgf ・ m, 24 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 26 N ・…

• Page 239
  FRONT FORK (for YZF-R1) Disassembling the front fork legs (for YZF-R1) 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 40 N ・…
• Page 240
  FRONT FORK (for YZF-R1) Disassembling the front fork legs (for YZF-R1) 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 40 N ・…

• Page 241: Removing The Front Fork Legs (For Yzf-R1)

  FRONT FORK (for YZF-R1) EAS30206 EAS30207 REMOVING THE FRONT FORK LEGS (for DISASSEMBLING THE FRONT FORK LEGS YZF-R1) (for YZF-R1) The following procedure applies to both of the The following procedure applies to both of the front fork legs. front fork legs. 1.
• Page 242
  FRONT FORK (for YZF-R1) 5. Remove: ECA17390 NOTICE • Outer tube When loosening the nut, be sure not to break a. Hold the front fork leg horizontally. the projections on the cap bolt collar of the b. Securely clamp the brake caliper bracket cap bolt.

• Page 243: Checking The Front Fork Legs (For Yzf-R1)

  FRONT FORK (for YZF-R1) • When disassembling and assembling the front fork leg, do not allow any foreign ma- terial to enter the front fork. 4. Check: • Cap bolt “1” • Cap bolt collar projection “2” Cracks/damage → Replace. EAS30208 CHECKING THE FRONT FORK LEGS (for YZF-R1)

• Page 244
  3. Lubricate: • Inner tube’s outer surface 5. Install: • Outer tube Recommended oil (to the inner tube) Yamaha Suspension Oil 01 6. Install: • Outer tube bushing “1” 4. Install: • Washer “2” • Dust seal “1” (with the fork seal driver “3”) •…
• Page 245
  • Front fork leg (with the specified amount of the recom- mended fork oil) G088925 Recommended oil 9. Install: Yamaha Suspension Oil 01 • Dust seal “1” Quantity (left) (with the fork seal driver “2”) 470.0 cm³ (15.89 US oz, 16.58 Imp.oz)
• Page 246
  FRONT FORK (for YZF-R1) Install the fork spring with the smaller diameter “a” facing up “A”. G088929 13.Before measuring the fork oil level, wait ten minutes until the oil has settled and the air bubbles have dispersed. G088931 c. Install the locknut all the way onto the Be sure to bleed the front fork leg of any residual damper rod assembly.

• Page 247: Installing The Front Fork Legs (For Yzf-R1)

  FRONT FORK (for YZF-R1) EAS30210 INSTALLING THE FRONT FORK LEGS (for YZF-R1) The following procedure applies to both of the front fork legs. 1. Install: • Front fork leg Temporarily tighten the upper and lower bracket pinch bolts. EWA13680 WARNING Make sure the brake hoses are routed prop- i.

• Page 248
  FRONT FORK (for YZF-R1) • Handlebar bolt “2” Handlebar bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) • Handlebar pinch bolt “3” Handlebar pinch bolt 32 N·m (3.2 kgf·m, 24 lb·ft) • Upper bracket pinch bolt “4” Upper bracket pinch bolt 26 N·m (2.6 kgf·m, 19 lb·ft) When installing the front fork legs, make sure that the spring preload adjusting nuts are posi-…

• Page 249: Front Fork (For Yzf-R1M)

  FRONT FORK (for YZF-R1M) EAS20169 FRONT FORK (for YZF-R1M) Removing the front fork legs (for YZF-R1M) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 32 N ・ m (3.2 kgf ・ m, 24 lb ・ ft) 26 N ・…

• Page 250
  FRONT FORK (for YZF-R1M) Disassembling the front fork legs 20 N ・ m (2.0 kgf ・ m, 15 lb ・ ft) 19 N ・ m (1.9 kgf ・ m, 14 lb ・ ft) 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) ’…

• Page 251: Handling The Front Fork (For Yzf-R1M)

  FRONT FORK (for YZF-R1M) EAS33359 HANDLING THE FRONT FORK (for YZF-R1M) Place the vehicle on a maintenance stand so EWA20910 WARNING that the front wheel is elevated. This front fork contains highly compressed 2. Remove: nitrogen gas. Before handling the front fork, •…

• Page 252: Disassembling The Front Fork Legs (For Yzf-R1M)

  FRONT FORK (for YZF-R1M) b. Hold the spring preload adjusting bolt “5” 5. Remove: and loosen the locknut. • Front fork leg EAS31649 DISASSEMBLING THE FRONT FORK LEGS (for YZF-R1M) The following procedure applies to both of the front fork legs. 1.

• Page 253: Checking The Front Fork Legs (For Yzf-R1M)

  FRONT FORK (for YZF-R1M) 1. Lubricate: EAS31650 CHECKING THE FRONT FORK LEGS (for • Inner tube’s outer surface YZF-R1M) The following procedure applies to both of the Recommended oil front fork legs. Öhlins R&T 43 1. Check: • Inner tube 2.

• Page 254
  FRONT FORK (for YZF-R1M) 7. Fill: Fork seal driver • Front fork leg 90890-01442 (with the specified amount of the recom- Adjustable fork seal driver (36–46 mended fork oil) YM-01442 Recommended oil Öhlins R&T 43 Quantity (left) 263 cm³ (8.89 US oz, 9.26 Imp.oz) Quantity (right) 263 cm³…

• Page 255: Installing The Front Fork Legs

  FRONT FORK (for YZF-R1M) • Cap bolt d. Hold the spring preload adjusting bolt “3” and tighten the locknut “4” to specification. (along with the O-ring a. Install the spacer and fork spring. Front fork cap bolt locknut 19 N·m (1.9 kgf·m, 14 lb·ft) Install the fork spring with the marks “a”…

• Page 256
  FRONT FORK (for YZF-R1M) 2. Tighten: • Upper bracket pinch bolt “5” • Lower bracket pinch bolts “1” and “2” Upper bracket pinch bolt 26 N·m (2.6 kgf·m, 19 lb·ft) Lower bracket pinch bolt 23 N·m (2.3 kgf·m, 17 lb·ft) Tighten each bolt to 23 N·m (2.3 kgf·m, 17 lb·ft) in the order pinch bolt “1”…

• Page 257: Steering Head

  STEERING HEAD EAS20035 STEERING HEAD Removing the lower bracket 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 11 N ・ m (1.1 kgf ・ m, 8.1 lb ・ ft) 52 N ・ m (5.2 kgf ・ m, 38 lb ・ ft) 14 N ・…

• Page 258
  STEERING HEAD Removing the lower bracket 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 11 N ・ m (1.1 kgf ・ m, 8.1 lb ・ ft) 52 N ・ m (5.2 kgf ・ m, 38 lb ・ ft) 14 N ・…

• Page 259: Removing The Lower Bracket

  STEERING HEAD • Bearing race EAS30213 REMOVING THE LOWER BRACKET Damage/pitting → Replace the bearings and 1. Stand the vehicle on a level surface. bearing races as a set. EWA13120 3. Replace: WARNING • Bearing Securely support the vehicle so that there is •…

• Page 260: Installing The Steering Head

  STEERING HEAD EAS30216 INSTALLING THE STEERING HEAD 1. Lubricate: • Upper bearing • Lower bearing Recommended lubricant Lithium-soap-based grease 2. Install: • Lower ring nut “1” • Rubber washer “2” • Upper ring nut “3” • Lock washer “4” Refer to “CHECKING AND ADJUSTING THE STEERING HEAD”…

• Page 261
  REAR SHOCK ABSORBER ASSEMBLY EAS20036 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly (for YZF-R1) 40 N ・ m (4.0 kgf ・ m, 30 lb ・ ft) 40 N ・ m (4.0 kgf ・ m, 30 lb ・ ft) 40 N ・…
• Page 262
  REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly (for YZF-R1) 40 N ・ m (4.0 kgf ・ m, 30 lb ・ ft) 40 N ・ m (4.0 kgf ・ m, 30 lb ・ ft) 40 N ・ m (4.0 kgf ・ m, 30 lb ・ ft) ’…
• Page 263
  REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly (for YZF-R1M) 40 N ・ m (4.0 kgf ・ m, 30 lb ・ ft) 40 N ・ m (4.0 kgf ・ m, 30 lb ・ ft) 40 N ・ m (4.0 kgf ・ m, 30 lb ・ ft) ’…
• Page 264
  REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly (for YZF-R1M) 40 N ・ m (4.0 kgf ・ m, 30 lb ・ ft) 40 N ・ m (4.0 kgf ・ m, 30 lb ・ ft) 40 N ・ m (4.0 kgf ・ m, 30 lb ・ ft) ’…

• Page 265: Rear Shock Absorber Assembly

  REAR SHOCK ABSORBER ASSEMBLY EAS30826 HANDLING THE REAR SHOCK ABSORBER EWA13740 WARNING This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held responsi- ble for property damage or personal injury that may result from improper handling of the rear shock absorber.

• Page 266: Disassembling The Rear Shock Absorber Assembly

  REAR SHOCK ABSORBER ASSEMBLY • Collar “3” • Relay arm “4” Pull out the collar “3” from the left side of the ve- hicle. 4. Remove: • Oil seal • Bearing “1” Remove the bearing with a socket “2” that matches its outside diameter.

• Page 267: Assembling The Rear Shock Absorber Assembly

  REAR SHOCK ABSORBER ASSEMBLY • Oil seals EAS30222 INSTALLING THE RELAY ARM Damage/pitting → Replace. 1. Lubricate: 3. Check: • Collars • Collars • Oil seals Damage/scratches → Replace. Recommended lubricant EAS31654 Lithium-soap-based grease ASSEMBLING THE REAR SHOCK ABSORBER ASSEMBLY 2.

• Page 268: Installing The Rear Shock Absorber Assembly

  REAR SHOCK ABSORBER ASSEMBLY EAS30225 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Install: • Rear shock absorber assembly • Relay arm • Connecting arm • Install the rear shock absorber assembly upper bolt, relay arm bolt, connecting arm lower bolt and connecting arm upper bolt from the left.

• Page 269: Swingarm

  SWINGARM EAS20037 SWINGARM Removing the swingarm 65 N ・ m (6.5 kgf ・ m, 48 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 16 N ・…

• Page 270
  SWINGARM Removing the swingarm 65 N ・ m (6.5 kgf ・ m, 48 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 16 N ・…

• Page 271: Removing The Swingarm

  SWINGARM 5. Remove: EAS30226 REMOVING THE SWINGARM • Pivot shaft nut 1. Stand the vehicle on a level surface. • Pivot shaft ring nut “1” EWA13120 WARNING Loosen the pivot shaft ring nut with the ring nut Securely support the vehicle so that there is wrench “2”.

• Page 272: Installing The Swingarm

  SWINGARM Bends → Replace. Recommended lubricant EWA13770 WARNING Lithium-soap-based grease Do not attempt to straighten a bent pivot 2. Install: shaft. • Bearings “1” 3. Wash: (to the swingarm) • Pivot shaft • Oil seals “2” • Dust covers (to the swingarm) •…

• Page 273
  SWINGARM • Rear shock absorber assembly Refer to “REAR SHOCK ABSORBER AS- Tighten the pivot shaft with the damper rod hold- SEMBLY” on page 4-112. er “2”. • Rear wheel Refer to “REAR WHEEL” on page 4-43. Damper rod holder (ø22) 7.

• Page 274: Chain Drive

  CHAIN DRIVE EAS20038 CHAIN DRIVE Removing the drive chain 10 N m (1.0 kgf m, 7.4 lb • • • 140 N m (14 kgf m, 103 lb • • • m (0.7 kgf m, 5.2 lb • • • 28 N m (2.8 kgf m, 21 lb…

• Page 275: Removing The Drive Chain

  CHAIN DRIVE EAS30229 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a maintenance stand so G088937 that the rear wheel is elevated.

• Page 276: Checking The Drive Sprocket

  CHAIN DRIVE ECA19090 NOTICE • This vehicle has a drive chain with small rubber O-rings “1” between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to clean the drive chain.

• Page 277
  CHAIN DRIVE ECA17410 NOTICE Be sure to put on safety goggles when work- ing. Install the drive chain joint with the drive chain cut & rivet tool. Drive chain cut & rivet tool 90890-01550 2. Lubricate: Drive chain cut & rivet tool •…

• Page 278: Adjusting The Shift Pedal

  CHAIN DRIVE 6. Adjust: • Installed shift rod length Refer to “ADJUSTING THE SHIFT PEDAL” on page 4-129. 7. Adjust: • Drive chain slack Refer to “Adjusting the drive chain slack” on page 3-19. Drive chain slack 25.0–35.0 mm (0.98–1.38 in) 5.

• Page 279
  CHAIN DRIVE Be sure to place the shift rod joints in parallel. The allowable twist of the shift rod joints is ±5°. Shift rod locknut 7 N·m (0.7 kgf·m, 5.2 lb·ft) d. Make sure the installed shift rod length is within specification.
• Page 280
  CHAIN DRIVE 4-131…
• Page 281
  ENGINE LUBRICATION SYSTEM CHART AND DIAGRAMS……..5-1 ENGINE OIL LUBRICATION CHART …………5-1 LUBRICATION DIAGRAMS …………..5-2 ENGINE INSPECTION ………………5-9 MEASURE THE COMPRESSION PRESSURE……..5-9 ENGINE REMOVAL ………………5-11 REMOVING THE ENGINE …………..5-16 INSTALLING THE ENGINE…………..5-16 INSTALLING THE EXHAUST PIPE AND MUFFLER……5-17 CAMSHAFTS………………..5-18 REMOVING THE CAMSHAFTS…………..5-24 REMOVING THE ROCKER ARMS AND ROCKER ARM SHAFTS..
• Page 282
  ELECTRIC STARTER ……………….5-50 CHECKING THE STARTER MOTOR ………….5-52 ASSEMBLING THE STARTER MOTOR……….5-52 OIL PUMP…………………. 5-54 REMOVING THE OIL PAN…………..5-57 CHECKING THE SPROCKET AND CHAIN……….5-57 CHECKING THE OIL PUMP …………..5-57 CHECKING THE RELIEF VALVE …………5-57 CHECKING THE OIL DELIVERY PIPES ……….5-57 CHECKING THE OIL STRAINER …………
• Page 283
  CRANKSHAFT AND BALANCER SHAFT ………..5-91 REMOVING THE CRANKSHAFT AND BALANCER SHAFT….5-92 CHECKING THE OIL NOZZLES …………. 5-92 CHECKING THE CRANKSHAFT …………5-92 CHECKING THE BALANCER SHAFT …………5-94 INSTALLING THE CRANKSHAFT …………5-95 INSTALLING THE THRUST BEARING………..5-96 INSTALLING THE BALANCER ASSEMBLY………..5-96 TRANSMISSION………………..

• Page 284: Lubrication System Chart And Diagrams

  LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20298 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS32362 ENGINE OIL LUBRICATION CHART 1. Oil strainer 17. Exhaust camshaft 2. Oil pump 18. Shift fork guide bar (upper) 3. Relief valve 19. Main axle 4. Oil cooler 20.

• Page 285: Lubrication Diagrams

  LUBRICATION SYSTEM CHART AND DIAGRAMS EAS32363 LUBRICATION DIAGRAMS Crankcase, cylinder, and cylinder head (left side view) 1. Intake camshaft 2. Oil nozzle 3. Oil delivery pipe 2 4. Oil filter cartridge 5. Crankshaft 6. Exhaust camshaft 7. Sub gallery…

• Page 286
  LUBRICATION SYSTEM CHART AND DIAGRAMS Crankcase and cylinder (right side view) 1. Timing chain tensioner 2. Intake camshaft 3. Exhaust camshaft 4. Crankshaft 5. Relief valve 6. Oil pipe 1 7. Oil delivery pipe 1 8. Oil pan 9. Oil strainer 10.
• Page 287
  LUBRICATION SYSTEM CHART AND DIAGRAMS Timing chain cover and oil pipe (right side view) 1. Timing chain cover 2. Oil pipe 3 3. Oil pipe 2 4. Crankshaft 5. Crankcase…
• Page 288
  LUBRICATION SYSTEM CHART AND DIAGRAMS Oil pump and oil cooler (bottom view) 1. Oil cooler 2. Oil delivery pipe 1 3. Oil cooler outlet hose 4. Oil filter cartridge 5. Oil pressure switch 6. Oil delivery pipe 2 7. Oil strainer 8.
• Page 289
  LUBRICATION SYSTEM CHART AND DIAGRAMS Camshaft and balancer shaft (top view) 1. Cylinder head 2. Exhaust camshaft 3. Intake camshaft 4. Balancer shaft…
• Page 290
  LUBRICATION SYSTEM CHART AND DIAGRAMS Crankshaft (rear view) 1. Oil nozzle 2. Oil pipe 3 3. Timing chain cover 4. Crankshaft 5. Oil pipe 2 6. Oil pressure switch 7. Generator rotor 8. Shaft…
• Page 291
  LUBRICATION SYSTEM CHART AND DIAGRAMS Crankshaft and transmission (top view) 1. Oil pump 2. Main axle 3. Clutch housing 4. Drive axle 5. Oil delivery pipe 3…

• Page 292: Engine Inspection

  ENGINE INSPECTION EAS20041 ENGINE INSPECTION EAS30249 MEASURE THE COMPRESSION PRESSURE The following procedure applies to all of the cyl- inders. Insufficient compression pressure will result in a loss of performance. 1. Measure: 5. Measure: • Valve clearance • Compression pressure Out of specification →…

• Page 293
  ENGINE INSPECTION 6. Install: • Spark plugs Spark plug 13 N·m (1.3 kgf·m, 9.6 lb·ft) Spark plug (new) 18 N·m (1.8 kgf·m, 13 lb·ft) • Before installing the spark plug, clean the spark plug and gasket surface. • If the spark plug is a new one, tighten it to 18 N·m (1.8 kgf·m, 13 lb·ft).

• Page 294: Engine Removal

  ENGINE REMOVAL EAS20042 ENGINE REMOVAL Removing the muffler and exhaust pipe 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 2.0 N ・…

• Page 295
  ENGINE REMOVAL Removing the muffler and exhaust pipe 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 2.0 N ・…
• Page 296
  ENGINE REMOVAL Disconnecting the leads and hoses 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) ’ Order Job/Parts to remove Remarks Air filter case Refer to “AIR FILTER CASE”…
• Page 297
  ENGINE REMOVAL Disconnecting the leads and hoses 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) ’ Order Job/Parts to remove Remarks Stator coil coupler Disconnect.
• Page 298
  ENGINE REMOVAL Removing the engine 56 N ・ m (5.6 kgf ・ m, 41 lb ・ ft) 70 N ・ m (7.0 kgf ・ m, 52 lb ・ ft) 56 N ・ m (5.6 kgf ・ m, 41 lb ・ ft) 70 N ・…

• Page 299: Removing The Engine

  ENGINE REMOVAL 6. Tighten: EAS30250 REMOVING THE ENGINE • Engine mounting adjust bolt “1” 1. Loosen: • Engine mounting adjust bolt • Tighten the engine mounting adjust bolt to specification with the pivot shaft wrench. Loosen the engine mounting adjust bolt with the •…

• Page 300: Installing The Exhaust Pipe And Muffler

  ENGINE REMOVAL EAS30252 INSTALLING THE EXHAUST PIPE AND MUFFLER 1. Install: • Exhaust pipe • Gasket “1” (to exhaust chamber) • Muffler When installing the gasket, install it so that the chamfered side “a” of the gasket faces the ex- haust pipe side as shown in the illustration.

• Page 301: Camshafts

  CAMSHAFTS EAS20043 CAMSHAFTS Removing the cylinder head cover 13 N ・ m (1.3 kgf ・ m, 9.6 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) ’…

• Page 302
  CAMSHAFTS Removing the cylinder head cover 13 N ・ m (1.3 kgf ・ m, 9.6 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) ’…
• Page 303
  CAMSHAFTS Removing the camshafts 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) ’…
• Page 304
  CAMSHAFTS Removing the timing chain and timing chain guide 72 N ・ m (7.2 kgf ・ m, 53 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 3.0 N ・…
• Page 305
  CAMSHAFTS Removing the timing chain and timing chain guide 72 N ・ m (7.2 kgf ・ m, 53 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 3.0 N ・…

• Page 306: Engine

  CAMSHAFTS Removing the rocker arms 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) ’…

• Page 307: Removing The Camshafts

  CAMSHAFTS EAS30256 REMOVING THE CAMSHAFTS 1. Remove: • Timing mark accessing bolt • Crankshaft end cover Refer to “GENERATOR” on page 5-44. 2. Align: • Mark “a” on the generator rotor (with the generator rotor cover slot “b”) a. Turn the crankshaft counterclockwise. b.

• Page 308
  CAMSHAFTS Camshaft runout limit 0.050 mm (0.0020 in) a. Camshaft cap bolt (black): 40 mm (1.57 in) b. Camshaft cap bolt (silver): 35 mm (1.38 in) A. Intake side B. Exhaust side 4. Measure: • Camshaft-journal-to-camshaft-cap clearance Out of specification → Measure the camshaft •…

• Page 309: Checking The Rocker Arms And Rocker Arm Shafts

  CAMSHAFTS Camshaft journal diameter Rocker arm shaft outside diame- 25.459–25.472 mm (1.0023– 1.0028 in) 7.967–7.979 mm (0.3137–0.3141 Limit 7.936 mm (0.3124 in) G088949 EAS30259 CHECKING THE ROCKER ARMS AND G088952 ROCKER ARM SHAFTS The following procedure applies to all of the EAS30258 CHECKING THE TIMING CHAIN AND rocker arms and rocker arm shafts.

• Page 310: Checking The Timing Chain Tensioner

  CAMSHAFTS • Timing chain guide (top side) Damage/wear → Replace the defective part(s). EAS30266 CHECKING THE TIMING CHAIN TENSIONER 1. Check: • Timing chain tensioner Cracks/damage/rough movement → Re- place. a. Using the valve spring compressor “1”, push and insert timing chain tensioner rod EAS31744 “2”…

• Page 311: Installing The Timing Chain Cover

  CAMSHAFTS Rocker arm shaft bolt 6 N·m (0.6 kgf·m, 4.4 lb·ft) LOCTITE® Straight plug (rocker arm shaft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) LOCTITE® c. Install the oil pipe bolt “3” and tighten it temporarily until there is no clearance at “a”…

• Page 312: Installing The Camshafts

  CAMSHAFTS a. Turn the crankshaft counterclockwise. b. When piston #1 is at BTDC105°, align the BTDC105° mark “a” on the generator rotor with the generator rotor cover slot “b”. f. Install the oil pipe bolts “4” and tighten them temporarily. Apply locking agent (LOCTITE®) onto the oil 3.

• Page 313
  CAMSHAFTS 5. Tighten: a. Camshaft cap bolt (black): 40 mm (1.57 in) • Camshaft cap bolts b. Camshaft cap bolt (silver): 35 mm (1.38 in) A. Intake side Camshaft cap bolt B. Exhaust side 8 N·m (0.8 kgf·m, 5.9 lb·ft) Camshaft cap bolt (new) 6.
• Page 314
  CAMSHAFTS b. Keep pressing the timing chain tensioner rod, mount clip “4” into groove “5”, and lock the timing chain tensioner rod. c. In the status of step (b), install the rod as- sembly in the cylinder block. Always use a new gasket. Timing chain tensioner bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) LOCTITE®…
• Page 315
  CAMSHAFTS • After installing the cylinder head cover gasket “2” to the cylinder head cover, cut off the “a” section. 12.Install: • Spark plugs • Ignition coils “1” Spark plug 13 N·m (1.3 kgf·m, 9.6 lb·ft) Spark plug (new) 18 N·m (1.8 kgf·m, 13 lb·ft) •…

• Page 316: Cylinder Head

  CYLINDER HEAD EAS20044 CYLINDER HEAD Removing the cylinder head m (0.9 kgf m, 6.6 lb • • • 16 N m (1.6 kgf m, 12 lb • • • 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 25 N ・…

• Page 317: Removing The Cylinder Head

  CYLINDER HEAD EAS30276 REMOVING THE CYLINDER HEAD 1. Remove: • Intake camshaft • Exhaust camshaft Refer to “REMOVING THE CAMSHAFTS” on page 5-24. 2. Remove: • Cylinder head bolt (M6) (× 2) • Cylinder head bolt (M9) (× 10) G088956 a.

• Page 318
  CYLINDER HEAD • Lubricate the cylinder head bolt (M9) thread and mating surface with engine oil. 3. Tighten: • Cylinder head bolt “1”–“10” • Cylinder head bolt “11”, “12” Cylinder head bolt “1”–“10” 1st: 10 N·m (1.0 kgf·m, 7.4 lb·ft) 2nd: 25 N·m (2.5 kgf·m, 18 lb·ft) 3rd: 45 N·m (4.5 kgf·m, 33 lb·ft) *4th: 15 N·m (1.5 kgf·m, 11 lb·ft)

• Page 319: Valves And Valve Springs

  VALVES AND VALVE SPRINGS EAS20045 VALVES AND VALVE SPRINGS Removing the valves and valve springs ’ Order Job/Parts to remove Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-33. Exhaust valve pad Exhaust valve cotter Exhaust valve spring retainer Exhaust valve spring (outer) Exhaust valve spring (inner) Exhaust valve…

• Page 320
  VALVES AND VALVE SPRINGS Removing the valves and valve springs ’ Order Job/Parts to remove Remarks Intake valve spring retainer Intake valve spring (outer) Intake valve spring (inner) Intake valve Intake valve stem seal Intake valve spring seat Circlip Intake valve guide 5-37…

• Page 321: Removing The Valves

  VALVES AND VALVE SPRINGS EAS30283 REMOVING THE VALVES Valve spring compressor The following procedure applies to all of the 90890-04019 valves and related components. Valve spring compressor YM-04019 Valve spring compressor attach- Before removing the internal parts of the cylinder ment (ø26) head (e.g., valves, valve springs, valve seats), 90890-01243…

• Page 322
  VALVES AND VALVE SPRINGS b. Install the new valve guide with the valve Valve-stem-to-valve-guide clear- guide installer “2” and valve guide remov- ance (intake) er “1”. 0.010–0.037 mm (0.0004–0.0015 Valve guide position (intake) Limit 12.0–12.4 mm (0.47–0.49 in) 0.080 mm (0.0032 in) Valve guide position (exhaust) Valve-stem-to-valve-guide clear- 17.5–17.9 mm (0.69–0.70 in)

• Page 323: Checking The Valve Seats

  VALVES AND VALVE SPRINGS Valve guide remover (ø4.5) 90890-04116 Valve guide remover (4.5 mm) YM-04116 Valve guide remover (ø5) 90890-04097 Valve guide remover (5.0 mm) YM-04097 Valve guide installer (ø4.5) G088965 90890-04117 Valve guide installer (4.5 mm) EAS30285 YM-04117 CHECKING THE VALVE SEATS Valve guide installer (ø5) The following procedure applies to all of the 90890-04098…

• Page 324
  VALVES AND VALVE SPRINGS G088967 G088968 b. Apply molybdenum disulfide oil onto the b. Install the valve into the cylinder head. valve stem. c. Press the valve through the valve guide c. Install the valve into the cylinder head. and onto the valve seat to make a clear d.

• Page 325: Checking The Valve Springs

  VALVES AND VALVE SPRINGS j. Measure the valve seat contact width “c” 1. Check: again. If the valve seat width is out of spec- • Valve spring seat Damage/scratches → Replace the valve ification, reface and lap the valve seat. spring seat.

• Page 326
  VALVES AND VALVE SPRINGS G088975 6. Lubricate: b. Smaller pitch • Valve pad 4. Install: (with the recommended lubricant) • Valve cotters Recommended lubricant Molybdenum disulfide oil Install the valve cotters by compressing the valve spring with the valve spring compressor 7.

• Page 327: Generator

  GENERATOR EAS20134 GENERATOR Removing the stator coil and generator rotor 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 85 N ・…

• Page 328
  GENERATOR Removing the stator coil and generator rotor 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 85 N ・…

• Page 329: Removing The Generator

  GENERATOR EAS30829 REMOVING THE GENERATOR Flywheel puller 1. Remove: 90890-01404 • Generator rotor bolt “1” Flywheel puller • Washer YM-01404 While holding the generator rotor “2” with the 15mm pin type rotor holding tool “3”, loosen the generator rotor bolt. 15mm pin type rotor holding tool 90890-04171 YM-04171…

• Page 330
  • Crankshaft position sensor coupler To route the stator coil lead, refer to “CABLE ROUTING” on page 2-17. 3. Apply: • Sealant (onto the stator coil assembly lead grommet) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) G088980 4. Install: • Generator cover gasket •…

• Page 331: Starter Clutch

  STARTER CLUTCH EAS20049 STARTER CLUTCH Removing the starter clutch 14 N ・ m (1.4 kgf ・ m, 10 lb ・ ft) ’ Order Job/Parts to remove Remarks Clutch housing assembly Refer to “CLUTCH” on page 5-60. Starter clutch gear Bearing Starter clutch assembly Circlip Starter clutch idle gear…

• Page 332: Removing The Starter Clutch

  STARTER CLUTCH c. When turning the starter clutch gear coun- EAS30305 REMOVING THE STARTER CLUTCH terclockwise “B”, it should turn freely, oth- 1. Remove: erwise the starter clutch is faulty and must • Starter clutch bolt “1” be replaced. • While holding the clutch housing assembly “2” with the sheave holder “3”, remove the starter clutch bolt.

• Page 333: Electric Starter

  ELECTRIC STARTER EAS20052 ELECTRIC STARTER Removing the starter motor 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (1)” on page Rider seat 4-1.

• Page 334
  ELECTRIC STARTER Disassembling the starter motor 4.5 N ・ m (0.45 kgf ・ m, 3.3 lb ・ ft) ’ Order Job/Parts to remove Remarks O-ring Starter motor front cover Starter motor yoke Armature assembly Gasket Brush holder set Starter motor rear cover 5-51…

• Page 335: Checking The Starter Motor

  ELECTRIC STARTER EAS30325 CHECKING THE STARTER MOTOR Brush overall length limit 1. Check: 5.5 mm (0.22 in) • Commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • Mica undercut “a” Out of specification → Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator.

• Page 336
  ELECTRIC STARTER 5-53…

• Page 337: Oil Pump

  OIL PUMP EAS20054 OIL PUMP Removing the oil pan and oil pump 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・…

• Page 338
  OIL PUMP Removing the oil pan and oil pump 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・…
• Page 339
  OIL PUMP Disassembling the oil pump 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) ’ Order Job/Parts to remove Remarks Oil pump cover Dowel pin Oil pump outer rotor Oil pump inner rotor Oil pump housing Oil pump driven sprocket 5-56…

• Page 340: Removing The Oil Pan

  OIL PUMP EAS30333 REMOVING THE OIL PAN 1. Remove: • Oil pan • Gasket • Dowel pins Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. EAS30339 EAS30336 CHECKING THE OIL DELIVERY PIPES…

• Page 341: Installing The Oil Pump

  OIL PUMP When installing the inner rotor, align the pin “2” in the oil pump shaft with the groove in the inner rotor “3”. 3. Install: • Oil pump drive chain guide Oil pump drive chain guide bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) LOCTITE®…

• Page 342
  OIL PUMP • M6 × 25 mm (0.98 in) bolts: “1”–“6”, “9”–“12” • M6 × 30 mm (1.18 in) bolts: “7”, “8” 2. Tighten: • Oil pan bolt Oil pan bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) LOCTITE® 3. Install: •…

• Page 343: Clutch

  CLUTCH EAS20055 CLUTCH Removing the clutch cover 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) (10) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 3.0 N ・ m (0.30 kgf ・ m, 2.2 lb ・ ft) Specified angle 180˚…

• Page 344
  CLUTCH Removing the pull lever shaft 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) ’ Order Job/Parts to remove Remarks Circlip Pull lever Pull lever spring Circlip Pull lever shaft Oil seal Bearing Bearing Clutch cover damper plate Clutch cover damper 5-61…
• Page 345
  CLUTCH Removing the clutch 125 N ・ m (12.5 kgf ・ m, 92 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) ’ Order Job/Parts to remove Remarks Pressure plate 1 Compression spring Pressure plate 2 Pull rod Bearing Press the bearing into pressure plate 2.
• Page 346
  CLUTCH Removing the clutch 125 N ・ m (12.5 kgf ・ m, 92 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) ’ Order Job/Parts to remove Remarks Clutch damper spring Clutch damper spring seat Clutch boss nut Conical spring washer Clutch boss…

• Page 347: Removing The Clutch

  CLUTCH EAS30346 REMOVING THE CLUTCH 1. Remove: • Clutch cover • Gasket Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. G088993 6.

• Page 348: Checking The Clutch Springs

  CLUTCH 2. Measure: Clutch plate “1” • Clutch plate 1, 2 warpage Part No. Thickness (with a surface plate and thickness gauge) Out of specification → Replace the clutch 2CR-16325-10 2.0 mm (0.079 in) plates as a set. 2CR-16325-00 2.3 mm (0.091 in) Thickness gauge 2CR-16325-20 2.6 mm (0.102 in)

• Page 349: Checking The Clutch Boss

  CLUTCH EAS30357 CHECKING THE PRIMARY DRIVEN GEAR 1. Check: • Primary driven gear Damage/wear → Replace the clutch housing and crankshaft as a set. Excessive noise during operation → Replace the clutch housing and crankshaft as a set. EAS30358 CHECKING THE PULL LEVER SHAFT AND G088994 PULL ROD 2.

• Page 350
  CLUTCH 2. Install: 3. Lubricate: • Thrust plate • Friction plates • Clutch boss “1” • Clutch plates • Conical spring washer “2” (with the recommended lubricant) • Clutch boss nut “3” Recommended lubricant Engine oil Clutch boss nut 125 N·m (12.5 kgf·m, 92 lb·ft) 4.
• Page 351
  CLUTCH 5. Install: • Pull rod • Pressure plate 2 • Clutch springs • Pressure plate 1 • Clutch spring bolts Clutch spring bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) 8. Install: • Tighten the clutch spring bolts in stages and in •…

• Page 352: Shift Shaft

  SHIFT SHAFT EAS20057 SHIFT SHAFT Removing the shift shaft and stopper lever 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) ’ Order Job/Parts to remove Remarks Clutch assembly Refer to “CLUTCH” on page 5-60. Shift arm Refer to “CHAIN DRIVE”…

• Page 353: Checking The Shift Shaft

  SHIFT SHAFT EAS30377 CHECKING THE SHIFT SHAFT Lubricate the oil seal lips with lithium-soap- 1. Check: based grease. • Shift shaft Bends/damage/wear → Replace. • Shift shaft spring • Collar Damage/wear → Replace. EAS30378 CHECKING THE STOPPER LEVER 1. Check: •…

• Page 354: Crankcase

  CRANKCASE EAS20059 CRANKCASE Removing the crankcase breather cover and switches 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 3.0 N ・ m (0.30 kgf ・ m, 2.2 lb ・ ft) Specified angle 90˚…

• Page 355
  CRANKCASE Removing the crankcase breather cover and switches 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 3.0 N ・ m (0.30 kgf ・ m, 2.2 lb ・ ft) Specified angle 90˚…
• Page 356
  CRANKCASE Separating the crankcase 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 20 N ・ m (2.0 kgf ・ m, 15 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 24 N ・…

• Page 357: Disassembling The Crankcase

  Recommended lubricant Engine oil 2. Apply: • Sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) • Do not allow any sealant to come into contact 3. Remove: with the oil gallery or crankshaft journal bear- •…

• Page 358
  CRANKCASE • Lubricate the bolts “28”, “40” mating surfaces with engine oil. • Apply the bolts “28”, “40” thread with LOC- TITE®. • M9 × 100 mm (3.94 in) bolts with washers: “1”–“10” • M8 × 58 mm (2.28 in) bolts with new O-rings: “11”–“18”…

• Page 359: Installing The Crankcase Breather Cover

  CRANKCASE EWA16610 WARNING If the bolt is tightened more than the speci- fied angle, do not loosen the bolt and then re- tighten it. Instead, replace the bolt with a new one and perform the procedure again. ECA20890 NOTICE Do not use a torque wrench to tighten the bolt to the specified angle.

• Page 360: Installing The Oil Pressure Switch

  CRANKCASE EAS31071 INSTALLING THE OIL PRESSURE SWITCH Gear position sensor bolt 1. Install: 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) • Oil pressure switch “1” LOCTITE® • Oil pressure switch lead “2” Oil pressure switch • Lubricate the O-ring with lithium-soap-based 13 N·m (1.3 kgf·m, 9.6 lb·ft) grease.

• Page 361: Connecting Rods And Pistons

  CONNECTING RODS AND PISTONS EAS20132 CONNECTING RODS AND PISTONS Removing the connecting rods and pistons 25 N ・ m (2.5 kgf ・ m, 18 lb ・ ft) Specified angle 180˚ ’ Order Job/Parts to remove Remarks Lower crankcase Refer to “CRANKCASE” on page 5-71. Connecting rod cap Big end lower bearing Big end upper bearing…

• Page 362: Removing The Connecting Rods And Pistons

  CONNECTING RODS AND PISTONS EAS30745 REMOVING THE CONNECTING RODS AND Piston pin clip rotation tool PISTONS 90890-04175 The following procedure applies to all of the con- YM-04175 necting rods and pistons. 1. Remove: • Connecting rod cap • Connecting rod •…

• Page 363: Checking The Cylinder And Piston

  CONNECTING RODS AND PISTONS G088999 EAS30747 3. Remove: CHECKING THE CYLINDER AND PISTON • Piston pin “1” 1. Check: • Piston “2” • Piston wall ECA13810 • Cylinder wall NOTICE Vertical scratches → Replace the cylinder Do not use a hammer to drive the piston pin block, and replace the pistons and piston out.

• Page 364: Checking The Piston Rings

  CONNECTING RODS AND PISTONS Piston Piston ring Diameter Top ring 78.961–78.994 mm (3.1087– Ring side clearance 3.1100 in) 0.030–0.065 mm (0.0012– 0.0026 in) Side clearance limit 0.115 mm (0.0045 in) 2nd ring Ring side clearance 0.020–0.055 mm (0.0008– 0.0022 in) Side clearance limit 0.115 mm (0.0045 in) a.

• Page 365: Checking The Piston Pin

  CONNECTING RODS AND PISTONS G089005 3. Calculate: b. Upper of cylinder • Piston-pin-to-piston-pin-bore clearance Out of specification → Replace the piston pin EAS30749 CHECKING THE PISTON PIN and piston as a set. The following procedure applies to all of the pis- Piston-pin-to-piston-pin-bore clearance = Piston ton pins.

• Page 366
  CONNECTING RODS AND PISTONS b. Wait five minutes to dry the remaining oil cleaner component. c. Install the big end upper bearing into the connecting rod and the big end lower bearing into the connecting rod cap with the connecting rod big end metal installer “1”.
• Page 367
  CONNECTING RODS AND PISTONS • Make sure the “ ” marks “b” on the connecting rods face towards the left side of the crank- shaft. • Install the connecting rod so that the Plasti- gauge® is in position “c” or “d”. Install by carrying out the following procedures in order to assemble in the most suitable condition.
• Page 368
  CONNECTING RODS AND PISTONS 175°–185°. If torque is out of range, re- 2. Select: place the connecting rod bolt to new one • Big end bearings (P –P and repeat from step (h). • The numbers “A” stamped into the crankshaft Connecting rod bolt (final) web and the numbers “1”…

• Page 369: Installing The Connecting Rod And Piston

  CONNECTING RODS AND PISTONS EAS30751 INSTALLING THE CONNECTING ROD AND PISTON The following procedure applies to all of the con- necting rods and pistons. 1. Install: • Big end bearings • Connecting rod cap (onto the connecting rod) • Clean the big end bearings, crankshaft pins, and the connecting rods with oil cleaner, and then wait five minutes to dry the remaining oil cleaner component.

• Page 370
  CONNECTING RODS AND PISTONS 2. Tighten: 3. Install: • Top ring “1” • Connecting rod bolts (into the piston) ECA18390 NOTICE • 2nd ring “2” • Upper oil ring rail “3” Tighten the connecting rod bolts using the • Oil ring expander “4” plastic-region tightening angle method.
• Page 371
  CONNECTING RODS AND PISTONS d. Make sure the piston pin clip “1” is posi- tioned as shown in the illustration. Align the piston pin clip end with the position “a”. e. Install the piston pin clip installer tool “4” b. Push the piston pin clip insertion tool “3” in onto the piston.
• Page 372
  CONNECTING RODS AND PISTONS • While holding the piston rings with the hand, in- stall the piston assembly into the cylinder from underneath. • Install the piston assembly into the cylinder so that the piston ring end gap is aligned with the cylinder skirt “a”.
• Page 373
  CONNECTING RODS AND PISTONS 180˚ EWA16610 WARNING If the bolt is tightened more than the speci- Tighten the connecting rod bolts using the fol- fied angle, do not loosen the bolt and then re- lowing procedure. tighten it. Instead, replace the bolt with a new one and perform the procedure again.

• Page 374: Crankshaft And Balancer Shaft

  CRANKSHAFT AND BALANCER SHAFT EAS20178 CRANKSHAFT AND BALANCER SHAFT Removing the crankshaft and balancer shaft 3.0 N ・ m (0.30 kgf ・ m, 2.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) ’ Order Job/Parts to remove Remarks…

• Page 375: Removing The Crankshaft And Balancer Shaft

  CRANKSHAFT AND BALANCER SHAFT 2. Check: EAS31171 REMOVING THE CRANKSHAFT AND • Crankshaft journal surfaces BALANCER SHAFT • Crankshaft pin surfaces 1. Remove: Scratches/wear → Replace the crankshaft. • Balancer shaft “1” • Bearing surfaces • Balancer shaft journal bearing Scratches/wear →…

• Page 376
  CRANKSHAFT AND BALANCER SHAFT 4. Select: • Crankshaft journal bearings (J –J • The numbers “A” stamped into the crankshaft web and the numbers “B” stamped into the lower crankcase are used to determine the re- placement crankshaft journal bearing sizes. •…

• Page 377: Checking The Balancer Shaft

  CRANKSHAFT AND BALANCER SHAFT ing clearance and prevent engine damage, the balancer shaft journal bearings must be installed in their original positions. a. Clean the balancer shaft journal bearings, balancer shaft journals, and bearing por- tions of the crankcase. b. Place the upper crankcase upside down on a bench.

• Page 378: Installing The Crankshaft

  CRANKSHAFT AND BALANCER SHAFT Bearing color code Code 0 White Code 1 Blue Code 2 Black Code 3 Brown G089019 Code 4 Green f. Tighten the bolts to specification in the Code 5 tightening sequence cast on the crank- Yellow case.

• Page 379: Installing The Thrust Bearing

  CRANKSHAFT AND BALANCER SHAFT • Crankshaft journal lower bearings (into the lower crankcase) When installing the thrust bearing, shift the • Crankshaft crankshaft to the left to widen the gap between the crankshaft and the crankcase. • Align the projections “a” on the crankshaft jour- nal bearings “1”…

• Page 380
  CRANKSHAFT AND BALANCER SHAFT • Balancer shaft journal lower bearings (into the lower crankcase) • Align the projections “a” on the balancer shaft journal bearings “1” with the notches “b” in the crankcases. • Be sure to install each balancer shaft journal bearing in its original place.

• Page 381: Transmission

  TRANSMISSION EAS20062 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) ’…

• Page 382
  TRANSMISSION Disassembling the main axle assembly ’ Order Job/Parts to remove Remarks Make sure the chamfered side of the pinion 2nd pinion gear gear faces to the left. Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd pinion gear Circlip…
• Page 383
  TRANSMISSION Disassembling the drive axle assembly ’ Order Job/Parts to remove Remarks Circlip Bearing Washer 1st wheel gear Collar 5th wheel gear Circlip Washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 5-100…
• Page 384
  TRANSMISSION Disassembling the drive axle assembly ’ Order Job/Parts to remove Remarks 4th wheel gear Collar Washer Circlip 6th wheel gear Circlip Washer 2nd wheel gear Collar Collar Oil seal Circlip Bearing Drive axle 5-101…

• Page 385: Removing The Transmission

  TRANSMISSION EAS30430 EAS30431 REMOVING THE TRANSMISSION CHECKING THE SHIFT FORKS 1. Remove: The following procedure applies to all of the shift • Drive axle assembly “1” forks. • Shift drum retainers “2” 1. Check: • Shift fork guide bars • Shift fork cam follower “1” •…

• Page 386: Checking The Transmission

  TRANSMISSION • Shift drum segment “1” 3. Check: Damage/wear → Replace the shift drum as- • Transmission gears Blue discoloration/pitting/wear → Replace sembly. • Shift drum bearing “2” the defective gear(s). Damage/pitting → Replace the shift drum as- • Transmission gear dogs Cracks/damage/rounded edges →…

• Page 387: Installing The Transmission

  TRANSMISSION A. Main axle B. Drive axle EAS30438 INSTALLING THE TRANSMISSION 1. Install: • Bearings “1” • Oil delivery pipe 3 “2” Face the seal side of bearing to the outside. 2. Install: • Toothed lock washer retainer “1” Oil delivery pipe 3 bolt •…

• Page 388
  TRANSMISSION 3. Install: • Oil seal • Shift fork-C “1” • Circlip “4” • Shift drum assembly “2” • Drive axle assembly “5” • Shift fork guide bar “3” Shift drum retainer bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) • The embossed marks on the shift forks should LOCTITE®…

• Page 389: Cooling System

  COOLING SYSTEM COOLING SYSTEM DIAGRAMS …………..6-1 RADIATOR …………………. 6-3 REMOVING THE RADIATOR …………..6-5 CHECKING THE RADIATOR…………..6-5 INSTALLING THE RADIATOR…………..6-5 OIL COOLER………………..6-7 CHECKING THE OIL COOLER …………..6-8 INSTALLING THE OIL COOLER ………….. 6-8 THERMOSTAT ………………..6-9 REMOVING THE THERMOSTAT ASSEMBLY……..6-11 CHECKING THE THERMOSTAT…………

• Page 390
  COOLING SYSTEM DIAGRAMS EAS20299 COOLING SYSTEM DIAGRAMS 1. Radiator outlet hose 2. Cooling system air bleed hose 3. Thermostat assembly 4. Radiator inlet hose 5. Radiator 6. Water pump outlet pipe 7. Water pump 8. Water pump inlet pipe…
• Page 391
  COOLING SYSTEM DIAGRAMS 1. Cooling system air bleed hose 2. Radiator 3. Radiator outlet hose 4. Radiator inlet hose 5. Water pump inlet pipe 6. Water pump outlet pipe 7. Water pump 8. Thermostat assembly…
• Page 392
  RADIATOR EAS20063 RADIATOR Removing the radiator 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 10 N ・…
• Page 393
  RADIATOR Removing the radiator 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 10 N ・…
• Page 394
  RADIATOR 3. Measure: EAS31659 REMOVING THE RADIATOR • Radiator cap valve opening pressure 1. Remove: Below the specified pressure → Replace the • Hose clamp (Clic-R) “1” radiator cap. Radiator cap valve opening pres- • Remove the hose clamp using the hose clamp sure pliers “2”.
• Page 395
  RADIATOR • When installing the hose clamp, make sure Refer to “CHECKING THE RADIATOR” on that the thin tip “a” of the hose clamp pliers is page 6-5. directed as shown in the illustration. • For more information about installing the hose, refer to “CABLE ROUTING”…
• Page 396
  OIL COOLER EAS20064 OIL COOLER Removing the oil cooler 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・…
• Page 397
  OIL COOLER EAS30441 CHECKING THE OIL COOLER 1. Check: • Oil cooler Cracks/damage → Replace. • Oil cooler fins Obstruction → Clean. Apply compressed air to the rear of the oil cooler. Damage → Repair or replace. Straighten any flattened fins with a thin, flat-head screwdriver.
• Page 398
  THERMOSTAT EAS20065 THERMOSTAT Removing the thermostat 10 N m (1.0 kgf m, 7.4 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • ’ Order Job/Parts to remove Remarks…
• Page 399
  THERMOSTAT Removing the thermostat 10 N m (1.0 kgf m, 7.4 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • 10 N m (1.0 kgf m, 7.4 lb • • • ’ Order Job/Parts to remove Remarks Cooling system air bleed hose Disconnect.
• Page 400
  THERMOSTAT 2. Check: EAS31660 REMOVING THE THERMOSTAT ASSEMBLY • Thermostat housing 1. Remove: • Thermostat housing cover • Hose clamp (Clic-R) Cracks/damage → Replace. Refer to “REMOVING THE RADIATOR” on page 6-5. EAS30444 ASSEMBLING THE THERMOSTAT • Radiator inlet hose ASSEMBLY 2.
• Page 401
  THERMOSTAT Refer to “INSTALLING THE RADIATOR” on page 6-5. 5. Measure: • Radiator cap valve opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-5. 6-12…
• Page 402
  WATER PUMP EAS20066 WATER PUMP Removing the water pump 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 2.0 N ・ m (0.20 kgf ・ m, 1.5 lb ・ ft) 10 N ・…
• Page 403
  WATER PUMP Disassembling the water pump 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) ’ Order Job/Parts to remove Remarks Water pump housing cover O-ring Circlip Impeller shaft…
• Page 404
  WATER PUMP EAS30446 EAS30447 DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP 1. Remove: 1. Check: • Mechanical seal (housing side) “1” • Water pump housing cover • Impeller shaft Cracks/damage/wear → Replace. Remove the mechanical seal (housing side) • Water pump housing from the inside of the water pump housing “2”.
• Page 405
  WATER PUMP Mechanical seal installer (ø33) 90890-04132 Water pump seal installer (ø33) YM-33221-A Middle driven shaft bearing driv- 90890-04058 Middle drive bearing installer 40 & 50 mm YM-04058 2. Fill: • Cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT”…
• Page 406
  WATER PUMP 6-17…

• Page 407: Fuel System

  FUEL SYSTEM FUEL TANK………………… 7-1 REMOVING THE FUEL TANK …………..7-3 REMOVING THE FUEL PUMP …………..7-3 CHECKING THE FUEL PUMP BODY…………7-3 CHECKING THE FUEL PUMP OPERATION……….7-3 INSTALLING THE FUEL PUMP…………..7-4 INSTALLING THE FUEL TANK…………..7-4 AIR FILTER CASE ………………7-5 CHECKING THE SECONDARY INJECTORS (BEFORE REMOVING) …7-7 REMOVING THE FUEL HOSE (PRIMARY INJECTOR JOINT SIDE AND SECONDARY INJECTOR JOINT SIDE) ………

• Page 408
  FUEL TANK EAS20067 FUEL TANK Removing the fuel tank m (0.5 kgf m, 3.7 lb 4.0 N m (0.40 kgf m, 3.0 lb • • • • • • m (0.5 kgf m, 3.7 lb • • • 4.0 N m (0.40 kgf m, 3.0 lb •…
• Page 409
  FUEL TANK Removing the rollover valve and canister (for California only) 10 N m (1.0 kgf m, 7.4 lb • • • ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (1)” on page Rider seat 4-1. Fuel tank Refer to “FUEL TANK”…
• Page 410
  FUEL TANK EAS30450 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Rider seat Refer to “GENERAL CHASSIS (1)” on page 4-1. • Fuel tank cover Refer to “GENERAL CHASSIS (3)”…
• Page 411
  FUEL TANK EAS30456 INSTALLING THE FUEL PUMP • Install the fuel hose onto the fuel pump secure- 1. Install: ly, and slide the fuel hose connector cover “1” • Fuel pump gasket in the direction shown in the illustration. • Fuel pump •…
• Page 412
  AIR FILTER CASE EAS20068 AIR FILTER CASE Removing the air filter case and secondary injectors 3.5 N m (0.35 kgf m, 2.6 lb • • • m (0.8 kgf m, 5.9 lb • • • m (0.7 kgf m, 5.2 lb •…
• Page 413
  AIR FILTER CASE Removing the air filter case and secondary injectors 3.5 N m (0.35 kgf m, 2.6 lb • • • m (0.8 kgf m, 5.9 lb • • • m (0.7 kgf m, 5.2 lb • • • 3.5 N m (0.35 kgf m, 2.6 lb…
• Page 414
  AIR FILTER CASE EAS30458 CHECKING THE SECONDARY INJECTORS (BEFORE REMOVING) 1. Check: • Injectors Use the diagnostic code numbers “40”–“43”. Refer to “SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE” on page 9-32. EAS30459 REMOVING THE FUEL HOSE (PRIMARY INJECTOR JOINT SIDE AND SECONDARY INJECTOR JOINT SIDE) 1.
• Page 415
  AIR FILTER CASE Damage → Replace. 2. Loosen: • Intake funnel assembly bolt “1” 2. Check: • Injector resistance Refer to “CHECKING THE FUEL INJEC- TORS” on page 8-51. EAS31664 CHECKING THE AIR FILTER CASE SEAL 1. Check: • Air filter case seal Damage →…
• Page 416
  AIR FILTER CASE b. Temporary tighten the cross bar bolts “a”. c. Install the intake funnel assembly and air filter case. d. Tighten the Intake funnel assembly bolt “b” and air filter case bolt “c”. Intake funnel assembly bolt 8 N·m (0.8 kgf·m, 5.9 lb·ft) Air filter case bolt 8 N·m (0.8 kgf·m, 5.9 lb·ft) A.
• Page 417
  AIR FILTER CASE Upper air filter case screw 2.0 N·m (0.20 kgf·m, 1.5 lb·ft) EAS30468 INSTALLING THE FUEL HOSE (PRIMARY INJECTOR JOINT SIDE AND SECONDARY INJECTOR JOINT SIDE) 1. Connect: • Fuel hose (primary injector joint side and sec- ondary injector joint side) ECA17500 NOTICE When installing the fuel hose, make sure that…
• Page 418
  THROTTLE BODIES EAS20070 THROTTLE BODIES Removing the throttle bodies 10 N m (1.0 kgf m, 7.4 lb • • • 3.0 N m (0.30 kgf m, 2.2 lb • • • ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (1)” on page Rider seat 4-1.
• Page 419
  THROTTLE BODIES Removing the throttle bodies 10 N m (1.0 kgf m, 7.4 lb • • • 3.0 N m (0.30 kgf m, 2.2 lb • • • ’ Order Job/Parts to remove Remarks Throttle servo motor coupler Disconnect. Fuel hose 3 (fuel hose 2 to throttle body) Primary injector coupler Disconnect.
• Page 420
  THROTTLE BODIES Removing the primary injectors (except for California) 3.5 N m (0.35 kgf m, 2.6 lb • • • 3.5 N m (0.35 kgf m, 2.6 lb • • • 3.5 N m (0.35 kgf m, 2.6 lb • •…
• Page 421
  THROTTLE BODIES Removing the primary injectors (for California) 3.5 N m (0.35 kgf m, 2.6 lb • • • 3.5 N m (0.35 kgf m, 2.6 lb • • • 3.5 N m (0.35 kgf m, 2.6 lb • • •…
• Page 422
  Deposit → Replace. will be affected. Damage → Replace. 2. Check: Recommended cleaning solvent • Injector resistance Yamaha Oil & Brake Cleaner Refer to “CHECKING THE FUEL INJEC- TORS” on page 8-51. EAS30769 CHECKING AND CLEANING THE THROTTLE BODIES Clean the throttle bodies only if they cannot be synchronized using the bypass air screws.
• Page 423
  THROTTLE BODIES b. Install the caps (895-14169-00) onto the ECA17590 NOTICE hose fittings “a”. • Do not use a tool, such as a wire brush, to remove the carbon deposits; otherwise, the inside of the throttle bodies may be dam- aged.
• Page 424
  THROTTLE BODIES Refer to “SELF-DIAGNOSTIC FUNCTION • Be careful not to twist or pinch the O-rings AND DIAGNOSTIC CODE TABLE” on page when installing the injectors. 9-32. • When installing the injector, install it at the 6. Reset: same position as the removed cylinder. •…
• Page 425
  THROTTLE BODIES b. Connect the pressure gauge “4” to the fuel • Fuel tank cover injector pressure adapter “1”. Refer to “FUEL TANK” on page 7-1. 2. Check: Pressure gauge • Fuel pressure 90890-03153 a. Remove the fuel tank bolts and hold up the Pressure gauge fuel tank.
• Page 426
  Connect the throttle position sensor to the wire harness. d. Remove the protective cap, and then con- nect the Yamaha diagnostic tool to cou- pler. For information about using the Yamaha diag- nostic tool, refer to the operation manual that is included with the tool.
• Page 427
  AIR INDUCTION SYSTEM EAS20071 AIR INDUCTION SYSTEM 1. Air filter case 2. Air cut-off valve 3. Air induction system hose (air filter case to air cut-off valve) 4. Cylinder head cover 5. Air induction system hose (air cut-off valve to reed valve cover) 7-20…
• Page 428
  AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and reed valves m (0.9 kgf m, 6.6 lb 0.3 N m (0.03 kgf m, 0.22 lb • • • • • • 10 N m (1.0 kgf m, 7.4 lb •…
• Page 429
  AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and reed valves m (0.9 kgf m, 6.6 lb 0.3 N m (0.03 kgf m, 0.22 lb • • • • • • 10 N m (1.0 kgf m, 7.4 lb •…
• Page 430
  AIR INDUCTION SYSTEM EAS30488 CHECKING THE AIR INDUCTION SYSTEM Air injection The air induction system burns unburned ex- haust gases by injecting fresh air (secondary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the reed valve opens, allow- ing secondary air to flow into the exhaust port.
• Page 431
  AIR INDUCTION SYSTEM 3. Install: • Reed valve cover Reed valve cover bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) LOCTITE® G089044 4. Check: • Air cut-off valve Cracks/damage → Replace. 5. Check: • Air induction system solenoid Refer to “CHECKING THE AIR INDUCTION SYSTEM SOLENOID”…
• Page 432
  AIR INDUCTION SYSTEM 7-25…

• Page 433: Electrical System

  ELECTRICAL SYSTEM IGNITION SYSTEM ………………8-1 CIRCUIT DIAGRAM ……………… 8-1 ENGINE STOPPING DUE TO SIDESTAND OPERATION…….8-3 TROUBLESHOOTING …………….8-4 ELECTRIC STARTING SYSTEM …………..8-7 CIRCUIT DIAGRAM ……………… 8-7 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ……8-9 TROUBLESHOOTING …………….8-10 CHARGING SYSTEM………………8-12 CIRCUIT DIAGRAM …………….8-12 TROUBLESHOOTING …………….8-13 LIGHTING SYSTEM ………………8-15 CIRCUIT DIAGRAM …………….

• Page 434
  ELECTRICAL COMPONENTS…………..8-38 CHECKING THE SWITCHES …………..8-40 CHECKING THE FUSES …………….8-41 REPLACING THE ECU (Engine Control Unit) ……..8-41 CHECKING AND CHARGING THE BATTERY……..8-42 CHECKING THE RELAYS …………..8-42 CHECKING THE RELAY UNIT (DIODE) ……….8-43 CHECKING THE IGNITION COILS…………8-44 CHECKING THE IGNITION SPARK GAP……….
• Page 436
  IGNITION SYSTEM EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM…
• Page 437
  IGNITION SYSTEM 3. Main switch 4. Main fuse 9. Backup fuse 12.Ignition fuse 18.Engine ground 19.Battery 23.Joint coupler 25.Handlebar switch (right) 27.Start/engine stop switch 29.Relay unit 32.Neutral switch 33.Sidestand switch 43.Cylinder identification sensor 45.Crankshaft position sensor 48.ECU (Engine Control Unit) 49.Spark plug 50.Ignition coil #1 51.Ignition coil #2…
• Page 438
  IGNITION SYSTEM EAS30491 ENGINE STOPPING DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ECU does not flow to the ignition coils or fuel injectors when the neutral switch or sidestand switch is open.
• Page 439
  IGNITION SYSTEM EAS30492 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Front side cowling/Front panel 2. Rider seat 3. Fuel tank cover 4. Fuel tank 5. Air filter case NG →…
• Page 440
  IGNITION SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 8-40. OK ↓ NG → 9. Check the start/engine stop switch. Refer to “CHECKING THE Replace the handlebar switch (right). SWITCHES”…
• Page 441
  IGNITION SYSTEM…
• Page 442
  ELECTRIC STARTING SYSTEM EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM…
• Page 443
  ELECTRIC STARTING SYSTEM 3. Main switch 4. Main fuse 9. Backup fuse 12.Ignition fuse 18.Engine ground 19.Battery 20.Starter relay 22.Starter motor 23.Joint coupler 25.Handlebar switch (right) 27.Start/engine stop switch 29.Relay unit 30.Starting circuit cut-off relay 32.Neutral switch 33.Sidestand switch 48.ECU (Engine Control Unit) 89.Handlebar switch (left) 97.Clutch switch…
• Page 444
  ELECTRIC STARTING SYSTEM EAS30494 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is turned to “ON” and the “ ” side of the start/engine stop switch is pushed, the starter motor can only operate if at least one of the following conditions is met: •…
• Page 445
  ELECTRIC STARTING SYSTEM EAS30495 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Front side cowling/Front panel/Side cover 2. Rider seat 3. Fuel tank cover 4. Fuel tank 5. Air filter case 6. Throttle bodies NG →…
• Page 446
  ELECTRIC STARTING SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 8-40. OK ↓ NG → 9. Check the neutral switch. Refer to “CHECKING THE Replace the neutral switch. SWITCHES” on page 8-40. OK ↓…
• Page 447
  CHARGING SYSTEM EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM 1. AC magneto 2. Rectifier/regulator 4. Main fuse 18.Engine ground 19.Battery 8-12…
• Page 448
  CHARGING SYSTEM EAS30497 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Front side cowling/Front panel/Side cover bracket/Electrical components tray 2. Rider seat NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUS- ES”…
• Page 449
  CHARGING SYSTEM 8-14…
• Page 450
  LIGHTING SYSTEM EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM 8-15…
• Page 451
  LIGHTING SYSTEM 3. Main switch 4. Main fuse 9. Backup fuse 12.Ignition fuse 13.Signaling system fuse 16.Headlight fuse 18.Engine ground 19.Battery 23.Joint coupler 48.ECU (Engine Control Unit) 71.Meter assembly 76.Multi-function meter 82.Meter light 84.High beam indicator light 89.Handlebar switch (left) 91.Pass/LAP switch 92.Dimmer switch 100.Front turn signal/position light (right)
• Page 452
  LIGHTING SYSTEM EAS30499 TROUBLESHOOTING Any of the following fail to light: headlight, auxiliary light, high beam indicator light, tail/brake light, li- cense plate light or meter light. • Before troubleshooting, remove the following part(s): 1. Front side cowling/Front panel/Side cover 2.
• Page 453
  LIGHTING SYSTEM 8-18…
• Page 454
  SIGNALING SYSTEM EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM 8-19…
• Page 455
  SIGNALING SYSTEM 3. Main switch 4. Main fuse 9. Backup fuse 12.Ignition fuse 13.Signaling system fuse 14.ABS ECU fuse 15.Hazard lighting fuse 18.Engine ground 19.Battery 23.Joint coupler 24.Front brake light switch 25.Handlebar switch (right) 29.Relay unit 32.Neutral switch 34.Fuel sender 37.Gear position sensor 40.Shift sensor 46.Coolant temperature sensor…
• Page 456
  SIGNALING SYSTEM EAS30501 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. • The speedometer fails to operate. • Before troubleshooting, remove the following part(s): 1.
• Page 457
  SIGNALING SYSTEM NG → 2. Check the horn. Refer to “CHECKING THE HORN” Replace the horn. on page 8-47. OK ↓ NG → 3. Check the entire signaling sys- tem’s wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system’s wiring.
• Page 458
  SIGNALING SYSTEM NG → 3. Check the entire signaling sys- tem’s wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system’s wiring. page 8-19. OK ↓ Replace the meter assembly, front turn signal/position light or rear turn signal light.
• Page 459
  SIGNALING SYSTEM The oil pressure and coolant temperature warning light remains on after the engine is started. NG → 1. Check the entire signaling sys- tem’s wiring. Properly connect or replace the wiring har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-19.
• Page 460
  SIGNALING SYSTEM QSS (Quick Shift System) does not operate. NG → 1. Check that the malfunction indicator Repair the faulty parts. light does not come on. OK ↓ NG → 2. Check that the QSS is working un- Check the QSS operating conditions ex- der normal QSS operating condi- plained in the owner’s manual and operate tions.
• Page 461
  SIGNALING SYSTEM The speedometer fails to operate. NG → 1. Check the rear wheel sensor. Refer to “MAINTENANCE OF THE Replace the rear wheel sensor. REAR WHEEL SENSOR AND SENSOR ROTOR” on page 4-49. OK ↓ NG → 2. Check the entire wheel sensor wir- Properly connect or repair the wheel sen- ing.
• Page 462
  COOLING SYSTEM EAS20077 COOLING SYSTEM EAS30502 CIRCUIT DIAGRAM 8-27…
• Page 463
  COOLING SYSTEM 3. Main switch 4. Main fuse 5. Radiator fan motor relay 9. Backup fuse 10.Sub radiator fan motor fuse 11.Radiator fan motor fuse 12.Ignition fuse 18.Engine ground 19.Battery 46.Coolant temperature sensor 48.ECU (Engine Control Unit) 110.Sub radiator fan motor (right) 111.Radiator fan motor (left) A.
• Page 464
  COOLING SYSTEM EAS30503 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Front side cowling/Front panel/Side cover bracket/Electrical components tray 2. Rider seat 3. Fuel tank cover 4. Fuel tank 5. Air filter case 6. Throttle bodies NG → 1. Check the fuses. (Main, ignition, backup, radiator fan motor and sub radiator fan motor) Replace the fuse(s).
• Page 465
  COOLING SYSTEM NG → 7. Check the entire cooling system’s wiring. Properly connect or repair the cooling sys- Refer to “CIRCUIT DIAGRAM” on tem’s wiring. page 8-27. OK ↓ Replace the ECU. Refer to “REPLACING THE ECU (En- gine Control Unit)” on page 8-41. 8-30…
• Page 466
  FUEL PUMP SYSTEM EAS20081 FUEL PUMP SYSTEM EAS30513 CIRCUIT DIAGRAM 8-31…
• Page 467
  FUEL PUMP SYSTEM 3. Main switch 4. Main fuse 7. Fuel injection system fuse 9. Backup fuse 12.Ignition fuse 18.Engine ground 19.Battery 23.Joint coupler 25.Handlebar switch (right) 27.Start/engine stop switch 29.Relay unit 31.Fuel pump relay 35.Fuel pump 48.ECU (Engine Control Unit) 8-32…
• Page 468
  FUEL PUMP SYSTEM EAS30514 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Front side cowling/Front panel 2. Rider seat 3. Fuel tank cover 4. Fuel tank NG → 1. Check the fuses. (Main, ignition, backup and fuel in- jection system) Replace the fuse(s).
• Page 469
  FUEL PUMP SYSTEM NG → 7. Check the entire fuel pump sys- tem’s wiring. Properly connect or repair the fuel pump Refer to “CIRCUIT DIAGRAM” on system’s wiring. page 8-31. OK ↓ Replace the ECU. Refer to “REPLACING THE ECU (En- gine Control Unit)”…
• Page 470
  COMMUNICATION CONTROL SYSTEM (for YZF-R1M) EAS20212 COMMUNICATION CONTROL SYSTEM (for YZF-R1M) EAS31671 CIRCUIT DIAGRAM 8-35…
• Page 471
  COMMUNICATION CONTROL SYSTEM (for YZF-R1M) 3. Main switch 4. Main fuse 7. Fuel injection system fuse 9. Backup fuse 12.Ignition fuse 18.Engine ground 19.Battery 23.Joint coupler 48.ECU (Engine Control Unit) 70.IMU (Inertial Measurement Unit) 71.Meter assembly 76.Multi-function meter 85.YDT coupler 86.CCU (Communication Control Unit) 87.GPS unit A.
• Page 472
  COMMUNICATION CONTROL SYSTEM (for YZF-R1M) EAS31672 TROUBLESHOOTING The communication control system failed to function. • Before troubleshooting, remove the following part(s): 1. Front side cowling/Front panel/Side cover 2. Rider seat/Passenger seat/Battery cover/Tail cover NG → 1. Check the fuses. (Main, ignition and backup) Replace the fuse(s).
• Page 473
  ELECTRICAL COMPONENTS EAS20089 ELECTRICAL COMPONENTS 1. Accelerator position sensor 18. ECU (Engine Control Unit) 2. Intake funnel servo motor 19. Radiator fan motor 3. Throttle position sensor 20. Horn 4. Primary injector 21. Headlight control unit 5. Intake air pressure sensor 22.
• Page 474
  ELECTRICAL COMPONENTS 1. Intake solenoid 20. Front wheel sensor 2. Front fork stepping motor (for YZF-R1M) 21. Cylinder identification sensor 3. Air induction system solenoid 22. Fuse box 3 (SCU fuse) (for YZF-R1M) 4. Ignition coil 23. Rectifier/regulator 5. Atmospheric pressure sensor 24.
• Page 475
  ELECTRICAL COMPONENTS EAS30549 CHECKING THE SWITCHES Check each switch for continuity with the digital circuit tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. MODE DOWN L/B L/Y 1. Start/engine stop switch 2.
• Page 476
  ELECTRICAL COMPONENTS EAS30551 Amperage CHECKING THE FUSES Fuses Q’ty rating The following procedure applies to all of the fus- ABS ECU 7.5 A ECA13680 ABS solenoid 15 A NOTICE Auxiliary To avoid a short circuit, always set the main Backup 7.5 A switch to “OFF”…
• Page 477
  ELECTRICAL COMPONENTS EAS30552 CHECKING AND CHARGING THE BATTERY Refer to “CHECKING AND CHARGING THE BATTERY” in “BASIC INFORMATION” (sepa- rate volume). 1. Remove: • Rider seat/Battery cover Refer to “GENERAL CHASSIS (1)” on page 4-1. 2. Disconnect: Route the positive battery lead “1” to the outside •…
• Page 478
  ELECTRICAL COMPONENTS 1. Disconnect the relay from the wire harness. Relay unit (fuel pump relay) 2. Connect the digital circuit tester (Ω) and bat- tery (12 V) to the relay terminal as shown. Check the relay operation. Out of specification → Replace. Starter relay Br/W L/R L/W R/W L/B L/Y Sb B/Y Sb/W…
• Page 479
  ELECTRICAL COMPONENTS a. Disconnect the relay unit coupler from the wire harness. The digital circuit tester readings are shown in b. Connect the digital circuit tester (Ω) to the the following table. relay unit terminal as shown. c. Check the relay unit (diode) for continuity. Continuity d.
• Page 480
  ELECTRICAL COMPONENTS Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with ta- chometer YU-A1927 • Negative tester probe Ignition coil terminal “1” • Positive tester probe Spark plug terminal “2” 2. Ignition coil c. Turn the main switch to “ON”. d.
• Page 481
  ELECTRICAL COMPONENTS 2. Check: • Stator coil resistance Out of specification → Replace the stator coil. Stator coil resistance 0.112–0.168 Ω a. Connect the digital circuit tester to the sta- tor coil coupler as shown. Digital circuit tester (CD732) b. Measure the crankshaft position sensor 90890-03243 resistance.
• Page 482
  ELECTRICAL COMPONENTS Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with ta- chometer YU-A1927 • Positive tester probe white “1” • Negative tester probe white “2” b. Start the engine and let it run at approxi- • Positive tester probe mately 5000 r/min.
• Page 483
  ELECTRICAL COMPONENTS c. Measure the radiator fan motor move- EAS30574 CHECKING THE FUEL LEVEL WARNING ment. LIGHT EAS30578 This model is equipped with a self-diagnosis de- CHECKING THE COOLANT TEMPERATURE vice for the fuel level detection circuit. SENSOR 1. Check: 1.
• Page 484
  ELECTRICAL COMPONENTS   d. Heat the coolant or let it cool down to the specified temperatures. e. Measure the coolant temperature sensor resistance. 3. Install: • Coolant temperature sensor Coolant temperature sensor 16 N·m (1.6 kgf·m, 12 lb·ft) A. Check that the throttle valves “2” open. EAS30592 CHECKING THE THROTTLE SERVO MOTOR B.
• Page 485
  ELECTRICAL COMPONENTS • Positive tester probe white/black (wire harness color) • Negative tester probe black/blue (wire harness color) c. Measure the air induction system solenoid resistance. EAS30589 CHECKING THE CYLINDER IDENTIFICATION SENSOR c. Turn the main switch to “ON”. 1. Remove: d.
• Page 486
  ELECTRICAL COMPONENTS Digital circuit tester (CD732) Digital circuit tester (CD732) 90890-03243 90890-03243 Model 88 Multimeter with ta- Model 88 Multimeter with ta- chometer chometer YU-A1927 YU-A1927 b. Immerse the intake air temperature sen- • Positive tester probe sor “1” in a container filled with water “2”. black “1”…
• Page 487
  ELECTRICAL COMPONENTS • Positive tester probe white/black “4” • Negative tester probe black/yellow “3” e. When turning the wheel switch in direction “a”, check that the output voltage is within the specified values. Output voltage More than 5 V c. Measure the fuel injector resistance. f.
• Page 488
  ELECTRICAL COMPONENTS 8-53…

• Page 489: Self Diagnostic

  SELF DIAGNOSTIC SELF-DIAGNOSTIC FUNCTION…………..9-1 GLOSSARY………………..9-1 OUTLINE ………………..9-1 CHECKING THE WARNING LIGHT …………9-1 YDT ………………….9-2 PARTS CONNECTED TO THE ECU …………9-3 PARTS CONNECTED TO THE SCU (for YZF-R1M)……..9-3 PARTS CONNECTED TO THE ABS ECU……….9-4 PRECAUTIONS FOR ROAD TEST …………9-4 SYSTEM DIAGRAM ………………9-5 ECU CIRCUIT DIAGRAM…………….9-5 ECU COUPLER LAYOUT ……………..

• Page 490
  ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for YZF-R1M) ………………..9-29 CIRCUIT DIAGRAM …………….9-29 MAINTENANCE OF THE SCU (suspension control unit) …….9-31 BASIC INSTRUCTIONS FOR TROUBLESHOOTING ……9-31 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE..9-32 DTC TABLE………………… 9-32 SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM)…………9-38 SELF-DIAGNOSTIC FUNCTION TABLE (FOR ABS (Anti-lock Brake System)) ………….9-52 SELF-DIAGNOSTIC FUNCTION TABLE…
• Page 491
  C1007 ………………….9-86 TROUBLESHOOTING …………….9-86 P0030………………….9-87 TROUBLESHOOTING …………….9-87 P0050………………….9-91 TROUBLESHOOTING …………….9-91 P0069………………….9-95 TROUBLESHOOTING …………….9-95 P00D1, P2195………………..9-97 TROUBLESHOOTING …………….9-97 P00D3, P2197………………..9-101 TROUBLESHOOTING …………….9-101 P0107, P0108 ………………..9-105 TROUBLESHOOTING …………….9-105 P0112, P0113 ………………..9-109 TROUBLESHOOTING …………….9-109 P0117, P0118 ………………..9-113 TROUBLESHOOTING …………….9-113 P0122, P0123, P0222, P0223, P2135 …………9-117 TROUBLESHOOTING …………….9-117 P0132………………….9-121 TROUBLESHOOTING …………….9-121…
• Page 492
  P0204………………….9-136 TROUBLESHOOTING …………….9-136 P0335………………….9-139 TROUBLESHOOTING …………….9-139 P0340………………….9-142 TROUBLESHOOTING …………….9-142 P0351………………….9-145 TROUBLESHOOTING …………….9-145 P0352………………….9-149 TROUBLESHOOTING …………….9-149 P0353………………….9-153 TROUBLESHOOTING …………….9-153 P0354………………….9-157 TROUBLESHOOTING …………….9-157 P0475, P0476, P048B ……………..9-161 TROUBLESHOOTING …………….9-161 P0480………………….9-165 TROUBLESHOOTING …………….9-165 P048D, P048E …………………9-168 TROUBLESHOOTING …………….9-168 P0500 (FI), P1500………………9-171 TROUBLESHOOTING …………….9-171 P0500 (SCU)………………..9-183 TROUBLESHOOTING …………….9-183 P0560 (FI), P0563………………9-184…
• Page 493
  P0606………………….9-187 TROUBLESHOOTING …………….9-187 P062F ………………….9-188 TROUBLESHOOTING …………….9-188 P0638………………….9-189 TROUBLESHOOTING …………….9-189 P0657………………….9-193 TROUBLESHOOTING …………….9-193 P0916, P0917 ………………..9-197 TROUBLESHOOTING …………….9-197 P1400………………….9-201 TROUBLESHOOTING …………….9-201 P1600………………….9-205 TROUBLESHOOTING …………….9-205 P1601………………….9-209 TROUBLESHOOTING …………….9-209 P1602………………….9-213 TROUBLESHOOTING …………….9-213 P1806, P1807 ………………..9-217 TROUBLESHOOTING …………….9-217 P2122, P2123, P2127, P2128, P2138 …………9-221 TROUBLESHOOTING …………….9-221 P2158 (FI) ………………..9-225 TROUBLESHOOTING …………….9-225…
• Page 494
  P21D1 ………………….9-236 TROUBLESHOOTING …………….9-236 P21D2 ………………….9-239 TROUBLESHOOTING …………….9-239 P2228, P2229 ………………..9-242 TROUBLESHOOTING …………….9-242 U0100 ………………….9-246 TROUBLESHOOTING …………….9-246 U0121 ………………….9-249 TROUBLESHOOTING …………….9-249 U0125 (FI) ………………..9-252 TROUBLESHOOTING …………….9-252 U0125 (SCU)………………..9-256 TROUBLESHOOTING …………….9-256 U0155 or Err (FI) ………………9-259 TROUBLESHOOTING …………….9-259 U0155 or Err (SCU)………………9-263 TROUBLESHOOTING …………….9-263 11_ABS …………………..9-266 TROUBLESHOOTING …………….9-266…
• Page 495
  21_ABS …………………..9-274 TROUBLESHOOTING …………….9-274 31_ABS …………………..9-275 TROUBLESHOOTING …………….9-275 33_ABS …………………..9-277 TROUBLESHOOTING …………….9-277 34_ABS …………………..9-279 TROUBLESHOOTING …………….9-279 41_ABS …………………..9-280 TROUBLESHOOTING …………….9-280 42_ABS …………………..9-281 TROUBLESHOOTING …………….9-281 43, 45_ABS ………………..9-282 TROUBLESHOOTING …………….9-282 44, 46_ABS ………………..9-283 TROUBLESHOOTING …………….9-283 51_ABS …………………..9-284 TROUBLESHOOTING …………….9-284 53_ABS …………………..9-285 TROUBLESHOOTING …………….9-285 55_ABS …………………..9-287 TROUBLESHOOTING …………….9-287…
• Page 496
  89_ABS …………………..9-295 TROUBLESHOOTING …………….9-295 90_ABS …………………..9-298 TROUBLESHOOTING …………….9-298 91_ABS …………………..9-301 TROUBLESHOOTING …………….9-301…
• Page 498
  Generic diagnostic tool that complies with OBD standards. (Generic scan tool) (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.
• Page 499
  90890-03264 • 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.
• Page 500
  SELF-DIAGNOSTIC FUNCTION EAS32864 PARTS CONNECTED TO THE ECU The following parts are connected to the ECU. When checking for a power short circuit, the couplers must be disconnected from all of the following parts beforehand. • Crankshaft position sensor • O sensor 1 (left side) •…
• Page 501
  SELF-DIAGNOSTIC FUNCTION • Rear shock absorber assembly stepping motor (re- • Fuel sender bound damping) • Steering damper solenoid (OPTION) • Fuel pump • ECU (Engine Control Unit) • Handlebar switch (left) • Hydraulic unit assembly (ABS ECU) • Headlight control unit •…
• Page 502
  SYSTEM DIAGRAM EAS20387 SYSTEM DIAGRAM EAS32920 ECU CIRCUIT DIAGRAM 2. Electronic throttle valve fuse 34. Primary injector #1 10. Fuel pump 3. Backup fuse 35. Primary injector #2 relay 4. Fuel injection 9. Start/engine 36. Primary injector #3 11. Fuel pump system fuse stop switch 37.
• Page 503
  SYSTEM DIAGRAM 47. Intake funnel servo motor 28. Gear position sensor 29. O sensor 1 (left side) 22. EXUP servo motor 30. O sensor 2 (right side) 48. Steering damper solenoid 31. Throttle position 49. Intake solenoid sensor 31. Throttle position sensor 50.
• Page 504
  SYSTEM DIAGRAM 1. ECU (Engine Control Unit) 54. Headlight control unit 2. Electronic throttle valve fuse 55. Meter assembly 3. Backup fuse 56. CAN communication circuit 4. Fuel injection system fuse 5. Ignition fuse 6. Main switch 7. Main fuse 8.
• Page 505
  SYSTEM DIAGRAM EAS33369 ECU COUPLER LAYOUT 1 2 3 4 5 6 7 8 9 35 36 37 38 39 40 41 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 10 11 12 13 14 15 16 17 42 43 44 45 46 47 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 18 19 20 21 22 23 24 25…
• Page 506
  SYSTEM DIAGRAM Wire harness Wire harness Connected parts Connected parts color color — — — — EXUP servo motor sensor 1 (left side) Gy/G Accelerator position sensor — — — — Intake air tempera- Br/W ture sensor Throttle position sen- —…
• Page 507
  SYSTEM DIAGRAM 9-10…
• Page 508
  FUEL INJECTION SYSTEM EAS20440 FUEL INJECTION SYSTEM EAS32871 CIRCUIT DIAGRAM 9-11…
• Page 509
  FUEL INJECTION SYSTEM 3. Main switch 69.Throttle position sensor 4. Main fuse 70.IMU (Inertial Measurement Unit) 5. Radiator fan motor relay 71.Meter assembly 7. Fuel injection system fuse 73.MIL (Malfunction indicator light) 8. Electronic throttle valve fuse 76.Multi-function meter 9. Backup fuse 79.Auxiliary system warning light 12.Ignition fuse 85.YDT coupler…
• Page 510
  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 to Does the MIL (LED) work Check the MIL (LED).
• Page 511
  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.
• Page 512
  ABS (Anti-lock Brake System) EAS20443 ABS (Anti-lock Brake System) EAS32890 CIRCUIT DIAGRAM 9-15…
• Page 513
  ABS (Anti-lock Brake System) 3. Main switch 4. Main fuse 6. ABS solenoid fuse 7. Fuel injection system fuse 9. Backup fuse 12.Ignition fuse 13.Signaling system fuse 14.ABS ECU fuse 18.Engine ground 19.Battery 21.ABS motor fuse 23.Joint coupler 24.Front brake light switch 25.Handlebar switch (right) 48.ECU (Engine Control Unit) 66.Hydraulic unit assembly (ABS ECU)
• Page 514
  ABS (Anti-lock Brake System) EAS32891 ABS COMPONENTS CHART 15,16 1. Meter assembly 2. Hydraulic unit assembly (ABS ECU) 3. Fuse box 1 4. ABS solenoid fuse 5. YDT coupler 6. Starter relay 7. ABS motor fuse 8. Rear brake caliper 9.
• Page 515
  ABS (Anti-lock Brake System) EAS32892 ABS COUPLER LOCATION CHART L/W B/W B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y L/B G/W R/G L/B R/GR/G Sb/W G/L G/Y G G/B W/B W/G G/O Y (Gy) Gy/B L Y G R/B B L/W G/O W/L L B W W L/B 1.
• Page 516
  ABS (Anti-lock Brake System) EAS32893 MAINTENANCE OF THE ABS ECU Checking the ABS ECU 1. Check: • Terminals “1” of the hydraulic unit assembly (ABS ECU) Cracks/damages → Replace the hydraulic unit assembly, brake hoses, and brake pipes that are connected to the assembly as a set.
• Page 517
  ABS (Anti-lock Brake System) The ABS performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the main switch was turned to “ON”. During this test, a “clicking” noise can be heard from under the seat, and if the brake lever or brake pedal are even slightly applied, a vibration can be felt at the lever and pedal, but these do not indicate a malfunction.
• Page 518
  ABS (Anti-lock Brake System) Fails to Turn the main switch to “ON”, [A-1] Does only the ABS • The ABS warning light (LED) is come on and check the ABS warning Return to [A]. warning light fail to defective. light. •…
• Page 519
  ABS (Anti-lock Brake System) 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] •…
• Page 520
  90890-03264 • 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. Details about the displayed DTCs are shown in the following chart. Refer to this chart and check the vehicle.
• Page 521
  Yamaha diagnostic tool (A/I) 90890-03264 • 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. EAS32905 [C-1] FINAL CHECK…
• Page 522
  STEERING DAMPER SYSTEM EAS20445 STEERING DAMPER SYSTEM EAS32912 CIRCUIT DIAGRAM 9-25…
• Page 523
  STEERING DAMPER SYSTEM 3. Main switch 4. Main fuse 7. Fuel injection system fuse 9. Backup fuse 12.Ignition fuse 18.Engine ground 19.Battery 23.Joint coupler 48.ECU (Engine Control Unit) 65.Steering damper solenoid 71.Meter assembly 76.Multi-function meter 79.Auxiliary system warning light 85.YDT coupler *.
• Page 524
  STEERING DAMPER SYSTEM EAS32913 BASIC INSTRUCTIONS FOR TROUBLESHOOTING The auxiliary system warning light comes on. 1. Check the DTC of “malfunction” using the YDT. 2. Check and repair the malfunction according to applicable DTC troubleshooting. 3. Turn the main switch from “OFF” to “ON”, and then check the DTC of “malfunction” is not displayed. •…
• Page 525
  STEERING DAMPER SYSTEM 9-28…
• Page 526
  ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for YZF-R1M) EAS20446 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for YZF-R1M) EAS32914 CIRCUIT DIAGRAM 9-29…
• Page 527
  ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for YZF-R1M) 3. Main switch 4. Main fuse 7. Fuel injection system fuse 9. Backup fuse 12.Ignition fuse 18.Engine ground 19.Battery 23.Joint coupler 48.ECU (Engine Control Unit) 70.IMU (Inertial Measurement Unit) 71.Meter assembly 76.Multi-function meter 79.Auxiliary system warning light 85.YDT coupler 112.SCU fuse 113.SCU (Suspension Control Unit)
• Page 528
  ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for YZF-R1M) EAS32915 MAINTENANCE OF THE SCU (suspension control unit) Checking the SCU (suspension control unit) 1. Check: • Terminals “1” of the SCU Cracks/damages → Replace the SCU. • Terminals “2” of the SCU couplers Connection defective, contaminated, come-off →…
• Page 529
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS20551 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS33149 DTC TABLE Fail-safe system Diagnostic Symptom Starting the Driving the code engine vehicle Front wheel sensor (intermittent pulses or no “11_ABS” — — — pulses) Rear wheel sensor (intermittent pulses or no “12_ABS”…
• Page 530
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fail-safe system Diagnostic Symptom Starting the Driving the code engine vehicle CAN communication (between meter as- “89_ABS” — — — sembly and hydraulic unit assembly) CAN communication (between ECU and hy- “90_ABS” — — —…
• Page 531
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fail-safe system Diagnostic Symptom Starting the Driving the code engine vehicle [P0122] Throttle position sensor: ground short circuit detected. [P0123] Throttle position sensor: open or “P0122, power short circuit detected. P0123, [P0222] Throttle position sensor: open or P0222, Able/Unable Able/Unable…
• Page 532
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fail-safe system Diagnostic Symptom Starting the Driving the code engine vehicle Able Able Cylinder-#3 ignition coil: open or short circuit (depending on (depending on the number of the number of “P0353” detected in the primary lead of the cylinder- #3 ignition coil.
• Page 533
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fail-safe system Diagnostic Symptom Starting the Driving the code engine vehicle Air induction system solenoid: open or short “P1400” Able Able circuit detected. Lean angle sensor: open or short circuit de- “P1600” Unable Unable tected.
• Page 534
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fail-safe system Diagnostic Symptom Starting the Driving the code engine vehicle Abnormal CAN communication (between “U0121” Able Able — ABS ECU and SCU) Signals cannot be transmitted between the “U0125 (FI)” Unable Able/Unable — ECU and the IMU.
• Page 535
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS33028 SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM) For details of the DTC, refer to “BASIC PROCESS FOR TROUBLESHOOTING” on page 9-13. Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration 30_EVEN Latch up detected.
• Page 536
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration Engine is difficult to Intake air pressure is P0069 Intake air pressure • Malfunction in ECU. sensor or atmospher- • Intake air pressure start.
• Page 537
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration Engine idling speed is Intake air pressure P0107 [P0107] Intake air [P0107] Low voltage P0108 pressure sensor: of the intake air pres- unstable. difference is fixed to 0 ground short circuit sure sensor circuit…
• Page 538
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration Engine is difficult to The radiator fan motor P0117 [P0117] Coolant tem- [P0117] Low voltage P0118 perature sensor: of the coolant tem- start. relay is on only when ground short circuit perature sensor circuit…
• Page 539
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration P0132 sensor 1: short cir- [P0132] High voltage Increased exhaust feedback is not of the O sensor 1 cir- emissions. cuit detected (power carried out.
• Page 540
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration Engine cannot be Does not operate. P0335 Crankshaft position • Defective coupler sensor: no normal between crankshaft started. ISC feedback is not signals are received position sensor and carried out.
• Page 541
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration • Defective coupler Engine stops. Injection to the appli- P0351 [P0351] Cylinder-#1 P0352 ignition coil: open or between ignition coil Loss of engine power. cable cylinder group P0353 short circuit detected…
• Page 542
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration Radiator fan motor re- P0480 Radiator fan motor re- • Open or short cir- Engine is difficult to lay: open or short cir- cuit in wire harness.
• Page 543
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration Vehicle speed is not Vehicle speed dis- P0500 [P0500] Rear wheel • Open or short cir- P1500 sensor: no normal cuit in wire harness displayed on the me- played on the meter = signals are received…
• Page 544
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration P0606 Internal malfunction in • Malfunction in ECU. Engine cannot be Engine cannot be ECU. (When this mal- started. started. function is detected in Engine response is Ignition and injection the ECU, the DTC…
• Page 545
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration Improper display for Maintains the gear P0916 [P0916] Gear posi- [P0916] Low voltage P0917 tion sensor: open or of the gear position position. position value at the ground short circuit sensor circuit (0.2 V…
• Page 546
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration P1602 Malfunction in ECU • Open or short cir- Engine idling speed is feedback learning internal circuit (mal- cuit in wire harness unstable. is not carried out.
• Page 547
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration Traction control does P2158 Front wheel sensor: • Open or short cir- Traction control does no normal signals are cuit in wire harness not work.
• Page 548
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration • Defective coupler Loss of engine power. O P21CF [P21CF] Secondary feedback is not P21D0 injector #1: malfunc- between secondary carried out. P21D1 tion in secondary in- injector and ECU.
• Page 549
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS33286 SELF-DIAGNOSTIC FUNCTION TABLE (FOR ABS (Anti-lock Brake System)) For details of the DTC, refer to “BASIC INSTRUCTIONS FOR TROUBLESHOOTING” on page 9-20. Item Symptom Check point Front wheel sensor (intermit- Front wheel sensor signal is •…
• Page 550
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Item Symptom Check point Front wheel sensor (open or Open or short circuit is de- • Defective coupler between short circuit) tected in the front wheel sen- the front wheel sensor and sor. the hydraulic unit assembly •…
• Page 551
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Item Symptom Check point Rear wheel ABS (intermit- • Pulses from the rear wheel • Incorrect installation of the tent wheel speed pulses or sensor are received inter- rear wheel sensor incorrect depressurization) mittently while the vehicle •…
• Page 552
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Item Symptom Check point Vehicle CAN communication Short-circuit in CAN commu- • Short-circuit in CAN com- line or power source of vehi- nication line or the voltage munication line cle system that supplies the hydraulic •…
• Page 553
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS33287 SELF-DIAGNOSTIC FUNCTION TABLE (FOR STEERING DAMPER SYSTEM) For details of the DTC, refer to “BASIC INSTRUCTIONS FOR TROUBLESHOOTING” on page 9-27. Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration C1000 Steering damper sole- •…
• Page 554
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Item Vehicle symptom Fail-safe system operation malfunction • Defective connec- tion of stepping mo- tor and SCU • ERS adjustments can- couplers. not be performed. • Defective connec- • The damping preset Stepping motor: tion of sub-wire har- value is fixed on the de-…
• Page 555
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Probable cause of Item Vehicle symptom Fail-safe system operation malfunction • Defective connec- tion of wire harness, • ERS adjustments can- ABS ECU, and SCU not be performed. Abnormal CAN couplers. • The damping preset communication U0121 •…
• Page 556
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS33030 COMMUNICATION ERROR WITH THE METER Probable cause of Fail-safe system op- Item Vehicle symptom malfunction eration U0155 [U0155 (FI)] Multi- Communication be- Defective meter dis- MAP changeover: play. State is fixed. (YDT) function meter: sig- tween the ECU and Err (multi- nals cannot be trans-…
• Page 557
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Tool display Procedure code No. Throttle position sensor sig- nal 2 • Fully closed position 9–23 Check with throttle valves ful- ly closed. • Fully open position 93–109 Check with throttle valves ful- ly open.
• Page 558
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Tool display Procedure code No. EEPROM DTC display — • No history • No malfunctions detected (If the DTC P062F is indi- cated, the ECU is defec- tive.) • History exists 01–04 (CO adjustment val- •…
• Page 559
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS33032 DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE Diagnostic Item Actuation Procedure code No. Cylinder-#1 ignition coil Actuates the cylinder-#1 igni- Check that a spark is gener- tion coil five times at one- ated five times. •…
• Page 560
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Actuation Procedure code No. Primary injector #4 Actuates the primary injec- Disconnect the fuel pump tor #4 five times at one-sec- coupler before doing this ond intervals. procedure. The “check” indicator on the Check that primary injector YDT screen come on each #4 is actuated five times by…
• Page 561
  SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Actuation Procedure code No. Intake solenoid Actuates the intake solenoid Check that the intake sole- five times at one-second in- noid is actuated five times by tervals. listening for the operating The “check” indicator on the sound.
• Page 562
  EVENT CODE TABLE EAS20707 EVENT CODE TABLE The event code numbers listed below cannot be displayed on the meter. To display the event code numbers, use the YDT. Item Symptom Possible causes Note Intake air pres- Brief abnormality de- Same as for DTC num- Perform the inspection sure sensor tected in the intake air…
• Page 563
  EVENT CODE TABLE Item Symptom Possible causes Note sensor During O feedback, • Open or short circuit in • If a DTC is occurring, re- the wire harness be- spond to that first. (Stuck at the low- the adjustment is tween the sensor and * Rarely, Code 241 occurs er limit for adjust-…
• Page 564
  30_EVENT EAS20552 30_EVENT EAS33033 TROUBLESHOOTING Item Latch up detected. Fail-safe system • Unable to start engine • Unable to drive vehicle Procedure 1. The vehicle has overturned. • Raise the overturned vehicle vertically and check again. • Turn the main switch to “ON”, then to “OFF”, and then back to “ON”. Is the MIL on? →…
• Page 565
  30_EVENT → Service is completed. 4. Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41. 9-68…
• Page 566
  70_EVENT EAS20554 70_EVENT EAS33034 TROUBLESHOOTING Item Engine forcibly stops when the vehicle is left idling for a long period. Procedure If another error code is displayed at the same time, check the other error code first and repair it. 1. Allow to idle for a long period. •…
• Page 567
  C0044 EAS20559 C0044 EAS33039 TROUBLESHOOTING Item Abnormal ABS Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Abnormal ABS • Check the items of DTCs 62 and 68 for the ABS. Refer to “[B-2] DIAGNOSIS USING THE DTC” on page 9-23. •…
• Page 568
  C0520 (FI) EAS20689 C0520 (FI) EAS33319 TROUBLESHOOTING Item Abnormal IMU Fail-safe system • Able/Unable to start engine • Able/Unable to drive vehicle Procedure 1. Connection of IMU 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).
• Page 569
  C0520 (FI) blue/white–blue/white Between joint coupler and IMU coupler blue/black–blue/black Between IMU coupler and ignition fuse holder red/white–red/white Between IMU coupler and ECU coupler black/white–black/white Gy/G Gy/R Lg/R O/B R/B Br/R Br/Y Br/B Sb/W B R/L B/W L/W L/W L/W L/W L/W L/W L/B L/B L/B L/B L/B L/B P/W P Gy/G Br/W…
• Page 570
  C0520 (FI) blue/white–any other coupler terminal Joint coupler “2” blue/black–any other coupler terminal blue/white–any other coupler terminal IMU coupler blue/black–any other coupler terminal red/white–any other coupler terminal P/W P P/W P Gy/G Br/W Gy/G Br/W Gy/Y G/W G Gy/B Gy/Y G/W G Gy/B L/W L/W L/W L/W L/W L/W L/B L/B L/B L/B L/B L/B…
• Page 571
  C0520 (FI) a. Fix the IMU installation condition. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? → Go to step 7, and complete the service. →…
• Page 572
  C0520 (SCU) EAS20664 C0520 (SCU) EAS33290 TROUBLESHOOTING Item Abnormal IMU Fail-safe system • Unable to start engine • Able/Unable to drive vehicle Procedure 1. Abnormal front wheel sensor • Check the item of DTC C0520 for the ECU. Refer to “SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM)” on page 9-38.
• Page 573
  C1000 EAS20561 C1000 EAS33041 TROUBLESHOOTING Item Steering damper solenoid: open or short circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Connection of steering damper solenoid coupler. • Check the locking condition of the coupler. •…
• Page 574
  C1000 Between steering damper solenoid coupler and en- black–black gine ground Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT.
• Page 575
  C1000 a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? → Go to step 6, and complete the service. →…
• Page 576
  C1002 EAS20562 C1002 EAS33042 TROUBLESHOOTING Item Abnormal SCU EEPROM Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Confirmation after correction of abnormality. • Turn the main switch to “OFF” and back to “ON”. • Check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”…
• Page 577
  C1003 EAS20563 C1003 EAS33043 TROUBLESHOOTING Item Stepping motor: open or short circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Connection of front fork stepping motor coupler. • Check the locking condition of the coupler. –Front fork stepping motor (left) –Front fork stepping motor (right) –Rear shock absorber assembly stepping motor (×2)
• Page 578
  C1003 • Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Is the coupler condition normal? → Go to step 4. a. Connect the coupler securely or replace the wire harness and/or sub-wire harness. b.
• Page 579
  C1003 yellow–yellow Between SCU coupler “1” and rear shock absorber yellow/black–yellow/black assembly stepping motor (rebound damping) “2” yellow/red–yellow/red yellow/green–yellow/green Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness and/or sub-wire harness. b. Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT.
• Page 580
  C1003 white–black Between rear shock absorber assembly stepping white/black–black motor (compression damping) “4” and power ground white/red–black “2” white/green–black yellow–black Between rear shock absorber assembly stepping yellow/black–black motor (rebound damping) “5” and power ground “2” yellow/red–black yellow/green–black green–brown/white Between front fork stepping motor (left) “1” and pow- green/black–brown/white er battery “6”…
• Page 581
  C1003 2 3 4 A. Stepping motor coupler B. Connection wiring diagram b. Measure the resistance of the stepping motor between “1” and “2”. 14.8–18.2 Ω (When the motor is cold at 20 °C (68 °F))? → Go to step c. a.
• Page 582
  C1003 • Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? → Service is completed. → Refer to the item corresponding to DTC. 9-85…
• Page 583
  C1007 EAS20566 C1007 EAS33046 TROUBLESHOOTING Item Abnormality inside SCU Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Malfunction in SCU. • Replace the SCU. Refer to “GENERAL CHASSIS (6)” on page 4-23. • Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT.
• Page 584
  P0030 EAS20397 P0030 EAS33134 TROUBLESHOOTING Item sensor 1 heater: defective heater controller detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •…
• Page 585
  P0030 a. Connect the coupler securely or replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? → Go to step 6, and complete the service. →…
• Page 586
  P0030 Is it in the “Recovered” condition? → Go to step 6, and complete the service. → Go to “Short circuit check”. For this check, also set the start/engine stop switch to “ON”. • Short circuit check Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU”…
• Page 587
  P0030 → Go to step 4. For this check, also set the start/engine stop switch to “ON”. 4. Defective O sensor 1. • Replace the O sensor 1. Refer to “ENGINE REMOVAL” on page 5-11. • Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT.
• Page 588
  P0050 EAS20398 P0050 EAS33135 TROUBLESHOOTING Item sensor 2 heater: defective heater controller detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •…
• Page 589
  P0050 a. Connect the coupler securely or replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? → Go to step 6, and complete the service. →…
• Page 590
  P0050 Is it in the “Recovered” condition? → Go to step 6, and complete the service. → Go to “Short circuit check”. For this check, also set the start/engine stop switch to “ON”. • Short circuit check Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU”…
• Page 591
  P0050 → Go to step 4. For this check, also set the start/engine stop switch to “ON”. 4. Defective O sensor 2. • Replace the O sensor 2. Refer to “ENGINE REMOVAL” on page 5-11. • Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT.
• Page 592
  P0069 EAS20390 P0069 EAS33136 TROUBLESHOOTING Item Intake air pressure sensor or atmospheric pressure sensor: when the main switch is turned to “ON”, the intake air pressure sensor voltage and atmospheric pressure sensor voltage differ greatly. Fail-safe system • Able to start engine •…
• Page 593
  P0069 a. Replace the atmospheric pressure sensor. Refer to “AIR INDUCTION SYSTEM” on page 7-20. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →…
• Page 594
  P00D1, P2195 EAS20660 P00D1, P2195 EAS33115 TROUBLESHOOTING Item • [P00D1] O sensor 1: heater performance deterioration • [P2195] O sensor 1: open circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •…
• Page 595
  P00D1, P2195 3. Connection of ECU coupler. • Check the locking condition of the coupler. • Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Is the coupler condition normal? → Go to step 4. a.
• Page 596
  P00D1, P2195 Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-3. Ground short circuit check “A” gray/green–ground pink/black–ground Between O sensor 1 coupler “1” and ground black/blue–ground red/white–ground Lines short circuit check “B” gray/green–any other coupler terminal pink/black–any other coupler terminal sensor 1 coupler…
• Page 597
  P00D1, P2195 a. Replace the fuel pump. Refer to “REMOVING THE FUEL PUMP” on page 7-3. b. Start the engine and let it idle for approximately 1 minute. c. Check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”…
• Page 598
  P00D3, P2197 EAS20661 P00D3, P2197 EAS33338 TROUBLESHOOTING Item • [P00D3] O sensor 2: heater performance deterioration • [P2197] O sensor 2: open circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •…
• Page 599
  P00D3, P2197 3. Connection of ECU coupler. • Check the locking condition of the coupler. • Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Is the coupler condition normal? → Go to step 4. a.
• Page 600
  P00D3, P2197 Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-3. Ground short circuit check “A” gray/yellow–ground pink/white–ground Between O sensor 2 coupler “1” and ground black/blue–ground red/white–ground Lines short circuit check “B” gray/yellow–any other coupler terminal pink/white–any other coupler terminal sensor 2 coupler…
• Page 601
  P00D3, P2197 a. Replace the fuel pump. Refer to “REMOVING THE FUEL PUMP” on page 7-3. b. Start the engine and let it idle for approximately 1 minute. c. Check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”…
• Page 602
  P0107, P0108 EAS20567 P0107, P0108 EAS33047 TROUBLESHOOTING Item • [P0107] Intake air pressure sensor: ground short circuit detected. • [P0108] Intake air pressure sensor: open or power short circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1.
• Page 603
  P0107, P0108 blue–blue Between intake air pressure sensor coupler and pink/white–pink/white ECU coupler black/blue–black/blue P/W P Gy/G Br/W Gy/Y G/W G Gy/B Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT.
• Page 604
  P0107, P0108 Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →…
• Page 605
  P0107, P0108 Is it in the “Recovered” condition? → Go to step 7, and complete the service. → Go to step 6. 6. Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41. 7.
• Page 606
  P0112, P0113 EAS20568 P0112, P0113 EAS33048 TROUBLESHOOTING Item • [P0112] Intake air temperature sensor: ground short circuit detected. • [P0113] Intake air temperature sensor: open or power short circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure Perform this procedure when the engine is cold.
• Page 607
  P0112, P0113 • Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Is the coupler condition normal? → Go to step 4. a. Connect the coupler securely or replace the wire harness. b.
• Page 608
  P0112, P0113 Refer to “PARTS CONNECTED TO THE ECU” on page 9-3. Ground short circuit check “A” Between intake air temperature sensor coupler “1” brown/white–ground and ground Between wire harness coupler (sub-wire harness brown/white–ground side) “3” and ground Lines short circuit check “B” brown/white–any other coupler terminal Intake air temperature sensor coupler black/blue–any other coupler terminal…
• Page 609
  P0112, P0113 a. Reinstall the sensor. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? → Go to step 8, and complete the service. →…
• Page 610
  P0117, P0118 EAS20569 P0117, P0118 EAS33049 TROUBLESHOOTING Item • [P0117] Coolant temperature sensor: ground short circuit detected. • [P0118] Coolant temperature sensor: open or power short circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure Perform this procedure when the engine is cold.
• Page 611
  P0117, P0118 • Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Is the coupler condition normal? → Go to step 4. a. Connect the coupler securely or replace the wire harness. b.
• Page 612
  P0117, P0118 Refer to “PARTS CONNECTED TO THE ECU” on page 9-3. Ground short circuit check “A” Between coolant temperature sensor coupler “1” green/white–ground and ground Between wire harness coupler (sub-wire harness green/white–ground side) “3” and ground Lines short circuit check “B” green/white–any other coupler terminal Coolant temperature sensor coupler black/blue–any other coupler terminal…
• Page 613
  P0117, P0118 a. Reinstall the sensor. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? → Go to step 8, and complete the service. →…
• Page 614
  P0122, P0123, P0222, P0223, P2135 EAS20570 P0122, P0123, P0222, P0223, P2135 EAS33050 TROUBLESHOOTING Item • [P0122] Throttle position sensor: ground short circuit detected. • [P0123] Throttle position sensor: open or power short circuit detected. • [P0222] Throttle position sensor: open or ground short circuit detected. •…
• Page 615
  P0122, P0123, P0222, P0223, P2135 → Go to step 3. 3. Wire harness continuity. • Disconnect the throttle position sensor coupler “1” and ECU coupler “2”. • Open circuit check white–white Between throttle position sensor coupler and ECU black/green–black/green coupler blue–blue black–black Is resistance 0 Ω?
• Page 616
  P0122, P0123, P0222, P0223, P2135 Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”…
• Page 617
  P0122, P0123, P0222, P0223, P2135 a. Replace the throttle position sensor. Refer to “ADJUSTING THE THROTTLE POSITION SENSOR” on page 7-19. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT.
• Page 618
  P0132 EAS20571 P0132 EAS33051 TROUBLESHOOTING Item sensor 1: short circuit detected (power short circuit). Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Installed condition of O sensor 1. • Check for looseness or pinching. Refer to “ENGINE REMOVAL”…
• Page 619
  P0132 → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →…
• Page 620
  P0132 black/blue–any other coupler terminal ECU coupler “2” gray/green–any other coupler terminal P/W P Gy/G Br/W Gy/Y G/W G Gy/B Is resistance ∞ Ω? → Go to step 5. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT.
• Page 621
  P0152 EAS20572 P0152 EAS33052 TROUBLESHOOTING Item sensor 2: short circuit detected (power short circuit). Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Installed condition of O sensor 2. • Check for looseness or pinching. Refer to “ENGINE REMOVAL”…
• Page 622
  P0152 → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →…
• Page 623
  P0152 black/blue–any other coupler terminal ECU coupler “2” gray/yellow–any other coupler terminal P/W P Gy/G Br/W Gy/Y G/W G Gy/B Is resistance ∞ Ω? → Go to step 5. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT.
• Page 624
  P0201 EAS20574 P0201 EAS33054 TROUBLESHOOTING Item Primary injector #1: malfunction in primary injector #1. Fail-safe system • Able to start engine (depending on the number of faulty cylinders) • Able to drive vehicle (depending on the number of faulty cylinders) Procedure 1.
• Page 625
  P0201 → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Execute the diagnostic mode. (Code D36) Is it hear operating sound? → Go to step 6. → Go to step 4. 4. Wire harness continuity. •…
• Page 626
  P0201 ECU coupler “2” red/black–any other coupler terminal Relay unit coupler “3” red/blue–any other coupler terminal R/LR/B R/LR/B Gy/G Gy/R Lg/R O/B R/B Br/R Br/Y Br/B Sb/W B R/L B/W Br/W L R/L L/R L/W R/W L/B L/Y B/Y Sb/W Is resistance ∞…
• Page 627
  P0202 EAS20575 P0202 EAS33055 TROUBLESHOOTING Item Primary injector #2: malfunction in primary injector #2. Fail-safe system • Able to start engine (depending on the number of faulty cylinders) • Able to drive vehicle (depending on the number of faulty cylinders) Procedure 1.
• Page 628
  P0202 → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Execute the diagnostic mode. (Code D37) Is it hear operating sound? → Go to step 6. → Go to step 4. 4. Wire harness continuity. •…
• Page 629
  P0202 ECU coupler “2” green/black–any other coupler terminal Relay unit coupler “3” red/blue–any other coupler terminal R/LG/B R/LG/B Gy/G Gy/R Lg/R O/B R/B Br/R Br/Y Br/B Sb/W B R/L B/W Br/W L R/L L/R L/W R/W L/B L/Y B/Y Sb/W Is resistance ∞…
• Page 630
  P0203 EAS20576 P0203 EAS33056 TROUBLESHOOTING Item Primary injector #3: malfunction in primary injector #3. Fail-safe system • Able to start engine (depending on the number of faulty cylinders) • Able to drive vehicle (depending on the number of faulty cylinders) Procedure 1.
• Page 631
  P0203 → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Execute the diagnostic mode. (Code D38) Is it hear operating sound? → Go to step 6. → Go to step 4. 4. Wire harness continuity. •…
• Page 632
  P0203 ECU coupler “2” blue/black–any other coupler terminal Relay unit coupler “3” red/blue–any other coupler terminal R/L L/B R/L L/B Gy/G Gy/R Lg/R O/B R/B Br/R Br/Y Br/B Sb/W B R/L B/W Br/W L R/L L/R L/W R/W L/B L/Y B/Y Sb/W Is resistance ∞…
• Page 633
  P0204 EAS20577 P0204 EAS33057 TROUBLESHOOTING Item Primary injector #4: malfunction in primary injector #4. Fail-safe system • Able to start engine (depending on the number of faulty cylinders) • Able to drive vehicle (depending on the number of faulty cylinders) Procedure 1.
• Page 634
  P0204 → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Execute the diagnostic mode. (Code D39) Is it hear operating sound? → Go to step 6. → Go to step 4. 4. Wire harness continuity. •…
• Page 635
  P0204 ECU coupler “2” orange/black–any other coupler terminal Relay unit coupler “3” red/blue–any other coupler terminal R/LO/B R/LO/B Gy/G Gy/R Lg/R O/B R/B Br/R Br/Y Br/B Sb/W B R/L B/W Br/W L R/L L/R L/W R/W L/B L/Y B/Y Sb/W Is resistance ∞…
• Page 636
  P0335 EAS20578 P0335 EAS33058 TROUBLESHOOTING Item Crankshaft position sensor: no normal signals are 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. •…
• Page 637
  P0335 P/W P B/L Gy Gy/G Br/W Gy/Y G/W G Gy/B Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness. b. Crank the engine, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”…
• Page 638
  P0335 a. Replace the wire harness. b. Crank the engine, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? → Go to step 7, and complete the service. →…
• Page 639
  P0340 EAS20579 P0340 EAS32839 TROUBLESHOOTING Item • Cylinder identification sensor: no normal signals are received from the cylinder identification sensor. Fail-safe system • Unable to start engine • Able to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •…
• Page 640
  P0340 white/black–white/black Between cylinder identification sensor coupler and blue–blue ECU coupler black/blue–black/blue P/W P L W/B Gy/G Br/W Gy/Y G/W G Gy/B Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness. b. Crank the engine, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”…
• Page 641
  P0340 Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Crank the engine, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →…
• Page 642
  P0351 EAS20580 P0351 EAS33060 TROUBLESHOOTING Item Cylinder-#1 ignition coil: open or short circuit detected in the primary lead of the cylinder-#1 ignition coil. Fail-safe system • Able to start engine (depending on the number of faulty cylinders) • Able to drive vehicle (depending on the number of faulty cylinders) Procedure 1.
• Page 643
  P0351 Between cylinder-#1 ignition coil coupler and ECU orange–orange coupler Between cylinder-#1 ignition coil coupler and han- red/white–red/white dlebar switch (right) coupler “3” Gy/G Gy/R Lg/R O/B R/B Br/R Br/Y Br/B Sb/W B R/L B/W Is resistance 0 Ω? → Go to “Short circuit check”. a.
• Page 644
  P0351 Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Start the engine and let it idle for approximately 5 seconds. c. Check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”…
• Page 645
  P0351 • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41. 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. 9-148…
• Page 646
  P0352 EAS20581 P0352 EAS33061 TROUBLESHOOTING Item Cylinder-#2 ignition coil: open or short circuit detected in the primary lead of the cylinder-#2 ignition coil. Fail-safe system • Able to start engine (depending on the number of faulty cylinders) • Able to drive vehicle (depending on the number of faulty cylinders) Procedure 1.
• Page 647
  P0352 Between cylinder-#2 ignition coil coupler and ECU gray/red–gray/red coupler Between cylinder-#2 ignition coil coupler and han- red/white–red/white dlebar switch (right) coupler Gy/G Gy/R Lg/R O/B R/B Gy/R Br/R Br/Y Br/B Sb/W B R/L B/W Is resistance 0 Ω? → Go to “Short circuit check”. a.
• Page 648
  P0352 Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Start the engine and let it idle for approximately 5 seconds. c. Check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”…
• Page 649
  P0352 • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41. 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. 9-152…
• Page 650
  P0353 EAS20582 P0353 EAS33062 TROUBLESHOOTING Item Cylinder-#3 ignition coil: open or short circuit detected in the primary lead of the cylinder-#3 ignition coil. Fail-safe system • Able to start engine (depending on the number of faulty cylinders) • Able to drive vehicle (depending on the number of faulty cylinders) Procedure 1.
• Page 651
  P0353 Between cylinder-#3 ignition coil coupler and ECU orange/green–orange/green coupler Between cylinder-#3 ignition coil coupler and han- red/white–red/white dlebar switch (right) coupler Gy/G Gy/R Lg/R O/B R/B Br/R Br/Y Br/B Sb/W B R/L B/W Is resistance 0 Ω? → Go to “Short circuit check”. a.
• Page 652
  P0353 Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Start the engine and let it idle for approximately 5 seconds. c. Check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”…
• Page 653
  P0353 • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41. 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. 9-156…
• Page 654
  P0354 EAS20583 P0354 EAS33063 TROUBLESHOOTING Item Cylinder-#4 ignition coil: open or short circuit detected in the primary lead of the cylinder-#4 ignition coil. Fail-safe system • Able to start engine (depending on the number of faulty cylinders) • Able to drive vehicle (depending on the number of faulty cylinders) Procedure 1.
• Page 655
  P0354 Between cylinder-#4 ignition coil coupler and ECU gray/green–gray/green coupler Between cylinder-#4 ignition coil coupler and han- red/white–red/white dlebar switch (right) coupler Gy/G Gy/R Lg/R O/B R/B Gy/G Br/R Br/Y Br/B Sb/W B R/L B/W Is resistance 0 Ω? → Go to “Short circuit check”. a.
• Page 656
  P0354 Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Start the engine and let it idle for approximately 5 seconds. c. Check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”…
• Page 657
  P0354 • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41. 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. 9-160…
• Page 658
  P0475, P0476, P048B EAS20672 P0475, P0476, P048B EAS32841 TROUBLESHOOTING Item • [P0475] EXUP servo motor: performance deterioration • [P0476] EXUP servo motor: stuck EXUP servo motor is detected. • [P048B] EXUP servo motor: signal stuck Fail-safe system • Able to start engine •…
• Page 659
  P0475, P0476, P048B 3. Wire harness continuity. • Disconnect the EXUP servo motor coupler “1” and ECU coupler “2”. • Open circuit check Between EXUP servo motor coupler and ECU cou- black/green–black/green pler black/red–black/red Is resistance 0 Ω? → Go to “Short circuit check”. a.
• Page 660
  P0475, P0476, P048B Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →…
• Page 661
  P0475, P0476, P048B a. Replace the cables. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? → Go to step 7, and complete the service. →…
• Page 662
  P0480 EAS20585 P0480 EAS33065 TROUBLESHOOTING Item Radiator fan motor relay: open or short circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Connection of radiator fan motor relay coupler. • Check the locking condition of the coupler. •…
• Page 663
  P0480 Between radiator fan motor relay and ECU coupler green/yellow–green/yellow Gy/G Gy/R Lg/R O/B R/B Br/R Br/Y Br/B Sb/W B R/L B/W Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT.
• Page 664
  P0480 a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? → Go to step 6, and complete the service. →…
• Page 665
  P048D, P048E EAS20586 P048D, P048E EAS33066 TROUBLESHOOTING Item • [P048D] EXUP servo motor: open or ground short circuit detected. • [P048E] EXUP servo motor: power short circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure If “P048D/P048E”…
• Page 666
  P048D, P048E • Open circuit check blue–blue Between EXUP servo motor coupler and ECU cou- white/yellow–white/yellow pler black/blue–black/blue P/W P Gy/G Br/W Gy/Y G/W G Gy/B Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness. b.
• Page 667
  P048D, P048E P/W P Gy/G Br/W Gy/Y G/W G Gy/B Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT.
• Page 668
  P0500 (FI), P1500 EAS20674 P0500 (FI), P1500 EAS33303 TROUBLESHOOTING Item • Rear wheel sensor: no normal signals are received from the rear wheel sensor. • Neutral switch: open or short circuit is detected. • Clutch switch: open or short circuit is detected. Fail-safe system •…
• Page 669
  P0500 (FI), P1500 Is check result OK? → Go to step 21. → Go to step 15. Perform the procedure from step 15 to step 21. 2. Connection of rear wheel sensor coupler. • Check the locking condition of the coupler. •…
• Page 670
  P0500 (FI), P1500 a. Connect the coupler securely or replace the wire harness. b. Execute the diagnostic mode. (Code D07) c. Rotate the rear wheel by hand and check that the indicated value increases. Is that value increased? → Go to step 21. →…
• Page 671
  P0500 (FI), P1500 Lines short circuit check “B” black–any other coupler terminal Rear wheel sensor coupler “1” white–any other coupler terminal black–any other coupler terminal ABS ECU coupler white–any other coupler terminal white/blue–any other coupler terminal ECU coupler “3” white/blue–any other coupler terminal Gy/B L Y G R/B B L/W G/O W/L L B W W L/B Gy/B L Y G R/B B L/W…
• Page 672
  P0500 (FI), P1500 → Go to step 21. → Go to step 7. 7. Malfunction in ABS ECU. • Replace the ABS ECU and go to step 21. 8. Connection of neutral switch coupler. • Check the locking condition of the coupler. •…
• Page 673
  P0500 (FI), P1500 Between relay unit coupler and neutral switch cou- sky blue–sky blue pler Br/W L R/L L/R L/W R/W L/B L/Y B/Y Sb/W P/W P Gy/G Br/W Gy/Y G/W G Gy/B Is resistance 0 Ω? → Go to “Short circuit check”. a.
• Page 674
  P0500 (FI), P1500 Br/W L R/L Br/W L R/L L/R L/W R/W L/B L/Y B/Y Sb/W L/R L/W R/W L/B L/Y B/Y Sb/W P/W P Gy/G Br/W Gy/Y G/W G Gy/B Is resistance ∞ Ω? → Go to step 11. a.
• Page 675
  P0500 (FI), P1500 • Refer to “CHECKING THE SWITCHES” on page 8-40. Is check result OK? → Go to step 13. a. Replace the neutral switch. Refer to “CRANKCASE” on page 5-71. b. Execute the diagnostic mode. (Code D21) When the transmission is in neutral When the transmission is in gear with the clutch lever released Is it correct indication? →…
• Page 676
  P0500 (FI), P1500 Is the coupler condition normal? → Go to step 17. a. Connect the coupler securely or replace the wire harness. b. Execute the diagnostic mode. (Code D21) When the clutch lever is released with the transmission in gear and when the sidestand is retracted When the clutch lever is squeezed with the transmission in gear and when the sidestand is retracted…
• Page 677
  P0500 (FI), P1500 Br/W L R/L L/R L/W R/W L/B L/Y B/Y Sb/W P/W P Gy/G Br/W Gy/Y G/W G Gy/B Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness. b. Execute the diagnostic mode. (Code D21) When the clutch lever is released with the transmission in gear and when the sidestand is retracted When the clutch lever is squeezed with the transmission in gear and when the…
• Page 678
  P0500 (FI), P1500 Br/W L R/L Br/W L R/L L/R L/W R/W L/B L/Y B/Y Sb/W L/R L/W R/W L/B L/Y B/Y Sb/W P/W P Gy/G Br/W Gy/Y G/W G Gy/B Is resistance ∞ Ω? → Go to step 19. a.
• Page 679
  P0500 (FI), P1500 → Go to step 20. 20.Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41. 21.Delete the DTC and check that the MIL goes off. •…
• Page 680
  P0500 (SCU) EAS20588 P0500 (SCU) EAS33068 TROUBLESHOOTING Item Abnormal rear wheel sensor Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Abnormal rear wheel sensor • Check the item of DTC P0500 for the ECU. Refer to “SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM)”…
• Page 681
  P0560 (FI), P0563 EAS20675 P0560 (FI), P0563 EAS33304 TROUBLESHOOTING Item • [P0560 (FI)] Charging voltage is abnormal. • [P0563] Vehicle system power voltage out of range Fail-safe system • Able to start engine • Able to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •…
• Page 682
  P0560 (SCU) EAS20593 P0560 (SCU) EAS33073 TROUBLESHOOTING Item Abnormal SCU power supply voltage 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 8-12. Is check result OK? →…
• Page 683
  P0601 EAS20676 P0601 EAS33305 TROUBLESHOOTING Item Internal malfunction in ECU. (When this malfunction is detected in the ECU, the DTC might not appear on the tool display.) Fail-safe system • Unable to start engine • Unable to drive vehicle Procedure 1.
• Page 684
  P0606 EAS20677 P0606 EAS33306 TROUBLESHOOTING Item Internal malfunction in ECU. (When this malfunction is detected in the ECU, the DTC might not appear on the tool display.) Fail-safe system • Able/Unable to start engine • Able/Unable to drive vehicle Procedure 1.
• Page 685
  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 D60) 2.
• Page 686
  P0638 EAS20599 P0638 EAS33079 TROUBLESHOOTING Item YCC-T drive system: malfunction detected. Fail-safe system • Able/Unable to start engine • Able/Unable to drive vehicle Procedure 1. Connection of throttle servo motor 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).
• Page 687
  P0638 a. Replace the electronic throttle valve fuse. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? → Go to step 8, and complete the service. →…
• Page 688
  P0638 Lines short circuit check “B” yellow/red–any other coupler terminal Throttle servo motor coupler “1” light green/red–any other coupler terminal yellow/red–any other coupler terminal ECU coupler light green/red–any other coupler terminal red/blue–any other coupler terminal Lg/R Y/R Gy/G Gy/R Lg/R O/B R/B Br/R Br/Y Br/B…
• Page 689
  P0638 Is check result OK? → Go to step 7. a. Replace the throttle bodies. Refer to “REPLACING THE THROTTLE BODIES” on page 7-17. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT.
• Page 690
  P0657 EAS20601 P0657 EAS33081 TROUBLESHOOTING Item Fuel system voltage: incorrect voltage supplied to the fuel injector and fuel pump. Fail-safe system • Able to start engine • Able to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •…
• Page 691
  P0657 • Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins). Is the coupler condition normal? → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Start the engine and let it idle for approximately 5 seconds. c.
• Page 692
  P0657 • Short circuit check Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-3. Ground short circuit check “A” brown/white–ground blue/white–ground Between relay unit coupler “2” and ground red/white–ground red/blue–ground Between handlebar switch (right) coupler “4” and red/white–ground ground Lines short circuit check “B”…
• Page 693
  P0657 Is check result OK? → Go to step 6. a. Replace the relay unit. b. Start the engine and let it idle for approximately 5 seconds. c. Check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”…
• Page 694
  P0916, P0917 EAS20611 P0916, P0917 EAS33091 TROUBLESHOOTING Item • [P0916] Gear position sensor: open or ground short circuit detected. • [P0917] Gear position sensor: power short circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1.
• Page 695
  P0916, P0917 white–white Between gear position sensor coupler and ECU green–green coupler blue/red–blue/red P/W P L/R G W Gy/G Br/W Gy/Y G/W G Gy/B Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT.
• Page 696
  P0916, P0917 Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →…
• Page 697
  P0916, P0917 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. 9-200…
• Page 698
  P1400 EAS20612 P1400 EAS33092 TROUBLESHOOTING Item Air induction system solenoid: open or short circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Connection of air induction system solenoid coupler. • Check the locking condition of the coupler. •…
• Page 699
  P1400 → Go to step 6, and complete the service. → Start the engine and check the status of the DTC. Is it in the “Recovered” condition? → Go to step 6, and complete the service. → Go to step 3. Check that the start/engine stop switch is turned to “ON”…
• Page 700
  P1400 • Short circuit check Disconnect the ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-3. Ground short circuit check “A” Between air induction system solenoid coupler “1” brown/red–ground and ground red/white–ground Lines short circuit check “B” brown/red–any other coupler terminal Air induction system solenoid coupler red/white–any other coupler terminal…
• Page 701
  P1400 Is it in the “Recovered” condition? → Go to step 6, and complete the service. → Start the engine and check the status of the DTC. Is it in the “Recovered” condition? → Go to step 6, and complete the service. →…
• Page 702
  P1600 EAS20613 P1600 EAS33093 TROUBLESHOOTING Item Lean angle sensor: open or short circuit detected. Fail-safe system • Unable to start engine • Unable to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •…
• Page 703
  P1600 • Open circuit check blue/white–blue/white Between ECU coupler and joint coupler blue/black–blue/black blue/white–blue/white Between joint coupler and IMU coupler blue/black–blue/black Between ECU coupler and IMU coupler black/white–black/white Between ignition fuse holder and IMU coupler red/white–red/white Gy/G Gy/R Lg/R O/B R/B Br/R Br/Y Br/B Sb/W B…
• Page 704
  P1600 Lines short circuit check “B” blue/white–any other coupler terminal ECU coupler black/black–any other coupler terminal blue/white–any other coupler terminal Joint coupler “2” black/black–any other coupler terminal blue/white–any other coupler terminal IMU coupler blue/black–any other coupler terminal red/white–any other coupler terminal P/W P P/W P Gy/G…
• Page 705
  P1600 → Go to step 5. a. Fix the IMU installation condition. b. Turn the main switch to “ON”, then to “OFF”, and back to “ON”. c. Check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”…
• Page 706
  P1601 EAS20614 P1601 EAS33094 TROUBLESHOOTING Item Sidestand switch: open or short circuit of the blue/yellow lead of the ECU is detected. Fail-safe system • Unable to start engine • Unable to drive vehicle Procedure 1. Connection of sidestand switch coupler. •…
• Page 707
  P1601 Is the coupler condition normal? → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Turn the main switch to “ON”, and then extend and retract the sidestand. c. Check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered”…
• Page 708
  P1601 Ground short circuit check “A” blue/yellow–ground Between main switch coupler “1” and ground blue/black–ground blue/yellow–ground Between relay unit coupler “3” and ground blue/black–ground Lines short circuit check “B” blue/yellow–any other coupler terminal Main switch coupler “1” blue/black–any other coupler terminal ECU coupler “2”…
• Page 709
  P1601 a. Replace the sidestand switch. b. Turn the main switch to “ON”, and then extend and retract the sidestand. c. Check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →…
• Page 710
  P1602 EAS20615 P1602 EAS33095 TROUBLESHOOTING Item Malfunction in ECU internal circuit (malfunction of ECU 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? →…
• Page 711
  P1602 → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →…
• Page 712
  P1602 → Go to “Short circuit check”. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →…
• Page 713
  P1602 → Go to step 6. 6. Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41. 7. Delete the DTC and check that the MIL goes off. •…
• Page 714
  P1806, P1807 EAS20623 P1806, P1807 EAS33103 TROUBLESHOOTING Item • [P1806] Shift sensor: open or ground short circuit detected. • [P1807] Shift sensor: power short circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Connection of shift sensor coupler. •…
• Page 715
  P1806, P1807 black/blue–black/blue Between shift sensor coupler and ECU coupler violet–violet blue–blue P/W P B/L V L Gy/G Br/W Gy/Y G/W G Gy/B Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT.
• Page 716
  P1806, P1807 Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →…
• Page 717
  P1806, P1807 → Go to step 6. 6. Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41. 7. Delete the DTC and check that the MIL goes off. •…
• Page 718
  P2122, P2123, P2127, P2128, P2138 EAS20632 P2122, P2123, P2127, P2128, P2138 EAS33112 TROUBLESHOOTING Item • [P2122] Accelerator position sensor: open or ground short circuit detected. • [P2123] Accelerator position sensor: power short circuit detected. • [P2127] Accelerator position sensor: open or ground short circuit detected. •…
• Page 719
  P2122, P2123, P2127, P2128, P2138 → Go to step 3. 3. Wire harness continuity. • Disconnect the accelerator position sensor coupler “1” and ECU coupler “2”. • Open circuit check blue/yellow–blue/yellow white–white Between accelerator position sensor coupler and black/blue–black/blue ECU coupler blue/green–blue/green black–black black/yellow–black/yellow…
• Page 720
  P2122, P2123, P2127, P2128, P2138 Lines short circuit check “B” blue/yellow–any other coupler terminal white–any other coupler terminal black/blue–any other coupler terminal Accelerator position sensor coupler blue/green–any other coupler terminal black–any other coupler terminal black/yellow–any other coupler terminal blue/yellow–any other coupler terminal white–any other coupler terminal black/blue–any other coupler terminal ECU coupler “2”…
• Page 721
  P2122, P2123, P2127, P2128, P2138 Is it in the “Recovered” condition? → Go to step 6, and complete the service. → Go to step 5. 5. Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41. 6.
• Page 722
  P2158 (FI) EAS20633 P2158 (FI) EAS33113 TROUBLESHOOTING Item Front wheel sensor: no normal signals are received from the front 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? →…
• Page 723
  P2158 (FI) Is the coupler condition normal? → Go to step 5. a. Connect the coupler securely or replace the wire harness. b. Execute the diagnostic mode. (Code D16) c. Rotate the front wheel by hand and check that the indicated value increases. Is that value increased? →…
• Page 724
  P2158 (FI) a. Replace the wire harness. b. Execute the diagnostic mode. (Code D16) c. Rotate the front wheel by hand and check that the indicated value increases. Is that value increased? → Go to step 10, and complete the service. →…
• Page 725
  P2158 (FI) → Go to step 7. a. Replace the wire harness. b. Execute the diagnostic mode. (Code D16) c. Rotate the front wheel by hand and check that the indicated value increases. Is that value increased? → Go to step 10, and complete the service. →…
• Page 726
  P2158 (SCU) EAS20634 P2158 (SCU) EAS33114 TROUBLESHOOTING Item Front wheel sensor: no normal signals are received from the front wheel sensor. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Abnormal front wheel sensor • Check the item of DTC P2158 for the ECU. Refer to “SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM)”…
• Page 727
  P21CF EAS20637 P21CF EAS33117 TROUBLESHOOTING Item Secondary injector #1: malfunction in secondary injector #1. Fail-safe system • Able to start engine (depending on the number of faulty cylinders) • Able to drive vehicle (depending on the number of faulty cylinders) Procedure 1.
• Page 728
  P21CF → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Execute the diagnostic mode. (Code D40) Is it hear operating sound? → Go to step 6. → Go to step 4. 4. Wire harness continuity. •…
• Page 729
  P21CF ECU coupler “2” white/blue–any other coupler terminal Relay unit coupler “3” red/blue–any other coupler terminal W/L R/L W/L R/L Gy/G Gy/R Lg/R O/B R/B Br/R Br/Y Br/B Sb/W B R/L B/W Br/W L R/L L/R L/W R/W L/B L/Y B/Y Sb/W Is resistance ∞…
• Page 730
  P21D0 EAS20638 P21D0 EAS33118 TROUBLESHOOTING Item Secondary injector #2: malfunction in secondary injector #2. Fail-safe system • Able to start engine (depending on the number of faulty cylinders) • Able to drive vehicle (depending on the number of faulty cylinders) Procedure 1.
• Page 731
  P21D0 → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Execute the diagnostic mode. (Code D41) Is it hear operating sound? → Go to step 6. → Go to step 4. 4. Wire harness continuity. •…
• Page 732
  P21D0 ECU coupler “2” sky blue/white–any other coupler terminal Relay unit coupler “3” red/blue–any other coupler terminal Sb/WR/L Sb/WR/L Gy/G Gy/R Lg/R O/B R/B Br/R Br/Y Br/B Sb/W B R/L B/W Br/W L R/L L/R L/W R/W L/B L/Y B/Y Sb/W Is resistance ∞…
• Page 733
  P21D1 EAS20639 P21D1 EAS33119 TROUBLESHOOTING Item Secondary injector #3: malfunction in secondary injector #3. Fail-safe system • Able to start engine (depending on the number of faulty cylinders) • Able to drive vehicle (depending on the number of faulty cylinders) Procedure 1.
• Page 734
  P21D1 → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Execute the diagnostic mode. (Code D42) Is it hear operating sound? → Go to step 6. → Go to step 4. 4. Wire harness continuity. •…
• Page 735
  P21D1 ECU coupler “2” brown/yellow–any other coupler terminal Relay unit coupler “3” red/blue–any other coupler terminal Br/Y R/L Br/Y R/L Gy/G Gy/R Lg/R O/B R/B Br/R Br/Y Br/B Sb/W B R/L B/W Br/W L R/L L/R L/W R/W L/B L/Y B/Y Sb/W Is resistance ∞…
• Page 736
  P21D2 EAS20640 P21D2 EAS33120 TROUBLESHOOTING Item Secondary injector #4: malfunction in secondary injector #4. Fail-safe system • Able to start engine (depending on the number of faulty cylinders) • Able to drive vehicle (depending on the number of faulty cylinders) Procedure 1.
• Page 737
  P21D2 → Go to step 4. a. Connect the coupler securely or replace the wire harness. b. Execute the diagnostic mode. (Code D43) Is it hear operating sound? → Go to step 6. → Go to step 4. 4. Wire harness continuity. •…
• Page 738
  P21D2 ECU coupler “2” brown/black–any other coupler terminal Relay unit coupler “3” red/blue–any other coupler terminal Br/B R/L Br/B R/L Gy/G Gy/R Lg/R O/B R/B Br/R Br/Y Br/B Sb/W B R/L B/W Br/W L R/L L/R L/W R/W L/B L/Y B/Y Sb/W Is resistance ∞…
• Page 739
  P2228, P2229 EAS20641 P2228, P2229 EAS33121 TROUBLESHOOTING Item • [P2228] Atmospheric pressure sensor: ground short circuit detected. • [P2229] Atmospheric pressure sensor: open or power short circuit detected. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1.
• Page 740
  P2228, P2229 blue–blue Between atmospheric pressure sensor coupler and pink–pink ECU coupler black/blue–black/blue P/W P B/L P L Gy/G Br/W Gy/Y G/W G Gy/B Is resistance 0 Ω? → Go to “Short circuit check”. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT.
• Page 741
  P2228, P2229 Is resistance ∞ Ω? → Go to step 4. a. Replace the wire harness. b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode of the YDT. Is it in the “Recovered” condition? →…
• Page 742
  P2228, P2229 Is it in the “Recovered” condition? → Go to step 7, and complete the service. → Go to step 6. 6. Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41. 7.
• Page 743
  U0100 EAS20644 U0100 EAS33124 TROUBLESHOOTING Item Abnormal CAN communication (between ECU and SCU) Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Connection of ECU coupler. • Check the locking condition of the coupler. • Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the pins).
• Page 744
  U0100 Br/W Y/R Gy/G P/L G/B Gy/B Gy/R W/R W/B L/W L/W L/W L/W L/W L/W L/B L/B L/B L/B L/B L/B P/W P Gy/G Br/W Gy/Y G/W G Gy/B L/W L/W L/W L/W L/W L/W L/W L/B L/B L/B L/B L/B L/B L/B *.
• Page 745
  U0100 Br/W Br/W Y/R Gy/G Y/R Gy/G P/L G/B Gy/B Gy/R P/L G/B Gy/B Gy/R W/R W/B W/R W/B P/W P P/W P Gy/G Br/W Gy/G Br/W Gy/Y G/W G Gy/B Gy/Y G/W G Gy/B L/W L/W L/W L/W L/W L/W L/B L/B L/B L/B L/B L/B L/W L/W L/W L/W L/W L/W L/W L/B L/B L/B L/B L/B L/B L/B *.
• Page 746
  U0121 EAS20646 U0121 EAS33126 TROUBLESHOOTING Item Abnormal CAN communication (between ABS ECU and SCU) Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Connection of ABS ECU coupler. • Check the locking condition of the coupler. •…
• Page 747
  U0121 Br/W Y/R Gy/G P/L G/B Gy/B Gy/R W/R W/B Gy/B L Y G R/B B L/W G/O W/L L B W W L/B L/W L/W L/W L/W L/W L/W L/B L/B L/B L/B L/B L/B L/W L/W L/W L/W L/W L/W L/W L/B L/B L/B L/B L/B L/B L/B *.
• Page 748
  U0121 Br/W Br/W Y/R Gy/G Y/R Gy/G P/L G/B Gy/B Gy/R P/L G/B Gy/B Gy/R W/R W/B W/R W/B Gy/B L Y G R/B B L/W Gy/B L Y G R/B B L/W G/O W/L L B W W L/B G/O W/L L B W W L/B L/W L/W L/W L/W L/W L/W L/B L/B L/B L/B L/B L/B L/W L/W L/W L/W L/W L/W L/W…
• Page 749
  U0125 (FI) EAS20647 U0125 (FI) EAS33127 TROUBLESHOOTING Item Signals cannot be transmitted between the ECU and the IMU. Fail-safe system • Unable to start engine • Able/Unable to drive vehicle Procedure If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first. •…
• Page 750
  U0125 (FI) • Open circuit check blue/white–blue/white Between ECU coupler and joint coupler blue/black–blue/black blue/white–blue/white Between joint coupler and IMU coupler blue/black–blue/black Between IMU coupler and ignition fuse holder red/white–red/white Between IMU coupler and ECU coupler black/white–black/white Gy/G Gy/R Lg/R O/B R/B Br/R Br/Y Br/B…
• Page 751
  U0125 (FI) Lines short circuit check “B” blue/white–any other coupler terminal ECU coupler blue/black–any other coupler terminal blue/white–any other coupler terminal Joint coupler “2” blue/black–any other coupler terminal blue/white–any other coupler terminal IMU coupler blue/black–any other coupler terminal red/white–any other coupler terminal P/W P P/W P Gy/G…
• Page 752
  U0125 (FI) Is it in the “Recovered” condition? → Go to step 6, and complete the service. → Go to step 5. 5. Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41. 6.
• Page 753
  U0125 (SCU) EAS20648 U0125 (SCU) EAS33128 TROUBLESHOOTING Item Abnormal CAN communication (between IMU and SCU) Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Connection of IMU coupler. • Check the locking condition of the coupler. •…
• Page 754
  U0125 (SCU) Br/W Y/R Gy/G P/L G/B Gy/B Gy/R W/R W/B L/W L/W L/W L/W L/W L/W L/B L/B L/B L/B L/B L/B L/W L/W L/W L/W L/W L/W L/W L/B L/B L/B L/B L/B L/B L/B *. Joint coupler for YZF-R1 **.
• Page 755
  U0125 (SCU) Br/W Br/W Y/R Gy/G Y/R Gy/G P/L G/B Gy/B Gy/R P/L G/B Gy/B Gy/R W/R W/B W/R W/B L/W L/W L/W L/W L/W L/W L/B L/B L/B L/B L/B L/B L/W L/W L/W L/W L/W L/W L/W L/B L/B L/B L/B L/B L/B L/B *.
• Page 756
  U0155 or Err (FI) EAS20649 U0155 or Err (FI) EAS33129 TROUBLESHOOTING Item Multi-function meter: signals cannot be transmitted between the ECU and the multi-function meter. Fail-safe system • Able to start engine • Able to drive vehicle Procedure “Err” is displayed on the clock display of the multi-function meter, but the MIL does not come on. 1.
• Page 757
  U0155 or Err (FI) blue/white–blue/white Between meter assembly coupler and joint coupler blue/black–blue/black blue/white–blue/white Between joint coupler and ECU coupler blue/black–blue/black B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y L/B G/W R/GR/G Sb/W G/L G/Y G G/B W/B W/G G/O Y L/W L/W L/W L/W L/W L/W L/B L/B L/B L/B L/B L/B P/W P…
• Page 758
  U0155 or Err (FI) blue/white–any other coupler terminal ECU coupler blue/black–any other coupler terminal B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y L/B G/W B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y L/B G/W R/GR/G Sb/W G/L G/Y G G/B W/B W/G G/O Y R/GR/G Sb/W G/L G/Y…
• Page 759
  U0155 or Err (FI) 5. Malfunction in ECU. • Replace the ECU, and complete the service. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41. 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. 9-262…
• Page 760
  U0155 or Err (SCU) EAS20650 U0155 or Err (SCU) EAS33130 TROUBLESHOOTING Item Abnormal CAN communication (between meter assembly and SCU) Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Connection of meter assembly coupler. • Check the locking condition of the coupler. •…
• Page 761
  U0155 or Err (SCU) Br/W Y/R Gy/G B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y L/B G/W P/L G/B Gy/B Gy/R R/GR/G Sb/W G/L G/Y G G/B W/B W/G G/O Y W/R W/B L/W L/W L/W L/W L/W L/W L/B L/B L/B L/B L/B L/B L/W L/W L/W L/W L/W L/W L/W L/B L/B L/B L/B L/B L/B L/B *.
• Page 762
  U0155 or Err (SCU) Br/W Br/W Y/R Gy/G Y/R Gy/G P/L G/B Gy/B Gy/R P/L G/B Gy/B Gy/R W/R W/B W/R W/B B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y L/B G/W B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y L/B G/W R/GR/G Sb/W G/L G/Y…
• Page 763
  11_ABS EAS20685 11_ABS EAS33314 TROUBLESHOOTING Item Front wheel sensor (intermittent pulses or no pulses) Procedure If the rear wheel continues to turn for more than 20 seconds after the front wheel has stopped, this will be recorded. 1. Foreign material adhered around the front wheel sensor •…
• Page 764
  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? →…
• Page 765
  13, 26_ABS EAS20687 13, 26_ABS EAS33316 TROUBLESHOOTING Item Front wheel sensor (abnormal pulse period) Procedure • 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. •…
• Page 766
  14, 27_ABS EAS20688 14, 27_ABS EAS33317 TROUBLESHOOTING Item Rear wheel sensor (abnormal pulse period) Procedure • 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. •…
• Page 767
  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. Turn the main switch to “OFF”…
• Page 768
  15_ABS Lines short circuit check “B” white–any other coupler terminal ABS ECU coupler black–any other coupler terminal Gy/B L Y G R/B B L/W Gy/B L Y G R/B B L/W G/O W/L L B W W L/B G/O W/L L B W W L/B Is resistance ∞…
• Page 769
  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. Turn the main switch to “OFF”…
• Page 770
  16_ABS Lines short circuit check “B” white–any other coupler terminal ABS ECU coupler black–any other coupler terminal Gy/B L Y G R/B B L/W Gy/B L Y G R/B B L/W G/O W/L L B W W L/B G/O W/L L B W W L/B Is resistance ∞…
• Page 771
  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 4-74. 9-274…
• Page 772
  31_ABS EAS20691 31_ABS EAS33321 TROUBLESHOOTING Hydraulic unit assembly (defective ABS solenoid power circuit) Procedure 1. Blown ABS solenoid fuse • Check the ABS solenoid fuse. Refer to “CHECKING THE FUSES” on page 8-41. Is check result OK? → Go to step 2. →…
• Page 773
  31_ABS 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 “1” and ground blue/white–ground Lines short circuit check “B” ABS ECU coupler blue/white–any other coupler terminal Gy/B L Y G R/B B L/W Gy/B L Y G R/B B L/W…
• Page 774
  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 8-41. Is check result OK? → Go to step 2. →…
• Page 775
  33_ABS 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 “1” and ground red/white–ground Lines short circuit check “B” ABS ECU coupler red/white–any other coupler terminal Gy/B L Y G R/B B L/W Gy/B L Y G R/B B L/W…
• Page 776
  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 4-74. 9-279…
• Page 777
  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 4-40.
• Page 778
  42_ABS EAS20695 42_ABS EAS33324 TROUBLESHOOTING Item Rear wheel ABS (intermittent wheel speed pulses or incorrect depressurization) Procedure 1. Incorrect installation of the rear wheel sensor • Check the components for looseness, distortion, and bends. Refer to “MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR” on page 4-49.
• Page 779
  43, 45_ABS EAS20696 43, 45_ABS EAS33330 TROUBLESHOOTING Item Front wheel sensor (missing pulses) Procedure After the DTC 45 is recorded, DTC 43 will be recorded if a certain speed and time are exceeded. 1. Foreign material adhered around the front wheel sensor •…
• Page 780
  44, 46_ABS EAS20697 44, 46_ABS EAS33325 TROUBLESHOOTING Item Rear wheel sensor (missing pulses) Procedure After the DTC 46 is recorded, DTC 44 will be recorded if a certain speed and time are exceeded. 1. Foreign material adhered around the rear wheel sensor •…
• Page 781
  51_ABS EAS20698 51_ABS EAS33326 TROUBLESHOOTING Item Vehicle system power supply (voltage of ABS ECU power supply is high) Procedure 1. Defective battery • Recharge or replace the battery, and check again. Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-42. 2.
• Page 782
  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 8-42. 2.
• Page 783
  53_ABS Lines short circuit check “B” ABS ECU coupler red/black–any other coupler terminal Gy/B L Y G R/B B L/W Gy/B L Y G R/B B L/W G/O W/L L B W W L/B G/O W/L L B W W L/B Is resistance ∞…
• Page 784
  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 4-74. 9-287…
• Page 785
  56_ABS EAS20701 56_ABS EAS33329 TROUBLESHOOTING Item Hydraulic unit assembly (abnormal internal circuit) Procedure 1. Defective hydraulic unit assembly • Replace the hydraulic unit assembly. Refer to “ABS (Anti-lock Brake System)” on page 4-74. 9-288…
• Page 786
  57_ABS EAS20666 57_ABS EAS33292 TROUBLESHOOTING Item Vehicle CAN communication line or power source of vehicle system Procedure 1. Wire harness continuity. • Disconnect the ECU coupler “1”, joint coupler “2” and ABS ECU coupler “3”. • Open circuit check blue/white–blue/white Between ECU coupler and joint coupler blue/black–blue/black blue/white–blue/white…
• Page 787
  57_ABS blue/white–ground Between ABS ECU coupler “3” and ground blue/black–ground Lines short circuit check “B” blue/white–any other coupler terminal ECU coupler blue/black–any other coupler terminal blue/white–any other coupler terminal Joint coupler “2” blue/black–any other coupler terminal blue/white–any other coupler terminal ABS ECU coupler blue/black–any other coupler terminal P/W P…
• Page 788
  57_ABS → Go to step 4. → If there is a malfunction, repair it and connect the coupler securely. 4. Wire harness continuity • Disconnect the ABS ECU fuse “1”, ABS solenoid fuse “2” and ABS ECU coupler “3”. • Open circuit check Between ABS ECU fuse holder and ABS ECU cou- red/black–red/black pler…
• Page 789
  57_ABS → Go to step 5. → Replace the wire harness. 5. Defective charging system • Check the charging system. Refer to “CHARGING SYSTEM” on page 8-12. Is resistance ∞ Ω? → Replace the hydraulic unit assembly (ABS ECU). → Confirm the cause of the problem and repair it, and check again. 9-292…
• Page 790
  62_ABS EAS20702 62_ABS EAS33333 TROUBLESHOOTING Item Power supply voltage failure in pressure sensor Procedure 1. Defective hydraulic unit assembly • Replace the hydraulic unit assembly. Refer to “ABS (Anti-lock Brake System)” on page 4-74. 9-293…
• Page 791
  68_ABS EAS20705 68_ABS EAS33336 TROUBLESHOOTING Item Defective hydraulic unit assembly (defective front pressure sensor) Procedure 1. Defective front brake line • Check the front brake line. Is check result OK? → Go to step 2. → If there is bending or blocking, replace the front brake line. 2.
• Page 792
  89_ABS EAS20669 89_ABS EAS33299 TROUBLESHOOTING Item CAN communication (between meter assembly and hydraulic unit assembly) Procedure 1. Defective coupler between the meter assembly and the hydraulic unit assembly • Check the coupler for any pins that may be pulled out. •…
• Page 793
  89_ABS • Short circuit check 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” blue/white–ground Between meter assembly coupler “1” and ground blue/black–ground blue/white–ground Between ABS ECU coupler “3” and ground blue/black–ground Lines short circuit check “B”…
• Page 794
  89_ABS 3. Defective meter assembly • Replace the meter assembly, and check again. 4. Defective hydraulic unit assembly • Replace the hydraulic unit assembly. 9-297…
• Page 795
  90_ABS EAS20670 90_ABS EAS33300 TROUBLESHOOTING Item CAN communication (between ECU and hydraulic unit assembly) Procedure 1. Defective coupler between the ECU and the hydraulic unit assembly • Check the coupler for any pins that may be pulled out. • Check the locking condition of the coupler. Turn the main switch to “OFF”…
• Page 796
  90_ABS → Replace the wire harness. • Short circuit check Disconnect the ECU and ABS ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE ECU” on page 9-3 and “PARTS CONNECTED TO THE ABS ECU” on page 9-4. Ground short circuit check “A”…
• Page 797
  90_ABS 3. Defective ECU • Replace the ECU, and check again. 4. Defective hydraulic unit assembly • Replace the hydraulic unit assembly. 9-300…
• Page 798
  91_ABS EAS20671 91_ABS EAS33301 TROUBLESHOOTING Item CAN communication (between IMU and hydraulic unit assembly) Procedure 1. Defective coupler between the IMU and the hydraulic unit assembly • Check the coupler for any pins that may be pulled out. • Check the locking condition of the coupler. Turn the main switch to “OFF”…
• Page 799
  91_ABS • Short circuit check 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” blue/white–ground Between IMU coupler “1” and ground blue/black–ground blue/white–ground Between ABS ECU coupler “3” and ground blue/black–ground Lines short circuit check “B”…
• Page 800
  91_ABS 4. Defective hydraulic unit assembly • Replace the hydraulic unit assembly. 9-303…
• Page 801
  91_ABS 9-304…
• Page 802
  57. Primary injector #3 111.Radiator fan motor (left) EAS20091 WIRING DIAGRAM 58. Primary injector #4 112.SCU fuse (for YZF-R1M) 59. Secondary injector #1 113.SCU (Suspension Control YZFR1L/YZFR1LC/YZFR1ML/ 60. Secondary injector #2 Unit) (for YZF-R1M) YZFR1MLC 2020 61. Secondary injector #3 114.Front fork stepping motor (left) 1.
• Page 803
  EAS30613 Yellow/Red COLOR CODE Black Brown Chocolate Dark green Dark blue Green Gray Blue Light green Orange Pink Sky blue Violet White Yellow Black/Green Black/Blue Black/Red Black/White Black/Yellow Br/B Brown/Black Br/L Brown/Blue Br/R Brown/Red Br/W Brown/White Br/Y Brown/Yellow Green/Black Green/Blue Green/Orange Green/Red Green/White…
• Page 807
  YZFR1L/YZFR1LC/YZFR1ML/YZFR1MLC 2020 WIRING DIAGRAM R/L R/L R/L R/L R/W R/W R/L R/L R/W R/W (Dgy) W W W W W W L/R R/W O R/W L/B L/Y Br/L Sb/W Br/W Gy/R Gy/R Gy/R R/W Br/L L/Y L/Y L/B Br/L Gy/G L/R G W Br/W L R/L…
• Page 808
  YZFR1L/YZFR1LC/YZFR1ML/YZFR1MLC 2020 WIRING DIAGRAM (Dgy) (Dl) (Dl) (Dl) (Gy) (Gy) (Gy) (Gy) (Gy) MODE DOWN 96 97 107 106 (Gy) (Gy) (Gy)