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• Page 1: Table Of Contents

  Smart key system Special features Instrument and control functions For your safety – pre-operation checks Operation and important riding points Periodic maintenance and adjustment Scooter care and storage MOTORCYCLE Specifications XP560E (TMAX) Consumer information XP560D (TMAX TECH MAX) Index B3T-28199-E0…

• Page 2
  XMTR COMP. (Hand Unit) Frequency band: 433.92 MHz The maximum radio frequency power: 10 mW Manufacturer: MITSUBISHI ELECTRIC CORPORATION, HIMEJI WORKS 840, Chiyoda-machi, Himeji, Hyogo 670-8677, Japan Importer: YAMAHA MOTOR EUROPE N.V. Koolhovenlaan 101, 1119 NC Schiphol-Rijk, 1117 ZN, Schiphol, the Netherlands…
• Page 3
  EAU79575 For XP560D: This model is equipped with My TMAX Connect GPS system. This system must be activated before it can be used. Please refer to the Vodafone Customer Portal User Guide for instructions on how to register and activate the system.
• Page 5
  Welcome to the Yamaha world of motorcycling! As the owner of the XP560E / XP560D, you are benefiting from Yamaha’s vast experience and newest technology regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability.
• Page 6
  Important manual information EAU10134 Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
• Page 7
  Important manual information EAU10201 XP560E / XP560D OWNER’S MANUAL ©2020 by Yamaha Motor Co., Ltd. 1st edition, August 2019 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.
• Page 8
  Table of contents Safety information……1-1 Indicator lights and warning Tips for reducing fuel Further safe-riding points ….1-5 lights ……….5-2 consumption ……. 7-4 Speedometer ……..5-4 Parking……….7-4 Description ……..2-1 Tachometer ……..5-5 Left view ……… 2-1 Multi-function display……5-5 Periodic maintenance and Right view……..
• Page 9
  Table of contents Adjusting the rear brake lock Storage ……….. 9-3 cable ……….8-22 Checking the rear brake lock ..8-23 Specifications ……… 10-1 Checking the front and rear brake pads ………..8-24 Consumer information….11-1 Checking the brake fluid level ..8-24 Identification numbers ….11-1 Changing the brake fluid ….8-25 Diagnostic connector….

• Page 10: Safety Information

  Safety information  Never operate a scooter without conspicuous appears to be very EAU1026B proper training or instruction. Take effective in reducing the chance of training course. Beginners this type of accident. Be a Responsible Owner should receive training from a cer- Therefore: As the vehicle’s owner, you are re- tified instructor.

• Page 11
  Safety information  Many accidents involve inexperi- • Always signal before turning or Protective Apparel enced operators. In fact, many op- changing lanes. Make sure that The majority of fatalities from scooter erators who have been involved in other motorists can see you. accidents are the result of head inju- …
• Page 12
  Safety information  Do not run engine outdoors where Avoid Carbon Monoxide Poisoning When loading within this weight limit, All engine exhaust contains carbon engine exhaust can be drawn into keep the following in mind:  Cargo and accessory weight monoxide, a deadly gas.
• Page 13
  Yamaha accessories, which are avail- characteristics can put you and others effects. Wind may attempt to lift able only from a Yamaha dealer, have at greater risk of serious injury or the scooter, or the scooter may been designed, tested, and approved death.

• Page 14: Further Safe-Riding Points

  Safety information Aftermarket Tires and Rims cation for the straps carefully so EAU57600 Further safe-riding points The tires and rims that came with your the straps will not rub against  Be sure to signal clearly when scooter were designed to match the painted surfaces during transport.

• Page 15
  Safety information  Always wear a helmet, gloves, trousers (tapered around the cuff and ankle so they do not flap), and a brightly colored jacket.  Do not carry too much luggage on the scooter. An overloaded scoot- er is unstable. Use a strong cord to secure any luggage to the carri- er (if equipped).

• Page 16: Description

  Description EAU10411 Left view 1. Fuses (page 8-31) 9. Coolant level check window (page 8-15) 2. Battery (page 8-30) 3. Fuel tank cap (page 5-20) 4. Engine oil filler cap (page 8-12) 5. Sidestand (page 5-29) 6. Engine oil drain bolt (page 8-12) 7.

• Page 17: Right View

  Description EAU10421 Right view 1. Grab bar (page 7-3) 2. Tool kit (page 8-2) 3. Rear storage compartment (page 5-23) 4. Air filter element (page 8-17) 5. Front storage compartment (page 5-23) 6. Windshield (page 5-25/5-8) 7. Centerstand (page 8-28)

• Page 18: Controls And Instruments

  Description EAU10431 Controls and instruments 10,11 1. Rear brake lever (page 5-18) 9. Throttle grip (page 8-18) 2. Left handlebar switches (page 5-1) 10.Front storage compartment (page 5-23) 3. Rear brake lock lever (page 5-18) 11.Auxiliary DC jack (page 5-28) 4.

• Page 19: Smart Key System

  Smart key system EAU77202 Smart key system The smart key system enables the ve- hicle to be operated without using a mechanical key. EWA14704 WARNING  Keep implanted pacemakers or cardiac defibrillators, as well as other electric medical devices 1. Vehicle mounted antenna 1.

• Page 20: Operating Range Of The Smart Key System

  Smart key system  You are carrying or using com- EAU77214 Operating range of the smart munication equipment such as key system radios or mobile phones in The operating range of the smart key close proximity of the smart key …

• Page 21: Handling Of The Smart Key And Mechanical Key

  Smart key system system may be disabled. The EAU61647 Handling of the smart key and smart key should always carried  As the smart key system uses mechanical key on your person. weak radio waves, the operating Included with the vehicle is one smart EWA17952 range may be affected by the sur- key (with a built-in mechanical key) and…

• Page 22
   Do not place or store the smart system still does not operate, have a key in a storage compartment. Yamaha dealer check the vehicle. The smart key may be damaged from road vibrations or exces- sive heat.

• Page 23: Smart Key

  “ON/OFF” switch for one second. keys for the same vehicle. See a The smart key indicator light will flash. Yamaha dealer regarding spare If the key does a short flash, the key is smart keys. on. If the key does a long flash, the key …

• Page 24: Replacing The Smart Key Battery

  Smart key system  If the battery compartment does EAU79071 ECA24010 Replacing the smart key bat- NOTICE not close securely, stop using tery  Do not apply excessive force to the smart key and keep it away Replace the battery in the following sit- from children.

• Page 25: Powering On The Vehicle

  Smart key system 4. Install a new battery as shown. EAU77233 Powering on the vehicle Note the polarity of the battery. 1. With the smart key on and in oper- ating range, briefly press the Specified battery: “ON/ ” switch. CR2025 2.

• Page 26: Powering Off The Vehicle

  “OFF/LOCK” switch. bar gently to the left and right to key system indicator light is flash- help release the steering lock and ing, have a Yamaha dealer check the then press the “ON/ ” switch smart key system. again.

• Page 27: How To Lock The Steering

  Smart key system  The power of the vehicle cannot leased. When seconds have EAU80002 How to lock the steering be turned off via the “OFF/LOCK” passed, all compartments will auto- With the vehicle power off, turn the switch when the vehicle is moving. matically lock.

• Page 28: How To Lock The Centerstand

  Smart key system vehicle forward or backward and EWA14742 EAU78052 How to lock the centerstand WARNING press the “OFF/LOCK” switch for Park the vehicle on a firm level surface Do not operate the steering lock one second. and then place it on the centerstand. while the vehicle is moving.

• Page 29: Storage Compartment And Fuel Tank Access

  Smart key system  In case of an emergency, the seat EAU81291 Storage compartment and can be opened with a mechanical fuel tank access key. (See page 8-38.) To open the seat To open the fuel tank cap lid 1. Place the vehicle on the center- With the smart key on and in operating stand.

• Page 30
  Smart key system 1. Fuel tank cap lid 1. Button 1. Lid 2. Open the front storage compart- To close the fuel tank cap lid ment as shown. Push the lid to the original position. To open the front storage compart- ment lid (XP560D) With the smart key on and in operating range, briefly press the “…

• Page 31: Parking Mode

  Smart key system EAU80842 ECA20760 Parking mode NOTICE The steering is locked, and the hazard Using the hazard or turn signal lights lights and turn signal lights can be for an extended length of time may turned on, but all other electrical sys- cause the battery to discharge.

• Page 32: Special Features

  Special features 2. Push the “SET–” side of the cruise EAU77264 Cruise control system control setting switch to activate (XP560D) the cruise control system. Your The cruise control system is designed current traveling speed will be- to maintain a set cruising speed be- come the set cruising speed.

• Page 33
  Special features you return the throttle grip, the vehicle Using the resume function Automatic deactivation of the cruise will decelerate to the previously set Push the “RES+” side of the cruise control system cruising speed. The cruise control system is electroni- control setting switch to reactivate the cruise control system.

• Page 34: D-Mode (Drive Mode)

  Special features  When going uphill, the actual trav- EAU81392 D-mode (drive mode) eling speed may become lower  The current drive mode is shown D-mode is an electronically controlled than the set cruising speed. If this in the drive mode display (page engine performance system with two occurs, accelerate to the desired 5-7).

• Page 35: Traction Control System

  Special features Setting the traction control system EAU88850 ECA16801 Traction control system NOTICE The traction control system (TCS) Use only the specified tires. (See 1 1 1 helps maintain traction when acceler- page 8-19.) Using different sized ating on slippery surfaces, such as un- tires will prevent the traction control paved or wet roads.

• Page 36
  Special features If the “ ” indicator light remains on after resetting, the vehicle may still be ridden; however, have a Yamaha deal- er check the vehicle as soon as possi- ble.

• Page 37: Instrument And Control Functions

  Instrument and control functions  When the switch is set to high Right EAU77490 Handlebar switches beam, the outer two headlights come on. Left EAU66040 Turn signal switch “ ” To signal a right-hand turn, push this switch to “ ”.

• Page 38: Indicator Lights And Warning

  Instrument and control functions sidestand up and while applying the EAU77301 EAU77122 Menu switch “MENU” Indicator lights and warning front or rear brake, push this switch to This switch is used to make setting lights crank the engine with the starter. See changes within the multi-function dis- page 7-2 for starting instructions prior play.

• Page 39
  To vehicle control system. If this occurs, This warning light comes on when a prevent this, observe these precau- have a Yamaha dealer check the on- problem is detected with the ABS. (See tions. board diagnostic system. The electri- page 5-19.)

• Page 40: Speedometer

  Instrument and control functions the anti-lock brake system may not EAU77131 Speedometer work correctly. Have a Yamaha dealer When the vehicle is turned on, the light check the vehicle as soon as possible. should come on for a few seconds and EWA16043 then go off.

• Page 41: Tachometer

  Instrument and control functions EAU77141 EAU7733A Tachometer Multi-function display 1. Oil change indicator “Oil” 2. V-belt replacement indicator “V-Belt” 1. Information display 3. Eco indicator “ECO” 2. Function select icon 1. Tachometer EWA12313 3. Fuel meter 2. High-r/min zone WARNING 4.

• Page 42
  The information display cannot be ter electrical circuit, the fuel meter will changed while the engine is overheat- acceleration.  Travel at a constant speed. flash repeatedly. Have a Yamaha deal- ing. er check the vehicle. ECA10022 NOTICE Do not continue to operate the en-…
• Page 43
  Instrument and control functions Drive mode display This indicator flashes every 20000 km This indicator flashes at the initial 1000 (12500 mi) when the V-belt needs to be km (600 mi), then at 5000 km (3000 mi) and every 5000 km (3000 mi) thereafter replaced.
• Page 44
  Instrument and control functions  If the handlebar grip or throttle Function selection Adjusting the grip warmer This vehicle can be equipped with grip grip becomes worn or dam- warmers, which can only be used aged, stop using the grip warm- when the engine is running.
• Page 45
  Instrument and control functions Push the “ ” or “ ” side of the se- To reset a tripmeter, use the select ECA23980 NOTICE lect switch to rotate among the 3 dis- switch to select the information display  Be sure to wear protective play pages.
• Page 46
  The estimated distance that can be Average fuel consumption: traveled with the remaining fuel under If there is a malfunction, “– –.–” will the current riding conditions is shown. be continuously displayed. Have a Yamaha dealer check the vehicle. 5-10…
• Page 47
  “MENU” switch change the items shown in Display be continuously displayed. Have a 3 information displays. again seconds Yamaha dealer check the vehicle. This function allows you to select “ ”. adjust the brightness of Brightness the instrument panel.
• Page 48
  Instrument and control functions Grip warmer settings Use the select switch to set the 1. Use the select switch to highlight temperature level, and then push “Grip Warmer”. the “MENU” switch. 2. Push the “MENU” switch. The seat heater setting display will be shown.
• Page 49
  Instrument and control functions 4. Use the select switch to highlight 2. Push the “MENU” switch. The 4. To set the traction control system “Mid” or “Low”, and then change traction control system setting to “ON” again, push the select the setting using the same proce- display will be shown.
• Page 50
  Instrument and control functions 2. Push the “MENU” switch, and 4. When you finished resetting, use 2. Push the “MENU” switch. The unit then use the select switch to se- the select switch to highlight “ ”, setting display will be shown. lect the item to reset.
• Page 51
  Instrument and control functions 2. Push the “MENU” switch, use the select switch to highlight the dis- Display item order is as follows. play to change, and then push the “MENU” switch again. A.TEMP TRIP-1 TRIP-2 4. Push the “MENU” switch to make CRNT.F F.AVG RANGE…
• Page 52
  Instrument and control functions 5. When you finished changing the 2. Push the “MENU” switch. settings, use the select switch to 3. When the hour digits are highlight- highlight “ ”, and then push the ed, use the select switch to set the “MENU”…
• Page 53
  Instrument and control functions 6. Push the “MENU” switch to return 2. Push the “MENU” switch to exit to the menu screen. the setting mode and return to the standard display mode. Resetting all of the display items 1. Use the select switch to highlight “All Reset”.

• Page 54: Front Brake Lever

  Instrument and control functions EAU44916 EAU44926 EAU63230 Front brake lever Rear brake lever Rear brake lock lever 1. Front brake lever 1. Rear brake lever 1. Rear brake lock lever 2. Distance 2. Distance This vehicle is equipped with a rear 3.

• Page 55: Anti-Lock Brake System (Abs)

  ABS is operating. How- EWA16051 WARNING ever, special tools are required, so please consult your Yamaha deal- Always keep a sufficient distance from the vehicle ahead to match the riding speed even with ABS. ECA20100  The ABS performs best with NOTICE long braking distances.

• Page 56: Fuel Tank Cap

  Instrument and control functions To install the fuel tank cap, turn it EAU77324 Fuel tank cap clockwise until the lock release button To access the fuel tank, open the fuel pops out. tank cap lid. (See page 3-11.) EWA11263 WARNING Make sure that the fuel tank cap is properly installed and locked in place before operating the vehicle.

• Page 57: Fuel

  EWA10882 WARNING EAU86072 Gasoline and gasoline vapors are Your Yamaha engine was designed to extremely flammable. To avoid fires use unleaded gasoline with a research and explosions and to reduce the octane number of 95 or higher. If en- risk of injury when refueling, follow 1.

• Page 58: Fuel Tank Overflow Hose

  10% (E10). Gas- ohol containing methanol is recommended by Yamaha because it See page 8-12 for canister information. can cause damage to the fuel system or vehicle performance problems. 5-22…

• Page 59: Catalytic Converter

  Instrument and control functions To close the storage compartment, EAU13435 EAU88751 Catalytic converter Storage compartments push the lid into the original position. The exhaust system contains catalytic converter(s) to reduce harmful exhaust Front storage compartment emissions. To open the storage compartment, EWA10863 press the button.

• Page 60
  Instrument and control functions  Since the storage compartment  Do not exceed the load limit of may get wet when washing the 5.0 kg (11 lb) for the rear storage vehicle, wrap any articles stored compartment.  Do not exceed the maximum in the compartment in a plastic bag.

• Page 61: Windshield (Xp560E)

  Instrument and control functions EAU81442 Windshield (XP560E) The windshield height can be changed to one of two positions. 1. Quick fastener 1. Cap 2. Screw access cover 3. Remove the windshield by remov- ing the screws. 1. Windshield To remove the quick fastener, rotate its screwed portion counterclockwise…

• Page 62: Rear View Mirrors

  Instrument and control functions EAU39672 Rear view mirrors To install the quick fastener, set it with The rear view mirrors of this vehicle its screwed portion pulled out from the can be folded forward or backward for surface of the quick fastener, and then parking in narrow spaces.

• Page 63: Shock Absorber Assembly

  3. Position indicator worn-out shock absorber as-  Align the appropriate notch in the sembly yourself. Take the shock absorber assembly to a Yamaha adjusting ring with the position in- dicator on the shock absorber. dealer for any service.  Use the special wrench included in the tool kit to make the adjust- ment.

• Page 64: Auxiliary Dc Jack

  Instrument and control functions ECA10102 EAU77352 Auxiliary DC jack NOTICE This model is equipped with a 12 V To avoid damaging the mechanism, auxiliary DC jack. The DC jack is locat- do not attempt to turn beyond the ed inside the front storage compart- maximum or minimum settings.

• Page 65: Sidestand

  EAU15306 Sidestand 3. Remove the auxiliary DC jack cap. Yamaha dealer repair it if it does not The sidestand is located on the left 4. Turn the accessory off. function properly. side of the frame. Raise the sidestand 5.

• Page 66: Ignition Circuit Cut-Off System

  Instrument and control functions EAU63612 Ignition circuit cut-off system The ignition circuit cut-off system (comprising the sidestand switch and brake light switches) has the following functions.  It prevents starting when the side- stand is up, but neither brake is applied.

• Page 67
  2. Make sure that the engine stop switch is turned on. stand during this inspection. 3. Turn the vehicle power on. If a malfunction is noted, have a Yamaha 4. Keep the front or rear brake applied. dealer check the system before riding.

• Page 68: For Your Safety — Pre-Operation Checks

  • If necessary, add recommended coolant to specified level. 8-15 Coolant • Check cooling system for leakage. • Check operation. • If soft or spongy, have Yamaha dealer bleed hydraulic system. • Check brake pads for wear. Front brake • Replace if necessary. 8-22, 8-24, 8-24 •…

• Page 69
  • Make sure that operation is smooth. • Check throttle grip free play. Throttle grip 8-18, 8-27 • If necessary, have Yamaha dealer adjust throttle grip free play and lubricate ca- ble and grip housing. • Check for damage. • Check tire condition and tread depth.

• Page 70: Operation And Important Riding Points

  ECA25880 NOTICE there is a control or function you do not between 0 and 1600 km (1000 mi). For understand, ask your Yamaha dealer. this reason, you should read the fol-  Keep the engine speed out of EWA10272 lowing material carefully.

• Page 71: Starting The Engine

  This model is equipped with: be up. Yamaha dealer check the vehicle.  a lean angle sensor. This sensor stops the engine in case of a vehi- 4. Close the throttle completely.

• Page 72: Starting Off

  Operation and important riding points EAU45093 EAU16782 EAU60650 Starting off Acceleration and deceleration Braking 1. While pulling the rear brake lever EWA17790 WARNING with your left hand and holding the  Avoid braking hard or suddenly grab bar with your right hand, push the scooter off the center- (especially when leaning over to stand.

• Page 73: Tips For Reducing Fuel Consumption

  Operation and important riding points Front EAU16821 EAU77962 Tips for reducing fuel con- Parking sumption When parking, turn the vehicle power off and then turn the smart key off. Fuel consumption depends largely on If the sidestand is lowered when the your riding style.

• Page 74
   The sidestand alarm beeper can be set to not activate. Contact your Yamaha dealer. EWA10312 WARNING  Since the engine and exhaust system can become very hot, park in a place where pedestri- ans or children are not likely to touch them and be burned.

• Page 75: Periodic Maintenance And Adjustment

  To avoid possible burns, let tivities incorrectly may increase brake components cool before your risk of injury or death during touching them. service or while using the vehicle. If you are not familiar with vehicle ser- vice, have a Yamaha dealer perform service.

• Page 76: Tool Kit

  However, a torque wrench and other tools are necessary to perform certain maintenance work correctly. If you do not have the tools or experi- ence required for a particular job, have your Yamaha dealer perform it for you.

• Page 77: Periodic Maintenance Charts

  EAU71033 Periodic maintenance charts  Items marked with an asterisk should be performed by your Yamaha dealer because these items require special tools, data, and technical skills.  From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).

• Page 78
  Periodic maintenance and adjustment ODOMETER READING ANNUAL ITEM CHECK OR MAINTENANCE JOB 1000 km 10000 km 20000 km 30000 km 40000 km CHECK (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) • Check control system for dam- Evaporative emis- √…

• Page 79: General Maintenance And Lubrication Chart

  (24000 mi) • Perform dynamic inspection us- Diagnostic system √ √ √ √ √ √ ing Yamaha diagnostic tool. check • Check the error codes. √ √ 2 * Air filter element • Replace. Air filter case check √ √…

• Page 80
  Periodic maintenance and adjustment ODOMETER READING ANNUAL ITEM CHECK OR MAINTENANCE JOB 1000 km 10000 km 20000 km 30000 km 40000 km CHECK (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) • Check tread depth and for dam- age.
• Page 81
  Periodic maintenance and adjustment ODOMETER READING ANNUAL ITEM CHECK OR MAINTENANCE JOB 1000 km 10000 km 20000 km 30000 km 40000 km CHECK (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) • Check operation and for oil leak- √…
• Page 82
  Periodic maintenance and adjustment ODOMETER READING ANNUAL ITEM CHECK OR MAINTENANCE JOB 1000 km 10000 km 20000 km 30000 km 40000 km CHECK (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) • Check operation and free play. • Adjust the throttle cable free play Throttle grip hous- √…

• Page 83: Removing And Installing Panels

  Periodic maintenance and adjustment EAU18773 Removing and installing pan- The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. 1.

• Page 84
  Periodic maintenance and adjustment 2. Gently pry up the upper portion of the panel, and then slide the panel upwards. 1. Panel A 3. Install the screws. 3. Remove the panel as shown. Panel B To install the panel To remove the panel Place the panel in the original position, 1.

• Page 85: Checking The Spark Plugs

  Before installing a spark plug, the checked periodically, preferably by a spark plug gap should be measured Yamaha dealer. Since heat and depos- with a wire thickness gauge and, if its will cause any spark plug to slowly necessary, adjusted to specification.

• Page 86: Canister

  Periodic maintenance and adjustment EAU36112 EAU77364 Canister Engine oil and oil filter car- If a torque wrench is not available tridge when installing a spark plug, a good The engine oil level should be checked estimate of the correct torque is 1/4– before each ride.

• Page 87
  An oil filter wrench is available at a 1. Place the vehicle on a level sur- Yamaha dealer. face. 2. Start the engine, warm it up for 7. Apply a thin coat of clean engine…
• Page 88
  Periodic maintenance and adjustment Tightening torque: Engine oil: Oil filter cartridge: Recommended brand: 17 N·m (1.7 kgf·m, 13 lb·ft) YAMALUBE SAE viscosity grades: 10W-40 9. Install the engine oil drain bolt and Recommended engine oil grade: its new gasket, and then tighten API service SG type or higher, the bolt to the specified torque.

• Page 89: Why Yamalube

  Thus, Yamalube mineral, semisynthetic and If genuine Yamaha coolant is not avail- synthetic oils have their own distinct able, use an ethylene glycol antifreeze characters and value. Yamaha’s expe-…

• Page 90
  If water has been added to the coolant, have a Yamaha dealer check the anti- freeze content of the coolant as soon as possible, otherwise the effectiveness of the coolant will 1.

• Page 91: Replacing The Engine Air Filter Element And Cleaning The Check Hose

  3. Pull the air filter element out. [EWA10382] Yamaha dealer at the intervals speci- fied in the periodic maintenance and lubrication chart. To replace the air filter element 1. Remove panel C. (See page 8-9.) 2.

• Page 92: Checking The Engine Idling Speed

  Engine idling speed: 6. Install the panel. 1100–1300 r/min 1. Throttle grip free play Throttle grip free play: 1.0–3.0 mm (0.04–0.12 in) Periodically check the throttle grip free play and, if necessary, have a Yamaha dealer adjust it. 8-18…

• Page 93: Valve Clearance

  2 persons: To prevent this from occurring, have Front: your Yamaha dealer check and adjust Tire air pressure 225 kPa (2.25 kgf/cm², 33 psi) Rear: the valve clearance at regular intervals. The tire air pressure should be 280 kPa (2.80 kgf/cm², 41 psi)

• Page 94
  “broken avoid tire deflation during a ride. wall is cracked, have a Yamaha dealer in” for it to develop its optimal After extensive tests, only the tires list- replace the tire immediately.

• Page 95: Cast Wheels

  Rear tire: ride. If any damage is found, have Size: 1. Valve stem nut 160/60R15M/C 67H a Yamaha dealer replace the 2. Valve stem locknut Manufacturer/model: wheel. Do not attempt even the BRIDGESTONE/BATTLAX SCR smallest repair to the wheel. A de-…

• Page 96: Checking The Front And Rear Brake Lever Free Play

  Checking the front and rear Adjusting the rear brake lock brake lever ends. If there is free play, brake lever free play cable have a Yamaha dealer inspect the brake system. Front EWA14212 WARNING A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system.

• Page 97: Checking The Rear Brake Lock

  2. Apply the rear brake lock, and If proper adjustment cannot be ob- then try to push the vehicle to con- tained as described, have a Yamaha firm that the rear brake lock func- dealer make this adjustment. tions properly.

• Page 98: Checking The Front And Rear Brake Pads

  ECA17641 NOTICE the wear indicator almost touches the brake disc, have a Yamaha dealer re- Brake fluid may damage painted place the brake pads as a set. surfaces or plastic parts. Always 1.

• Page 99: Changing The Brake Fluid

  Periodic maintenance and adjustment  Insufficient brake fluid may al- Rear brake EAU22734 Changing the brake fluid low air to enter the brake sys- Have a Yamaha dealer change the tem, reducing braking brake fluid every 2 years. In addition, performance.

• Page 100: Drive Belt

  4. If the drive belt or drive belt so, the drive belt tension must be sprocket is dirty, remove the drive checked and adjusted by a Yamaha belt covers by removing the bolts dealer at the intervals specified in the and quick fasteners.

• Page 101: Checking And Lubricating The Cables

  Yamaha dealer at the intervals cated if necessary. If a cable is specified in the periodic maintenance damaged or does not move smoothly, chart.

• Page 102: Checking And Lubricating The Centerstand And Sidestand

  EWA10742 WARNING If the centerstand or sidestand does not move up and down smoothly, have a Yamaha dealer check or re- pair it. Otherwise, the centerstand or sidestand could contact the ground and distract the operator, resulting in a possible loss of control.

• Page 103: Checking The Front Fork

  2. Hold the lower ends of the front fork does not operate smoothly, tion. WARNING! To avoid injury, fork legs and try to move them for- have a Yamaha dealer check or re- securely support the vehicle so ward and backward. If any free pair it.

• Page 104: Checking The Wheel Bearings

  EWA10761 WARNING To charge the battery  Electrolyte is poisonous and Have a Yamaha dealer charge the bat- dangerous since it contains sul- tery as soon as possible if it seems to furic acid, which causes severe have discharged. Keep in mind that the…

• Page 105: Replacing The Fuses

  Periodic maintenance and adjustment battery tends to discharge more quick- 3. Fully charge the battery before in- EAU81472 Replacing the fuses stallation. NOTICE: When install- ly if the vehicle is equipped with op- Fuse box1, brake light fuse and cruise tional electrical accessories.

• Page 106
  Periodic maintenance and adjustment 1. Remove the screw access covers by removing the quick fasteners. 13,14 11 1. Starter relay cover 1. Windshield 2. Main fuse 2. Screw 3. Spare main fuse 1. Screw access cover 4. Remove the inner panel by remov- 4.
• Page 107
  Headlight fuse: 8. Install the screw access covers by 4. If the fuse immediately blows 7.5 A installing the quick fasteners. again, have a Yamaha dealer Taillight fuse: check the electrical system. 7.5 A Signaling system fuse: 7.5 A Ignition fuse: 7.5 A…

• Page 108: Vehicle Lights

  2. Pull the license plate light unit sep- 5. Install the license plate unit onto Yamaha dealer check the vehicle. If the arate from the rear fender. (Rein- the rear fender. license plate light does not come on, stall the collars if they fall out.)

• Page 109: Troubleshooting

   Is the smart key being used in a lo- properly service your Yamaha vehicle. Be sure to use only genuine Yamaha cation with strong radio waves or replacement parts. Although imitation other electromagnetic noise? (See page 3-1.)

• Page 110: Troubleshooting Chart

  Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the vehicle. Check the compression. 4. Compression The engine does not start. There is compression.

• Page 111
  Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK. If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended cool- ant as soon as possible.

• Page 112: Emergency Mode

  Periodic maintenance and adjustment EAU77373 Emergency mode When the smart key is lost, damaged, or its battery has discharged, the vehi- cle can still be turned on and the en- gine started. will need mechanical key and the smart key sys- tem identification number.

• Page 113
  Periodic maintenance and adjustment  When the smart key system indi- 7. Inputting the identification number is done by counting the number of cator light is allowed to flash 9 or flashes of the smart key system in- more times. dicator light.

• Page 114: Scooter Care And Storage

  Be performance and extend the useful life  high-pressure washers sure to consult a Yamaha dealer for of many components. Washing, clean- steam-jet cleaners. Excessive ing, and polishing will also give you a advice on what products to use be-…

• Page 115
  Scooter care and storage chemicals such as, solvents, Washing plastic may scratch the wind- gasoline, rust removers, brake 1. Rinse off any degreaser and spray shield, so be sure to test all fluid, or antifreeze, etc. down the vehicle with a garden cleaning products before gen- hose.

• Page 116: Storage

  Scooter care and storage  Do not use abrasive polishing will become slippery, which EAU83472 Storage could cause loss of control. compounds as they will wear Always store the vehicle in a cool, dry Thoroughly clean the surfaces away the paint. place.

• Page 117
  Scooter care and storage 1. Make all necessary repairs and b. Pour a teaspoonful of engine wheels a little once a month in or- perform any outstanding mainte- oil into the spark plug bore. der to prevent the tires from be- nance.

• Page 118: Specifications

  Specifications Bore × stroke: Dimensions: Fuel reserve amount: 70.0 × 73.0 mm (2.76 × 2.87 in) 3.0 L (0.79 US gal, 0.66 Imp.gal) Overall length: Starting system: Fuel injection: 2200 mm (86.6 in) Electric starter Overall width: Throttle body: Engine oil: 765 mm (30.1 in) ID mark: Overall height:…

• Page 119
  Specifications Front suspension: Type: Telescopic fork Rear suspension: Type: Swingarm (link suspension) Electrical system: System voltage: 12 V Battery: Model: YTZ12S Voltage, capacity: 12 V, 11.0 Ah (10 HR) Bulb wattage: Headlight: Brake/tail light: Front turn signal light: Rear turn signal light: Auxiliary light: License plate light: 5.0 W…

• Page 120: Consumer Information

  These identification numbers are needed when registering the vehicle with the authorities in your area and when ordering spare parts from a Yamaha dealer. VEHICLE IDENTIFICATION NUMBER: 1. Vehicle identification number 1. Engine serial number The vehicle identification number is The engine serial number is stamped stamped into the frame.

• Page 121: Diagnostic Connector

  This malfunctions and for research, statisti- information will be needed when order- cal analysis and development purpos- ing spare parts from a Yamaha dealer. Although the sensors and recorded data will vary by model, the main data points are: …

• Page 122
  Consumer information Yamaha will not disclose this data to a third party except in the following cas- es. In addition, Yamaha may provide vehicle data to a contractor in order to outsource services related to the han- dling of vehicle data. Even in this case,…

• Page 123: Index

  Index ABS warning light ……..5-3 Emergency mode ……… 8-38 Maintenance and lubrication, periodic … 8-5 Acceleration and deceleration….7-3 Engine break-in ……..7-1 Maintenance, emission control Air filter element and check hose, Engine idling speed, checking ….. 8-18 system ……….8-3 replacing and cleaning …….

• Page 124
  Index Smart key system indicator light ….5-4 Smart key system, troubleshooting ..8-35 Yamalube ……….8-15 Spark plugs, checking ……8-11 Special features ……..4-1 Specifications ……..10-1 Speedometer ……….5-4 Starting off ……….7-3 Starting the engine……..7-2 Steering, checking ……..8-29 Storage ………..9-3 Storage compartment and fuel tank access ……….3-11 Storage compartments ……5-23 Tachometer……….5-5…
• Page 126
  Original instructions PRINTED IN JAPAN 2019.10-1.2×1 CR (E)

• Page 1: Service Manual

  2009 SERVICE MANUAL XP500Y LIT-11616-22-08 4B5-28197-10…

• Page 2
  EAS20050 XP500Y SERVICE MANUAL ©2008 by Yamaha Motor Corporation, U.S.A. First edition, March 2008 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-22-08…
• 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 his vehicle and to conform to federal environmental quality objectives.
• Page 4
  EAS20090 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
  EAS20100 1. Serviceable with engine mounted SYMBOLS 2. Filling fluid The following symbols are used in this manual 3. Lubricant for easier understanding. 4. Special tool 5. Tightening torque The following symbols are not relevant to every 6. Wear limit, clearance vehicle.

• Page 7: Table Of Contents

  EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING…

• Page 9: General Information

  GENERAL INFORMATION IDENTIFICATION ……………….. 1-1 VEHICLE IDENTIFICATION NUMBER ………….1-1 MODEL LABEL………………1-1 FEATURES…………………. 1-2 OUTLINE OF FI SYSTEM …………….. 1-2 FI SYSTEM………………..1-3 MULTI-FUNCTION DISPLAY…………..1-4 IMPORTANT INFORMATION …………….. 1-7 PREPARATION FOR REMOVAL AND DISASSEMBLY……1-7 REPLACEMENT PARTS…………….1-7 GASKETS, OIL SEALS AND O-RINGS ………… 1-7 LOCK WASHERS/PLATES AND COTTER PINS ……..

• Page 10: Identification

  IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the frame. EAS20150 MODEL LABEL The model label “1” is affixed to the storage box. This information will be needed to order spare parts.

• Page 11: Features

  FEATURES EAS20170 FEATURES EAS4B51038 OUTLINE OF FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions. In a conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective chamber.

• Page 12: Fi System

  FEATURES EAS4B51039 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator (in the fuel pump) maintains the fuel pressure that is applied to the fuel injector at 240–260 kPa (2.40–2.60 kg/cm², 34.1– 37.0 psi) higher than the intake manifold pressure.

• Page 13: Multi-Function Display

  FEATURES • an odometer (which shows the total distance EAS4B51037 MULTI-FUNCTION DISPLAY traveled) EWA4B54001 • two tripmeters (which show the distance trav- WARNING eled since they were last set to zero) Be sure to stop the vehicle before making • a fuel reserve tripmeter (which shows the dis- any setting changes to the multi-function tance traveled when the remaining fuel in the display.

• Page 14
  FEATURES Odometer and tripmeter modes 1. Fuel reserve tripmeter 1. Odometer/tripmeters To reset a tripmeter, select it by pushing the “SE- LECT” button until “F Trip”, “Trip-A” or “Trip-B” is displayed. While “F Trip”, “Trip-A” or “Trip-B” is displayed, push the “RESET” button for at least one second.
• Page 15
  FEATURES “OIL” must be reset after the oil change for the Self-diagnosis device next periodic oil change to be indicated at the correct time. The electrical circuit of the indicator can be checked according to the following procedure. 1. Set the engine stop switch to “ ”…

• Page 16: Important Information

  5. Keep all parts away from any source of fire. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but…

• Page 17: Bearings And Oil Seals

  IMPORTANT INFORMATION EAS20230 BEARINGS AND OIL SEALS Install bearings “1” and oil seals “2” so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate.

• Page 18: Checking The Connections

  CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Check the leads, couplers, and connectors for Analog pocket tester stains, rust, moisture, etc. YU-03112-C 1. Disconnect: • Lead • Coupler • If there is no continuity, clean the terminals. •…

• Page 19: Special Tools

  SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.

• Page 20
  SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Compression gauge 3-10 90890-03081 Engine compression tester YU-33223 Oil filter wrench 3-12, 6-6 90890-01469 YM-01469 66.8 Oil pressure gauge set 3-13 90890-03120 Oil pressure adapter B 3-13 90890-03124 Pressure gauge 3-13, 7-4 90890-03153 YU-03153 Steering nut wrench…
• Page 21
  Fork seal driver weight 4-54, 4-55 90890-01367 Replacement hammer YM-A9409-7 Fork seal driver attachment (ø43) 4-54 90890-01374 Replacement 43 mm YM-A5142-3 Yamaha bond No. 1215 5-14, 5-44, 90890-85505 5-52, 5-69, (Three Bond No.1215®) 6-12 Valve spring compressor 5-19, 5-24 90890-04019 YM-04019…
• Page 22
  SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve guide installer (ø4) 5-21 90890-04112 Valve guide installer (4.0 mm) YM-04112 Valve guide reamer (ø4) 5-21 90890-04113 Valve guide reamer (4.0 mm) YM-04113 Piston pin puller set 5-27 90890-01304 Piston pin puller YU-01304 YU-01304 Sheave holder…
• Page 23
  SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Sheave spring compressor 5-41, 5-44 90890-04134 YM-04134 Sheave fixed block 5-41, 5-44 90890-04135 Sheave fixed bracket YM-04135 Oil seal guide (ø41) 5-43 90890-01396 Sheave holder 5-50, 5-51, 90890-01701 5-52 Primary clutch holder YS-01880-A Flywheel puller 5-50…
• Page 24
  SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Clutch spring compressor 5-57, 5-60 90890-01482 Universal clutch holder 5-57, 5-60 90890-04086 YM-91042 Plane bearing installer 5-73, 5-76 90890-04139 Radiator cap tester 90890-01325 Radiator pressure tester YU-24460-01 YU-24460-01 Radiator cap tester adapter 90890-01352 Radiator pressure tester adapter YU-33984…
• Page 25
  SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Mechanical seal installer 6-12 90890-04078 Water pump seal installer YM-33221-A Middle driven shaft bearing driver 6-12 90890-04058 Bearing driver 40 mm YM-04058 Fuel pressure adapter 90890-03181 Ignition checker 8-72 90890-06754 Opama pet-4000 spark checker YM-34487 1-16…
• Page 26
  SPECIAL TOOLS 1-17…

• Page 27: Specifications

  SPECIFICATIONS GENERAL SPECIFICATIONS ……………. 2-1 ENGINE SPECIFICATIONS …………….2-2 CHASSIS SPECIFICATIONS …………….2-10 ELECTRICAL SPECIFICATIONS …………..2-13 TIGHTENING TORQUES …………….2-16 GENERAL TIGHTENING TORQUE SPECIFICATIONS……2-16 ENGINE TIGHTENING TORQUES…………2-17 CHASSIS TIGHTENING TORQUES…………2-21 LUBRICATION POINTS AND LUBRICANT TYPES ……..2-24 ENGINE………………..2-24 CHASSIS………………..2-26 LUBRICATION SYSTEM DIAGRAMS …………

• Page 28: General Specifications

  GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 4B54 (USA) Dimensions Overall length 2195 mm (86.4 in) Overall width 775 mm (30.5 in) Overall height 1445 mm (56.9 in) Seat height 800 mm (31.5 in) Wheelbase 1580 mm (62.2 in) Ground clearance 125 mm (4.92 in) Minimum turning radius 2800 mm (110.2 in)

• Page 29: Engine Specifications

  ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 499.0 cm³ Cylinder arrangement Forward-inclined parallel 2-cylinder Bore × stroke 66.0 × 73.0 mm (2.60 × 2.87 in) Compression ratio 11.00 :1 Standard compression pressure (at sea level) 1400 kPa/360 r/min (199.1 psi/360 r/min) (14.0 kgf/cm²/360 r/min) Minimum–maximum…

• Page 30
  ENGINE SPECIFICATIONS Pressure check location MAIN GALLERY Cooling system Radiator capacity (including all routes) 1.48 L (1.56 US qt) (1.30 Imp.qt) Coolant reservoir capacity (up to the maximum level mark) 0.25 L (0.26 US qt) (0.22 Imp.qt) Radiator cap opening pressure 107.9–137.3 kPa (15.6–19.9 psi) (1.08–1.37 kgf/cm²) Thermostat…
• Page 31
  ENGINE SPECIFICATIONS Limit 24.856 mm (0.9786 in) Camshaft runout limit 0.030 mm (0.0012 in) Timing chain Model/number of links SCR-0409 SV/132 Tensioning system Automatic Valve, valve seat, valve guide Valve clearance (cold) Intake 0.15–0.20 mm (0.0059–0.0079 in) Exhaust 0.25–0.30 mm (0.0098–0.0118 in) Valve dimensions Valve head diameter A (intake) 24.90–25.10 mm (0.9803–0.9882 in)
• Page 32
  ENGINE SPECIFICATIONS Valve margin thickness D (exhaust) 0.60–0.80 mm (0.0236–0.0315 in) Valve stem diameter (intake) 3.975–3.990 mm (0.1565–0.1571 in) Limit 3.945 mm (0.1553 in) Valve stem diameter (exhaust) 3.960–3.975 mm (0.1559–0.1565 in) Limit 3.930 mm (0.1547 in) Valve guide inside diameter (intake) 4.000–4.012 mm (0.1575–0.1580 in) Limit 4.050 mm (0.1594 in)
• Page 33
  ENGINE SPECIFICATIONS Winding direction (exhaust) Clockwise Valve lifter Valve lifter outside diameter (intake) 24.476–24.500 mm (0.9636–0.9646 in) Limit 24.451 mm (0.9626 in) Valve lifter outside diameter (exhaust) 24.476–24.500 mm (0.9636–0.9646 in) Limit 24.451 mm (0.9626 in) Cylinder Bore 66.000–66.010 mm (2.5984–2.5988 in) Wear limit 66.100 mm (2.6024 in) Taper limit…
• Page 34
  ENGINE SPECIFICATIONS Dimensions (B × T) 0.80 × 2.50 mm (0.03 × 0.10 in) End gap (installed) 0.40–0.50 mm (0.0157–0.0197 in) Limit 0.75 mm (0.0295 in) Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in) Limit 0.100 mm (0.0039 in) Oil ring Dimensions (B ×…
• Page 35
  ENGINE SPECIFICATIONS Plate quantity 4 pcs Warpage limit 0.10 mm (0.0039 in) Clutch plate 2 thickness 1.80–2.00 mm (0.071–0.079 in) Plate quantity 2 pcs Warpage limit 0.20 mm (0.0079 in) Clutch spring free length 25.80 mm (1.02 in) Minimum length 20.40 mm (0.80 in) Spring quantity 6 pcs…
• Page 36
  ENGINE SPECIFICATIONS Intake air pressure sensor output voltage 3.15–4.15 V Intake air temperature sensor resistance 2.21–2.69 kΩ at 20 °C (68 °F) Coolant temperature sensor resistance 2.32–2.59 kΩ at 20 °C (68 °F) 310–326 Ω at 80 °C (176 °F) Idling condition Engine idling speed 1100–1300 r/min…

• Page 37: Chassis Specifications

  CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Diamond Caster angle 25.00° Trail 92.0 mm (3.62 in) Front wheel Wheel type Cast wheel 15M/C × MT3.50 Rim size Rim material Aluminum Wheel travel 120.0 mm (4.72 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)

• Page 38
  Inner tube outer diameter 43.0 mm (1.69 in) Inner tube bending limit 0.2 mm (0.01 in) Optional spring available Recommended oil Yamaha fork oil 10WT Quantity 517.0 cm³ (17.48 US oz) (18.23 Imp.oz) Level 87.0 mm (3.43 in) Rear suspension…
• Page 39
  CHASSIS SPECIFICATIONS Installed length 180.0 mm (7.09 in) Spring rate K1 225.60 N/mm (1288.18 lb/in) (23.00 kgf/mm) Spring rate K2 294.00 N/mm (1678.74 lb/in) (29.98 kgf/mm) Spring stroke K1 0.0–28.8 mm (0.00–1.13 in) Spring stroke K2 28.8–43.0 mm (1.13–1.69 in) Optional spring available Enclosed gas/air pressure (STD) 4900 kPa (696.9 psi) (49.0 kgf/cm²)

• Page 40: Electrical Specifications

  ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Transistorized coil ignition (digital) Advancer type Digital Ignition timing (B.T.D.C.) 10.0°/1200 r/min Engine control unit Model/manufacturer TBDF81/DENSO Ignition coil Model/manufacturer JO313/DENSO Minimum ignition spark gap 6.0 mm (0.24 in) 1.87–2.53 Ω…

• Page 41
  ELECTRICAL SPECIFICATIONS Meter lighting Indicator light LED × 2 Turn signal indicator light High beam indicator light Engine trouble warning light Electric starting system System type Constant mesh Starter motor Model/manufacturer SM-18/MITSUBA Power output 0.70 kW 0.0100–0.0200 Ω at 20 °C (68 °F) Armature coil resistance Brush overall length 12.0 mm (0.47 in)
• Page 42
  ELECTRICAL SPECIFICATIONS Fuel injection system relay Model/manufacturer 5JJ/MATSUSHITA Fuses Main fuse 30.0 A Headlight fuse 20.0 A Taillight fuse 10.0 A Signaling system fuse 15.0 A Ignition fuse 10.0 A Radiator fan fuse 15.0 A Fuel injection system fuse 10.0 A Backup fuse 10.0 A Spare fuse…

• Page 43: Tightening Torques

  TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.

• Page 44: Engine Tightening Torques

  TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Camshaft cap 10 Nm (1.0 m·kg, 7.2 ft·lb) Engine oil check bolt 20 Nm (2.0 m·kg, 14 ft·lb) Exhaust pipe stud bolt 15 Nm (1.5 m·kg, 11 ft·lb) Cylinder head nut 35 Nm (3.5 m·kg, 25 ft·lb) Cylinder head nut…

• Page 45
  TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Muffler nut 31 Nm (3.1 m·kg, 22 ft·lb) Muffler end protector bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Exhaust pipe protector bolt 8 Nm (0.8 m·kg, 5.8 ft·lb) Muffler end protector cover bolt 8 Nm (0.8 m·kg, 5.8 ft·lb) Muffler protector (side) bolt 8 Nm (0.8 m·kg, 5.8 ft·lb)
• Page 46
  TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size BEL-RAY Secondary sheave nut 90 Nm (9.0 m·kg, 65 ft·lb) assem- bly lube® Crankshaft right end bearing re- 11 Nm (1.1 m·kg, 8.0 ft·lb) tainer screw Secondary shaft bearing retainer 12 Nm (1.2 m·kg, 8.7 ft·lb) bolt Stator coil bolt 10 Nm (1.0 m·kg, 7.2 ft·lb)
• Page 47
  TIGHTENING TORQUES Cylinder head tightening sequence: 2-20…

• Page 48: Chassis Tightening Torques

  TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting bolt (front upper 88 Nm (8.8 m·kg, 64 ft·lb) side) Engine mounting bolt (front right 45 Nm (4.5 m·kg, 32 ft·lb) lower side) Engine mounting bolt (front left 45 Nm (4.5 m·kg, 32 ft·lb) lower side) Engine mounting nut (rear side)

• Page 49
  TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Pivot shaft 7 Nm (0.7 m·kg, 5.1 ft·lb) Pivot shaft nut 100 Nm (10.0 m·kg, 72 ft·lb) Swingarm bolt 40 Nm (4.0 m·kg, 29 ft·lb) Swingarm damper nut 7 Nm (0.7 m·kg, 5.1 ft·lb) Rear shock absorber assembly 53 Nm (5.3 m·kg, 38 ft·lb) rear nut…
• Page 50
  TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear brake disc bolt 18 Nm (1.8 m·kg, 13 ft·lb) Rear wheel drive hub bolt 69 Nm (6.9 m·kg, 50 ft·lb) Front brake hose joint bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Front brake hose holder bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Rear brake hose holder bolt…

• Page 51: Lubrication Points And Lubricant Types

  LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings Cylinder head nut seats and washers Camshaft cap bolt seats Big end bearings and crank pins Connecting rod big end contact surfaces (to crank) Balancer big end bearings and crank pin Balancer connecting rod big end contact surface (to crank) Pistons, ring grooves, and piston rings…

• Page 52
  BEL-RAY assembly Secondary sheave nut seats lube® Outer V-belt case crankshaft right end point Pivot shaft taper roller bearing Yamaha bond Cylinder head cover inner gaskets mating surface No.1215 (Three bond No.1215®) Yamaha bond Timing chain guide (upper side) mating surface No.1215 (Three bond…

• Page 53: Chassis

  LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Steering bearings (upper and lower) Upper bearing cover seal lip and lower bearing dust seal lip Steering bearing races (inner and outer) Tube guide (throttle grip) inner surface and throttle cables Rear brake lock cable end (lever end) Brake lever pivoting point and metal-to-metal moving parts Drive axle spline…

• Page 54: Lubrication System Diagrams

  LUBRICATION SYSTEM DIAGRAMS EAS4B51021 LUBRICATION SYSTEM DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-27…

• Page 55
  LUBRICATION SYSTEM DIAGRAMS 1. Oil delivery pipe 2. Oil pump 3. Oil cooler 4. Oil filter cartridge 5. Oil pipe 6. Oil strainer 2-28…
• Page 56
  LUBRICATION SYSTEM DIAGRAMS 2-29…
• Page 57
  LUBRICATION SYSTEM DIAGRAMS 1. Secondary shaft 2. Drive axle 3. Clutch 4. Crankshaft 2-30…

• Page 58: Cooling System Diagrams

  COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-31…

• Page 59
  COOLING SYSTEM DIAGRAMS 1. Radiator cap 2. Radiator filler hose 3. Radiator inlet hose 4. Coolant reservoir 5. Coolant pipe 6. Thermostat outlet hose 7. Oil cooler outlet hose 8. Thermostat 9. Oil cooler 10. Coolant hose 11. Water pump inlet pipe 12.
• Page 60
  COOLING SYSTEM DIAGRAMS 2-33…
• Page 61
  COOLING SYSTEM DIAGRAMS 1. Thermostat outlet hose 2. Cooling system air bleed hose 3. Radiator cap 4. Radiator filler pipe 5. Radiator filler hose 6. Coolant reservoir hose 7. Radiator 8. Radiator inlet hose 9. Coolant reservoir 10. Coolant reservoir breather hose 11.

• Page 62: Cable Routing

  CABLE ROUTING EAS20430 CABLE ROUTING A B C 2-35…

• Page 63
  CABLE ROUTING 1. Rear brake hose 2. Left handlebar switch lead 3. Right handlebar switch lead 4. Front brake hose 5. Throttle cable (decelerator cable) 6. Throttle cable (accelerator cable) 7. Rear brake lock cable 8. Front brake light switch connectors A.
• Page 64
  CABLE ROUTING 2-37…
• Page 65
  CABLE ROUTING 1. Front brake pipe 2. Wire harness (to horn) 3. Front brake hose (to left front brake caliper) 4. Front brake hose (to right front brake caliper) 5. Horn 6. Speed sensor lead 7. Speed sensor A. Fasten the wire harness (to horn) and front brake pipe with plastic locking ties, making sure to –…
• Page 66
  CABLE ROUTING 26 27 2-39…
• Page 67
  CABLE ROUTING 1. Left handlebar switch lead P. Route the starter motor lead and generator lead to the outside of the wire harness. 2. Right handlebar switch lead Q. To meter assembly 3. Rectifier/regulator R. Route the wire harness (to starter relay) behind 4.
• Page 68
  CABLE ROUTING 22 23 2-41…
• Page 69
  CABLE ROUTING 1. Positive battery lead L. Fasten the main switch lead with the holder, making sure that the plastic locking tie is 2. Fuse box positioned to the inside of the holder. Face the 3. Negative battery lead catch of the holder forward. 4.
• Page 70
  CABLE ROUTING 2-43…
• Page 71
  CABLE ROUTING 1. Intake air temperature sensor coupler P. Pass the wire harness (to storage box light switch) between the rear frame and the tail/brake light 2. Cylinder head breather hose assembly. 3. Fast idle plunger intake hose Q. Pass the plastic band through the holes in the 4.
• Page 72
  CABLE ROUTING 2-45…
• Page 73
  CABLE ROUTING 1. Rear brake hose 2. Rear brake pipe 3. Rear brake lock cable 4. Ribs (bottom of storage box) A. Install the rear brake hose holder to the front cowling stay, making sure to fit the projection on the holder into the hole in the stay.
• Page 74
  CABLE ROUTING H I J 2-47…
• Page 75
  CABLE ROUTING 1. Fast idle plunger intake hose 2. Cylinder head breather hose 3. Intake air pressure sensor hose 4. Fuel hose 5. Fast idle plunger inlet coolant hose 6. Fast idle plunger outlet coolant hose 7. Fuel injector #2 8.
• Page 76
  CABLE ROUTING 2-49…
• Page 77
  CABLE ROUTING 1. Rollover valve U. Route the canister purge hose (3-way joint to canister) over the frame cross member. 2. Fuel tank breather hose (fuel tank to rollover valve) 3. Fuel tank breather hose (rollover valve to canister) 4. Canister purge hose (throttle body #2 to 3-way joint) 5.
• Page 78
  CABLE ROUTING 2-51…

• Page 79: Periodic Checks And Adjustments

  PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE …………….3-1 INTRODUCTION ………………3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ………………..3-1 GENERAL MAINTENANCE AND LUBRICATION CHART …….3-1 ENGINE ………………….3-4 ADJUSTING THE VALVE CLEARANCE ……….3-4 SYNCHRONIZING THE THROTTLE BODY ……….3-7 ADJUSTING THE ENGINE IDLING SPEED ……….3-8 ADJUSTING THE THROTTLE CABLE FREE PLAY ……..3-9 CHECKING THE SPARK PLUGS ………….

• Page 80
  ELECTRICAL SYSTEM…………….. 3-30 CHECKING AND CHARGING THE BATTERY……..3-30 CHECKING THE FUSES …………….3-30 REPLACING THE HEADLIGHT BULBS ……….3-30 ADJUSTING THE HEADLIGHT BEAMS……….3-30…

• Page 82: Periodic Maintenance

  • Check control system for √ sion control sys- damage. • Replace if necessary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. EAU32185 GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL ODOMETER READINGS…

• Page 83
  • Adjust headlight beam. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi…
• Page 84
  PERIODIC MAINTENANCE EAU38260 • The air filter and V-belt filter need more frequent service if you are riding in unusually wet or dusty areas. • Hydraulic brake service • After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid levels and fill the reservoirs as required.

• Page 85: Engine

  ENGINE 6. Measure: EAS20471 ENGINE • Valve clearance Out of specification → Adjust. EAS20490 ADJUSTING THE VALVE CLEARANCE Valve clearance (cold) The following procedure applies to all of the Intake valves. 0.15–0.20 mm (0.0059–0.0079 in) Exhaust • Valve clearance adjustment should be made 0.25–0.30 mm (0.0098–0.0118 in) on a cold engine, at room temperature.

• Page 86
  ENGINE 0˚ 360˚ 720˚ A. Degrees that the crankshaft is turned c. Measure the valve clearance with a thickness clockwise gauge “1”. B. Cylinder C. Combustion cycle Cylinder #2 360° L LLL L LLL L LLL L LLL L LLL 7.
• Page 87
  ENGINE Last digit Rounded value 3, 4, 5, 6 7, 8, 9 Refer to the following table for the available valve pads. Valve pad range Nos. 120–240 1.20–2.40 mm b. Calculate the difference between the speci- Valve pad thickness (0.0472–0.0945 in) fied valve clearance and the measured valve clearance.

• Page 88: Synchronizing The Throttle Body

  ENGINE • Turn the crankshaft clockwise several full turns Vacuum gauge to seat the parts. 90890-03094 h. Measure the valve clearance again. Carburetor synchronizer i. If the valve clearance is still out of specifica- YU-44456 Digital tachometer tion, repeat all of the valve clearance adjust- 90890-06760 ment steps until the specified clearance is YU-39951-B…

• Page 89: Adjusting The Engine Idling Speed

  ENGINE 3. Install: ECA14900 NOTICE • Digital tachometer Do not use the throttle valve adjusting (onto the spark plug lead of cylinder #1) screws to adjust the throttle body syncroni- Digital tachometer zation. 90890-06760 YU-39951-B Carburetor angle driver 90890-03158 4. Check: •…

• Page 90: Adjusting The Throttle Cable Free Play

  ENGINE EAS20630 EAS20680 ADJUSTING THE THROTTLE CABLE FREE CHECKING THE SPARK PLUGS PLAY The following procedure applies to all of the spark plugs. 1. Remove: Prior to adjusting the throttle cable free play, the • Bottom cowling engine idling speed and throttle body synchroni- Refer to “GENERAL CHASSIS”…

• Page 91: Measuring The Compression Pressure

  ENGINE Spark plug 13 Nm (1.3 m·kg, 9.4 ft·lb) Before installing the spark plug, clean the spark plug and gasket surface. 9. Connect: • Spark plug 10.Remove: • Bottom cowling 7. Measure: Refer to “GENERAL CHASSIS” on page 4-1. • Compression pressure Out of specification →…

• Page 92: Checking The Engine Oil Level

  ENGINE Compression pressure (with oil applied into Type the cylinder) YAMALUBE 4 (10W-40) or SAE Reading Diagnosis 10W-40, YAMALUBE 4 (20W-50) or SAE 20W-50 Higher than without Piston ring(s) wear or Recommended engine oil grade damage → Repair. API service SG type or higher, Piston, valves, cylin- JASO standard MA der head gasket or…

• Page 93: Changing The Engine Oil

  ENGINE b. Lubricate the O-ring “3” of the new oil filter EAS20780 CHANGING THE ENGINE OIL cartridge with a thin coat of engine oil. 1. Start the engine, warm it up for several min- ECA13390 utes, and then turn it off. NOTICE 2.

• Page 94: Measuring The Engine Oil Pressure

  ENGINE 10.Start the engine, warm it up for several min- 2. Start the engine, warm it up for several min- utes, and then turn it off. utes, and then turn it off. 11.Check: ECA13410 NOTICE • Engine When the engine is cold, the engine oil will (for engine oil leaks) have a higher viscosity, causing the engine 12.Check:…

• Page 95: Replacing The Air Filter Element

  ENGINE Oil pressure (hot) 150.0 kPa/1200 r/min (21.8 psi/1200 r/min) (1.50 kgf/cm²/1200 r/min) Oil temperature 70.0 °C (158.00 °F) Out of specification → Adjust. Engine oil pressure Possible causes 4. Install: • Faulty oil pump • Clogged oil filter • Air filter case cover Below specification •…

• Page 96: Cleaning The V-Belt Case Air Filter Element

  ENGINE EAS20980 CLEANING THE V-BELT CASE AIR FILTER ELEMENT 1. Remove: • Footrest boards Refer to “GENERAL CHASSIS” on page 4-1. 2. Remove: • V-belt case air filter element (left) “1” 3. Remove: • V-belt case air filter case cover “1” •…

• Page 97: Checking The Fuel Line

  ENGINE 2. Check: 2. Check: • Throttle body joints “1” • Cylinder head breather hose “1” Cracks/damage → Replace the intake mani- Cracks/damage → Replace. Loose connection → Connect properly. folds. ECA14920 NOTICE Make sure the cylinder head breather hose is routed correctly.

• Page 98: Checking The Canister

  ENGINE Below the minimum level mark → Add the 4. Install: • Bottom cowling recommended coolant to the proper level. Refer to “GENERAL CHASSIS” on page 4-1. EAS21090 CHECKING THE CANISTER 1. Remove: • Storage box Refer to “GENERAL CHASSIS” on page 4-1. •…

• Page 99: Changing The Coolant

  ENGINE 3. Install: • Footrest boards • Bottom cowling Refer to “GENERAL CHASSIS” on page 4-1. EAS21130 CHANGING THE COOLANT 1. Remove: • Bottom cowling Refer to “GENERAL CHASSIS” on page 4-1. 2. Disconnect: • Coolant reservoir hose “1” 3. Drain: •…

• Page 100
  ENGINE be blown out, which could cause serious in- Recommended antifreeze jury. When the engine has cooled, open the High-quality ethylene glycol an- radiator cap as follows: tifreeze containing corrosion in- Place a thick rag or a towel over the radiator hibitors for aluminum engines cap and slowly turn the radiator cap counter- Mixing ratio…
• Page 101
  ENGINE 12.Install: • Coolant reservoir cap 13.Start the engine, warm it up for several min- utes, and then stop it. 14.Check: • Coolant level Refer to “CHECKING THE COOLANT LEV- EL” on page 3-17. Before checking the coolant level, wait a few minutes until the coolant has settled.

• Page 102: Chassis

  CHASSIS EAS21140 M MMM M MMM M MMM M MMM M MMM CHASSIS a. While pushing the brake lever forward, turn the adjusting dial “1” until the brake lever is in EAS21160 the desired position. ADJUSTING THE FRONT DISC BRAKE 1.

• Page 103: Checking The Front Brake Pads

  CHASSIS 1. Operate the brake. 2. Check: • Front brake pad Wear indicator groove “a” has almost disap- peared → Replace the brake pads as a set. Refer to “FRONT BRAKE” on page 4-18. EAS21260 CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pads.

• Page 104: Checking The Rear Brake Hose

  CHASSIS 2. Check: Rear brake lock cable length • Brake hose holders 45–47 mm (1.77–1.85 in) Loose → Tighten the holder bolt. 3. Hold the vehicle upright and apply the brake 2. Adjust: several times. • Rear brake lock cable length “a” 4.

• Page 105: Checking The Chain Drive Oil Level

  CHASSIS caution could allow air to enter the hydraulic i. Repeat steps (e) to (h) until all of the air bub- brake system, considerably lengthening the bles have disappeared from the brake fluid in bleeding procedure. the plastic hose. • If bleeding is difficult, it may be necessary to let j.

• Page 106: Changing The Chain Drive Oil

  CHASSIS 3. Check: • Chain drive oil level Wipe the dipstick clean, insert it into the oil fill- er hole (without screw it in), and then remove it to check the oil level. The chain drive oil level should be between the minimum level mark “a”…

• Page 107
  CHASSIS 2. Check: EWA13140 WARNING • Steering head Do not overtighten the lower ring nut. Grasp the bottom of the front fork legs and gently rock the front fork. Binding/looseness → Adjust the steering Lower ring nut (final tightening torque) head.

• Page 108: Checking The Front Fork

  CHASSIS 2. Check: • Inner tube Damage/scratches → Replace. • Oil seal Oil leakage → Replace. 3. Hold the vehicle upright and apply the front brake. 4. Check: • Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds d.

• Page 109
  No guarantee con- cerning handling characteristics can be giv- en if a tire combination other than one approved by Yamaha is used on this vehicle. 1. Tire tread depth Front tire 2. Side wall Size 3.

• Page 110: Checking The Wheels

  CHASSIS 1. Check: EWA13210 WARNING • Outer cable Damage → Replace. New tires have a relatively low grip on the road surface until they have been slightly 2. Check: worn. Therefore, approximately 100 km • Cable operation Rough movement → Lubricate. should be traveled at normal speed before any high-speed riding is done.

• Page 111
  ELECTRICAL SYSTEM 6. Install: EAS21750 ELECTRICAL SYSTEM • Headlight bulb Secure the new headlight bulb with the head- EAS21760 CHECKING AND CHARGING THE BATTERY light bulb holder. Refer to “ELECTRICAL COMPONENTS” on ECA13690 NOTICE page 8-57. Avoid touching the glass part of the head- EAS21770 light bulb to keep it free from oil, otherwise CHECKING THE FUSES…
• Page 112
  ELECTRICAL SYSTEM Direction “a” Headlight beam moves to the right. Direction “b” Headlight beam moves to the left. Right headlight Direction “a” Headlight beam moves to the left. Direction “b” Headlight beam moves to the right. L LLL L LLL L LLL L LLL L LLL…
• Page 113
  CHASSIS GENERAL CHASSIS………………4-1 REMOVING THE FUEL HOSE …………..4-7 INSTALLING THE FUEL HOSE …………..4-7 FRONT WHEEL………………..4-8 REMOVING THE FRONT WHEEL…………4-11 DISASSEMBLING THE FRONT WHEEL……….4-11 CHECKING THE FRONT WHEEL …………4-11 ASSEMBLING THE FRONT WHEEL…………4-12 ADJUSTING THE FRONT WHEEL STATIC BALANCE ……4-12 INSTALLING THE FRONT WHEEL (DISC) ……….4-13 REAR WHEEL ………………..4-15 REMOVING THE REAR WHEEL (DISC) ……….
• Page 114
  HANDLEBAR ………………..4-44 REMOVING THE HANDLEBAR…………..4-46 CHECKING THE HANDLEBAR …………..4-46 INSTALLING THE HANDLEBAR …………4-46 FRONT FORK………………..4-49 REMOVING THE FRONT FORK LEGS……….4-52 DISASSEMBLING THE FRONT FORK LEGS ……..4-52 CHECKING THE FRONT FORK LEGS ……….4-53 ASSEMBLING THE FRONT FORK LEGS ……….4-53 INSTALLING THE FRONT FORK LEGS ……….
• Page 116
  GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the battery and windshield 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Rear view mirror…
• Page 117
  GENERAL CHASSIS Removing the bottom cowling 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Footrest board mat Footrest board cover Side panel Left side cowling Bottom panel Right side cowling Wire harness (to ignition coil) Unhook.
• Page 118
  GENERAL CHASSIS Removing the footrest boards 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Front lower outer panel Front lower inner panel Center panel Fuel tank overflow hose Unhook. Rear brake pipe Unhook. Left footrest board Fuel tank breather hose Unhook.
• Page 119
  GENERAL CHASSIS Removing the front cowling assembly 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Upper handlebar cover Windshield bracket lower cover Meter ring Meter assembly cover Meter assembly coupler Disconnect. Meter assembly Storage compartment Headlight sub-wire harness coupler Disconnect.
• Page 120
  GENERAL CHASSIS Removing the rear cowling assembly 7 Nm (0.7 m kg, 5.1 ft • • 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •…

• Page 121: General Chassis

  GENERAL CHASSIS Removing the storage box 10 Nm (1.0 m kg, 7.2 ft 16 Nm (1.6 m kg, 11 ft 7 Nm (0.7 m kg, 5.1 ft • • • • • • 10 Nm (1.0 m kg, 7.2 ft •…

• Page 122: Removing The Fuel Hose

  GENERAL CHASSIS EAS4B51010 ECA4B51021 REMOVING THE FUEL HOSE NOTICE 1. Remove: When installing the fuel hose, make sure that • Fuel hose connector cover “1” it is securely connected, and that the fuel 2. Disconnect: hose connector cover is in the correct posi- •…

• Page 123: Front Wheel

  FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs 7 Nm (0.7 m kg, 5.1 ft 40 Nm (4.0 m kg, 29 ft 7 Nm (0.7 m kg, 5.1 ft • • • • • • 72 Nm (7.2 m kg, 52 ft •…

• Page 124
  FRONT WHEEL Removing the front wheel and brake discs 7 Nm (0.7 m kg, 5.1 ft 40 Nm (4.0 m kg, 29 ft 7 Nm (0.7 m kg, 5.1 ft • • • • • • 72 Nm (7.2 m kg, 52 ft •…
• Page 125
  FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Collar For assembly, reverse the disassembly pro- cedure. 4-10…

• Page 126: Removing The Front Wheel

  FRONT WHEEL EAS21900 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Front brake calipers Do not apply the brake lever when removing the L LLL L LLL L LLL…

• Page 127: Assembling The Front Wheel

  FRONT WHEEL 4. Check: L LLL L LLL L LLL L LLL L LLL • Wheel bearings EAS21970 Front wheel turns roughly or is loose → Re- ADJUSTING THE FRONT WHEEL STATIC place the wheel bearings. BALANCE • Oil seal Damage/wear →…

• Page 128: Installing The Front Wheel (Disc)

  FRONT WHEEL M MMM M MMM M MMM M MMM M MMM a. Turn the front wheel and make sure it stays at each position shown. f. Repeat steps (c) through (e) several times until all the marks come to rest at the same spot.

• Page 129
  FRONT WHEEL Be sure to fit the two projections on the speed sensor in between the projections on the wheel hub. 5. Install: • Front wheel Make sure the slot “a” in the speed sensor fits over the stopper “b” on the outer tube. 6.

• Page 130: Rear Wheel

  REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel and brake disc 40 Nm (4.0 m kg, 29 ft • • 17 Nm (1.7 m kg, 12 ft • • 105 Nm (10.5 m kg, 75 ft • • 7 Nm (0.7 m kg, 5.1 ft •…

• Page 131
  REAR WHEEL Disassembling the rear wheel 69 Nm (6.9 m • kg, 50 ft • Ib) Order Job/Parts to remove Q’ty Remarks Rear wheel drive hub O-ring Oil seal Wheel bearing For assembly, reverse the disassembly pro- cedure. 4-16…

• Page 132: Removing The Rear Wheel (Disc)

  REAR WHEEL EAS22040 REMOVING THE REAR WHEEL (DISC) 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 the centerstand so that the rear wheel is elevated.

• Page 133: Front Brake

  FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads 7 Nm (0.7 m kg, 5.1 ft • • 5 Nm (0.5 m kg, 3.6 ft • • 40 Nm (4.0 m kg, 29 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of…

• Page 134
  FRONT BRAKE Removing the front brake master cylinder 10 Nm (1.0 m kg, 7.2 ft • • 6 Nm ( 0.6 m Ib ) kg, 4.3 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”…
• Page 135
  FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-20…
• Page 136
  FRONT BRAKE Removing the front brake calipers 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • • 40 Nm (4.0 m kg, 29 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
• Page 137
  FRONT BRAKE Disassembling the front brake calipers 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring Front brake pad Brake caliper piston Brake caliper piston dust seal…

• Page 138: Introduction

  FRONT BRAKE e. Measure the deflection 1.5 mm (0.06 in) be- EAS22220 INTRODUCTION low the edge of the brake disc. EWA4B51008 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • Never disassemble brake components un- less absolutely necessary.

• Page 139: Replacing The Front Brake Pads

  FRONT BRAKE d. Measure the brake disc deflection. 2. Install: e. If out of specification, repeat the adjustment • Front brake pads steps until the brake disc deflection is within • Brake pad spring specification. f. If the brake disc deflection cannot be brought Always install new brake pads and a new brake within specification, replace the brake disc.

• Page 140: Removing The Front Brake Calipers

  FRONT BRAKE Put the end of the brake hose into a container and pump out the brake fluid carefully. e. Install the brake pad pin and brake pad clips. L LLL L LLL L LLL L LLL L LLL 3. Install: •…

• Page 141: Checking The Front Brake Calipers

  FRONT BRAKE EWA4B51006 WARNING Whenever a brake caliper is disassembled, replace the brake caliper piston dust seals and piston seals. EAS22410 ASSEMBLING THE FRONT BRAKE CALIPERS EWA4B51007 WARNING • Before installation, all internal brake com- b. Remove the brake caliper piston dust seals ponents should be cleaned and lubricated and piston seals.

• Page 142: Removing The Front Brake Master Cylinder

  FRONT BRAKE • When refilling, be careful that water does ECA14170 NOTICE not enter the brake fluid reservoir. Water When installing the brake hose onto the will significantly lower the boiling point of brake caliper “1”, make sure the brake pipe the brake fluid and could cause vapor lock.

• Page 143: Checking The Front Brake Master Cylinder

  FRONT BRAKE • Install the brake master cylinder holder with the “UP” mark “a” facing up. • Align the end of the brake master cylinder hold- er with the punch mark “b” on the handlebar. • First, tighten the upper bolt, then the lower bolt. EAS22500 CHECKING THE FRONT BRAKE MASTER CYLINDER…

• Page 144
  FRONT BRAKE 3. Fill: Refer to “BLEEDING THE HYDRAULIC • Brake master cylinder reservoir BRAKE SYSTEM” on page 3-23. (with the specified amount of the recom- mended brake fluid) Recommended fluid DOT 4 EWA13540 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

• Page 145: Rear Brake

  REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads 40 Nm (4.0 m kg, 29 ft • • 31 Nm (3.1 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Rear brake caliper retaining bolt (rear) Rear brake caliper bolt Rear brake caliper Rear brake pad…

• Page 146
  REAR BRAKE Removing the rear brake master cylinder 10 Nm (1.0 m kg, 7.2 ft • • 6 Nm ( 0.6 m Ib ) kg, 4.3 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”…
• Page 147
  REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-32…
• Page 148
  REAR BRAKE Removing the rear brake caliper 30 Nm (3.0 m kg, 22 ft • • 40 Nm (4.0 m kg, 29 ft • • 31 Nm (3.1 m kg, 22 ft • • 22 Nm (2.2 m kg, 16 ft •…
• Page 149
  REAR BRAKE Removing the rear brake caliper 30 Nm (3.0 m kg, 22 ft • • 40 Nm (4.0 m kg, 29 ft • • 31 Nm (3.1 m kg, 22 ft • • 22 Nm (2.2 m kg, 16 ft •…
• Page 150
  REAR BRAKE Disassembling the rear brake caliper 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw Brake caliper body For assembly, reverse the disassembly pro- cedure.

• Page 151: Introduction

  REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit EWA4B51008 4.5 mm (0.18 in) WARNING Disc brake components rarely require disas- 5. Adjust: sembly. Therefore, always follow these pre- • Brake disc deflection ventive measures: Refer to “CHECKING THE FRONT BRAKE •…

• Page 152
  REAR BRAKE 3. Measure: • Brake pad wear limit “a” Out of specification → Replace the brake pads as a set. Brake pad lining thickness (in- ner) 8.0 mm (0.31 in) Limit 0.8 mm (0.03 in) Brake pad lining thickness (out- M MMM M MMM M MMM…

• Page 153: Removing The Rear Brake Caliper

  REAR BRAKE 7. Install: • Rear brake caliper bolts Rear brake caliper bolt 40 Nm (4.0 m·kg, 29 ft·lb) 8. Check: • Brake fluid level Below the minimum level mark “a” → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”…

• Page 154: Disassembling The Rear Brake Caliper

  REAR BRAKE Recommended brake component replace- ment schedule Brake hose Every four years Every two years and Brake fluid whenever the brake is disassembled 1. Check: • Brake caliper piston “1” Rust/scratches/wear → Replace the brake caliper piston. EAS22630 DISASSEMBLING THE REAR BRAKE •…

• Page 155: Assembling The Rear Brake Caliper

  REAR BRAKE • Rear brake caliper “1” EAS22660 ASSEMBLING THE REAR BRAKE CALIPER (temporarily) EWA4B51010 WARNING • Brake hose gaskets • Rear brake hose “2” • Before installation, all internal brake com- • Brake hose union bolt “3” ponents should be cleaned and lubricated with clean or new brake fluid.

• Page 156: Removing The Rear Brake Master Cylinder

  REAR BRAKE 4. Fill: Refer to “BLEEDING THE HYDRAULIC • Brake master cylinder reservoir BRAKE SYSTEM” on page 3-23. (with the specified amount of the recom- 8. Install: mended brake fluid) • Rear brake lock cable holder • Spring Recommended fluid •…

• Page 157: Assembling The Rear Brake Master Cylinder

  REAR BRAKE 2. Check: • Rear brake hose “2” • Brake master cylinder kit • Brake hose union bolt “3” Damage/scratches/wear → Replace. Brake hose union bolt 3. Check: 30 Nm (3.0 m·kg, 22 ft·lb) • Brake master cylinder reservoir •…

• Page 158
  REAR BRAKE • When refilling, be careful that water does not enter the brake master cylinder reser- voir. Water will significantly lower the boil- ing point of the brake fluid and could cause vapor lock. ECA13540 NOTICE Brake fluid may damage painted surfaces and plastic parts.

• Page 159: Handlebar

  HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar 26 Nm (2.6 m kg, 19 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 26 Nm (2.6 m kg, 19 ft •…

• Page 160
  HANDLEBAR Removing the handlebar 26 Nm (2.6 m kg, 19 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 26 Nm (2.6 m kg, 19 ft • • 40 Nm (4.0 m kg, 29 ft •…

• Page 161: Removing The Handlebar

  HANDLEBAR EAS4B51014 REMOVING THE HANDLEBAR 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Handlebar grip “1” 3. Install: Blow compressed air between the left end of the •…

• Page 162
  HANDLEBAR 6. Connect: 9. Install: • Rear brake lock cable • Throttle grip “1” (to rear brake lock lever) • Throttle cables “2” Lubricate the inside of the rear brake lock cable Lubricate the inside of the throttle grip with a thin and rear brake lock lever with a thin coat of lithi- coat of lithium-soap-based grease and install it um-soap-based grease.
• Page 163
  HANDLEBAR Throttle cable free play 3.0–5.0 mm (0.12–0.20 in) 12.Adjust: • Rear brake lock cable length Refer to “ADJUSTING THE REAR BRAKE LOCK CABLE” on page 3-23. 4-48…

• Page 164: Front Fork

  FRONT FORK EAS22950 FRONT FORK Removing the front fork legs 23 Nm (2.3 m kg, 17 ft • • 30 Nm (3.0 m kg, 22 ft • • 26 Nm (2.6 m kg, 19 ft • • 7 Nm (0.7 m kg, 5.1 ft •…

• Page 165
  FRONT FORK Disassembling the front fork legs 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Cap bolt O-ring Spacer Fork spring seat Fork spring Dust seal Oil seal clip…
• Page 166
  FRONT FORK Disassembling the front fork legs 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Oil flow stopper Outer tube For assembly, reverse the disassembly pro- cedure. 4-51…

• Page 167: Removing The Front Fork Legs

  FRONT FORK EAS22960 EAS22980 REMOVING THE FRONT FORK LEGS DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the The following procedure applies to both of the front fork legs. front fork legs. 1. Stand the vehicle on a level surface. 1.

• Page 168: Checking The Front Fork Legs

  FRONT FORK • Outer tube Damper rod holder Bends/damage/scratches → Replace. 90890-01460 EWA13650 T-handle WARNING 90890-01326 Do not attempt to straighten a bent inner T-handle 3/8″ drive 60 cm long tube as this may dangerously weaken it. YM-01326 2. Measure: •…

• Page 169
  3. Lubricate: (with the fork seal driver weight “3” and fork • Inner tube’s outer surface “2” seal driver attachment “4”) Recommended oil Fork seal driver weight Yamaha fork oil 10WT 90890-01367 Replacement hammer YM-A9409-7 Fork seal driver attachment (ø43) 90890-01374…
• Page 170
  10.Fill: • Front fork leg (with the specified amount of the recom- mended fork oil) Recommended oil Yamaha fork oil 10WT Quantity 517.0 cm³ (17.48 US oz) (18.23 Imp.oz) ECA14230 NOTICE • Be sure to use the recommended fork oil.

• Page 171: Installing The Front Fork Legs

  FRONT FORK 11.After filling the front fork leg, slowly stroke the • Temporarily tighten the cap bolt. inner tube “1” up and down (at least ten times) to distribute the fork oil. EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the Be sure to stroke the inner tube slowly because front fork legs.

• Page 172
  FRONT FORK 4-57…

• Page 173: Steering Head

  STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket 115 Nm (11.5 m kg, 85 ft • • 1st 52 Nm (5.2 m kg, 37 ft • • final 14 Nm (1.4 m kg, 10 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”…

• Page 174
  STEERING HEAD Removing the lower bracket 115 Nm (11.5 m kg, 85 ft • • 1st 52 Nm (5.2 m kg, 37 ft • • final 14 Nm (1.4 m kg, 10 ft • • Order Job/Parts to remove Q’ty Remarks Dust seal Lower bearing inner race…

• Page 175: Removing The Lower Bracket

  STEERING HEAD EAS23110 REMOVING THE LOWER BRACKET 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Upper ring nut • Rubber washer •…

• Page 176: Installing The Steering Head

  STEERING HEAD 4. Check: • Upper bracket • Lower bracket (along with the steering stem) Bends/cracks/damage → Replace. EAS23140 INSTALLING THE STEERING HEAD 1. Lubricate: • Upper bearing • Lower bearing • Bearing races Recommended lubricant Lithium-soap-based grease 2. Install: •…

• Page 177: Rear Shock Absorber Assembly

  REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 53 Nm (5.3 m kg, 38 ft • • 68 Nm (6.8 m kg, 49 ft • • Order Job/Parts to remove Q’ty Remarks Exhaust assembly Refer to “ENGINE REMOVAL”…

• Page 178: Handling The Rear Shock Absorber

  REAR SHOCK ABSORBER ASSEMBLY EAS23180 HANDLING THE REAR SHOCK ABSORBER Place the vehicle on the centerstand so that the EWA13740 WARNING rear wheel is elevated. This rear shock absorber contains highly 2. Remove: compressed nitrogen gas. Before handling • Rear shock absorber assembly bolts “1” the rear shock absorber, read and make sure you understand the following information.

• Page 179
  REAR SHOCK ABSORBER ASSEMBLY • Lubricate the rear shock absorber assembly front bolt seats with lithium-soap-based grease. 3. Tighten: • Rear shock absorber assembly rear nut Rear shock absorber assembly rear nut 53 Nm (5.3 m·kg, 38 ft·lb) 4. Tighten: •…

• Page 180: Swingarm And Transmission Chain Drive

  SWINGARM AND TRANSMISSION CHAIN DRIVE EAS4B51015 SWINGARM AND TRANSMISSION CHAIN DRIVE Removing the swingarm and transmission chain drive assembly 7 Nm (0.7 m kg, 5.1 ft • • 100 Nm (10.0 m kg, 72 ft • • 30 Nm (3.0 m kg, 22 ft •…

• Page 181
  SWINGARM AND TRANSMISSION CHAIN DRIVE Removing the swingarm and transmission chain drive assembly 7 Nm (0.7 m kg, 5.1 ft • • 100 Nm (10.0 m kg, 72 ft • • 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft •…
• Page 182
  SWINGARM AND TRANSMISSION CHAIN DRIVE Disassembling the transmission chain drive assembly (18) 8 12 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Outer chain drive case Secondary drive gear Secondary drive chain Secondary driven gear Chain drive case gasket Dowel pin Middle shaft…
• Page 183
  SWINGARM AND TRANSMISSION CHAIN DRIVE Disassembling the transmission chain drive assembly (18) 8 12 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Bearing retainer For assembly, reverse the disassembly pro- cedure. * Apply chain drive oil. 4-68…

• Page 184: Checking The Swingarm

  SWINGARM AND TRANSMISSION CHAIN DRIVE EAS4B51017 CHECKING THE SWINGARM 1. Check: • Swingarm “1” Damage/wear → Replace. EAS4B51018 ASSEMBLING THE TRANSMISSION CHAIN DRIVE ASSEMBLY 1. Install: • Outer chain drive case 2. Check: • Pivot shaft Chain drive case bolt •…

• Page 185
  SWINGARM AND TRANSMISSION CHAIN DRIVE 5. Fill: • Transmission chain drive case Refer to “CHANGING THE CHAIN DRIVE OIL” on page 3-25. 6. Check: • Chain drive oil level Refer to “CHECKING THE CHAIN DRIVE OIL LEVEL” on page 3-24. 2.
• Page 186
  SWINGARM AND TRANSMISSION CHAIN DRIVE 4-71…

• Page 187: Engine

  ENGINE ENGINE REMOVAL ………………5-1 INSTALLING THE ENGINE…………… 5-5 CAMSHAFTS………………..5-6 REMOVING THE CAMSHAFTS…………..5-9 CHECKING THE CAMSHAFTS …………..5-10 CHECKING THE CAMSHAFT SPROCKETS ………5-11 CHECKING THE TIMING CHAIN GUIDES……….5-11 CHECKING THE TIMING CHAIN TENSIONER……..5-12 INSTALLING THE CAMSHAFTS …………5-12 CYLINDER HEAD………………5-15 REMOVING THE CYLINDER HEAD…………5-16 CHECKING THE CYLINDER HEAD …………5-16 INSTALLING THE CYLINDER HEAD ………….5-16…

• Page 188
  V-BELT AUTOMATIC TRANSMISSION …………5-35 REMOVING THE PRIMARY SHEAVE AND SECONDARY SHEAVE..5-41 DISASSEMBLING THE SECONDARY SHEAVE……..5-41 CHECKING THE V-BELT…………….5-42 CHECKING THE PRIMARY SHEAVE …………5-42 CHECKING THE V-BELT CASE AIR DUCT ………..5-42 CHECKING THE PRIMARY SHEAVE WEIGHTS……..5-42 CHECKING THE SLIDERS …………..5-42 CHECKING THE SECONDARY SHEAVE ……….
• Page 189
  CRANKSHAFT ………………..5-71 REMOVING THE CONNECTING RODS ……….5-73 REMOVING THE CRANKSHAFT JOURNAL BEARINGS ……5-73 CHECKING THE CRANKSHAFT AND CONNECTING RODS….5-73 INSTALLING THE CRANKSHAFT JOURNAL BEARINGS…..5-76 INSTALLING THE CONNECTING RODS……….5-77 INSTALLING THE CRANKSHAFT ASSEMBLY……..5-78 TRANSMISSION……………….. 5-79 CHECKING THE TRANSMISSION …………5-80…

• Page 190: Engine Removal

  ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the exhaust assembly 8 Nm (0.8 m kg, 5.8 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 45 Nm (4.5 m kg, 32 ft • • 8 Nm (0.8 m kg, 5.8 ft •…

• Page 191
  ENGINE REMOVAL Disconnecting the leads 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Front cowling/Storage box 4-1. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL”…
• Page 192
  ENGINE REMOVAL Disconnecting the leads 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “SWINGARM AND TRANSMIS- Transmission chain drive holder assembly SION CHAIN DRIVE” on page 4-65. Refer to “ELECTRIC STARTER”…
• Page 193
  ENGINE REMOVAL Removing the engine 83 Nm (8.3 m kg, 60 ft • • 105 Nm (10.5 m kg, 75 ft • • 45 Nm (4.5 m kg, 32 ft • • 88 Nm (8.8 m kg, 64 ft • •…

• Page 194: Installing The Engine

  ENGINE REMOVAL EAS23720 INSTALLING THE ENGINE 1. Install: • All removed parts • Apply locking agent (LOCTITE®) to engine mounting bolts (front right lower side) “1”, en- gine mounting bolts (front left lower side) “2”, and rear frame bolts “3”. •…

• Page 195: Camshafts

  CAMSHAFTS EAS23760 CAMSHAFTS Removing the cylinder head cover 7 Nm (0.7 m kg, 5.1 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 10 Nm (1.0 m kg, 7.2 ft • • (10) 8 Nm (0.8 m kg, 5.8 ft •…

• Page 196
  CAMSHAFTS Removing the cylinder head cover 7 Nm (0.7 m kg, 5.1 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 10 Nm (1.0 m kg, 7.2 ft • • (10) 8 Nm (0.8 m kg, 5.8 ft •…
• Page 197
  CAMSHAFTS Removing the camshafts 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Parts to remove Q’ty Remarks Timing chain tensioner rod accessing plug Timing chain tensioner Timing chain tensioner gasket Intake camshaft cap…

• Page 198: Removing The Camshafts

  CAMSHAFTS EAS23810 REMOVING THE CAMSHAFTS 1. Align: • “I” mark “a” on the generator rotor (with the stationary pointer “b” on the genera- tor cover) M MMM M MMM M MMM M MMM M MMM a. Turn the crankshaft clockwise. L LLL L LLL L LLL…

• Page 199: Checking The Camshafts

  CAMSHAFTS 3. Measure: • Camshaft runout EAS23850 Out of specification → Replace. CHECKING THE CAMSHAFTS 1. Check: Camshaft runout limit • Camshaft lobes 0.030 mm (0.0012 in) Blue discoloration/pitting/scratches → Re- place the camshaft. 2. Measure: • Camshaft lobe dimensions “a” and “b” Out of specification →…

• Page 200: Checking The Camshaft Sprockets

  CAMSHAFTS EAS4B51035 c. Install the dowel pins and camshaft caps. CHECKING THE CAMSHAFT SPROCKETS The following procedure applies to both of the • Tighten the camshaft cap bolts in stages and in camshaft sprockets. a crisscross pattern, working from the inner 1.

• Page 201: Checking The Timing Chain Tensioner

  CAMSHAFTS EAS23960 EAS24000 CHECKING THE TIMING CHAIN TENSIONER INSTALLING THE CAMSHAFTS 1. Check: 1. Install: • Timing chain tensioner • Exhaust camshaft “1” Cracks/damage → Replace. • Intake camshaft “2” M MMM M MMM M MMM M MMM M MMM a.

• Page 202
  CAMSHAFTS hole “d” on the exhaust camshaft sprocket ECA13730 NOTICE align with the cylinder head mating surface, as The camshaft cap bolts must be tightened shown in the illustration. evenly or damage to the cylinder head, cam- ECA4B51015 shaft caps, and camshafts will result. NOTICE 4.
• Page 203
  • Timing chain guide (upper side) • Gaskets (to the cylinder head cover) ECA4B51014 • Apply Yamaha bond No.1215 “1” onto the mat- NOTICE ing surface of the cylinder head cover and tim- Do not push up the timing chain. Push up “c”…

• Page 204: Cylinder Head

  CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head 10 Nm (1.0 m kg, 7.2 ft • • 46 Nm (4.6 m kg, 33 ft • • 35 Nm (3.5 m kg, 25 ft • • Order Job/Parts to remove Q’ty Remarks Camshafts…

• Page 205: Removing The Cylinder Head

  CYLINDER HEAD EAS24120 REMOVING THE CYLINDER HEAD Warpage limit 1. Remove: 0.03 mm (0.0012 in) • Cylinder head bolts • Cylinder head nuts • Loosen the bolts and nuts in the proper se- quence as shown. • Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them.

• Page 206
  CYLINDER HEAD Cylinder head nut 35 Nm (3.5 m·kg, 25 ft·lb) • Cylinder head nuts “2” Cylinder head nut 46 Nm (4.6 m·kg, 33 ft·lb) • Cylinder head bolts “3” Cylinder head bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) • Lubricate the cylinder head nuts and washers with engine oil.
• Page 207
  VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-15. Valve lifter Valve pad Valve cotter Valve retainer Valve spring Intake valve Exhaust valve Valve stem seal…

• Page 208: Valves And Valve Springs

  VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES Remove the valve cotters by compressing the The following procedure applies to all of the valve spring with the valve spring compressor valves and related components. “2” and the valve spring compressor attachment “3”.

• Page 209
  VALVES AND VALVE SPRINGS 1. Measure: • Valve-stem-to-valve-guide clearance Out of specification → Replace the valve guide. • Valve-stem-to-valve-guide clearance = Valve guide inside diameter “a” — Valve stem diameter “b” Valve-stem-to-valve-guide clear- ance (intake) b. Install the new valve guide with the valve 0.010–0.037 mm (0.0004–0.0015 guide installer “2”…

• Page 210: Checking The Valve Seats

  VALVES AND VALVE SPRINGS Valve guide remover (ø4) Valve stem runout 90890-04111 0.040 mm (0.0016 in) Valve guide remover (4.0 mm) YM-04111 Valve guide installer (ø4) 90890-04112 Valve guide installer (4.0 mm) YM-04112 Valve guide reamer (ø4) 90890-04113 Valve guide reamer (4.0 mm) YM-04113 L LLL L LLL…

• Page 211
  VALVES AND VALVE SPRINGS b. Install the valve into the cylinder head. c. Install the valve into the cylinder head. c. Press the valve through the valve guide and d. Turn the valve until the valve face and valve onto the valve seat to make a clear impres- seat are evenly polished, then clean off all of sion.

• Page 212: Checking The Valve Springs

  VALVES AND VALVE SPRINGS j. Measure the valve seat width again. If the valve seat width is out of specification, reface and lap the valve seat. L LLL L LLL L LLL L LLL L LLL EAS24310 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs.

• Page 213
  VALVES AND VALVE SPRINGS 1. Deburr: • Valve stem end (with an oil stone) 2. Lubricate: • Valve stem “1” • Valve stem seal “2” (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil b. Smaller pitch 4. Install: • Valve cotters “1” Install the valve cotters by compressing the valve spring with the valve spring compressor “2”…
• Page 214
  VALVES AND VALVE SPRINGS 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. ECA13800 NOTICE Hitting the valve tip with excessive force could damage the valve. 6. Lubricate: • Valve pad (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil…
• Page 215
  CYLINDER AND PISTONS EAS24370 CYLINDER AND PISTONS Removing the cylinder and pistons 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-15. Timing chain guide (exhaust side) Cylinder Cylinder gasket Dowel pin…

• Page 216: Cylinder And Pistons

  CYLINDER AND PISTONS • 2nd ring EAS24380 REMOVING THE PISTONS • Oil ring The following procedure applies to all of the pis- ton. When removing a piston ring, open the end gap 1. Remove: with your fingers and lift the other side of the ring •…

• Page 217: Checking The Piston Rings

  CYLINDER AND PISTONS EAS24430 CHECKING THE PISTON RINGS 1. Measure: • Piston ring side clearance Out of specification → Replace the piston and piston rings as a set. Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings.

• Page 218: Checking The Piston Pins

  CYLINDER AND PISTONS 3. Measure: • Piston ring end gap Out of specification → Replace the piston ring. The oil ring expander spacer end gap cannot be measured. If the oil ring rail gap is excessive, re- place all three piston rings. Piston ring 3.

• Page 219
  CYLINDER AND PISTONS 3. Install: • Dowel pins Be sure to install the top and 2nd rings so that the manufacturer marks or numbers face up. • Cylinder gasket 4. Lubricate: • Piston • Piston rings • Cylinder (with the recommended lubricant) Recommended lubricant Engine oil 5.

• Page 220: Electric Starter

  ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Storage box 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Negative battery lead Starter motor lead Starter motor…

• Page 221
  ELECTRIC STARTER Disassembling the starter motor 11 Nm (1.1 m kg, 8.0 ft • • Order Job/Parts to remove Q’ty Remarks Starter motor front cover Bearing Oil seal Circlip Armature assembly Starter motor yoke O-ring Insulator Brush Brush spring Brush holder Starter motor rear cover For assembly, reverse the disassembly pro- cedure.

• Page 222: Checking The Starter Motor

  ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR 1. Check: • 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. L LLL L LLL L LLL…

• Page 223: Installing The Starter Motor

  ELECTRIC STARTER 2. Install: • Starter motor yoke “1” • Starter motor front cover “2” • Starter motor rear cover “3” Align the match marks “a” on the starter motor yoke with the match marks “b” on the front and starter motor rear covers.

• Page 224
  V-BELT AUTOMATIC TRANSMISSION EAS24610 V-BELT AUTOMATIC TRANSMISSION Removing the V-belt case cover 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 11 Nm (1.1 m kg, 8.0 ft • • 10 Nm (1.0 m kg, 7.2 ft •…

• Page 225: V-Belt Automatic Transmission

  V-BELT AUTOMATIC TRANSMISSION Removing the V-belt case cover 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 11 Nm (1.1 m kg, 8.0 ft • • 10 Nm (1.0 m kg, 7.2 ft •…

• Page 226
  V-BELT AUTOMATIC TRANSMISSION Removing the V-belt and primary/secondary sheave 24 Nm (2.4 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 24 Nm (2.4 m kg, 17 ft • • 90 Nm (9.0 m kg, 65 ft •…
• Page 227
  V-BELT AUTOMATIC TRANSMISSION Removing the V-belt and primary/secondary sheave 24 Nm (2.4 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 24 Nm (2.4 m kg, 17 ft • • 90 Nm (9.0 m kg, 65 ft •…
• Page 228
  V-BELT AUTOMATIC TRANSMISSION Disassembling the primary sheave Order Job/Parts to remove Q’ty Remarks Slider Primary sheave weight Primary sliding sheave Collar Oil seal For assembly, reverse the disassembly pro- cedure. * Apply BEL-RAY assembly lube®. 5-39…
• Page 229
  V-BELT AUTOMATIC TRANSMISSION Disassembling the secondary sheave 90 Nm (9.0 m kg, 65 ft • • Order Job/Parts to remove Q’ty Remarks Secondary sheave spring seat nut Upper spring seat Secondary sheave compression spring Spring seat Guide pin Secondary sliding sheave O-ring Oil seal Secondary fixed sheave…

• Page 230: Removing The Primary Sheave And Secondary Sheave

  V-BELT AUTOMATIC TRANSMISSION EAS4B51022 EAS24640 REMOVING THE PRIMARY SHEAVE AND DISASSEMBLING THE SECONDARY SECONDARY SHEAVE SHEAVE 1. Remove: 1. Loosen: • Primary sheave nut “1” • Secondary sheave spring seat nut “1” • Secondary sheave nut “2” • While holding the secondary fixed sheave “2” While holding the primary and secondary with the sheave holder “3”, loosen the second- sheave with the sheave holder “3”, loosen the…

• Page 231: Checking The V-Belt

  V-BELT AUTOMATIC TRANSMISSION EAS24690 CHECKING THE PRIMARY SHEAVE WEIGHTS The following procedure applies to all of the pri- mary sheave weights. 1. Check: • Primary sheave weight Cracks/damage/wear → Replace. 2. Measure: • Primary sheave weight outside diameter Out of specification → Replace. EAS24670 CHECKING THE V-BELT Primary sheave weight outside…

• Page 232: Assembling The Primary Sheave

  V-BELT AUTOMATIC TRANSMISSION 2. Install: EAS24720 • Secondary sliding sheave “1” ASSEMBLING THE PRIMARY SHEAVE 1. Clean: Install the secondary sliding sheave onto the • Primary fixed sheave secondary fixed sheave “2” with the oil seal • Primary sliding sheave guide “3”.

• Page 233: Installing The Primary Sheave Assembly, Secondary Sheave Assembly And V-Belt

  INSTALLING THE PRIMARY SHEAVE ASSEMBLY, SECONDARY SHEAVE ASSEMBLY AND V-BELT 1. Apply: • Sealant (onto the inner V-belt case seal) Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) 2. Install: • V-belt case air duct joint clamp “1” 6. Tighten: •…

• Page 234
  V-BELT AUTOMATIC TRANSMISSION While holding the secondary sheave with the sheave holder “2”, tighten the secondary sheave nut. Secondary sheave nut 90 Nm (9.0 m·kg, 65 ft·lb) Sheave holder 90890-01481 3. Install: • Primary fixed sheave “1” • V-belt “2” •…

• Page 235: Installing The V-Belt Case

  V-BELT AUTOMATIC TRANSMISSION EAS4B51025 INSTALLING THE V-BELT CASE 1. Install: • Oil seal “1” (into outer V-belt case) Installed depth of oil seal “a” 4.0–4.3 mm (0.16–0.17 in) 2. Fill the space “b” shown in the illustration with 10 g or more of lithium-soap-based grease. 3.

• Page 236
  GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch 30 Nm (3.0 m kg, 22 ft • • (19) 7 Nm (0.7 m kg, 5.1 ft • • 1st 65 Nm (6.5 m kg, 47 ft •…

• Page 237: Generator And Starter Clutch

  GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch 30 Nm (3.0 m kg, 22 ft • • (19) 7 Nm (0.7 m kg, 5.1 ft • • 1st 65 Nm (6.5 m kg, 47 ft • • 30 Nm (3.0 m kg, 22 ft 10 Nm (1.0 m…

• Page 238
  GENERATOR AND STARTER CLUTCH Removing the stator coil and oil tank 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Oil tank…

• Page 239: Removing The Generator

  GENERATOR AND STARTER CLUTCH EAS24490 REMOVING THE GENERATOR 1. Remove: • Generator cover 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.

• Page 240: Checking The Starter Clutch

  GENERATOR AND STARTER CLUTCH c. When turning the starter clutch gear clock- wise “B”, it should turn freely, otherwise the starter clutch is faulty and must be replaced. EAS24570 CHECKING THE STARTER CLUTCH 1. Check: • Starter clutch rollers “1” L LLL L LLL L LLL…

• Page 241: Installing The Generator

  • While holding the generator rotor “2” with the (onto the crankshaft position sensor lead sheave holder “3”, tighten the generator rotor grommet) nut. Yamaha bond No. 1215 • Do not allow the sheave holder to touch the 90890-85505 projection on the generator rotor. (Three Bond No.1215®)

• Page 242
  GENERATOR AND STARTER CLUTCH Generator cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Tighten the generator cover bolts in stages and in a crisscross pattern. 5-53…

• Page 243: Clutch

  CLUTCH EAS25061 CLUTCH Removing the clutch 65 Nm (6.5 m kg, 47 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERATOR AND STARTER Generator cover CLUTCH” on page 5-47. Clutch assembly nut Clutch assembly Washer For installation, reverse the removal proce- dure.

• Page 244
  CLUTCH Disassembling the clutch 130 Nm (13.0 m kg, 94 ft • • (12) Order Job/Parts to remove Q’ty Remarks Circlip Spring stopper plate Clutch spring plate Pressure plate Clutch plate 2 Clutch damper spring Friction plate Clutch plate 1 Clutch spring Clutch boss nut Primary drive gear…
• Page 245
  CLUTCH Disassembling the clutch 130 Nm (13.0 m kg, 94 ft • • (12) Order Job/Parts to remove Q’ty Remarks Clutch housing For assembly, reverse the disassembly pro- cedure. 5-56…

• Page 246: Removing The Clutch

  CLUTCH EAS25070 REMOVING THE CLUTCH 1. Remove: • Clutch assembly nut “1” • Clutch assembly “2” • Before removal, put alignment marks “a” and “b” as shown. • While holding the clutch assembly with the ro- tor holding tool “3”, loosen the clutch assembly nut.

• Page 247: Checking The Friction Plates

  CLUTCH EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric- tion plates. 1. Check: • Friction plate Damage/wear → Replace the friction plates as a set. 2. Measure: • Friction plate thickness Out of specification → Replace the friction EAS4B51027 plates as a set.

• Page 248: Checking The Clutch Springs

  CLUTCH EAS25140 EAS25160 CHECKING THE CLUTCH SPRINGS CHECKING THE CLUTCH BOSS The following procedure applies to all of the 1. Check: clutch springs. • Clutch boss splines 1. Check: Damage/pitting/wear → Replace the clutch • Clutch spring boss. Damage → Replace the clutch springs as a set.

• Page 249: Installing The Clutch

  CLUTCH • Friction plates “4” Recommended lubricant • Clutch plates 1 “5” Engine oil • Pressure plate “6” • Clutch spring plate “7” 2. Install: • Clutch boss • Primary drive gear • Clutch boss nut 3. Tighten: • Clutch boss nut “1” Clutch boss nut 130 Nm (13.0 m·kg, 94 ft·lb) While holding the clutch boss “2”…

• Page 250
  CLUTCH Clutch assembly nut 65 Nm (6.5 m·kg, 47 ft·lb) • Align the “a” and “b” during reassembly. • While holding the clutch assembly with the ro- tor holding tool “3”, tighten the clutch assembly nut. Rotor holding tool 90890-01235 Universal magneto &…

• Page 251: Oil Pump

  OIL PUMP EAS24901 OIL PUMP Removing the oil pump 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERATOR AND STARTER Starter clutch gear CLUTCH”…

• Page 252
  OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Oil pump housing 1 Dowel pin Oil pump outer rotor 1 Oil pump inner rotor 1 Washer Oil pump housing center Oil pump outer rotor 2 Oil pump inner rotor 2 Oil pump driven gear Oil pump housing 2 For assembly, reverse the disassembly pro-…

• Page 253: Checking The Oil Pump

  OIL PUMP EAS24960 CHECKING THE OIL PUMP Inner-rotor-to-outer-rotor-tip 1. Check: clearance • Oil pump driven gear “1” 0.040–0.120 mm (0.0016–0.0047 • Oil pump housing 2 “2” Limit • Oil pump housing 1 “3” Cracks/damage/wear → Replace the defec- 0.20 mm (0.0079 in) Outer-rotor-to-oil-pump-housing tive part(s).

• Page 254: Assembling The Oil Pump

  OIL PUMP ECA13890 NOTICE After tightening the bolts, make sure the oil pump turns smoothly. EAS25000 ASSEMBLING THE OIL PUMP 1. Lubricate: • Inner rotor • Outer rotor • Oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2.

• Page 255: Crankcase

  CRANKCASE EAS25540 CRANKCASE Separating the crankcase 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 43 Nm (4.3 m kg, 31 ft •…

• Page 256
  CRANKCASE Separating the crankcase 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 43 Nm (4.3 m kg, 31 ft • • 24 Nm (2.4 m kg, 17 ft •…
• Page 257
  CRANKCASE Removing the oil seals and bearings 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Parts to remove Q’ty Remarks Crankshaft assembly Refer to “CRANKSHAFT” on page 5-71. Transmission Refer to “TRANSMISSION” on page 5-79. Bearing retainer Oil seal Bearing For installation, reverse the removal proce- dure.

• Page 258: Disassembling The Crankcase

  (onto the crankcase mating surfaces) es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. Yamaha bond No. 1215 • M8 × 110 mm bolts “1” 90890-85505 • M6 × 50 mm bolts “2”…

• Page 259
  CRANKCASE • M6 × 35 mm bolts “3” 5. Check: • Crankshaft and transmission operation Rough movement → Repair. 5-70…

• Page 260: Crankshaft

  CRANKSHAFT EAS25960 CRANKSHAFT Removing the crankshaft assembly 58 Nm (5.8 m kg, 42 ft • • Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-66. Dowel pin Crankshaft assembly Balancer cylinder Oil seal Crankshaft journal bearing For installation, reverse the removal proce- dure.

• Page 261
  CRANKSHAFT Removing the connecting rods 16 Nm (1.6 m kg, 11 ft • • final Specified angle 90˚ 60 Nm (6.0 m kg, 43 ft • • 16 Nm (1.6 m kg, 11 ft • • final Specified angle 90˚ Order Job/Parts to remove Q’ty…

• Page 262: Removing The Connecting Rods

  CRANKSHAFT EAS26010 REMOVING THE CONNECTING RODS The following procedure applies to all of the con- necting rods. 1. Remove: • Connecting rod cap • Connecting rod “1” • Big end bearings Identify the position of each big end bearing so that it can be reinstalled in its original place.

• Page 263
  CRANKSHAFT 3. Measure: • Crankshaft-pin-to-big-end-bearing clearance • Do not move the connecting rod or crankshaft Out of specification → Replace the big end until the clearance measurement has been bearings. completed. • Lubricate the bolts threads and nut seats with Oil clearance (using plasti- molybdenum disulfide grease.
• Page 264
  CRANKSHAFT • P –P refer to the bearings shown in the crank- Journal oil clearance (using plas- shaft illustration. tigauge®) 0.040–0.082 mm (0.0016–0.0032 The following procedure applies to all of the crankshaft journal bearings. ECA13920 NOTICE Do not interchange the crankshaft journal bearings.

• Page 265: Installing The Crankshaft Journal Bearings

  CRANKSHAFT d. Measure the crankshaft journal bearing in- side diameter “b” of each crankshaft journal bearing at two places. e. If crankshaft journal bearing inside diameter is “45.03” and crankshaft journal diameter is “44.98”, then the journal oil clearance is: Journal oil clearance: Crankshaft journal bearing inside diameter — Crankshaft journal diameter…

• Page 266: Installing The Connecting Rods

  CRANKSHAFT • Make sure the characters “d” on both the con- necting rod and connecting rod cap are aligned. EAS26150 INSTALLING THE CONNECTING RODS 1. Lubricate: • Bolt threads • Nut seats 4. Tighten: (with the recommended lubricant) • Connecting rod nuts M MMM M MMM M MMM…

• Page 267: Installing The Crankshaft Assembly

  CRANKSHAFT c. Tighten the connecting rod nuts further to (6.0 m·kg, 43 ft·lb), loosen the nut to less reach the specified angle 90°. than 30 Nm (3.0 m·kg, 22 ft·lb) and start again. Connecting rod nut (final) Specified angle 90° EAS4B51033 INSTALLING THE CRANKSHAFT ASSEMBLY…

• Page 268: Transmission

  TRANSMISSION EAS26240 TRANSMISSION Removing the transmission Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-66. Secondary shaft Collar Primary driven gear Main axle 1st pinion gear Drive axle 1st wheel gear Circlip For installation, reverse the removal proce- dure.

• Page 269: Checking The Transmission

  TRANSMISSION EAS26300 CHECKING THE TRANSMISSION 1. Measure: • Main axle runout (with a centering device and dial gauge) Out of specification → Replace the main axle. Main axle runout limit 0.08 mm (0.0032 in) 4. Check: • Transmission gear movement Rough movement →…

• Page 270
  TRANSMISSION 5-81…

• Page 271: Cooling System

  COOLING SYSTEM RADIATOR …………………. 6-1 CHECKING THE RADIATOR…………..6-3 INSTALLING THE RADIATOR…………..6-3 OIL COOLER………………..6-4 CHECKING THE OIL COOLER …………..6-6 INSTALLING THE OIL COOLER ………….. 6-6 THERMOSTAT ………………..6-7 CHECKING THE THERMOSTAT………….. 6-8 INSTALLING THE THERMOSTAT ASSEMBLY ……..6-8 WATER PUMP………………..6-9 DISASSEMBLING THE WATER PUMP……….6-11 CHECKING THE WATER PUMP …………

• Page 272
  RADIATOR EAS26380 RADIATOR Removing the radiator 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Footrest boards 4-1.
• Page 273
  RADIATOR Removing the radiator 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Radiator fan Radiator bracket For installation, reverse the removal proce- dure.

• Page 274: Radiator

  RADIATOR EAS26390 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radia- tor. Damage → Repair or replace. Straighten any flattened fins with a thin, flat-head screwdriver. b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.

• Page 275: Oil Cooler

  OIL COOLER EAS26410 OIL COOLER Removing the oil cooler 10 Nm (1.0 m kg, 7.2 ft • • 17 Nm (1.7 m kg, 12 ft • • 63 Nm (6.3 m kg, 45 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”…

• Page 276
  OIL COOLER Removing the oil cooler 10 Nm (1.0 m kg, 7.2 ft • • 17 Nm (1.7 m kg, 12 ft • • 63 Nm (6.3 m kg, 45 ft • • Order Job/Parts to remove Q’ty Remarks Oil cooler For installation, reverse the removal proce- dure.

• Page 277: Checking The Oil Cooler

  OIL COOLER 4. Fill: EAS26420 CHECKING THE OIL COOLER • Cooling system 1. Check: (with the specified amount of the recom- • Oil cooler mended coolant) Cracks/damage → Replace. Refer to “CHANGING THE COOLANT” on 2. Check: page 3-18. • Oil cooler inlet hose •…

• Page 278: Thermostat

  THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat 10 Nm (1.0 m kg, 7.2 ft • • 18 Nm (1.8 m kg, 13 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Storage box 4-1. Fuel tank Refer to “FUEL TANK”…

• Page 279: Checking The Thermostat

  THERMOSTAT 2. Check: EAS26450 CHECKING THE THERMOSTAT • Thermostat cover 1. Check: Cracks/damage → Replace. • Thermostat Does not open at 71–85 °C (159.8–185.0 °F) EAS26480 INSTALLING THE THERMOSTAT → Replace. ASSEMBLY 1. Install: • Thermostat Install the thermostat with its breather hole “a” facing forward.

• Page 280: Water Pump

  WATER PUMP EAS26500 WATER PUMP Removing the water pump 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Left footrest board 4-1.

• Page 281
  WATER PUMP Disassembling the water pump 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks It is not necessary to remove the impeller shaft, unless the coolant level is extremely low or coolant contains engine oil.

• Page 282: Disassembling The Water Pump

  WATER PUMP EAS26510 EAS26550 DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP 1. Remove: 1. Check: • Rubber damper holder “1” • Water pump housing cover • Rubber damper “2” • Water pump housing (from the impeller, with a thin, flat-head •…

• Page 283: Installing The Water Pump

  WATER PUMP • Before installing the water pump seal, apply ECA14090 NOTICE Yamaha bond No.1215 “2” to the water pump Make sure the rubber damper and rubber housing “3”. damper holder are flush with the impeller. Mechanical seal installer Impeller shaft tilt limit 90890-04078 0.15 mm (0.0059 in)

• Page 284
  WATER PUMP 3. Check: • Cooling system Leaks → Repair or replace any faulty part. 4. Measure: • Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-3. 6-13…

• Page 285: 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 ROLLOVER VALVE …………7-3 INSTALLING THE FUEL PUMP…………..7-3 CHECKING THE FUEL PRESSURE …………7-3 THROTTLE BODY………………. 7-5 CHECKING THE INJECTORS …………..7-8 CHECKING THE THROTTLE BODY …………7-8 ADJUSTING THE THROTTLE POSITION SENSOR……..7-8…

• Page 286
  FUEL TANK EAS26620 FUEL TANK Removing the fuel tank 4 Nm (0.4 m kg, 2.9 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Storage box 4-1.
• Page 287
  FUEL TANK Removing the canister 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Storage box 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Fuel tank breather hose Canister purge hose (3-way joint to canister) Canister purge hose (throttle body to 3-way joint)

• Page 288: Fuel Tank

  FUEL TANK EAS26630 REMOVING THE FUEL TANK • Do not damage the installation surfaces of the 1. Extract the fuel in the fuel tank through the fuel tank when installing the fuel pump. fuel tank cap with a pump. • Always use a new fuel pump gasket. 2.

• Page 289
  FUEL TANK b. Connect the pressure gauge “1” and fuel pressure adapter “2” to the fuel pump and the fuel hose “3”. Pressure gauge 90890-03153 YU-03153 Fuel pressure adapter 90890-03181 c. Start the engine. d. Measure the fuel pressure. Faulty → Replace the fuel pump. Output pressure 246.0–254.0 kPa (35.7–36.8 psi) (2.46–2.54 kgf/cm²)

• Page 290: Throttle Body

  THROTTLE BODY EAS26970 THROTTLE BODY Removing the throttle body assembly 9 Nm (0.9 m kg, 6.5 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”…

• Page 291
  THROTTLE BODY Removing the throttle body assembly 9 Nm (0.9 m kg, 6.5 ft • • 10 Nm (1.0 m kg, 7.2 ft 12 Nm (1.2 m kg, 8.7 ft • • • • Order Job/Parts to remove Q’ty Remarks Throttle body assembly Plastic band Coupler cover…
• Page 292
  THROTTLE BODY Disassembling the throttle body assembly Order Job/Parts to remove Q’ty Remarks Before disassembling the throttle body as- sembly, make sure to note the number of times the air screw is turned out from the seated position to its set position. Throttle position sensor Fast idle plunger Idling speed adjusting screw…
• Page 293
  THROTTLE BODY EAS26980 CHECKING THE INJECTORS 1. Check: • Injectors Damage → Replace. EAS26990 CHECKING THE THROTTLE BODY 1. Check: B/L Y • Throttle body Cracks/damage → Replace the throttle body. 2. Check: d. Measure the throttle position sensor output •…
• Page 294
  THROTTLE BODY…

• Page 295: Electrical System

  ELECTRICAL SYSTEM IGNITION SYSTEM ………………8-1 CIRCUIT DIAGRAM ……………… 8-1 TROUBLESHOOTING …………….8-3 ELECTRIC STARTING SYSTEM …………..8-5 CIRCUIT DIAGRAM ……………… 8-5 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ……8-7 TROUBLESHOOTING …………….8-9 CHARGING SYSTEM………………8-11 CIRCUIT DIAGRAM …………….8-11 TROUBLESHOOTING …………….8-13 LIGHTING SYSTEM ………………8-15 CIRCUIT DIAGRAM …………….

• Page 296
  ELECTRICAL COMPONENTS…………..8-57 CHECKING THE SWITCHES …………..8-61 CHECKING THE BULBS AND BULB SOCKETS ……..8-64 CHECKING THE FUSES …………….8-65 CHECKING AND CHARGING THE BATTERY……..8-66 CHECKING THE RELAYS …………..8-69 CHECKING THE TURN SIGNAL RELAY ……….8-70 CHECKING THE DIODE ……………..8-71 CHECKING THE SPARK PLUG CAPS………..8-71 CHECKING THE IGNITION COIL …………

• Page 298: Ignition System

  IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM…

• Page 299
  IGNITION SYSTEM 1. Crankshaft position sensor 4. Main switch 11.Ignition fuse 14.Battery 15.Main fuse 20.Engine stop switch 28.Sidestand switch 29.ECU (engine control unit) 30.Ignition coil 31.Spark plug 39.Lean angle sensor…

• Page 300: Troubleshooting

  IGNITION SYSTEM EAS27140 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Footrest boards 2. Front cowling assembly NG → 1. Check the fuses. (Main and ignition) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”…

• Page 301
  IGNITION SYSTEM NG → 9. Check the engine stop switch. The engine stop switch is faulty. Replace Refer to “CHECKING THE the right handlebar switch. SWITCHES” on page 8-61. OK ↓ NG → 10.Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch.

• Page 302: Electric Starting System

  ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM…

• Page 303
  ELECTRIC STARTING SYSTEM 4. Main switch 9. Signaling system fuse 11.Ignition fuse 14.Battery 15.Main fuse 16.Starter relay 17.Starter motor 18.Diode 1 20.Engine stop switch 21.Start switch 22.Front brake light switch 23.Diode 2 24.Starting circuit cut-off relay 28.Sidestand switch 57.Rear brake light switch…

• Page 304: Starting Circuit Cut-Off System Operation

  ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •…

• Page 305
  ELECTRIC STARTING SYSTEM 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6. Diode 2 7. Starting circuit cut-off relay 8. Sidestand switch 9. Signaling system fuse 10. Front brake light switch 11. Rear brake light switch 12.

• Page 306: Troubleshooting

  ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Storage box 3. Fuel tank NG → 1. Check the fuses. (Main, ignition and signaling sys- tem) Replace the fuse(s).

• Page 307
  ELECTRIC STARTING SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 8-61. OK ↓ NG → 9. Check the engine stop switch. The engine stop switch is faulty. Replace Refer to “CHECKING THE the right handlebar switch.

• Page 308: Charging System

  CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-11…

• Page 309
  CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 14.Battery 15.Main fuse 8-12…

• Page 310: Troubleshooting

  CHARGING SYSTEM EAS27220 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUS- ES” on page 8-65. OK ↓…

• Page 311
  CHARGING SYSTEM 8-14…

• Page 312: Lighting System

  LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 8-15…

• Page 313
  LIGHTING SYSTEM 4. Main switch 5. Storage box light switch 6. Storage box light 8. Backup fuse (odometer and clock) 10.Headlight fuse 13.Taillight fuse 14.Battery 15.Main fuse 29.ECU (engine control unit) 47.License plate light 51.Tail/brake light 54.Dimmer switch 59.Front right turn signal/position light 60.Front left turn signal/position light 61.Headlight relay 62.Headlight (high beam)

• Page 314: Troubleshooting

  LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license plate light, position lights, or meter light. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Mudguard NG → 1.

• Page 315
  LIGHTING SYSTEM NG → 8. Check the entire lighting system wiring. Properly connect or repair the lighting sys- Refer to “CIRCUIT DIAGRAM” on tem wiring. page 8-15. OK ↓ Replace the ECU (engine control unit) or meter assembly. 8-18…

• Page 316: Signaling System

  SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-19…

• Page 317
  SIGNALING SYSTEM 4. Main switch 8. Backup fuse (odometer and clock) 9. Signaling system fuse 11.Ignition fuse 13.Taillight fuse 14.Battery 15.Main fuse 22.Front brake light switch 27.Fuel sender 29.ECU (engine control unit) 40.Speed sensor 49.Rear left turn signal light 50.Rear right turn signal light 51.Tail/brake light 52.Turn signal relay 55.Horn switch…

• Page 318: Troubleshooting

  SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. • The fuel meter fails to operate. • The speedometer fails to operate. •…

• Page 319
  SIGNALING SYSTEM NG → 3. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring. page 8-19. OK ↓ This circuit is OK. The tail/brake light fails to come on. NG → 1.
• Page 320
  SIGNALING SYSTEM NG → 3. Check the turn signal relay. Refer to “CHECKING THE TURN Replace the turn signal relay. SIGNAL RELAY” on page 8-70. OK ↓ NG → 4. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM”…
• Page 321
  SIGNALING SYSTEM 8-24…

• Page 322: Cooling System

  COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-25…

• Page 323
  COOLING SYSTEM 4. Main switch 11.Ignition fuse 12.Radiator fan fuse 14.Battery 15.Main fuse 29.ECU (engine control unit) 34.Coolant temperature sensor 45.Radiator fan motor relay 46.Radiator fan motor 65.Multi-function meter 66.Coolant temperature meter 8-26…

• Page 324: Troubleshooting

  COOLING SYSTEM EAS27320 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Storage box 3. Fuel tank NG → 1. Check the fuses. (Main, ignition and radiator fan) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”…

• Page 325
  COOLING SYSTEM 8-28…

• Page 326: Fuel Injection System

  FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-29…

• Page 327
  FUEL INJECTION SYSTEM 1. Crankshaft position sensor 4. Main switch 7. Fuel injection system fuse 9. Signaling system fuse 10.Headlight fuse 11.Ignition fuse 14.Battery 15.Main fuse 20.Engine stop switch 23.Diode 2 24.Starting circuit cut-off relay 25.Fuel injection system relay 28.Sidestand switch 29.ECU (engine control unit) 30.Ignition coil 31.Spark plug…

• Page 328: Ecu Self-Diagnostic Function

  FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU (engine control unit) is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

• Page 329: Self-Diagnostic Function Table

  FUEL INJECTION SYSTEM a. Main switch “OFF” d. Engine trouble warning light on for 1.4 seconds b. Main switch “ON” c. Engine trouble warning light off EAS4B51034 SELF-DIAGNOSTIC FUNCTION TABLE If the ECU (engine control unit) detects an abnormal signal from a sensor while the vehicle is being driv- en, the ECU (engine control unit) illuminates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction.

• Page 330
  FUEL INJECTION SYSTEM Able / un- Fault Able / un- Item Symptom able to code No. able to start drive Coolant temperature Coolant temperature sensor-open Able Able sensor or short circuit detected. Intake air tempera- Intake air temperature sensor- Able Able ture sensor open or short circuit detected.

• Page 331: Troubleshooting Method

  FUEL INJECTION SYSTEM Able / un- Fault Able / un- Item Symptom able to code No. able to start drive ECU (engine control unit) internal malfunc- Non-registered data has been re- Er-4 Unable Unable tion ceived from the meter. (input signal error) EAS27400 5.

• Page 332: Diagnostic Mode

  FUEL INJECTION SYSTEM EAS27431 DIAGNOSTIC MODE Setting the diagnostic mode 1. Turn the main switch to “OFF” and set the engine stop switch to “ ”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the “SELECT” and “RESET” buttons, turn the main switch to “ON”, and continue to press the buttons for 8 seconds or more.

• Page 333
  FUEL INJECTION SYSTEM 8. Turn the main switch to “OFF” to cancel the diagnostic mode. Diagnostic code table Fault Diagnostic code Symptom Probable cause of malfunction code No. • Open or short circuit in wire harness. No normal signals are re- •…
• Page 334
  FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Stuck fast idle plunger (in fully open posi- Engine speed is high when tion). the engine is idling. • Malfunction in ECU (engine control unit). • Open or short circuit in wire harness. Lean angle sensor: open or •…
• Page 335
  FUEL INJECTION SYSTEM Sensor operation table Diag- nostic Item Meter display Checking method code Throttle angle • Fully closed position (15–16) Check with throttle fully closed. • Fully opened position (97–102) Check with throttle fully open. Pressure difference Displays the intake air pres- Set the engine stop switch (atmospheric pressure and sure.
• Page 336
  FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Malfunction history code — display • No history • History exists Fault codes 12–50 • (If more than one code number is detected, the dis- play alternates every two seconds to show all the de- tected code numbers.

• Page 337: Troubleshooting Details

  FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Actuates the fuel injection system relay five times at one-second intervals. Illuminates the engine trou- Check the operating sound ble warning light. Fuel injection system relay of the fuel injection system (The engine trouble warning relay five times.

• Page 338
  FUEL INJECTION SYSTEM Fault code No. Symptom No normal signals are received from the crankshaft posi- tion sensor. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of crankshaft posi- Check the installed area for Cranking the tion sensor.
• Page 339
  FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor: open or short circuit detected. Diagnostic code No. Intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Cranking the •…
• Page 340
  FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor: hose system malfunction (clogged or detached hose). Diagnostic code No. Intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Intake air pressure sensor hose •…
• Page 341
  FUEL INJECTION SYSTEM Fault code No. Symptom Throttle position sensor: open or short circuit detected. Diagnostic code No. Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of throttle position • Check for looseness or pinch- Turning the sensor.
• Page 342
  FUEL INJECTION SYSTEM Fault code No. Symptom Stuck throttle position sensor detected. Diagnostic code No. Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of throttle position • Check for looseness or pinch- Reinstated by sensor.
• Page 343
  FUEL INJECTION SYSTEM Fault code No. Symptom Coolant temperature sensor: open or short circuit detect- Diagnostic code No. Coolant temperature sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of coolant tempera- Check for looseness or pinching. Turning the ture sensor.
• Page 344
  FUEL INJECTION SYSTEM Fault code No. Symptom Intake air temperature sensor: open or short circuit de- tected. Diagnostic code No. Intake air temperature sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of intake air tem- Check for looseness or pinching.
• Page 345
  FUEL INJECTION SYSTEM Fault code No. Symptom No normal signal is received from the O sensor. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of O sensor. Check for looseness or pinching. Starting and warming up the Connections •…
• Page 346
  FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the ignition coil. Diagnostic code No. Ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Starting the en- •…
• Page 347
  FUEL INJECTION SYSTEM Fault code No. Symptom Lean angle sensor: open or short circuit detected. Diagnostic code No. Lean angle sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Reinstated im- •…
• Page 348
  FUEL INJECTION SYSTEM Fault code No. Symptom The ECU (engine control unit) is unable to monitor the battery voltage (an open or short circuit in the line to the ECU). Diagnostic code No. Fuel injection system relay Order Item/components and probable Check or maintenance job Reinstatement cause…
• Page 349
  FUEL INJECTION SYSTEM Fault code No. Symptom Power supply to the fuel injection system is not normal. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connection. • Check the coupler for any pins Starting the en- •…

• Page 350: Fuel Pump System

  FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 8-53…

• Page 351
  FUEL PUMP SYSTEM 4. Main switch 7. Fuel injection system fuse 11.Ignition fuse 14.Battery 15.Main fuse 20.Engine stop switch 25.Fuel injection system relay 26.Fuel pump 29.ECU (engine control unit) 8-54…

• Page 352: Troubleshooting

  FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Storage box NG → 1. Check the fuses. (Main, ignition and fuel injection system) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”…

• Page 353
  FUEL PUMP SYSTEM 8-56…

• Page 354: Electrical Components

  ELECTRICAL COMPONENTS EAS27971 ELECTRICAL COMPONENTS 8-57…

• Page 355
  ELECTRICAL COMPONENTS 1. Front brake light switch 2. Rear brake light switch 3. Battery 4. Main fuse 5. Starter relay 6. Diode 2 7. Diode 1 8. Rectifier/regulator 9. Ignition coil 10.Speed sensor 11.Turn signal relay 12.Horn 13.ECU (electronic control unit) 14.Lean angle sensor 15.Starting circuit cut-off relay 16.Headlight relay…
• Page 356
  ELECTRICAL COMPONENTS 8-59…
• Page 357
  ELECTRICAL COMPONENTS 1. Main switch 2. Intake air temperature sensor 3. Throttle position sensor 4. Intake air pressure sensor 5. Coolant temperature sensor 6. Fuel pump 7. O sensor 8. Crankshaft position sensor 9. Stator coil 10.Sidestand switch 11.Radiator fan 8-60…

• Page 358: Checking The Switches

  ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES B/Y B/W Br/W Y Br/W Ch Dg Br B/Y L/B L/Y B (BLACK) B L/W R/W R/B R/W L/W R Br/L L/G L/B R L/G ( BLUE ) Br/L 8-61…

• Page 359
  ELECTRICAL COMPONENTS 1. Dimmer switch 2. Horn switch 3. Turn signal switch 4. Rear brake light switch 5. Engine stop switch 6. Start switch 7. Front brake light switch 8. Main switch 9. Sidestand switch 10. Storage box light switch 8-62…
• Page 360
  ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 NOTICE Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.

• Page 361: Checking The Bulbs And Bulb Sockets

  ELECTRICAL COMPONENTS 1. Remove: EAS27990 CHECKING THE BULBS AND BULB • Bulb SOCKETS EWA4B51012 WARNING Do not check any of the lights that use LEDs. Since the headlight bulbs get extremely hot, keep flammable products and your hands Check each bulb and bulb socket for damage or away from them until they have cooled wear, proper connections, and also for continuity down.

• Page 362: Checking The Fuses

  ELECTRICAL COMPONENTS Set the pocket tester selector to “Ω × 1”. Pocket tester 90890-03112 Analog pocket tester YU-03112-C b. If the pocket tester indicates “∞”, replace the fuse. L LLL L LLL L LLL L LLL L LLL Checking the condition of the bulb sockets 3.

• Page 363: Checking And Charging The Battery

  ELECTRICAL COMPONENTS 4. Install: • Battery cover Since VRLA (Valve Regulated Lead Acid) bat- Refer to “GENERAL CHASSIS” on page 4-1. teries are sealed, it is not possible to check the charge state of the battery by measuring the EAS28030 CHECKING AND CHARGING THE BATTERY specific gravity of the electrolyte.

• Page 364
  ELECTRICAL COMPONENTS • When charging a battery, be sure to remove Example it from the vehicle. (If charging has to be Open-circuit voltage = 12.0 V done with the battery mounted on the vehi- Charging time = 6.5 hours Charge of the battery = 20–30% cle, disconnect the negative battery lead from the battery terminal.) •…
• Page 365
  ELECTRICAL COMPONENTS c. Make sure that the current is higher than the standard charging current written on the bat- Voltage should be measured 30 minutes after tery. the engine is turned off. b. Connect a charger and ammeter to the bat- If the current is lower than the standard charging tery and start charging.

• Page 366: Checking The Relays

  ELECTRICAL COMPONENTS • Battery cover 4. Negative tester probe Refer to “GENERAL CHASSIS” on page 4-1. Result EAS28040 Continuity CHECKING THE RELAYS (between “3” and “4”) Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, re- place the relay.

• Page 367: Checking The Turn Signal Relay

  ELECTRICAL COMPONENTS Fuel injection system relay M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester (DC 20 V) to the turn signal relay terminal as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C L/ R •…

• Page 368: Checking The Diode

  ELECTRICAL COMPONENTS c. Check the diode 1 for continuity. d. Check the diode 1 for no continuity. L LLL L LLL L LLL L LLL L LLL EAS28070 CHECKING THE SPARK PLUG CAPS The following procedure applies to all of the spark plug caps.

• Page 369: Checking The Ignition Spark Gap

  ELECTRICAL COMPONENTS c. Measure the secondary coil resistance. Pocket tester L LLL L LLL L LLL L LLL L LLL 90890-03112 EAS28930 Analog pocket tester CHECKING THE IGNITION SPARK GAP YU-03112-C 1. Check: • Ignition spark gap • Positive tester probe→ Out of specification →…

• Page 370: Checking The Lean Angle Sensor

  ELECTRICAL COMPONENTS 2. Check: Pocket tester • Crankshaft position sensor resistance 90890-03112 Out of specification → Replace the crank- Analog pocket tester shaft position sensor/stator assembly. YU-03112-C Crankshaft position sensor resis- • Positive tester probe → tance 189–231 Ω at 20 °C (68 °F) yellow/green “1”…

• Page 371: Checking The Stator Coil

  ELECTRICAL COMPONENTS b. Check the starter motor operation. b. Measure the stator coil resistance. L LLL L LLL L LLL L LLL L LLL L LLL L LLL L LLL L LLL L LLL EAS28150 EAS28170 CHECKING THE STATOR COIL CHECKING THE RECTIFIER/REGULATOR 1.

• Page 372: Checking The Horn

  ELECTRICAL COMPONENTS EAS28180 EAS28230 CHECKING THE HORN CHECKING THE FUEL SENDER 1. Check: 1. Disconnect: • Horn resistance • Fuel pump coupler Out of specification → Replace. • Fuel hose (from the fuel pump) Coil resistance Refer to “GENERAL CHASSIS” on page 4-1. 1.06–1.11 Ω…

• Page 373: Checking The Speed Sensor

  ELECTRICAL COMPONENTS c. Elevate the front wheel and slowly rotate it. d. Measure the voltage of white and black/blue. With each full rotation of the front wheel, the voltage reading should cycle from 0 V to 5.0 V to 0 V to 5.0 V. L LLL L LLL L LLL…

• Page 374: Checking The Throttle Position Sensor

  ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester (Ω × 100) to the Pocket tester 90890-03112 coolant temperature sensor terminals as Analog pocket tester shown. YU-03112-C Pocket tester • Tester positive lead → 90890-03112 Analog pocket tester blue “1”…

• Page 375: Checking The Intake Air Temperature Sensor

  ELECTRICAL COMPONENTS • Positive tester probe → blue “1” • Negative tester probe → pink/white “2” B/L P/W L b. Measure the intake air temperature sensor resistance. L LLL L LLL L LLL L LLL L LLL b. Turn the main switch to “ON”. c.

• Page 376
  ELECTRICAL COMPONENTS 8-79…

• Page 377: Troubleshooting

  TROUBLESHOOTING TROUBLESHOOTING………………9-1 GENERAL INFORMATION …………… 9-1 STARTING FAILURE/HARD STARTING……….9-1 INCORRECT ENGINE IDLING SPEED ………… 9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ……9-2 FAULTY CLUTCH ………………9-2 OVERHEATING ………………9-2 OVERCOOLING………………9-3 POOR BRAKING PERFORMANCE…………9-3 FAULTY FRONT FORK LEGS…………..9-3 UNSTABLE HANDLING …………….9-3 FAULTY LIGHTING OR SIGNALING SYSTEM ……..9-4…

• Page 378: Troubleshooting

  TROUBLESHOOTING • Sucked-in air EAS28450 TROUBLESHOOTING Electrical system EAS28460 1. Battery GENERAL INFORMATION • Discharged battery • Faulty battery The following guide for troubleshooting does not 2. Fuse(s) cover all the possible causes of trouble. It should • Blown, damaged or incorrect fuse be helpful, however, as a guide to basic trouble- •…

• Page 379: Poor Medium-And-High-Speed Performance

  TROUBLESHOOTING • Improper throttle cable free play 2. Engine oil • Flooded throttle body • Incorrect oil level • Incorrect oil viscosity (low) Electrical system • Deteriorated oil 1. Battery 3. Primary sliding sheave • Discharged battery • Seized primary sliding sheave •…

• Page 380: Overcooling

  TROUBLESHOOTING • Thermostat • Damaged oil seal lip • Thermostat stays closed • Incorrect oil level (high) • Oil cooler • Loose damper rod bolt • Clogged or damaged oil cooler • Damaged damper rod bolt copper washer • Hose(s) and pipe(s) •…

• Page 381: Faulty Lighting Or Signaling System

  TROUBLESHOOTING Turn signal flashes quickly EAS28710 FAULTY LIGHTING OR SIGNALING SYSTEM • Incorrect turn signal bulb • Faulty turn signal relay Headlight does not come on • Burnt-out turn signal bulb • Wrong headlight bulb • Too many electrical accessories Horn does not sound •…

• Page 382: Wiring Diagram

  EAS28740 57. Rear brake light switch EAS28750 WIRING DIAGRAM COLOR CODE 58. Horn Black 59. Front right turn signal/position XP500Y 2009 Brown light 1. Crankshaft position sensor Chocolate 60. Front left turn signal/position 2. AC magneto Dark green light 3. Rectifier/regulator Green 61.

• Page 384
  YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN…
• Page 385
  XP500Y 2009 WIRING DIAGRAM HEADLIGHT HEADLIGHT GRIP WARMER STORAGE BOX WIRE HARNESS SUB-WIRE WIRE HARNESS SUB-WIRE WIRE HARNESS SUB-WIRE WIRE HARNESS LIGHT SUB-WIRE HARNESS HARNESS HARNESS HARNESS W/Y Y/R L/Y B/L P/W Br/W G/R R/B R/W B/W B/Y W Gy/G Y/G Y/L (BLACK) W W W W W W…
• Page 386
  XP500Y 2009 WIRING DIAGRAM HEADLIGHT HEADLIGHT GRIP WARMER STORAGE BOX WIRE HARNESS SUB-WIRE WIRE HARNESS SUB-WIRE WIRE HARNESS SUB-WIRE WIRE HARNESS LIGHT SUB-WIRE HARNESS HARNESS HARNESS HARNESS (BLACK) (BLACK) (GREEN) (BLACK) (GREEN) ( GREEN ) ( GREEN ) (DARK BLUE) ( BLACK ) ( BLUE ) ( BLACK )

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