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2017
SERVICE MANUAL
GDR155/GDR155-A
B63-F8197-EZ
B63-F8197-EZ.book Page 1 Monday, January 23, 2017 4:12 PM
EAS20003
IMPORTANT
This manual was produced by the Yamaha Motor Vietnam Co.,Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-
cle unsafe and unfit for use.
Yamaha Motor Vietnam Co.,Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers
and will appear in future editions of this manual where applicable.
TIP
Designs and specifications are subject to change without notice.
EAS30001
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations.
EAS20002
This is the safety alert symbol. It is used to alert you to potential personal inju-
ry hazards. Obey all safety messages that follow this symbol to avoid possible
injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could result
in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid damage to
the vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
NVX
SERVICE MANUAL
©2016 by Yamaha Motor Vietnam Co.,Ltd.
1st edition, December 2016
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Vietnam Co.,Ltd.
is expressly prohibited.
WARNING
NOTICE
TIP
B63-F8197-EZ.book Page 1 Monday, January 23, 2017 4:12 PM
EAS20004
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc. This step explains removal and disassembly procedure only. For installation
and assembly procedure, reverse the steps.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
1
7
3
5
6
2
4
B63-F8197-EZ.book Page 2 Monday, January 23, 2017 4:12 PM
EAS20005
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
Serviceable with engine mounted Gear oil
Filling fluid Molybdenum disulfide oil
Lubricant Brake fluid
Special tool Wheel bearing grease
Tightening torque Lithium-soap-based grease
Wear limit, clearance Molybdenum disulfide grease
Engine speed Silicone grease
Electrical data Apply locking agent (LOCTITE®).
Engine oil Replace the part with a new one.
Silicone fluid
G
M
BF
B
T
R
.
.
LS
M
S
LT
E
New
S
B63-F8197-EZ.book Page 3 Monday, January 23, 2017 4:12 PM
B63-F8197-EZ.book Page 2 Monday, January 23, 2017 4:12 PM
1
GENERAL INFORMATION
IDENTIFICATION ............................................................................................ 1-1
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
ENGINE SERIAL NUMBER ......................................................................1-1
IMPORTANT INFORMATION ......................................................................... 1-2
PREPARATION FOR REMOVAL AND DISASSEMBLY...........................1-2
REPLACEMENT PARTS...........................................................................1-2
GASKETS, OIL SEALS AND O-RINGS ....................................................1-2
LOCK WASHERS/PLATES AND COTTER PINS .....................................1-2
BEARINGS AND OIL SEALS ....................................................................1-3
CIRCLIPS .................................................................................................. 1-3
RUBBER PARTS.......................................................................................1-3
BASIC SERVICE INFORMATION................................................................... 1-4
QUICK FASTENERS.................................................................................1-4
ELECTRICAL SYSTEM.............................................................................1-5
SPECIAL TOOLS ..........................................................................................1-10
B63-F8197-EZ.book Page 1 Monday, January 23, 2017 4:12 PM
IDENTIFICATION
1-1
EAS20007
IDENTIFICATION
EAS30002
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1” is stamped
into the frame.
EAS30004
ENGINE SERIAL NUMBER
The engine serial number “1” is stamped into the
crankcase.
1
1
B63-F8197-EZ.book Page 1 Monday, January 23, 2017 4:12 PM
IMPORTANT INFORMATION
1-2
EAS20009
IMPORTANT INFORMATION
EAS30006
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning equip-
ment.
Refer to “SPECIAL TOOLS” on page 1-10.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders,
pistons and other parts that have been “mat-
ed” through normal wear. Mated parts must
always be reused or replaced as an assem-
bly.
4. During disassembly, clean all of the parts and
place them in trays in the order of disassem-
bly. This will speed up assembly and allow for
the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS30007
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
inferior in quality.
EAS30008
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfac-
es, oil seal lips and O-rings must be cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.
EAS30009
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
“1” and cotter pins. After the bolt or nut has been
tightened to specification, bend the lock tabs
along a flat of the bolt or nut.
1. Oil
2. Lip
3. Spring
4. Grease
B63-F8197-EZ.book Page 2 Monday, January 23, 2017 4:12 PM
IMPORTANT INFORMATION
1-3
EAS30010
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.
NOTICE
ECA13300
Do not spin the bearing with compressed air
because this will damage the bearing surfac-
es.
EAS30011
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al-
ways replace piston pin clips after one use.
When installing a circlip “1”, make sure the
sharp-edged corner “2” is positioned opposite
the thrust “3” that the circlip receives.
EAS30012
RUBBER PARTS
Check rubber parts for deterioration during in-
spection. Some of the rubber parts are sensitive
to gasoline, flammable oil, grease, etc. Do not al-
low any items other than the specified one to
contact the parts.
B63-F8197-EZ.book Page 3 Monday, January 23, 2017 4:12 PM
BASIC SERVICE INFORMATION
1-4
EAS20010
BASIC SERVICE INFORMATION
EAS30013
QUICK FASTENERS
Rivet type
1. Remove:
• Quick fastener
TIP
To remove the quick fastener, push its pin with a
screwdriver, then pull the fastener out.
2. Install:
• Quick fastener
TIP
To install the quick fastener, push its pin so that
it protrudes from the fastener head, then insert
the fastener into the part to be secured and push
the pin in with a screwdriver. Make sure that the
pin is flush with the fastener’s head.
Screw type
1. Remove:
• Quick fastener
TIP
To remove the quick fastener, loosen the screw
with a screwdriver, then pull the fastener out.
2. Install:
• Quick fastener
TIP
To install the quick fastener, insert the fastener
into the part to be secured and tighten the screw.
B63-F8197-EZ.book Page 4 Monday, January 23, 2017 4:12 PM
BASIC SERVICE INFORMATION
1-5
EAS30014
ELECTRICAL SYSTEM
Electrical parts handling
NOTICE
ECA16600
Never disconnect a battery lead while the en-
gine is running; otherwise, the electrical
components could be damaged.
NOTICE
ECA16751
When disconnecting the battery leads from
the battery, be sure to disconnect the nega-
tive battery lead first, then the positive bat-
tery lead. If the positive battery lead is
disconnected first and a tool or similar item
contacts the vehicle, a spark could be gener-
ated, which is extremely dangerous.
TIP
If a battery lead is difficult to disconnect due to
rust on the battery terminal, remove the rust us-
ing hot water.
NOTICE
ECA16760
Be sure to connect the battery leads to the
correct battery terminals. Reversing the bat-
tery lead connections could damage the
electrical components.
NOTICE
ECA16771
When connecting the battery leads to the
battery, be sure to connect the positive bat-
tery lead first, then the negative battery lead.
If the negative battery lead is connected first
and a tool or similar item contacts the vehi-
cle while the positive battery lead is being
connected, a spark could be generated,
which is extremely dangerous.
NOTICE
ECA16610
Turn the main switch to “OFF” before dis-
connecting or connecting an electrical com-
ponent.
B63-F8197-EZ.book Page 5 Monday, January 23, 2017 4:12 PM
BASIC SERVICE INFORMATION
1-6
NOTICE
ECA16620
Handle electrical components with special
care, and do not subject them to strong
shocks.
NOTICE
ECA16630
Electrical components are very sensitive to
and can be damaged by static electricity.
Therefore, never touch the terminals and be
sure to keep the contacts clean.
TIP
When resetting the ECU by turning the main
switch to “OFF”, be sure to wait approximately 5
seconds before turning the main switch back to
“ON”.
Checking the electrical system
TIP
Before checking the electrical system, make
sure that the battery voltage is at least 12 V.
NOTICE
ECA14371
Never insert the tester probes into the cou-
pler terminal slots. Always insert the probes
from the opposite end “a” of the coupler, tak-
ing care not to loosen or damage the leads.
NOTICE
ECA16640
For waterproof couplers, never insert the
tester probes directly into the coupler. When
performing any checks using a waterproof
coupler, use the specified test harness or a
suitable commercially available test har-
ness.
a
B63-F8197-EZ.book Page 6 Monday, January 23, 2017 4:12 PM
BASIC SERVICE INFORMATION
1-7
Checking the connections
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
• Lead
• Coupler
• Connector
NOTICE
ECA16780
• When disconnecting a coupler, release the
coupler lock, hold both sections of the cou-
pler securely, and then disconnect the cou-
pler.
• There are many types of coupler locks;
therefore, be sure to check the type of cou-
pler lock before disconnecting the coupler.
NOTICE
ECA16790
When disconnecting a connector, do not pull
the leads. Hold both sections of the connec-
tor securely, and then disconnect the con-
nector.
2. Check:
• Lead
• Coupler
• Connector
Moisture Dry with an air blower.
Rust/stains Connect and disconnect sev-
eral times.
3. Check:
• All connections
Loose connection Connect properly.
TIP
• If the pin “1” on the terminal is flattened, bend
it up.
• After disassembling and assembling a coupler,
pull on the leads to make sure that they are in-
stalled securely.
1
B63-F8197-EZ.book Page 7 Monday, January 23, 2017 4:12 PM
BASIC SERVICE INFORMATION
1-8
4. Connect:
• Lead
• Coupler
• Connector
TIP
• When connecting a coupler or connector, push
both sections of the coupler or connector to-
gether until they are connected securely.
• Make sure all connections are tight.
5. Check:
• Continuity
(with the pocket tester)
TIP
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (3).
• As a quick remedy, use a contact revitalizer
available at most part stores.
6. Check:
• Resistance
TIP
The resistance values shown were obtained at
the standard measuring temperature of 20 °C
(68 °F). If the measuring temperature is not 20
°C (68 °F), the specified measuring conditions
will be shown.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Coolant temperature sensor re-
sistance
2512-2777 at 20 °C (2512-2777
at 68 °F)
Coolant temperature sensor re-
sistance
210–221 at 100 °C (210–221
at 212 °F)
B63-F8197-EZ.book Page 8 Monday, January 23, 2017 4:12 PM
BASIC SERVICE INFORMATION
1-9
B63-F8197-EZ.book Page 9 Monday, January 23, 2017 4:12 PM
SPECIAL TOOLS
1-10
EAS20012
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
TIP
• For U.S.A. and Canada, use part numbers starting with “YM-”, “YU-”, or “ACC-”.
• For others, use part numbers starting with “90890-”.
Tool name/Tool No. Illustration
Reference
pages
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
1-8, 1-8, 8-97,
8-98, 8-98, 8-99,
8-102, 8-103,
8-103, 8-103,
8-104, 8-104,
8-105, 8-105,
8-106, 8-107,
8-108, 8-108
Tappet adjusting tool
90890-01311
Six piece tappet set
YM-A5970
3-7
Yamaha diagnostic tool USB
90890-03250
3-7, 3-8, 4-51,
4-55, 7-14, 7-14,
8-28, 8-69, 8-90
Yamaha diagnostic tool (A/I)
90890-03252
3-7, 3-8, 4-51,
4-55, 7-14, 7-14,
8-28, 8-69, 8-90
Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472
3-14, 3-15, 4-69
Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9
4-26
ø9ø8 ø10
ø3 ø4
YM-A5970
B63-F8197-EZ.book Page 10 Monday, January 23, 2017 4:12 PM
SPECIAL TOOLS
1-11
T-handle
90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
4-63, 4-64
Fork seal driver weight
90890-01367
Replacement hammer
YM-A9409-7
4-64, 4-65
Fork seal driver attachment (ø30)
90890-01400
4-64, 4-65
Compression gauge
90890-03081
Engine compression tester
YU-33223
5-1
Extension
90890-04136
5-1
Camshaft wrench
90890-04162
Camshaft wrench
YM-04162
5-13, 5-17
Yamaha bond No. 1215
90890-85505
(Three bond No.1215®)
5-16, 5-55
Tool name/Tool No. Illustration
Reference
pages
YM-A9409-7/YM-A5142-4
90890-03081
YU-33223
B63-F8197-EZ.book Page 11 Monday, January 23, 2017 4:12 PM
SPECIAL TOOLS
1-12
Slide hammer bolt
90890-01085
Slide hammer bolt 8 mm
YU-01083-2
5-19
Weight
90890-01084
Weight
YU-01083-3
5-19
Valve spring compressor
90890-04019
Valve spring compressor
YM-04019
5-23, 5-28
Valve spring compressor attachment
90890-04108
Valve spring compressor adapter 22 mm
YM-04108
5-23, 5-28
Valve guide remover (ø5)
90890-04097
Valve guide remover (5.0 mm)
YM-04097
5-24
Valve guide installer (ø5)
90890-04098
Valve guide installer (5.0 mm)
YM-04098
5-24
Valve guide reamer (ø5)
90890-04099
Valve guide reamer (5.0 mm)
YM-04099
5-24
Tool name/Tool No. Illustration
Reference
pages
YU-01083-3
B63-F8197-EZ.book Page 12 Monday, January 23, 2017 4:12 PM
SPECIAL TOOLS
1-13
Piston pin puller set
90890-01304
Piston pin puller
YU-01304
5-30
Rotor holding tool
90890-01235
Universal magneto and rotor holder
YU-01235
5-37, 5-42, 5-44,
5-44
Rotor holding tool
90890-01701
5-37, 5-41
Socket wrench (39 mm)
90890-01493
5-37, 5-41
Sheave spring compressor
90890-04134
Sheave spring compressor
YM-04134
5-37, 5-40
Tool name/Tool No. Illustration
Reference
pages
YU-01304
B63-F8197-EZ.book Page 13 Monday, January 23, 2017 4:12 PM
SPECIAL TOOLS
1-14
Sheave fixed block
90890-04135
Sheave fixed bracket
YM-04135
5-37, 5-40
Oil seal guide (37 mm)
90890-04177
5-40
Flywheel puller
90890-01189
Flywheel puller
YM-01189
5-44
Digital circuit tester
90890-03174
Model 88 Multimeter with tachometer
YU-A1927
5-51, 8-106,
8-109
Crankcase separating tool
90890-01135
Crankcase separator
YU-01135-B
5-53
Tool name/Tool No. Illustration
Reference
pages
ø37
B63-F8197-EZ.book Page 14 Monday, January 23, 2017 4:12 PM
SPECIAL TOOLS
1-15
Crankshaft installer pot
90890-01274
Installing pot
YU-90058
5-54
Crankshaft installer bolt
90890-01275
Bolt
YU-90060
5-54
Adapter (M12)
90890-01278
Adapter #3
YU-90063
5-54
Spacer (crankshaft installer)
90890-04081
Pot spacer
YM-91044
5-54
Radiator cap tester
90890-05375
6-3, 6-3
Mechanical seal installer
90890-04145
6-8
Middle driven shaft bearing driver
90890-04058
Middle drive bearing installer 40 & 50 mm
YM-04058
6-8
Tool name/Tool No. Illustration
Reference
pages
YU-90058/YU-90059
YM-91044
ø10
ø30
B63-F8197-EZ.book Page 15 Monday, January 23, 2017 4:12 PM
SPECIAL TOOLS
1-17
B63-F8197-EZ.book Page 17 Monday, January 23, 2017 4:12 PM
2
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................2-1
ENGINE SPECIFICATIONS ............................................................................2-2
CHASSIS SPECIFICATIONS..........................................................................2-6
ELECTRICAL SPECIFICATIONS ...................................................................2-8
TIGHTENING TORQUES ..............................................................................2-10
GENERAL TIGHTENING TORQUE SPECIFICATIONS.........................2-10
ENGINE TIGHTENING TORQUES ......................................................... 2-11
CHASSIS TIGHTENING TORQUES.......................................................2-13
LUBRICATION POINTS AND LUBRICANT TYPES ....................................2-15
ENGINE...................................................................................................2-15
LUBRICATION SYSTEM CHART AND DIAGRAMS....................................2-16
ENGINE OIL LUBRICATION CHART .....................................................2-16
LUBRICATION DIAGRAMS ....................................................................2-17
COOLING SYSTEM DIAGRAMS..................................................................2-19
CABLE ROUTING .........................................................................................2-20
B63-F8197-EZ.book Page 1 Monday, January 23, 2017 4:12 PM
GENERAL SPECIFICATIONS
2-1
EAS20013
GENERAL SPECIFICATIONS
Model
Model B631/B633
Dimensions
Overall length 1990 mm (78.3 in)
Overall width 700 mm (27.5 in)
Overall height 1125 mm (44.3 in)
Seat height 790 mm (31.1 in)
Wheelbase 1350 mm (53.1 in)
Ground clearance 140 mm (5.50 in)
Minimum turning radius 2.0 m
Weight
Curb weight 116 kg (255 lb) (GDR155)
118 kg (260 lb) (GDR155-A)
Maximum load 154 kg (339 lb) (GDR155)
153 kg (336 lb) (GDR155-A)
B63-F8197-EZ.book Page 1 Monday, January 23, 2017 4:12 PM
ENGINE SPECIFICATIONS
2-2
EAS20014
ENGINE SPECIFICATIONS
Engine
Engine type Liquid cooled 4-stroke, SOHC
Displacement 155 cm³
Cylinder arrangement Single cylinder
Bore stroke 58.0 58.7 mm (2.28 2.31 in)
Compression ratio 10.5 : 1
Compression pressure 1374–1769 kPa/1393 r/min
Starting system Electric starter
Fuel
Recommended fuel Regular unleaded gasoline (Gasohol [E10]
acceptable)
Fuel tank capacity 4.6 L (1.2 US gal, 1.1 lmp.gal)
Fuel reserve amount 0.8 L
Engine oil
Lubrication system Wet sump
Recommended brand YAMALUBE
Type SAE 10W-40
Recommended engine oil grade API service SG type or higher, JASO standard
MA or MB
Engine oil quantity
Quantity (disassembled) 1.00 L (1.06 US qt, 0.88 Imp.qt)
Periodic oil change 0.90 L (0.95 US qt, 0.79 Imp.qt)
Final transmission oil
Type Motor oil SAE 10W-30 type SE or higher or Gear
oil SAE 85W GL-3
Quantity (disassembled) 0.16 L (0.17 US qt, 0.14 Imp.qt)
Quantity 0.15 L (0.16 US qt, 0.13 Imp.qt)
Oil filter
Oil filter type Centrifugal
Oil pump
Inner-rotor-to-outer-rotor-tip clearance 0.150 mm (0.0059 in)
Limit 0.23 mm (0.0091 in)
Outer-rotor-to-oil-pump-housing clearance 0.13–0.18 mm (0.0051–0.0071 in)
Limit 0.22 mm (0.0086 in)
Oil-pump-housing-to-inner-and-outer-rotor
clearance 0.06–0.11 mm (0.0024–0.0043 in)
Limit 0.18 mm (0.0071 in)
Coolant quantity
Radiator (including all routes) 0.46 L (0.49 US qt, 0.40 Imp.qt)
Coolant reservoir (up to the maximum level mark) 0.13 L (0.13 US qt, 0.11 lmp.qt)
B63-F8197-EZ.book Page 2 Monday, January 23, 2017 4:12 PM
ENGINE SPECIFICATIONS
2-3
Radiator cap valve opening pressure 78.6–137.4 kPa (0.79–1.37 kgf/cm²,
11.4–19.9 psi)
Thermostat
Valve opening temperature 74.0–78.0 °C (165.20–172.40 °F)
Valve full open temperature 90.0 °C (194.00 °F)
Valve lift (full open) 7.0 mm (0.28 in)
Water pump
Water pump type Single suction centrifugal pump
Spark plug(s)
Manufacturer/model NGK/CPR8EA-9
DENSO/U24EPR-9
Spark plug gap 0.8–0.9 mm (0.031–0.035 in)
Cylinder head
Warpage limit 0.05 mm (0.0020 in)
Camshaft
Camshaft lobe dimensions
Lobe height (Intake) 32.211–32.311 mm (1.2681–1.2721 in)
Limit 32.111 mm (1.2642 in)
Lobe height (Intake high speed) 32.587–32.687 mm (1.2830–1.2869 in)
Limit (High speed) 32.487 mm (1.2790 in)
Lobe height (Exhaust) 29.420–29.520 mm (1.1583–1.1622 in)
Limit 29.320 mm (1.1543 in)
Camshaft runout limit 0.030 mm (0.0012 in)
Rocker arm/rocker arm shaft
Rocker arm inside diameter 9.985–10.000 mm (0.3931–0.3937 in)
Limit 10.015 mm (0.3943 in)
Rocker arm shaft outside diameter 9.966–9.976 mm (0.3924–0.3928 in)
Limit 9.935 mm (0.3911 in)
Valve, valve seat, valve guide
Valve clearance (cold)
Intake 0.10–0.14 mm (0.0039–0.0055 in)
Exhaust 0.21–0.25 mm (0.0083–0.0098 in)
Valve dimensions
Valve seat contact width (intake) 0.90–1.20 mm (0.0354–0.0472 in)
Limit 1.7 mm (0.068 in)
Valve seat contact width (exhaust) 0.90–1.20 mm (0.0354–0.0472 in)
Limit 1.7 mm (0.068 in)
B63-F8197-EZ.book Page 3 Monday, January 23, 2017 4:12 PM
ENGINE SPECIFICATIONS
2-4
Valve stem diameter (intake) 4.975–4.990 mm (0.1959–0.1965 in)
Limit 4.945 mm (0.1946 in)
Valve stem diameter (exhaust) 4.960–4.975 mm (0.1953–0.1959 in)
Limit 4.930 mm (0.1940 in)
Valve guide inside diameter (intake) 5.000–5.012 mm (0.1969–0.1973 in)
Valve guide inside diameter (exhaust) 5.000–5.012 mm (0.1969–0.1973 in)
Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in)
Limit 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in)
Limit 0.100 mm (0.0039 in)
Valve stem runout 0.010 mm (0.0004 in)
Valve spring
Free length (intake) 33.81 mm (1.33 in)
Limit 32.11 mm (1.26 in)
Free length (exhaust) 33.81 mm (1.33 in)
Limit 32.11 mm (1.26 in)
Spring tilt (intake) 1.7 mm (0.068 in)
Spring tilt (exhaust) 1.7 mm (0.068 in)
Cylinder
Bore 58.000–58.010 mm (2.2835–2.2839 in)
Wear limit 58.060 mm (2.3224 in)
Piston
Diameter 57.962–57.985 mm (2.2820–2.2829 in)
Measuring point (from piston skirt bottom) 6.0 mm (0.24 in)
Piston pin bore inside diameter 14.002–14.013 mm (0.5513–0.5517 in)
Limit 14.043 mm (0.5529 in)
Piston pin outside diameter 13.995–14.000 mm (0.5510–0.5512 in)
Limit 13.975 mm (0.5502 in)
Piston-pin-to-piston-pin-bore clearance 0.002–0.018 mm (0.0001–0.0007 in)
Piston ring
Top ring
Ring type Barrel
End gap (installed) 0.10–0.25 mm (0.0039–0.0098 in)
Limit 0.50 mm (0.0197 in)
Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in)
Limit 0.115 mm (0.0045 in)
2nd ring
Ring type Taper
End gap (installed) 0.35–0.50 mm (0.0138–0.0197 in)
Limit 0.85 mm (0.0335 in)
Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in)
Limit 0.115 mm (0.0045 in)
Crankshaft
Crank assembly width 51.45–51.50 mm (2.026–2.028 in)
Runout limit 0.030 mm (0.0012 in)
B63-F8197-EZ.book Page 4 Monday, January 23, 2017 4:12 PM
ENGINE SPECIFICATIONS
2-5
Clutch
Clutch type Dry, centrifugal automatic
Automatic centrifugal clutch
Clutch shoe thickness 4.0 mm (0.16 in)
Limit 2.5 mm (0.10 in)
Clutch shoe spring free length 29.5 mm (1.16 in)
Clutch housing inside diameter 125.0 mm (4.92 in)
Limit 125.5 mm (4.94 in)
Compression spring free length 116.4 mm (4.58 in)
Limit 104.8 mm (4.12 in)
Weight outside diameter 20.0 mm (0.79 in)
Limit 19.5 mm (0.77 in)
Clutch-in revolution 2200–2600 r/min
Clutch-stall revolution 5000–5600 r/min
V-belt
V-belt width 24.1 mm (0.95 in)
Limit 21.7 mm (0.85 in)
Transmission
Transmission type V-belt automatic
Primary reduction ratio 1.000
Secondary reduction ratio 10.769 (56/16 40/13)
Final drive Gear
Gear ratio 2.300–0.724 : 1
Air filter
Air filter element Oil-coated paper element
Fuel injector
Resistance 12.2
Throttle body
ID mark B631 00
Fuel injection sensor
Intake air pressure sensor output voltage 3.88–4.12 V at 101.3 kPa (3.88–4.12 V at
1.01 kgf/cm², 3.88–4.12 V at 14.7 psi)
Intake air temperature sensor resistance 5850.0–6150.0 at 0 °C (5850.0–6150.0 at
32 °F)
Coolant temperature sensor resistance 2512–2777 at 20 °C (2512–2777 at 68 °F)
Coolant temperature sensor resistance 210–221 at 100 °C (210–221 at 212 °F)
Idling condition
Fuel line pressure at idling 220–300 kPa (2.2–3.0 kgf/cm², 31.9–43.5 psi)
Engine idling speed 1500–1700 r/min
CO% (Muffler tail pipe) 0.0–1.0 %
Water temperature 80 °C (175.2 °F)
Throttle grip free play 3.0–5.0 mm (0.12–0.20 in)
B63-F8197-EZ.book Page 5 Monday, January 23, 2017 4:12 PM
CHASSIS SPECIFICATIONS
2-6
EAS20015
CHASSIS SPECIFICATIONS
Chassis
Frame type Underbone
Caster angle 26.5°
Trail 95 mm (3.7 in)
Front wheel
Wheel type Cast wheel
Rim size 14M/C MT2.50
Rim material Aluminum
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 1.0 mm (0.04 in)
Rear wheel
Wheel type Cast wheel
Rim size 14M/C MT3.50
Rim material Aluminum
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 1.0 mm (0.04 in)
Front tire
Type Tubeless
Size 110/80-14M/C 53P
Manufacturer/model IRC/SCT-005F
Wear limit (front) 1.0 mm (0.04 in)
Rear tire
Type Tubeless
Size 140/70-14M/C 62P
Manufacturer/model IRC/SCT-005R
Wear limit (rear) 1.0 mm (0.04 in)
Tire air pressure (measured on cold tires)
Front (1 person) 200 kPa (2.00 kgf/cm², 29 psi)
Rear (1 person) 225 kPa (2.25 kgf/cm², 33 psi)
Front (2 persons) 200 kPa (2.00 kgf/cm², 29 psi)
Rear (2 persons) 225 kPa (2.25 kgf/cm², 33 psi)
Front brake
Type Hydraulic single disc brake
Front disc brake
Disc outside diameter thickness 230.0 4.0 mm (9.06 0.16 in)
Brake disc thickness limit 3.5 mm (0.14 in)
Brake disc runout limit (as measured on wheel) 0.15 mm (0.0059 in)
Brake pad lining thickness 4.4 mm (0.17 in)
Limit 0.8 mm (0.03 in)
B63-F8197-EZ.book Page 6 Monday, January 23, 2017 4:12 PM
CHASSIS SPECIFICATIONS
2-7
Master cylinder inside diameter 11.00 mm (0.43 in)
Caliper cylinder inside diameter 33.34 mm (1.31 in)
Specified brake fluid YAMAHA GENUINE BRAKE FLUID: DOT3 or
DOT 4 (GDR155)
YAMAHA GENUINE BRAKE FLUID: DOT
4-Plus (GDR155-A)
Rear brake
Type Drum barke
Rear barke lever free play 10.0–20.0 mm (0.39–0.79 in)
Rear drum brake
Drum brake type Leading, trailing
Brake drum inside diameter 130.0 mm (5.12 in)
Limit 131.0 mm (5.16 in)
Lining thickness 4.5 mm (0.18 in)
Limit 2.0 mm (0.08 in)
Shoe spring length 52.0 mm (2.05 in)
Shoe spring length 2 48.0 mm (1.89 in)
Steering
Steering bearing type Angular bearing
Center to lock angle (left) 47.5°
Center to lock angle (right) 47.5°
Front suspension
Type Telescopic fork
Spring/shock absorber type Coil spring/hydraulic damper
Wheel travel 100.0 mm (3.94 in)
Fork spring free length 282.1 mm (11.10 in)
Limit 276 mm (10.88 in)
Recommended oil Fork oil 10W or equivalent Yamaha Suspension
Oil G10
Quantity 55.0 cm³ (1.86 US oz, 1.93 Imp.oz)
Level 87.0 mm (3.06 in)
Rear suspension
Type Unit swing
Spring/shock absorber type Coil spring/hydraulic damper
Wheel travel 86.0 mm (3.39 in)
B63-F8197-EZ.book Page 7 Monday, January 23, 2017 4:12 PM
ELECTRICAL SPECIFICATIONS
2-8
EAS20016
ELECTRICAL SPECIFICATIONS
Voltage
System voltage 12 V
Ignition system
Ignition system TCI
Advancer type Digital
Ignition timing (B.T.D.C.) 5.0°/1600 r/min
Ignition coil
Primary coil resistance 2.16–2.64
Secondary coil resistance 8.64–12.96 k
Spark plug cap
Resistance 3.75–6.25 k
AC magneto
Standard output 14.0 V, 705 W at 5000 r/min
Stator coil resistance 0.048–0.072
Battery
Model GTZ7V
Voltage, capacity 12 V, 6.0 Ah (10HR)
Bulb voltage, wattage quantity
Headlight LED
Auxiliary light 12 V, 5.0 W 2
Tail/brake light LED
Front turn signal light 12 V, 10.0 W 2
Rear turn signal light 12 V, 10.0 W 2
Meter lighting LED
License plate light 12 V, 5.0 W 1
Indicator light
Turn signal indicator light LED
High beam indicator light LED
Coolant temperature warning light LED
Engine trouble warning light LED
ABS warning light LED (GDR155-A)
Stop and Start System indicator light LED (GDR155-A)
Smart key system indicator light LED (GDR155-A)
Starter generator
Power output 0.29 kW
Fuel sender unit
Sender unit resistance (full) 10–14.0
Sender unit resistance (empty) 267–273.0
B63-F8197-EZ.book Page 8 Monday, January 23, 2017 4:12 PM
ELECTRICAL SPECIFICATIONS
2-9
Fuses
Main fuse 30.0 A
Headlight fuse 7.5 A
Fuel injection system fuse 7.5 A
Signaling system fuse 7.5 A
Ignition fuse 7.5 A
Backup fuse 7.5 A
Terminal fuse 1 2.0 A
ABS motor fuse 10.0 A (GDR155-A)
ABS control unit fuse 2.0 A (GDR155-A)
ABS solenoid fuse 7.5 A (GDR155-A)
Smart key system fuse 2.0 A (GDR155-A)
Spare fuse 10.0 A (GDR155-A)
Spare fuse 30.0 A
Spare fuse 7.5 A
Spare fuse 2.0 A
B63-F8197-EZ.book Page 9 Monday, January 23, 2017 4:12 PM
TIGHTENING TORQUES
2-10
EAS20017
TIGHTENING TORQUES
EAS30015
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. Unless otherwise
specified, tightening torque specifications re-
quire clean, dry threads. Components should be
at room temperature.
A. Distance between flats
B. Outside thread diameter
A (nut) B (bolt)
General tightening torques
N·m kgf·m lb·ft
10 mm 6 mm 6 0.6 4.3
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 40
19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13.0 94
B63-F8197-EZ.book Page 10 Monday, January 23, 2017 4:12 PM
TIGHTENING TORQUES
2-11
EAS30016
ENGINE TIGHTENING TORQUES
Item
Thread
size
Q’ty Tightening torque Remarks
Muffler nut M8 2 20 N·m (2.0 kgf·m, 14 lb·ft)
Muffler bolt M10 3 57 N·m (5.7 kgf·m, 41 lb·ft)
Muffler protector bolt M6 2 8 N·m (0.8 kgf·m, 5.8 lb·ft)
Cylinder head bolt M6 2 10 N·m (1.0 kgf·m, 7.2 lb·ft)
Cylinder head nut M8 4 24 N·m (2.4 kgf·m, 17 lb·ft)
VVA (variable valve actuator) sole-
noid bolt
M6 2 10 N·m (1.0 kgf·m, 7.2 lb·ft)
Cylinder head cover bolt M6 4 10 N·m (1.0 kgf·m, 7.2 lb·ft)
Engine oil check bolt M6 1 7 N·m (0.7 kgf·m, 5.1 lb·ft)
Camshaft sprocket bolt M8 1 30 N·m (3.0 kgf·m, 22 lb·ft)
Spark plug M10 1 13 N·m (1.3 kgf·m, 9.4 lb·ft)
Valve clearance adjusting screw
locknut
M5 4 7 N·m (0.7 kgf·m, 5.1 lb·ft)
Coolant drain bolt (cylinder side) M6 1 10 N·m (1.0 kgf·m, 7.2 lb·ft)
Radiator fan case bolt M6 5 10 N·m (1.0 kgf·m, 7.2 lb·ft)
Radiator fan bolt M6 3 10 N·m (1.0 kgf·m, 7.2 lb·ft)
Radiator bolt M6 4 10 N·m (1.0 kgf·m, 7.2 lb·ft)
Coolant drain bolt (radiator side) M12 1 1.0 N·m (0.10 kgf·m, 0.72 lb·ft)
Radiator cover bolt M6 3 10 N·m (1.0 kgf·m, 7.2 lb·ft)
Fuel injector bolt M6 1 10 N·m (1.0 kgf·m, 7.2 lb·ft)
ISC (Idle Speed Control) unit holder
screw
M6 1 5 N·m (0.5 kgf·m, 3.6 lb·ft)
Air filter case bolt M6 2 10 N·m (1.0 kgf·m, 7.2 lb·ft)
AC magneto rotor nut M12 1 70 N·m (7.0 kgf·m, 51 lb·ft)
Transmission case cover bolt M8 6 20 N·m (2.0 kgf·m, 14 lb·ft)
Final transmission oil drain bolt M8 1 20 N·m (2.0 kgf·m, 14 lb·ft)
V-belt case bolt M6 10 10 N·m (1.0 kgf·m, 7.2 lb·ft)
Engine oil drain bolt M12 1 20 N·m (2.0 kgf·m, 14 lb·ft)
V-belt case air filter element cover
bolt
M6 6 7 N·m (0.7 kgf·m, 5.1 lb·ft)
Primary fixed sheave nut M12 1 49 N·m (4.9 kgf·m, 35 lb·ft)
Clutch housing nut M12 1 45 N·m (4.5 kgf·m, 33 lb·ft)
Secondary sheave nut M28 1 55 N·m (5.5 kgf·m, 40 lb·ft)
LT
M
B63-F8197-EZ.book Page 11 Monday, January 23, 2017 4:12 PM
TIGHTENING TORQUES
2-12
Cylinder head tightening sequence:
4
2
5
3
1
6
B63-F8197-EZ.book Page 12 Monday, January 23, 2017 4:12 PM
TIGHTENING TORQUES
2-13
EAS30017
CHASSIS TIGHTENING TORQUES
Item
Thread
size
Q’ty Tightening torque Remarks
Engine bracket nut M10 1 54 N·m (5.4 kgf·m, 39 lb·ft)
Engine mounting nut (front side) M10 2 50 N·m (5.0 kgf·m, 36 lb·ft)
Engine mounting nut (rear side) M10 2 54 N·m (5.4 kgf·m, 39 lb·ft)
Grab bar bolt M8 4 11 N·m (1.1 kgf·m, 8.0 lb·ft)
Seat hinge nut M6 2 7 N·m (0.7 kgf·m, 5.1 lb·ft)
Storage box bolt M6 4 9 N·m (0.9 kgf·m, 6.5 lb·ft)
Front brake master cylinder holder
bolt
M6 2 10 N·m (1.0 kgf·m, 7.2 lb·ft)
Brake master cylinder reservoir cap
screw
M4 2 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
Front brake hose union bolt (master
cylinder side)
M10 1 29 N·m (2.9 kgf·m, 21 lb·ft)
Throttle cable holder bolt (handlebar
switch side)
M5 1 3.5 N·m (0.35 kgf·m, 2.5 lb·ft)
Lower ring nut M25 1 See TIP.
Upper ring nut M25 1 See TIP.
Horn bracket bolt M6 1 7 N·m (0.7 kgf·m, 5.1 lb·ft)
Horn bolt M6 1 7 N·m (0.7 kgf·m, 5.1 lb·ft)
Lower bracket pinch bolt M10 4 53 N·m (5.3 kgf·m, 38 lb·ft)
Front fork damper rod bolt M10 2 23 N·m (2.3 kgf·m, 17 lb·ft)
Front wheel sensor bolt M6 1 7 N·m (0.7 kgf·m, 5.1 lb·ft)
Front brake caliper bolt M10 2 35 N·m (3.5 kgf·m, 25 lb·ft)
Front brake hose union bolt (brake
caliper side)
M10 1 29 N·m (2.9 kgf·m, 21 lb·ft)
Brake caliper bleed screw M8 1 6 N·m (0.6 kgf·m, 4.3 lb·ft)
Front wheel axle nut M10 1 26 N·m (2.6 kgf·m, 19 lb·ft)
Front brake hose holder bolt M6 1 7 N·m (0.7 kgf·m, 5.1 lb·ft)
Front brake disc bolt M8 3 23 N·m (2.3 kgf·m, 17 lb·ft)
Front wheel sensor rotor bolt M5 3 8 N·m (0.8 kgf·m, 5.8 lb·ft)
Camshaft lever bolt M6 1 7 N·m (0.7 kgf·m, 5.1 lb·ft)
Rear wheel axle nut M16 1 95 N·m (9.5 kgf·m, 69 lb·ft)
Hydraulic unit assembly bolt M6 2 7 N·m (0.7 kgf·m, 5.1 lb·ft)
Front brake hose union bolt
(hydraulic unit assembly side)
M10 2 29 N·m (2.9 kgf·m, 21 lb·ft)
Starter generator control unit assem-
bly bolt
M6 2 7 N·m (0.7 kgf·m, 5.1 lb·ft)
Rear shock absorber assembly nut
(upper)
M8 2 23 N·m (2.3 kgf·m, 17 lb·ft)
Rear shock absorber assembly bolt
(lower)
M8 2 23 N·m (2.3 kgf·m, 17 lb·ft)
Swingarm mounting bolt M10 2 57 N·m (5.7 kgf·m, 41 lb·ft)
Fuel tank bolt M6 4 9 N·m (0.9 kgf·m, 6.5 lb·ft)
LT
LT
LT
B63-F8197-EZ.book Page 13 Monday, January 23, 2017 4:12 PM
TIGHTENING TORQUES
2-14
TIP
Steering column ring nut
1. Tighten the lower ring nut 38 N·m (3.8 kgf·m, 27 lb·ft) with a torque wrench and the steering nut
wrench, and then loosen the nut 1/4 turn.
2. Tighten the lower ring nut 16 N·m (1.6 kgf·m, 12 lb·ft) with a torque wrench and the steering nut
wrench.
3. Install the rubber washer and the center ring nut.
4. Finger tighten the center ring nut, align the slots of both ring nuts, and then install the lock washer.
5. Hold the lower and center ring nuts, and then tighten the upper ring nut 75 N·m (7.5 kgf·m, 54 lb·ft)
with a torque wrench and the steering nut wrench.
Throttle cable holder bolt (throttle
body side)
M6 2 5 N·m (0.5 kgf·m, 3.6 lb·ft)
Sidestand switch bolt M5 1 7 N·m (0.7 kgf·m, 5.1 lb·ft)
Centerstand spring hook bolt M6 1 7 N·m (0.7 kgf·m, 5.1 lb·ft)
Sidestand nut M8 1 32 N·m (3.2 kgf·m, 23 31 lb·ft)
Item
Thread
size
Q’ty Tightening torque Remarks
LT
B63-F8197-EZ.book Page 14 Monday, January 23, 2017 4:12 PM
LUBRICATION POINTS AND LUBRICANT TYPES
2-15
EAS20018
LUBRICATION POINTS AND LUBRICANT TYPES
EAS30018
ENGINE
Lubrication point Lubricant
Bearings
O-rings
O-rings (cam shaft)
Oil seals
Rocker arm stopper pin
Cylinder head nut contact face and stud bolt thread
Camshaft lobes
Decompression cam
Rocker arm shafts
Valve stems and valve guide (intake and exhaust)
Valve stem seals
Valve stem ends (intake and exhaust)
Rocker arm valve inner surface
Camshaft sprocket
Connecting rod big end face
Piston pin outer surface
Piston, piston ring, and cylinder inner surface
Crank pin
Cam chain sprocket inner surface
Oil pump drive gear inner surface
Oil pump shaft
O-ring (fuel injector)
Starter wheel and bearing
Starter clutch idle gear inner surface
Drive axle and bearings
Crankshaft threads and conical spring washer outer mating surface
Timing chain tensioner bolts
Yamaha bond
No.1215®
Crankcase mating surfaces
Yamaha bond
No.1215®
Crankcase bolt
Yamaha bond
No.1215®
E
LS
M
LS
M
M
M
M
M
M
E
M
M
M
E
E
E
E
M
M
E
E
E
M
LS
LS
B63-F8197-EZ.book Page 15 Monday, January 23, 2017 4:12 PM
LUBRICATION SYSTEM CHART AND DIAGRAMS
2-16
EAS20019
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS30020
ENGINE OIL LUBRICATION CHART
5
4
3
2
1
1. Oil strainer
2. Oil pump assembly
3. Crankshaft
4. Oil nozzle
5. Camshaft
B63-F8197-EZ.book Page 16 Monday, January 23, 2017 4:12 PM
LUBRICATION SYSTEM CHART AND DIAGRAMS
2-17
EAS30021
LUBRICATION DIAGRAMS
2
3
1
1. Oil strainer
2. Oil pump assembly
3. Camshaft
B63-F8197-EZ.book Page 17 Monday, January 23, 2017 4:12 PM
LUBRICATION SYSTEM CHART AND DIAGRAMS
2-18
2
4
3
1
1. Oil strainer
2. Oil pump assembly
3. Crankshaft
4. Rocker arm/Valve stem end
B63-F8197-EZ.book Page 18 Monday, January 23, 2017 4:12 PM
COOLING SYSTEM DIAGRAMS
2-19
EAS20020
COOLING SYSTEM DIAGRAMS
1
2
3
4
6
7
8
5
7
6
7
5
4
3
1
2
1. Radiator cap
2. Coolant reservoir hose
3. Radiator
4. Radiator inlet hose
5. Radiator outlet hose
6. Thermostat assembly
7. Water pump inlet hose
8. Water pump assembly
B63-F8197-EZ.book Page 19 Monday, January 23, 2017 4:12 PM
CABLE ROUTING
2-20
EAS20021
CABLE ROUTING
Handlebar (front view)
A
B
C
D
E
F
G
1
5
6
6
2
3
3
2
4
8
7
9
8
9
6
3
10
11
11
H
I
B63-F8197-EZ.book Page 20 Monday, January 23, 2017 4:12 PM
CABLE ROUTING
2-21
1. Handlebar switch lead (right)
2. Front brake light switch lead
3. Front brake hose
4. Rear brake light switch lead
5. Handlebar switch lead (left)
6. Rear brake cable
7. Wire harness
8. Throttle cable (decelerator cable)
9. Throttle cable (accelerator cable)
10. Projection mark
11. Handlebar
A. Cover the meter coupler with the meter coupler
cover.
B. Route the rear brake light switch lead above the
left handlebar switch lead.
C. Route the wire harness to the rear of the front
brake hose.
D. Secure the grommet by inserting the front brake
hose grommet into the hose guide.
E. Secure the holder by inserting the projection on
the holder into the hole in the steering pipe.
F. 73.5°
G. Route the left handlebar switch couplers to the rear
of the rear brake cable.
H. Route the throttle cables through the hole of the
handlebar cover.
I. Route the right handlebar switch couplers to the
rear of the front brake hose.
B63-F8197-EZ.book Page 21 Monday, January 23, 2017 4:12 PM
CABLE ROUTING
2-22
Handlebar (left side view)
1
2
3
4
1
2
3
4
5
5
B63-F8197-EZ.book Page 22 Monday, January 23, 2017 4:12 PM
CABLE ROUTING
2-23
1. Rear brake cable
2. Throttle cable
3. Front brake hose
4. Wire harness
5. Handlebar
B63-F8197-EZ.book Page 23 Monday, January 23, 2017 4:12 PM
CABLE ROUTING
2-24
Headlight stay (right side view)
A
B
C
1
1
2
2
3
4
5
4
5
6
7
B63-F8197-EZ.book Page 24 Monday, January 23, 2017 4:12 PM
CABLE ROUTING
2-25
1. Front brake hose
2. Front wheel sensor lead
3. Hydraulic unit
4. Fuel lid cable
5. Seat lock cable
6. Front brake pipe (hydraulic unit to front brake
caliper)
7. Front brake pipe (front brake master cylinder to
hydraulic unit)
A. 30°
B. GDR155-A
C. GDR155
B63-F8197-EZ.book Page 25 Monday, January 23, 2017 4:12 PM
CABLE ROUTING
2-26
Headlight stay (left side view)
A
B
1
1
1
2
3
3
3
4
5
5
1
3
1
3
B63-F8197-EZ.book Page 26 Monday, January 23, 2017 4:12 PM
CABLE ROUTING
2-27
1. Front wheel sensor lead
2. Front brake pipe (front brake master cylinder to
hydraulic unit)
3. Front brake hose
4. Front brake pipe (hydraulic unit to front brake
caliper)
5. Headlight stay
A. GDR155-A
B. GDR155
B63-F8197-EZ.book Page 27 Monday, January 23, 2017 4:12 PM
CABLE ROUTING
2-28
Front fork (rear and right side view)
A
A
J
I
B
C
D
E F
G
H
1
2
2
3
2
4
5
6
7
1
7
5
5
5
6
6
6
4
1
1
6
5
5
6
B63-F8197-EZ.book Page 28 Monday, January 23, 2017 4:12 PM
CABLE ROUTING
2-29
1. Horn lead
2. Horn
3. Front wheel sensor
4. Front brake caliper
5. Front brake hose
6. Front wheel sensor lead
7. Front brake hose holder
A. Position the holder within the range shown in the
illustration.
B. Route the front brake hose through the guide.
C. Secure the clamp by hooking the horn lead clamp
into the hole of the front brake hose holder.
D. Make sure the brake pipe touches the projection
on the brake caliper.
E. Inward
F. O u t w a r d
G. Forward
H. Rearward
I. Align the holder with the white paint mark on the
brake hose.
J. Align the gap in the holder with the white paint
mark on the brake hose.
B63-F8197-EZ.book Page 29 Monday, January 23, 2017 4:12 PM
CABLE ROUTING
2-30
Front frame (left side view)
D
B
C
E
F
G
E
H
A
I
B
J
2
3
3
3
2
2
2
5
6
1
1
1
4
4
6
7
3
3
2
8
B63-F8197-EZ.book Page 30 Monday, January 23, 2017 4:12 PM
CABLE ROUTING
2-31
1. Rear brake cable
2. Throttle cable (decelerator cable)
3. Throttle cable (accelerator cable)
4. Fuel hose
5. Sidestand switch
6. Wire harness
7. Buzzer coupler (GDR155-A)
8. O
2
sensor lead
A. White tape
B. Secure the grommet by inserting the fuel hose
grommet into the hose guide.
C. Route the sidestand switch lead through the cable
guide.
D. Insert the projection on the brake cable holder
completely into the hole in the frame.
E. Insert the projection on the wire harness holder
completely into the hole in the headlight stay.
F. Install the front wheel sensor coupler to the
headlight stay.
G. Route the buzzer lead as shown in the illustration.
(GDR155-A)
H. Fasten the rear brake cable and throttle cables
with the holder.
I. Route the O
2
sensor lead between the cylinder
head cover and the fuel hose bracket.
J. Fasten the throttle cables with the holder.
B63-F8197-EZ.book Page 31 Monday, January 23, 2017 4:12 PM
CABLE ROUTING
2-32
Rear frame (left side view)
A
B
C D E
F
H
2
1
3
4
5
6
6
6
6
9
87
10
11
12
13
14
15
16
17
18
CG
B63-F8197-EZ.book Page 32 Monday, January 23, 2017 4:12 PM
CABLE ROUTING
2-33
1. Wire harness
2. License light lead
3. Rear turn signal light lead (left)
4. Rear turn signal light lead (right)
5. Tail/brake light lead
6. Rear brake cable
7. Yamaha diagnostic tool coupler
8. ABS test coupler (GDR155-A)
9. Starter generator lead
10. Ignition coil
11. Crankshaft position sensor lead
12. Engine ground
13. Ignition coil lead
14. Throttle body sensor assembly lead
15. ISC unit lead
16.
Injector lead
17. O
2
sensor lead
18. Fuel hose
A. Fit the slot in the ABS test coupler onto the battery
case rib. (GDR155-A)
B. Route the VVA solenoid lead under the fuel hose.
C. Route the starter generator lead above the wire
harness.
D. Secure the holder by inserting the wire harness
holder into the hole of the bracket.
E. Fasten the spark plug lead with the band and then
secure the holder to the coolant reservoir hose
bracket.
F. Cut off the excess end of the band to less than 5
mm (0.20 in).
G. Cut off the excess end of the band.
H. Route the crankshaft position sensor lead above
the starter generator lead.
B63-F8197-EZ.book Page 33 Monday, January 23, 2017 4:12 PM
CABLE ROUTING
2-34
Front frame (left side view)
A
B
C
C
R
M
C
D
6
1
2
3
4
5
8
6
6
7
9
6
10
11
11
E
F
G
H
I
K
L
N
O
P
G
C
Q
J
B63-F8197-EZ.book Page 34 Monday, January 23, 2017 4:12 PM
CABLE ROUTING
2-35
1. Main switch coupler
2. Hydraulic unit lead (GDR155-A)
3. Fuel lid cable
4. SGCU lead
5. Fuel pump lead
6. Seat lock cable
7. Frame
8. Fuel tank overflow hose
9. Inner fender
10. Frame ground lead
11. Sidestand switch lead
A. Route the wire harness to the inside of the
cross tube.
B. Insert the projection on the fuel lid cable
holder into the hole in the cover.
C. Insert the projection on the wire harness
holder into the hole in the frame.
D. Route the coolant reservoir hose through the
guide of the frame.
E. Route the wire harness above the engine
bracket.
F. Route the seat lock cable to the outside of the
holder.
G. Insert the projection on the wire harness
holder into the hole in the footrest board.
H. Fasten the coolant reservoir hose at the white
paint mark with the holder. Position the hose
end facing forward.
I. Route the seat lock cable through the bracket
hole and route the cable between the wire
harness and the frame.
J. Fit the slot in the turn signal relay onto the leg
shield rib.
K. Route the seat lock cable between the wire
harness holder and the frame.
L. Route the seat lock cable to the inside of the
footrest board.
M. Insert the end of the fuel tank overflow hose
into the inner fender. Make sure that the end
of the hose protector on the fuel tank overflow
hose contacts the edge of the hole in the
inner fender.
N. Install the frame ground lead terminal as
shown in the illustration.
O. Install the frame ground lead terminal so that
the crimped section of the terminal that
secures the lead is facing upward.
P. Route the coolant reservoir hose to the inside
of the sidestand switch lead.
Q. Route the seat lock cable between the
sidestand switch lead and the footrest board.
R. Do not route this SGCU lead above the other
SGCU leads.
B63-F8197-EZ.book Page 35 Monday, January 23, 2017 4:12 PM
CABLE ROUTING
2-36
Rear frame (right side view)
A
B
C
D
E
F
4
2
1
3
1
2
6
5
7
1
B63-F8197-EZ.book Page 36 Monday, January 23, 2017 4:12 PM
CABLE ROUTING
2-37
1. Seat lock cable
2. Wire harness
3. Coolant reservoir hose
4. Coolant temperature sensor lead
5. Spark plug lead
6. VVA solenoid
7. Radiator hose
A. Fasten the coolant reservoir hose at the white
paint mark with the holder.
B. Insert the projection on the wire harness holder
into the hole in the crankcase bracket.
C. Insert the projection on the wire harness holder
into the hole in the rear side cover.
D. Route the spark plug lead between the VVA
solenoid and the radiator hose.
E. Route the wire harness through the guide of the
frame.
F. Route the seat lock cable through the hole of the
rear frame.
B63-F8197-EZ.book Page 37 Monday, January 23, 2017 4:12 PM
CABLE ROUTING
2-38
Frame (top view)
A
B
C
D
E
G
H
I
S
T
Q
J
V
K
L
M
N
O
P
Q
Q
R
Q
F
R
U
1
2
3
4
5
5
5
5
5
5
6
6
7
8
9
8
10
11
11
10
12
11
10
13
13
16
14
15
15
12
10
10
12
11
11
Q
F
B63-F8197-EZ.book Page 38 Monday, January 23, 2017 4:12 PM
CABLE ROUTING
2-39
1. Auxiliary DC jack lead
2. Buzzer (GDR155-A)
3. Turn signal relay
4. Main switch
5. Wire harness
6. Fuse box
7. Main relay
8. Starter charge relay
9. Fuse box 2 (GDR155-A)
10. Rear turn signal light lead
11. License light lead
12. Tail/brake light lead
13. Smart key unit lead (GDR155-A)
14. Horn lead
15. Seat lock cable
16. Smart key unit (GDR155-A)
A. Fasten the sidestand switch lead with the band.
Point the end of the band rearward.
B. Route the sidestand switch lead between the wire
harness and the coolant reservoir hose.
C. Route the ABS test coupler lead above the relay.
(GDR155-A)
D. 30–40 mm (1.18–1.57 in)
E. 10 mm (0.39 in)
F. Fasten the license light lead, rear turn signal light
lead, and tail/brake light lead with the plastic
locking tie to the hole of the frame.
G. Route the seat lock cable outside of the wire
harness.
H. Position the plastic locking tie to the rear of the rib
on the grab bar.
I. Be sure not to pinch the leads when installing the
grab bar.
J. Route the sidestand switch lead under the throttle
cable and the fuel hose.
K. Route the sidestand switch lead over the frame.
L. Fasten the sidestand switch lead with the holder.
M. Insert the projection on the wire harness holder
into the hole in the front brake hose holder.
N. Insert the projection on the wire harness holder
into the hole in the main switch bracket.
O. Install the fuse to the fuse box as shown in the
illustration.
P. Fit the slot in the relay onto the rib on the battery
box.
Q. 5 mm (0.20 in)
R. Insert the projection on the wire harness holder
into the hole in the rear fender.
S. Fasten the license light lead, rear turn signal light
lead, and tail/brake light lead with the plastic
locking tie to the guide.
T. Position the buckle of the plastic locking tie to the
outside of the guide.
U. Insert the projection on the tail/brake light coupler
into the hole in the rear fender.
V. Insert the projection on the wire harness holder
into the hole in the frame.
B63-F8197-EZ.book Page 39 Monday, January 23, 2017 4:12 PM
CABLE ROUTING
2-40
Headlight
A B
C
D
E
F
G
H
I
J
K
1 2 3
2
3
2
1
3
6
5
4
2
1
B63-F8197-EZ.book Page 40 Monday, January 23, 2017 4:12 PM
CABLE ROUTING
2-41
1. Headlight lead
2. Front turn signal light lead
3. Auxiliary light lead
4. Auxiliary DC jack lead
5. Front wheel sensor lead
6. Buzzer lead (GDR155-A)
A. Insert the front turn signal light lead into the
groove in the headlight unit. Be sure to fasten
the front turn signal light lead before the split
in the lead.
B. Insert the coupler into the groove in the
headlight unit.
C. Route the front turn signal light lead above
the headlight lead and the auxiliary light lead.
D. Route the front turn signal light lead under the
headlight lead and the auxiliary light lead.
E. Route the front turn signal light lead trough
the hole of the front side panel.
F. Insert the auxiliary DC jack coupler into the
slot in the leg shield.
G. Route the front wheel sensor lead above the
auxiliary DC jack lead.
H. Fasten the front turn signal light lead and the
auxiliary light lead with the clamp, making
sure to align the clamp with the white tape on
the front turn signal light lead. Point the ends
of the clamp forward.
I. Be sure not to pinch the front turn signal light
lead when installing the front side panel.
J. Insert the headlight lead into the groove in the
headlight unit.
K. Route the headlight lead through the hole of
the headlight unit.
B63-F8197-EZ.book Page 41 Monday, January 23, 2017 4:12 PM
3
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE ............................................................................ 3-1
INTRODUCTION ....................................................................................... 3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION
CONTROL SYSTEM ................................................................................3-1
GENERAL MAINTENANCE AND LUBRICATION CHART ....................... 3-1
CHECKING THE FUEL LINE ....................................................................3-4
CHECKING THE FUEL FILTER................................................................3-4
CHECKING THE SPARK PLUG ...............................................................3-4
ADJUSTING THE VALVE CLEARANCE ..................................................3-5
CHECKING THE ENGINE IDLING SPEED ..............................................3-7
CHECKING THE EXHAUST SYSTEM......................................................3-7
ADJUSTING THE EXHAUST GAS VOLUME ...........................................3-8
REPLACING THE AIR FILTER ELEMENT AND CLEANING
THE CHECK HOSE.................................................................................. 3-8
CHECKING THE BREATHER HOSES .....................................................3-8
CLEANING THE V-BELT CASE AIR FILTER ELEMENT
AND CLEANING THE CHECK HOSE......................................................3-9
CHECKING AND CHARGING THE BATTERY.......................................3-10
CHECKING THE BRAKE OPERATION ..................................................3-10
CHECKING THE FRONT BRAKE PADS ................................................3-10
CHECKING THE REAR BRAKE SHOES................................................3-10
CHECKING THE BRAKE FLUID LEVEL.................................................3-10
CHECKING THE FRONT BRAKE HOSES .............................................3-11
BLEEDING THE HYDRAULIC BRAKE SYSTEM ...................................3-11
CHECKING THE WHEELS .....................................................................3-12
CHECKING THE TIRES..........................................................................3-12
CHECKING THE WHEEL BEARINGS ....................................................3-14
CHECKING AND ADJUSTING THE STEERING HEAD .........................3-14
LUBRICATING THE STEERING HEAD..................................................3-15
CHECKING THE CHASSIS FASTENERS ..............................................3-15
LUBRICATING THE LEVERS .................................................................3-15
CHECKING THE SIDESTAND................................................................3-15
LUBRICATING THE SIDESTAND...........................................................3-15
CHECKING THE CENTERSTAND .........................................................3-15
LUBRICATING THE CENTERSTAND ....................................................3-16
CHECKING THE SIDESTAND SWITCH.................................................3-16
CHECKING THE FRONT FORK .............................................................3-16
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES................3-16
CHECKING THE ENGINE OIL LEVEL....................................................3-16
CHANGING THE ENGINE OIL ...............................................................3-17
CHECKING THE COOLANT LEVEL.......................................................3-18
CHECKING THE COOLING SYSTEM ....................................................3-19
CHANGING THE COOLANT...................................................................3-19
CHANGING THE FINAL TRANSMISSION OIL.......................................3-21
REPLACING THE V-BELT ......................................................................3-22
B63-F8197-EZ.book Page 1 Monday, January 23, 2017 4:12 PM
LUBRICATING THE SECONDARY SHEAVE.........................................3-22
CHECKING THE BRAKE LIGHT SWITCHES.........................................3-22
CHECKING AND LUBRICATING THE CABLES ....................................3-22
CHECKING THE THROTTLE GRIP OPERATION .................................3-23
CHECKING THE SWITCHES, LIGHTS AND SIGNALS .........................3-24
ADJUSTING THE HEADLIGHT BEAM ...................................................3-24
B63-F8197-EZ.book Page 2 Monday, January 23, 2017 4:12 PM
B63-F8197-EZ.book Page 3 Monday, January 23, 2017 4:12 PM
PERIODIC MAINTENANCE
3-1
EAS20022
PERIODIC MAINTENANCE
EAS30022
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a lon-
ger service life and reduce the need for costly overhaul work. This information applies to vehicles al-
ready in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EAU46932
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM
TIP
• The annual checks must be performed every year, except if a kilometer-based maintenance is
performed instead.
• From 16000 km, repeat the maintenance intervals starting from 4000 km.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
EAUN0284
GENERAL MAINTENANCE AND LUBRICATION CHART
TIP
• The annual checks must be performed every year, except if a kilometer-based maintenance is
performed instead.
• From 16000 km, repeat the maintenance intervals starting from 4000 km.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
NO. ITEM
CHECK OR MAINTENANCE
JOB
ODOMETER READING (whichever comes first)
ANNUAL
CHECK
1000 km
or
1 month
4000 km
or
4 months
7000 km
or
7 months
10000 km
or
10 months
13000 km
or
13 months
1 * Fuel line
• Check fuel hoses for cracks or
damage.
2 * Fuel filter
• Check condition.
• Replace if necessary.
Every 12000 km (7500 mi)
3 Spark plug
• Check condition.
• Clean and regap.
• Replace. Every 10000 km (6000 mi)
4 * Valves
• Check valve clearance.
• Adjust if necessary.
5 * Fuel injection
• Check engine idle speed.
6 * Exhaust system
• Check for leakage.
• Tighten if necessary.
• Replace gasket(s) if neces-
sary.
NO. ITEM
CHECK OR MAINTENANCE
JOB
ODOMETER READING (whichever comes first)
ANNUAL
CHECK
1000 km
or
1 month
4000 km
or
4 months
7000 km
or
7 months
10000 km
or
10 months
13000 km
or
13 months
1 *
Diagnostic sys-
tem check
• Perform dynamic inspection
using Yamaha diagnostic tool.
• Check the error codes.
2
Air filter element
• Replace.
Every 16000 km (10000 mi)
3
Air filter check
hose
• Clean.
B63-F8197-EZ.book Page 1 Monday, January 23, 2017 4:12 PM
PERIODIC MAINTENANCE
3-2
4 *
V-belt case air fil-
ter element
• Clean.
• Replace if necessary.
5 *
Battery
• Check voltage.
• Charge if necessary.
6 *
Front brake
• Check operation, fluid level
and vehicle for fluid leakage.
• Replace brake pads.
Whenever worn to the limit
7 *
Rear brake
• Check operation and adjust
brake lever free play.
• Replace brake shoes.
Whenever worn to the limit
8 *
Brake hoses
• Check for cracks or damage.
• Check for correct routing and
clamping.
• Replace.
Every 4 years
9 *
Brake fluid • Change.
Every 2 years
10 *
Wheels
• Check runout and for dam-
age.
11 *
Tires
• Check tread depth and for
damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.
12 *
Wheel bearings
• Check bearings for loose-
ness or damage.
13 *
Steering bearings
• Check bearing play and steer-
ing for roughness.
• Lubricate with lithium-soap-
based grease.
Every 12000 km (7500 mi)
14 *
Chassis fasteners
• Make sure that all nuts, bolts
and screws are properly tight-
ened.
15
Front brake lever
pivot shaft
• Lubricate with silicone
grease.
16
Rear brake lever
pivot shaft
• Lubricate with silicone
grease.
17
Sidestand, center-
stand
• Check operation.
• Lubricate with lithium-soap-
based grease.
18 *
Sidestand switch • Check operation.
19 *
Front fork
• Check operation and for oil
leakage.
• Change the front fork oil.
Every 20000 km (12000 mi)
20 *
Shock absorber
assemblies
• Check operation and shock
absorbers for oil leakage.
21
Engine oil
• Change.
• Check oil level and vehicle for
oil leakage.
Every 3000 km (1800 mi)
22 *
Engine oil strainer • Clean.
23 *
Cooling system
• Check coolant level and vehi-
cle for coolant leakage.
• Change with Yamaha genuine
coolant.
Every 3 years
24
Final transmis-
sion oil
• Check vehicle for oil leakage.
• Change.
Every 10000 km (6000 mi)
25 *
V-belt
• Check for damage and wear.
• Replace.
Every 25000 km (15500 mi)
26 *
V-belt secondary
sheave
• Lubricate.
Every 12000 km (7500 mi)
27 *
Front and rear
brake switches
• Check operation.
28
Moving parts and
cables
• Lubricate.
NO. ITEM
CHECK OR MAINTENANCE
JOB
ODOMETER READING (whichever comes first)
ANNUAL
CHECK
1000 km
or
1 month
4000 km
or
4 months
7000 km
or
7 months
10000 km
or
10 months
13000 km
or
13 months
B63-F8197-EZ.book Page 2 Monday, January 23, 2017 4:12 PM
PERIODIC MAINTENANCE
3-3
EAU62401
TIP
•Air filter
• This model’s air filter is equipped with a disposable oil-coated paper element, which must not be
cleaned with compressed air to avoid damaging it.
• The air filter element needs to be replaced more frequently when riding in unusually wet or dusty
areas.
• V-belt case air filter
• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
• Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level. After dissembling the brake master
cylinders and calipers, always change the brake fluid.
• Every two years replace the internal components of the brake master cylinder and caliper, and
change the brake fluid.
• Replace the brake hose every four years and if cracked or damaged.
29 *
Throttle grip
• Check operation.
• Check throttle grip free play,
and adjust if necessary.
• Lubricate cable and grip
housing.
30 *
Lights, signals
and switches
• Check operation.
• Adjust headlight beam.
NO. ITEM
CHECK OR MAINTENANCE
JOB
ODOMETER READING (whichever comes first)
ANNUAL
CHECK
1000 km
or
1 month
4000 km
or
4 months
7000 km
or
7 months
10000 km
or
10 months
13000 km
or
13 months
B63-F8197-EZ.book Page 3 Monday, January 23, 2017 4:12 PM
PERIODIC MAINTENANCE
3-4
EAS30619
CHECKING THE FUEL LINE
1. Remove:
• Front side cover assembly (left)
Refer to “GENERAL CHASSIS (2)” on page
4-3.
• Footrest board (left)
Refer to “GENERAL CHASSIS (6)” on page
4-16.
2. Check:
• Fuel hose “1”
Cracks/damage Replace.
Loose connections Connect properly.
3. Install:
• Footrest board (left)
Refer to “GENERAL CHASSIS (6)” on page
4-16.
• Front side cover assembly (left)
Refer to “GENERAL CHASSIS (2)” on page
4-3.
EAS31178
CHECKING THE FUEL FILTER
1. Remove:
• Front side cover assembly (left)
Refer to “GENERAL CHASSIS (2)” on page
4-3.
• Footrest board (left)
Refer to “GENERAL CHASSIS (6)” on page
4-16.
• Fuel filter
Refer to “FUEL TANK” on page 7-1.
2. Check:
• Fuel filter “1”
Damage/contaminants Replace.
TIP
Replace the fuel filter every 12000 km (7500 mi)
of operation.
3. Install:
• Fuel filter
Refer to “FUEL TANK” on page 7-1.
• Footrest board (left)
Refer to “GENERAL CHASSIS (6)” on page
4-16.
• Front side cover assembly (left)
Refer to “GENERAL CHASSIS (2)” on page
4-3.
EAS30620
CHECKING THE SPARK PLUG
1. Remove:
• Front side cover assembly (right)
Refer to “GENERAL CHASSIS (2)” on page
4-3.
• Footrest board (right)
Refer to “GENERAL CHASSIS (6)” on page
4-16.
2. Remove:
• Spark plug cap
• Spark plug
NOTICE
ECA13330
Before removing the spark plug, blow away
any dirt accumulated in the spark plug well
with compressed air to prevent it from falling
into the cylinder.
3. Check:
• Spark plug type
Incorrect Change.
4. Check:
• Electrode “1”
Damage/wear Replace the spark plug.
• Insulator “2”
Abnormal color Replace the spark plug.
Normal color is medium-to-light tan.
1
Manufacturer/model
NGK/CPR8EA-9
DENSO/U24EPR-9
1
B63-F8197-EZ.book Page 4 Monday, January 23, 2017 4:12 PM
PERIODIC MAINTENANCE
3-5
5. Clean:
• Spark plug
(with a spark plug cleaner or wire brush)
6. Measure:
• Spark plug gap “a”
(with a wire thickness gauge)
Out of specification Regap.
7. Install:
• Spark plug “1”
• Spark plug cap
TIP
• Before installing the spark plug, clean the
spark plug and gasket surface.
• When tightening the spark plug, make sure
that the inside “a” of the spark plug wrench “2”
does not the contact the portion “b” of the spark
plug.
• To route the spark plug lead, refer to “CON-
NECTING THE LEADS” on page 5-8.
8. Install:
• Footrest board assembly (right)
Refer to “GENERAL CHASSIS (6)” on page
4-16.
• Front side cover (right)
Refer to “GENERAL CHASSIS (2)” on page
4-3.
EAS30622
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
TIP
• Valve clearance adjustment should be made
on a cold engine, at room temperature.
• When the valve clearance is to be measured or
adjusted, the piston must be at top dead center
(TDC) on the compression stroke.
1. Remove:
• Front side covers (left and right)
Refer to “GENERAL CHASSIS (2)” on page
4-3.
• Footrest boards (left and right)
Refer to “GENERAL CHASSIS (6)” on page
4-16.
• Radiator cover and radiator fan case
Refer to “RADIATOR” on page 6-1.
2. Move:
• Radiator “1”
• Radiator fan case “2”
TIP
Move the rear of the radiator outward.
Spark plug gap
0.8–0.9 mm (0.031–0.035 in)
T
R
.
.
Spark plug
13 N·m (1.3 kg lbf·m, 9.4 lb·ft)
a
b
2
1
B63-F8197-EZ.book Page 5 Monday, January 23, 2017 4:12 PM
PERIODIC MAINTENANCE
3-6
3. Move:
• Cylinder head cover “1”
4. Measure:
• Valve clearance
Out of specification Adjust.
a. Turn the crankshaft clockwise.
b. When the piston is at the Top Dead Center
(TDC) on the compression stroke, align the
“I” mark “a” on the camshaft sprocket with the
match mark “b” on the camshaft stopper
plate.
c. Align the “I” mark “c” on the A.C. magneto ro-
tor with the stationary pointer “d” on the
crankcase.
d. Measure the valve clearance with a thickness
gauge “1”.
Out of specification Adjust.
5. Adjust:
• Valve clearance
a. Loosen the locknut “1”.
b. Insert a thickness gauge “2” between the end
of the adjusting screw and the valve tip.
c. Turn the adjusting screw “3” in direction “a” or
“b” with the tappet adjusting tool “4” until the
specified valve clearance is obtained.
Valve clearance (cold)
Intake
0.10–0.14 mm (0.0039–0.0055 in)
Exhaust
0.21–0.25 mm (0.0083–0.0098 in)
2
1
1
d
c
Direction “a”
Valve clearance is increased.
Direction “b”
Valve clearance is decreased.
a
b
1
2
1
B63-F8197-EZ.book Page 6 Monday, January 23, 2017 4:12 PM
PERIODIC MAINTENANCE
3-7
d. Hold the adjusting screw to prevent it from
moving and tighten the locknut to specifica-
tion.
e. Measure the valve clearance again.
f. If the valve clearance is still out of specifica-
tion, repeat all of the valve clearance adjust-
ment steps until the specified clearance is
obtained.
6. Install:
• All removed parts
TIP
For installation, reverse the removal procedure.
EAS31017
CHECKING THE ENGINE IDLING SPEED
TIP
Prior to checking the engine idling speed, the air
filter element should be clean, and the engine
should have adequate compression.
1. Start the engine and let it warm up for several
minutes.
2. Check:
• Engine idling speed
Out of specification Go to next step.
3. Check:
• ISC (idle speed control) learning value
“00” or “01” Check the intake system.
“02” Clean the ISC (idle speed control) unit
and throttle body.
Refer to “CLEANING THE ISC (IDLE SPEED
CONTROL) UNIT AND THROTTLE BODY”
on page 7-12.
a. Connect the Yamaha diagnostic tool.
Use the diagnostic code number “67”.
Refer to “SELF-DIAGNOSTIC FUNCTION
AND DIAGNOSTIC CODE TABLE” on page
9-5.
EAS30625
CHECKING THE EXHAUST SYSTEM
1. Check:
• Muffler “1”
Cracks/damage Replace.
• Gasket “2”
Exhaust gas leaks Replace.
2. Check:
Tightening torque
• Muffler nuts “3”
• Muffler bolts “4”
Tappet adjusting tool
90890-0131m, 1
Six piece tappet set
YM-A5970
T
R
.
.
Valve clearance adjusting screw
locknut
7 N·m (0.7 kgf·m, 5.1 lb·ft)
Engine idling speed
1500–1700 r/min
4
(a)
(b)
3
Yamaha diagnostic tool USB
90890-03250
Yamaha diagnostic tool (A/I)
90890-03252
T
R
.
.
Muffler nut
20 N·m (2.0 kgf·m, 14 lb·ft)
Muffler bolt
57 N·m (5.7 kgf·m, 41 lb·ft)
4
1
4
3
2
B63-F8197-EZ.book Page 7 Monday, January 23, 2017 4:12 PM
PERIODIC MAINTENANCE
3-8
EAS30799
ADJUSTING THE EXHAUST GAS VOLUME
TIP
• Be sure to set the CO density level to standard,
and then adjust the exhaust gas volume.
• To adjust the exhaust gas volume, use the CO
adjustment mode of the Yamaha diagnostic
tool. For more information, refer to the opera-
tion manual of the Yamaha diagnostic tool.
1. Connect the Yamaha diagnostic tool to the
connector. For information about connecting
the Yamaha diagnostic tool, refer to “YAMA-
HA DIAGNOSTIC TOOL” on page 8-46.
EAS31130
REPLACING THE AIR FILTER ELEMENT
AND CLEANING THE CHECK HOSE
TIP
Check the air filter check hose “1” that is located
on the rear side of the air filter case. If dust or
water or both collects in the hose, clean the hose
and replace the air filter element.
1. Remove:
• Air filter case cover “1”
• Air filter element “2”
2. Check:
• Air filter element
Damage Replace.
TIP
• Replace the air filter element every 16000 km
(1000 mi) of operation.
• The air filter needs more frequent service if you
are riding in unusually wet or dusty areas.
3. Install:
• Air filter element
• Air filter case cover
NOTICE
ECA20480
Never operate the engine without the air filter
element installed. Unfiltered air will cause
rapid wear of engine parts and may damage
the engine. Operating the engine without the
air filter element will also affect throttle body
tuning, leading to poor engine performance
and possible overheating.
TIP
When installing the air filter element into the air
filter case, make sure that the sealing surfaces
are aligned to prevent any air leaks.
EAS31179
CHECKING THE BREATHER HOSES
1. Remove:
• Front side cover assembly (left)
Refer to “GENERAL CHASSIS (2)” on page
4-3.
2. Check:
• Cylinder head breather hose “1”
• Transmission case breather hose “2”
Cracks/damage Replace.
Loose connections Connect properly.
Yamaha diagnostic tool USB
90890-03250
Yamaha diagnostic tool (A/I)
90890-03252
1
1
T
R
.
.
Air filter case cover screw
1.2 N·m (0.12 kgf·m, 0.87 lb·ft)
2
B63-F8197-EZ.book Page 8 Monday, January 23, 2017 4:12 PM
PERIODIC MAINTENANCE
3-9
NOTICE
ECA21600
Make sure the cylinder head breather hose
and transmission case breather hose are
routed correctly.
3. Install:
• Front side cover assembly (left)
Refer to “GENERAL CHASSIS (2)” on page
4-3.
EAS31704
CLEANING THE V-BELT CASE AIR FILTER
ELEMENT AND CLEANING THE CHECK
HOSE
TIP
Check the V-belt case air filter check hose “1”
that is located on the rear side of the V-belt case.
If dust or water or both collects in the hose, clean
the hose and replace the V-belt case air filter el-
ement.
1. Remove:
• V-belt case air filter element cover “1”
• V-belt case air filter element “2”
2. Clean:
• V-belt case air filter element
(with solvent)
WARNING
EWA17971
Never use low flash point solvents, such as
gasoline, to clean the V-belt case air filter el-
ement. Such solvents may cause a fire or an
explosion.
TIP
• The air filter needs more frequent service if you
are riding in unusually wet or dusty areas.
• After cleaning, gently squeeze the V-belt case
air filter element to remove the excess solvent.
NOTICE
ECA21590
Do not twist the V-belt case air filter element
when squeezing it.
1
1
1
1
2
B63-F8197-EZ.book Page 9 Monday, January 23, 2017 4:12 PM
PERIODIC MAINTENANCE
3-10
3. Check:
• V-belt case air filter element
Damage Replace.
4. Apply the recommended oil to the entire sur-
face of the V-belt case air filter element and
squeeze out the excess oil. The V-belt case
air filter element should be wet but not drip-
ping.
5. Install:
• V-belt case air filter element
• V-belt case air filter element cover
EAS30816
CHECKING AND CHARGING THE BATTERY
Refer to “CHECKING AND CHARGING THE
BATTERY” on page 8-124.
EAS30801
CHECKING THE BRAKE OPERATION
1. Check:
• Brake operation
Brake not working properly Check the
brake system.
Refer to “FRONT BRAKE” on page 4-30 and
“REAR BRAKE” on page 4-43.
TIP
Drive on the road, operate the front and rear
brakes separately and check to see if the brakes
are operating properly.
EAS30633
CHECKING THE FRONT BRAKE PADS
The following procedure applies to all of the
brake pads.
1. Operate the brake.
2. Check:
• Front brake pad
Wear indicator grooves “a” almost disap-
peared Replace the brake pads as a set.
Refer to “FRONT BRAKE” on page 4-30.
EAS00126
CHECKING THE REAR BRAKE SHOES
1. Operate the brake.
2. Check:
• Wear indicator “1”
Reaches the wear limit line “2” Replace the
brake shoes as a set.
Refer to “REAR WHEEL AND BRAKE” in
chapter 4.
EAS30632
CHECKING THE BRAKE FLUID LEVEL
1. Stand the vehicle on a level surface.
TIP
• Place the vehicle on the centerstand.
• Make sure the vehicle is upright.
• In order to ensure a correct reading of the
brake fluid level, make sure the top of the brake
fluid reservoir is horizontal.
2. Check:
• Brake fluid level
Below the minimum level mark “1” Add the
specified brake fluid to the proper level.
Recommended oil
Engine oil
T
R
.
.
V-belt case air filter element cov-
er bolt
7 N·m (0.7 kgf·m, 5.1 lb·ft)
Specified brake fluid
YAMAHA GENUINE BRAKE FLUID
(DOT 3 or DOT 4)-GDR155
YAMAHA GENUINE BRAKE
FLUID (DOT 4-plus)-GDR155-A
a
a
2
1
B63-F8197-EZ.book Page 10 Monday, January 23, 2017 4:12 PM
PERIODIC MAINTENANCE
3-11
WARNING
EWA13540
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake master cylinder reser-
voir. Water will significantly lower the boil-
ing point of the brake fluid and could cause
vapor lock.
NOTICE
ECA13540
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
EAS30635
CHECKING THE FRONT BRAKE HOSES
1. Check:
• Brake hoses “1”
Cracks/damage Replace.
2. Check:
• Brake hose holder
• Brake hose guide
Loose Tighten the holder and guide bolt.
3. Hold the vehicle upright and apply the front
brake several times.
4. Check:
• Brake hoses
Brake fluid leakage Replace the damaged
hose.
Refer to “FRONT BRAKE” on page 4-30 and
“ABS (ANTI-LOCK BRAKE SYSTEM)
(GDR155-A)” on page 4-47.
EAS30893
BLEEDING THE HYDRAULIC BRAKE
SYSTEM
WARNING
EWA14000
Always bleed the brake system when the
brake related parts are removed.
NOTICE
ECA22780
• Bleed the brake system in the following or-
der.
• Front brake caliper
WARNING
EWA16530
Bleed the ABS whenever:
• the system is disassembled.
• a brake hose is loosened, disconnected or
replaced.
• the brake fluid level is very low.
• brake operation is faulty.
TIP
• Be careful not to spill any brake fluid or allow
the brake master cylinder reservoir to overflow.
• When bleeding the ABS, make sure that there
is always enough brake fluid before applying
the brake. Ignoring this precaution could allow
air to enter the ABS, considerably lengthening
the bleeding procedure.
• If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours.
• Repeat the bleeding procedure when the tiny
bubbles in the hose have disappeared.
1. Bleed:
•ABS
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Fill the brake master cylinder reservoir to the
proper level with the specified brake fluid.
b. Install the brake master cylinder diaphragm.
c. Connect a clear plastic hose “1” tightly to the
bleed screw “2”.
1
1
B63-F8197-EZ.book Page 11 Monday, January 23, 2017 4:12 PM
PERIODIC MAINTENANCE
3-12
d. Place the other end of the hose into a con-
tainer.
e. Slowly apply the brake several times.
f. Fully squeeze the brake lever and hold it in
position.
g. Loosen the bleed screw.
TIP
Loosening the bleed screw will release the pres-
sure and cause the brake lever to contact the
throttle grip or handlebar grip.
h. Tighten the bleed screw and then release the
brake lever.
i. Repeat steps (e) to (h) until all of the air bub-
bles have disappeared from the brake fluid in
the plastic hose.
j. Check the operation of the hydraulic unit.
Refer to “HYDRAULIC UNIT OPERATION
TESTS” on page 4-51.
NOTICE
ECA18060
Make sure that the main switch is turned to
“OFF” before checking the operation of the
hydraulic unit.
k. After operating the ABS, repeat steps (e) to
(i), and then fill the brake master cylinder res-
ervoir to the proper level with the specified
brake fluid.
l. Tighten the bleed screw to specification.
m. Fill the brake master cylinder reservoir to the
proper level with the specified brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-10.
WARNING
EWA13110
After bleeding the hydraulic brake system,
check the brake operation.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS30638
CHECKING THE WHEELS
The following procedure applies to all of the
wheels.
1. Check:
• Wheel
Damage/out-of-round Replace.
WARNING
EWA13260
Never attempt to make any repairs to the
wheel.
TIP
After a tire or wheel has been changed or re-
placed, always balance the wheel.
2. Measure:
• Radial wheel runout
• Lateral wheel runout
Refer to “CHECKING THE FRONT WHEEL”
on page 4-22 and “CHECKING THE REAR
WHEEL” on page 4-29.
EAS30640
CHECKING THE TIRES
The following procedure applies to all of the
tires.
1. Check:
• Tire pressure
Out of specification Regulate.
WARNING
EWA13181
• The tire pressure should only be checked
and regulated when the tire temperature
equals the ambient air temperature.
• The tire pressure and the suspension must
be adjusted according to the total weight
(including cargo, rider, passenger and ac-
cessories) and the anticipated riding
speed.
• Operation of an overloaded vehicle could
cause tire damage, an accident or an injury.
NEVER OVERLOAD THE VEHICLE.
T
R
.
.
Brake caliper bleed screw
6 N·m (0.6 kgf·m, 4.3 lb·ft)
2
1
B63-F8197-EZ.book Page 12 Monday, January 23, 2017 4:12 PM
PERIODIC MAINTENANCE
3-13
WARNING
EWA13190
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit, re-
place the tire immediately.
2. Check:
• Tire surfaces
Damage/wear Replace the tire.
WARNING
EWA14080
• Do not use a tubeless tire on a wheel de-
signed only for tube tires to avoid tire fail-
ure and personal injury from sudden
deflation.
• When using a tube tire, be sure to install the
correct tube.
• Always replace a new tube tire and a new
tube as a set.
• To avoid pinching the tube, make sure the
wheel rim band and tube are centered in the
wheel groove.
• Patching a punctured tube is not recom-
mended. If it is absolutely necessary to do
so, use great care and replace the tube as
soon as possible with a good quality re-
placement.
WARNING
EWA14090
After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Ltd. for this model. The front and rear tires
should always be by the same manufacturer
and of the same design. No guarantee con-
cerning handling characteristics can be giv-
en if a tire combination other than one
approved by Yamaha is used on this vehicle.
Tire air pressure (measured on
cold tires)
Front (1 person)
200 kPa (2.00 kgf/cm², 29 psi)
Rear (1 person)
225 kPa (2.25 kgf/cm², 33 psi)
Front (2 persons)
200 kPa (2.00 kgf/cm², 29 psi)
Rear (2 persons)
225 kPa (2.25 kgf/cm², 33 psi)
Maximum load
154 kg (339 lb) (GDR155)
153 kg (336 lb) (GDR155-A)
* Total weight of rider, passenger, cargo
and accessories
1. Tire tread depth
2. Side wall
3. Wear indicator
Wear limit (front)
1.0 mm (0.04 in)
Wear limit (rear)
1.0 mm (0.04 in)
A. Tire
B. Wheel
Tube wheel Tube tire only
Tubeless wheel Tube or tubeless tire
Front tire
Size
110/80–14M/C 53P
Manufacturer/model
IRC/SCT-005F
Rear tire
Size
140/70–14M/C 62P
Manufacturer/model
IRC/SCT-005R
A B
B63-F8197-EZ.book Page 13 Monday, January 23, 2017 4:12 PM
PERIODIC MAINTENANCE
3-14
WARNING
EWA13210
New tires have a relatively low grip on the
road surface until they have been slightly
worn. Therefore, approximately 100 km
should be traveled at normal speed before
any high-speed riding is done.
TIP
For tires with a direction of rotation mark “1”:
• Install the tire with the mark pointing in the di-
rection of wheel rotation.
• Align the mark “2” with the valve installation
point.
EAS30641
CHECKING THE WHEEL BEARINGS
The following procedure applies to all of the
wheel bearings.
1. Check:
• Wheel bearings
Refer to “CHECKING THE FRONT WHEEL”
on page 4-22.
EAS30645
CHECKING AND ADJUSTING THE
STEERING HEAD
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there is
no danger of it falling over.
TIP
Place the vehicle on a suitable stand so that the
front wheel elevated.
2. Check:
• Steering head
Grasp the handlebar and gently rock the han-
dlebar.
Binding/looseness Adjust the steering
head.
3. Remove:
• Front cover assembly
• Front cowling assembly
Refer to “GENERAL CHASSIS (4)” on page
4-9.
• Handlebar
Refer to “HANDLEBAR” on page 4-55.
4. Adjust:
• Steering head
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Remove the upper ring nut “1”, lock washer
“2”, center ring nut “3” and rubber washer “4”.
b. Loosen the lower ring nut “5” and then tighten
it to specification with a steering nut wrench
“6”.
TIP
Set the torque wrench at a right angle to the
steering nut wrench.
c. Loosen the lower ring nut 1/4 of a turn, and
then tighten it to specification with a steering
nut wrench.
1
2
Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472
T
R
.
.
Lower ring nut (initial tightening
torque)
38 N·m (3.8 kgf·m, 27 lb·ft)
1
3
4
2
5
6
B63-F8197-EZ.book Page 14 Monday, January 23, 2017 4:12 PM
PERIODIC MAINTENANCE
3-15
WARNING
EWA13140
Do not overtighten the lower ring nut.
d. Check the steering head for looseness or
binding by turning the front fork all the way in
both directions. If any binding is felt, remove
the lower bracket and check the upper and
lower bearings.
Refer to “STEERING HEAD” on page 4-67.
e. Install the rubber washer.
f. Install the center ring nut.
g. Finger tighten the center ring nut, then align
the slots of both ring nuts. If necessary, hold
the lower ring nut and tighten the center ring
nut until their slots are aligned.
h. Install the lock washer “2”.
TIP
Make sure the lock washer tabs “a” sit correctly
in the ring nut slots “b”.
i. Hold the lower and center ring nuts with a
steering nut wrench and tighten the upper
ring nut with a another steering nut wrench.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
5. Install:
• Handlebar
Refer to “HANDLEBAR” on page 4-55.
• Front cowling assembly
• Front cover assembly
Refer to “GENERAL CHASSIS (4)” on page
4-9.
EAS30646
LUBRICATING THE STEERING HEAD
1. Lubricate:
• Upper bearing
• Lower bearing
• Lower bearing dust seal
EAS31186
CHECKING THE CHASSIS FASTENERS
Make sure that all nuts, bolts, and screws are
properly tightened.
Refer to “CHASSIS TIGHTENING TORQUES”
on page 2-13.
EAS30648
LUBRICATING THE LEVERS
Lubricate the pivoting point and metal-to-metal
moving parts of the levers.
EAS30650
CHECKING THE SIDESTAND
1. Check:
• Sidestand operation
Check that the sidestand moves smoothly.
Rough movement Repair or replace.
EAS30651
LUBRICATING THE SIDESTAND
Lubricate the pivoting point, metal-to-metal mov-
ing parts, and spring contact point of the side-
stand.
EAS30856
CHECKING THE CENTERSTAND
1. Check:
• Centerstand operation
Check that the centerstand moves smoothly.
Rough movement Repair or replace.
T
R
.
.
Lower ring nut (final tightening
torque)
16 N·m (1.6 kgf·m, 12 lb·ft)
Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472
T
R
.
.
Upper ring nut
75 N·m (7.5 kgf·m, 54 lb·ft)
2
a
b
Recommended lubricant
Lithium-soap-based grease
Recommended lubricant
Silicone grease
Recommended lubricant
Lithium-soap-based grease
B63-F8197-EZ.book Page 15 Monday, January 23, 2017 4:12 PM
PERIODIC MAINTENANCE
3-16
EAS30857
LUBRICATING THE CENTERSTAND
Lubricate the pivoting point, metal-to-metal mov-
ing parts, and spring contact points of the center-
stand.
EAS30652
CHECKING THE SIDESTAND SWITCH
Refer to “CHECKING THE SWITCHES” on
page 8-120.
EAS30653
CHECKING THE FRONT FORK
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there is
no danger of it falling over.
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
smoothly.
Rough movement Repair.
Refer to “FRONT FORK” on page 4-60.
EAS30808
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLIES
The following procedure applies to both of the
rear shock absorber assemblies.
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there is
no danger of it falling over.
2. Check:
• Rear shock absorber assembly
Oil leaks Replace the rear shock absorber
assembly.
Refer to “CHECKING THE REAR SHOCK
ABSORBER ASSEMBLY” on page 4-81.
3. Check:
• Rear shock absorber assembly operation
Push down seat on the vehicle several times
and check if the rear shock absorber assem-
bly rebounds smoothly.
Rough movement Replace.
Refer to “REAR SHOCK ABSORBER AS-
SEMBLIES AND SWINGARM” on page
4-79.
EAS30656
CHECKING THE ENGINE OIL LEVEL
1. Stand the vehicle on a level surface.
TIP
• Place the vehicle on the centerstand.
• Make sure the vehicle is upright.
2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Remove:
• Dipstick “1”
4. Check:
• Engine oil level
The engine oil level should be between the
minimum level mark “a” and maximum level
mark “b”.
Below the minimum level mark Add the
recommended engine oil to the proper level.
TIP
• Before checking the engine oil level, wait a few
minutes until the oil has settled.
• Do not screw the dipstick in when inspecting
the oil level.
Recommended lubricant
Lithium-soap-based grease
B63-F8197-EZ.book Page 16 Monday, January 23, 2017 4:12 PM
PERIODIC MAINTENANCE
3-17
NOTICE
ECA13370
Do not allow foreign materials to enter the
crankcase.
5. Start the engine, warm it up for several min-
utes, and then turn it off.
6. Check the engine oil level again.
TIP
Before checking the engine oil level, wait a few
minutes until the oil has settled.
EAS30657
CHANGING THE ENGINE OIL
1. Start the engine, warm it up for several min-
utes, and then turn it off.
2. Place a container under the engine oil drain
bolt.
3. Remove:
•Dipstick “1”
• Engine oil drain bolt “2”
(along with the gasket “3”)
4. Drain:
• Engine oil
(completely from the crankcase)
5. If the oil strainer is also to be cleaned, per-
form the following procedure.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Remove the oil strainer cover “1”, spring “2”,
and oil strainer “3”.
b. Install a new O-ring “4”.
TIP
Lubricate the O-ring with lithium-soap-based
grease.
c. Clean the engine oil strainer with solvent, and
then check it for damage and replace it if nec-
essary.
d. Install the oil strainer, spring, and oil strainer
cover.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
Recommended brand
YAMALUBE
Type
SAE 10W-40
Recommended engine oil grade
API service SG type or higher,
JASO standard MA or MB
1
b
a
1
–20 –10 0
10
T
R
.
.
Oil strainer cover
32 N·m (3.2 kgf·m, 23 lb·ft)
1
3
2
3
2
1
4
New
B63-F8197-EZ.book Page 17 Monday, January 23, 2017 4:12 PM
PERIODIC MAINTENANCE
3-18
6. Install:
• Engine oil drain bolt
(along with the gasket )
7. Fill:
• Crankcase
(with the specified amount of the recom-
mended engine oil)
8. Install:
•Dipstick
9. Start the engine, warm it up for several min-
utes, and then turn it off.
10.Check:
• Engine
(for engine oil leaks)
11.Check:
• Engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL” on page 3-16.
12.Remove:
• Front side cover assembly (right)
Refer to “GENERAL CHASSIS (2)” on page
4-3.
13.Check:
• Engine oil pressure
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Slightly loosen the oil check bolt “1”.
b. Start the engine and keep it idling until engine
oil starts to seep from the oil check bolt. If no
engine oil comes out after one minute, turn
the engine off so that it will not seize.
c. Check the engine oil passages and the oil
pump for damage or leakage. Refer to “OIL
PUMP” on page 5-45.
d. Start the engine after solving the problem(s)
and check the engine oil pressure again.
e. Tighten the oil check bolt to specification.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS30811
CHECKING THE COOLANT LEVEL
1. Stand the vehicle on a level surface.
TIP
• Place the vehicle on the centerstand.
• Make sure the vehicle is upright.
2. Check:
• Coolant level
The coolant level should be between the min-
imum level mark “a” and maximum level mark
“b”.
Below the minimum level mark Add the
recommended coolant to the proper level.
NOTICE
ECA13470
• Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant check, and if nec-
essary, correct the antifreeze concentra-
tion of the coolant.
• Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.
3. Start the engine, warm it up for several min-
utes, and then turn it off.
4. Check:
• Coolant level
TIP
Before checking the coolant level, wait a few
minutes until the coolant has settled.
T
R
.
.
Engine oil drain bolt
20 N·m (2.0 kgf·m, 14 lb·ft)
Engine oil quantity
Quantity (disassembled)
1.00 L (1.06 US qt, 0.88 Imp.qt)
Periodic oil change
0.90 L (0.95 US qt, 0.79 Imp.qt)
New
1
T
R
.
.
Engine oil check bolt
7 N·m (0.7 kgf·m, 5.1 lb·ft)
b
a
B63-F8197-EZ.book Page 18 Monday, January 23, 2017 4:12 PM
PERIODIC MAINTENANCE
3-19
EAS30812
CHECKING THE COOLING SYSTEM
1. Remove:
•Radiator cover
Refer to “RADIATOR” on page 6-1.
2. Check:
• Radiator “1”
• Coolant reservoir hose “2”
• Radiator inlet hose “3”
• Radiator outlet hose “4”
• Thermostat assembly “5”
• Water pump inlet hose “6”
Cracks/tears Replace.
Refer to “RADIATOR” on page 6-1 and
“THERMOSTAT” on page 6-4.
3. Install:
•Radiator cover
Refer to “RADIATOR” on page 6-1.
EAS30813
CHANGING THE COOLANT
1. Remove:
• Front side cover assembly (right)
Refer to “GENERAL CHASSIS (2)” on page
4-3.
• Footrest board (right)
Refer to “GENERAL CHASSIS (6)” on page
4-16.
2. Remove:
• Coolant reservoir cap “1”
3. Disconnect:
• Coolant reservoir hose “1”
4. Drain:
• Coolant
(from the coolant reservoir)
5. Remove:
• Radiator cover “1”
6. Remove:
• Radiator cap “1”
WARNING
EWA13030
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the en-
gine is hot. Scalding hot fluid and steam may
be blown out, which could cause serious in-
jury. When the engine has cooled, open the
radiator cap as follows:
Place a thick rag or a towel over the radiator
cap and slowly turn the radiator cap counter-
clockwise toward the detent to allow any re-
sidual pressure to escape. When the hissing
2
6
4
3
1
5
1
1
1
1
B63-F8197-EZ.book Page 19 Monday, January 23, 2017 4:12 PM
PERIODIC MAINTENANCE
3-20
sound has stopped, press down on the radi-
ator cap and turn it counterclockwise to re-
move.
7. Remove:
• Coolant drain bolt (radiator side) “1”
(along with the O-ring)
• Coolant drain bolt (cylinder side) “2”
(along with the copper washer)
8. Drain:
• Coolant
(from the engine and radiator)
9. Install:
• Coolant drain bolt (cylinder side)
(along with the copper washer )
• Coolant drain bolt (radiator side)
(along with the O-ring )
10.Connect:
• Coolant reservoir hose
11.Fill:
• Cooling system
(with the specified amount of the recom-
mended coolant)
Handling notes for coolant
Coolant is potentially harmful and should be
handled with special care.
WARNING
EWA13040
• If coolant splashes in your eyes, thoroughly
wash them with water and consult a doctor.
• If coolant splashes on your clothes, quickly
wash it away with water and then with soap
and water.
• If coolant is swallowed, induce vomiting
and get immediate medical attention.
NOTICE
ECA13481
• Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant, check, and if nec-
essary, correct the antifreeze concentra-
tion of the coolant.
• Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.
• If coolant comes into contact with painted
surfaces, immediately wash them with wa-
ter.
• Do not mix different types of antifreeze.
12.Install:
• Radiator cap
13.Fill:
• Coolant reservoir
(with the recommended coolant to the maxi-
mum level mark “a”)
T
R
.
.
Coolant drain bolt (cylinder side)
10 N·m (1.0 kgf·m, 7.2 lb·ft)
Coolant drain bolt (radiator side)
1.0 N·m (0.10 kgf·m, 0.72 lb·ft)
1
2
New
New
Recommended antifreeze
YAMAHA GENUINE COOLANT
Mixing ratio
1:1 (antifreeze: water)
Radiator (including all routes)
0.46 L (0.49 US qt, 0.40 Imp.qt)
Coolant reservoir (up to the
maximum level mark)
0.13 L (0.13 US qt, 0.11 Imp.qt)
a
B63-F8197-EZ.book Page 20 Monday, January 23, 2017 4:12 PM
PERIODIC MAINTENANCE
3-21
14.Install:
• Coolant reservoir cap “1”
TIP
Point the tab “a” on the coolant reservoir cap for-
ward.
15.Start the engine, warm it up for several min-
utes, and then turn it off.
16.Check:
• Coolant level
Refer to “CHECKING THE COOLANT LEV-
EL” on page 3-18.
TIP
Before checking the coolant level, wait a few
minutes until the coolant has settled.
17.Install:
•Radiator cover
18.Install:
• Footrest board (right)
Refer to “GENERAL CHASSIS (6)” on page
4-16.
• Front side cover assembly (right)
Refer to “GENERAL CHASSIS (2)” on page
4-3.
EAS31187
CHANGING THE FINAL TRANSMISSION OIL
1. Stand the vehicle on a level surface.
TIP
• Place the vehicle on the centerstand.
• Make sure the vehicle is upright.
2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Place a container under the final transmis-
sion.
4. Remove:
• Final transmission oil filler cap “1”
(along with the O-ring “2”)
• Final transmission oil drain bolt “3”
(along with the copper washer “4”)
Completely drain the final transmission oil.
5. Install:
• Final transmission oil drain bolt
(along with the copper washer )
6. Fill:
• Final transmission oil
(with the specified amount of the recom-
mended final transmission oil)
7. Install:
• Final transmission oil filler cap
(along with the O-ring )
TIP
Lubricate the O-ring with lithium-soap-based
grease.
8. Start the engine, warm it up for several min-
utes, and then turn it off.
9. Check:
• Final transmission oil leakage
T
R
.
.
Radiator cover bolt
10 N·m (1.0 kgf·m, 7.2 lb·ft)
1
a
FWDFWD
T
R
.
.
Final transmission oil drain bolt
20 N·m (2.0 kgf·m, 14 lb·ft)
Final transmission oil
Type
Motor oil SAE 10W-30 type SE
or higher or Gear oil SAE 85W
GL-3
Quantity
0.15 L (0.16 US qt, 0.13 Imp.qt)
1
2
3 4
New
New
B63-F8197-EZ.book Page 21 Monday, January 23, 2017 4:12 PM
PERIODIC MAINTENANCE
3-22
EAS31188
REPLACING THE V-BELT
1. Remove:
• Air filter case
Refer to “AIR FILTER CASE” on page 7-7.
• V-belt case
Refer to “V-BELT AUTOMATIC TRANSMIS-
SION” on page 5-34.
2. Check:
• V-belt
Damage/wear Replace.
Grease/oil Clean the primary and second-
ary pulleys.
Refer to “V-BELT AUTOMATIC TRANSMIS-
SION” on page 5-34.
TIP
Replace the V-belt every 25000 km (15500 mi)
of operation.
3. Install:
• V-belt case
Refer to “V-BELT AUTOMATIC TRANSMIS-
SION” on page 5-34.
• Air filter case
Refer to “AIR FILTER CASE” on page 7-7.
EAS31705
LUBRICATING THE SECONDARY SHEAVE
1. Remove:
• Air filter case
Refer to “AIR FILTER CASE” on page 7-7.
• Secondary sheave assembly
Refer to “V-BELT AUTOMATIC TRANSMIS-
SION” on page 5-34.
2. Disassemble:
• Secondary sheave assembly
Refer to “V-BELT AUTOMATIC TRANSMIS-
SION” on page 5-34.
3. Lubricate:
• Spring seat“1”
• O-rings “2”
• Oil seals “3”
• Secondary sliding sheave“4”
• Secondary fixed sheave“5”
4. Assemble:
• Secondary sheave assembly
Refer to “V-BELT AUTOMATIC TRANSMIS-
SION” on page 5-34.
5. Install:
• Secondary sheave assembly
Refer to “V-BELT AUTOMATIC TRANSMIS-
SION” on page 5-34.
• Air filter case
Refer to “AIR FILTER CASE” on page 7-7.
EAS30658
CHECKING THE BRAKE LIGHT SWITCHES
1. Check:
• Front brake light switch operation
• Rear brake light switch operation
When operating the brake levers, confirm
that the brake light comes on.
Faulty Refer to “CHECKING THE
SWITCHES” on page 8-120.
EAS30660
CHECKING AND LUBRICATING THE
CABLES
The following procedure applies to all of the in-
ner and outer cables.
WARNING
EWA13270
Damaged outer cable may cause the cable to
corrode and interfere with its movement. Re-
place damaged outer cable and inner cables
as soon as possible.
Recommended lubricant
Shell dolium grease R®
3
3
1
5
4
2
B63-F8197-EZ.book Page 22 Monday, January 23, 2017 4:12 PM
PERIODIC MAINTENANCE
3-23
1. Check:
• Outer cable
Damage Replace.
2. Check:
• Cable operation
Rough movement Lubricate.
TIP
Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suit-
able lubricating device.
EAS30861
CHECKING THE THROTTLE GRIP
OPERATION
1. Check:
• Throttle cables
Damage/deterioration Replace.
• Throttle cable installation
Incorrect Reinstall the throttle cables.
Refer to “HANDLEBAR” on page 4-55.
2. Check:
• Throttle grip movement
Rough movement Lubricate or replace the
defective part(s).
TIP
With the engine stopped, turn the throttle grip
slowly and release it. Make sure that the throttle
grip turns smoothly and returns properly when
released.
Repeat this check with the handlebar turned all
the way to the left and right.
3. Check:
• Throttle grip free play “a”
Out of specification Adjust.
4. Adjust:
• Throttle grip free play
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Slide back the rubber cover “1”.
b. Loosen the locknut “3”.
c. Turn the adjusting nut “2” in direction “a” or “b”
until the specified throttle grip free play is ob-
tained.
d. Tighten the locknut.
e. Slide the rubber cover its original position.
TIP
Make sure that the adjusting nut is covered com-
pletely by the rubber cover.
WARNING
EWA17990
After adjusting the throttle grip free play,
start the engine and turn the handlebars to
the right and to the left to ensure that this
does not cause the engine idling speed to
change.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
Recommended lubricant
Engine oil or a suitable cable lu-
bricant
Recommended lubricant
Suitable cable lubricant
Throttle grip free play
3.0–5.0 mm (0.12–0.20 in)
Direction “a”
Throttle grip free play is increased.
Direction “b”
Throttle grip free play is decreased.
T
R
.
.
Throttle cable adjusting locknut
3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
A
A
a
b
a
12
3
B63-F8197-EZ.book Page 23 Monday, January 23, 2017 4:12 PM
PERIODIC MAINTENANCE
3-24
EAS30663
CHECKING THE SWITCHES, LIGHTS AND
SIGNALS
1. Check that all switches operate and that all
lights come on.
Refer to “INSTRUMENT AND CONTROL
FUNCTIONS” in Owner’s manual.
Faulty Refer to “CHECKING THE
SWITCHES” on page 8-120 and “CHECK-
ING THE BULBS AND BULB SOCKETS” on
page 8-123.
EAS30664
ADJUSTING THE HEADLIGHT BEAM
1. Adjust:
• Headlight beam (vertically)
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Turn the adjusting bolt “1” in direction “a” or
“b”.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
Direction “a”
Headlight beam is raised.
Direction “b”
Headlight beam is lowered.
B63-F8197-EZ.book Page 24 Monday, January 23, 2017 4:12 PM
PERIODIC MAINTENANCE
3-25
B63-F8197-EZ.book Page 25 Monday, January 23, 2017 4:12 PM
4
CHASSIS
GENERAL CHASSIS (1) .................................................................................4-1
REMOVING THE BATTERY COVER .......................................................4-2
INSTALLING THE BATTERY COVER ......................................................4-2
GENERAL CHASSIS (2) .................................................................................4-3
REMOVING THE TAIL/BRAKE LIGHT OUTER COVER ..........................4-4
INSTALLING THE TAIL/BRAKE LIGHT OUTER COVER.........................4-4
REMOVING THE FRONT SIDE COVER ASSEMBLY..............................4-4
INSTALLING THE FRONT SIDE COVER ASSEMBLY ............................4-5
REMOVING THE MOLE SIDE COVER .................................................... 4-5
INSTALLING THE MOLE SIDE COVER ................................................... 4-5
GENERAL CHASSIS (3) .................................................................................4-6
REMOVING THE REAR SIDE COVER ASSEMBLY ................................4-8
INSTALLING THE REAR SIDE COVER ASSEMBLY...............................4-8
GENERAL CHASSIS (4) .................................................................................4-9
REMOVING THE FRONT UPPER COWLING ASSEMBLY ...................4-10
INSTALLING THE FRONT UPPER COWLING ASSEMBLY ..................4-10
DISASSEMBLING THE FRONT UPPER COWLING ASSEMBLY..........4-10
ASSEMBLING THE FRONT UPPER COWLING ASSEMBLY................4-10
GENERAL CHASSIS (5) ...............................................................................4-12
REMOVING THE FRONT COWLING ASSEMBLY.................................4-13
INSTALLING THE FRONT COWLING ASSEMBLY ...............................4-13
REMOVING THE FRONT SIDE COWLING ............................................4-13
INSTALLING THE FRONT SIDE COWLING ..........................................4-14
REMOVING THE FRONT BODY COWLING .......................................... 4-14
INSTALLING THE FRONT BODY COWLING.........................................4-14
INSTALLING THE FRONT TURN SIGNAL LIGHT .................................4-15
GENERAL CHASSIS (6) ...............................................................................4-16
INSTALLING THE FOOTREST BOARD .................................................4-17
INSTALLING THE LOWER MOLE COVER ............................................4-17
GENERAL CHASSIS (7) ...............................................................................4-18
INSTALLING THE CENTER LOWER COVER........................................4-19
FRONT WHEEL.............................................................................................4-20
REMOVING THE FRONT WHEEL.......................................................... 4-22
DISASSEMBLING THE FRONT WHEEL ................................................4-22
CHECKING THE FRONT WHEEL ..........................................................4-22
B63-F8197-EZ.book Page 1 Monday, January 23, 2017 4:12 PM
MAINTENANCE OF THE FRONT WHEEL SENSOR
AND SENSOR ROTOR ..........................................................................4-23
ASSEMBLING THE FRONT WHEEL......................................................4-23
ADJUSTING THE FRONT WHEEL STATIC BALANCE .........................4-24
INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC)..................4-25
REAR WHEEL ...............................................................................................4-28
CHECKING THE REAR WHEEL.............................................................4-29
ADJUSTING THE REAR WHEEL STATIC BALANCE............................4-29
FRONT BRAKE.............................................................................................4-30
INTRODUCTION ..................................................................................... 4-36
CHECKING THE FRONT BRAKE DISC .................................................4-36
REPLACING THE FRONT BRAKE PADS ..............................................4-37
REMOVING THE FRONT BRAKE CALIPER..........................................4-38
DISASSEMBLING THE FRONT BRAKE CALIPER ................................4-38
CHECKING THE FRONT BRAKE CALIPER ..........................................4-39
ASSEMBLING THE FRONT BRAKE CALIPER ......................................4-39
INSTALLING THE FRONT BRAKE CALIPER ........................................4-39
REMOVING THE FRONT BRAKE MASTER CYLINDER .......................4-40
CHECKING THE FRONT BRAKE MASTER CYLINDER........................4-41
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ...................4-41
INSTALLING THE FRONT BRAKE MASTER CYLINDER......................4-41
REAR BRAKE ...............................................................................................4-43
REMOVING THE REAR BRAKE.............................................................4-44
CHECKING THE REAR BRAKE SHOES................................................4-44
ASSEMBLING THE REAR BRAKE SHOE PLATE .................................4-45
CHECKING THE REAR BRAKE DRUM WEAR LIMIT ...........................4-46
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)......................................4-47
REMOVING THE HYDRAULIC UNIT ASSEMBLY .................................4-49
CHECKING THE HYDRAULIC UNIT ASSEMBLY ..................................4-49
INSTALLING THE HYDRAULIC UNIT ASSEMBLY................................4-49
HYDRAULIC UNIT OPERATION TESTS................................................4-51
CHECKING THE ABS WARNING LIGHT ...............................................4-54
HANDLEBAR ................................................................................................4-55
REMOVING THE FRONT HANDLEBAR COVER ASSEMBLY ..............4-57
DISASSEMBLING THE FRONT HANDLEBAR COVER ASSEMBLY ....4-57
REMOVING THE HANDLEBAR..............................................................4-57
CHECKING THE HANDLEBAR ..............................................................4-57
INSTALLING THE HANDLEBAR ............................................................4-57
ASSEMBLING THE FRONT HANDLEBAR COVER ASSEMBLY ..........4-59
INSTALLING THE FRONT HANDLEBAR COVER ASSEMBLY.............4-59
B63-F8197-EZ.book Page 2 Monday, January 23, 2017 4:12 PM
FRONT FORK................................................................................................ 4-60
REMOVING THE FRONT FORK LEGS..................................................4-62
DISASSEMBLING THE FRONT FORK LEGS ........................................4-62
CHECKING THE FRONT FORK LEGS ..................................................4-63
ASSEMBLING THE FRONT FORK LEGS ..............................................4-63
INSTALLING THE FRONT FORK LEGS ................................................ 4-66
STEERING HEAD..........................................................................................4-67
REMOVING THE LOWER BRACKET.....................................................4-69
CHECKING THE STEERING HEAD .......................................................4-69
INSTALLING THE STEERING HEAD .....................................................4-69
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM...................4-71
REMOVING THE SWINGARM................................................................4-73
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ...................4-73
CHECKING THE SWINGARM ................................................................4-73
INSTALLING THE SWINGARM .............................................................. 4-73
B63-F8197-EZ.book Page 3 Monday, January 23, 2017 4:12 PM
GENERAL CHASSIS (1)
4-1
EAS20026
GENERAL CHASSIS (1)
Removing the battery and battery cover
Order Job/Parts to remove Q’ty Remarks
Seat Open.
1 Battery cover 1
2 Negative battery lead 1 Disconnect.
3 Positive battery lead 1 Disconnect.
4 Battery 1
2
1
3
4
B63-F8197-EZ.book Page 1 Monday, January 23, 2017 4:12 PM
GENERAL CHASSIS (1)
4-2
EAS31677
REMOVING THE BATTERY COVER
1. Remove:
• Battery cover “1”
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Open the seat.
b. Remove the battery cover screws.
c. Slide the battery cover rearward to remove
the projections “a” on the battery cover from
the holes “b” in the storage box.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS31678
INSTALLING THE BATTERY COVER
1. Install:
• Battery cover “1”
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Fit the projections “a” on the battery cover
into the holes “b” in the storage box, and then
slide the cover forward.
b. Install the battery cover screws, and then
tighten the screws to specification.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
1
a
a
b
T
R
.
.
Battery cover screw
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
1
a
a
b
B63-F8197-EZ.book Page 2 Monday, January 23, 2017 4:12 PM
GENERAL CHASSIS (2)
4-3
EAS20155
GENERAL CHASSIS (2)
Removing the front side cover assembly and tail/brake light outer cover
Order Job/Parts to remove Q’ty Remarks
1
Tail/brake light outer cover
1
2 Front side cover (right) 1
3 Mole side cover (right) 1
4 Front side cover (left) 1
5 Mole side cover (left) 1
2
3
5
1
4
B63-F8197-EZ.book Page 3 Monday, January 23, 2017 4:12 PM
GENERAL CHASSIS (2)
4-4
EAS31681
REMOVING THE TAIL/BRAKE LIGHT OUTER
COVER
1. Remove:
• Tail/brake light outer cover “1”
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Remove the tail/brake light outer cover
screws.
b. Slide the tail/brake light outer cover rearward
to remove the projection “a” on the cover from
the hole “b” in the tail/brake light.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS31682
INSTALLING THE TAIL/BRAKE LIGHT
OUTER COVER
1. Install:
• Tail/brake light outer cover “1”
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Slide the tail/brake light outer cover forward,
fit the projection “a” on the cover into the hole
“b” in the tail/brake light.
b. Install the tail/brake light outer cover screws,
and then tighten the screws to specification.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS31683
REMOVING THE FRONT SIDE COVER
ASSEMBLY
The following procedure applies to both of the
front side cover assembly.
1. Remove:
• Front side cover assembly “1”
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Remove the front side cover assembly
screws.
b. Pull the front side cover assembly outward to
remove the projections “a” from the grom-
mets “b”.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
1
a
b
T
R
.
.
Tail/brake light outer cover screw
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
1
a
b
1
a
b
B63-F8197-EZ.book Page 4 Monday, January 23, 2017 4:12 PM
GENERAL CHASSIS (2)
4-5
EAS31684
INSTALLING THE FRONT SIDE COVER
ASSEMBLY
The following procedure applies to both of the
front side cover assembly.
1. Install:
• Front side cover assembly “1”
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Fit the projections “a” on the front side cover
assembly into the grommets “b”.
b. Install the front side cover assembly screws,
and then tighten the screw to specification.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
REMOVING THE MOLE SIDE COVER
1. Remove:
• Mole side cover “1”
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Remove the mole side cover screws.
b. Pull the mole side cover outward to remove
the projections “a” from the grommets “b”.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
INSTALLING THE MOLE SIDE COVER
1. Install:
• Mole side cover “1”
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Fit the projections “a” on the mole side cover
into the grommets “b”.
b. Install the mole side cover screws and then
tighten the screws to specitification.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
T
R
.
.
Front side cover screw
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
1
a
b
T
R
.
.
Front side cover screw
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
b
a
1
b
a
1
B63-F8197-EZ.book Page 5 Monday, January 23, 2017 4:12 PM
GENERAL CHASSIS (3)
4-6
EAS20157
GENERAL CHASSIS (3)
Removing the rear side covers and storage box
Order Job/Parts to remove Q’ty Remarks
Battery
Refer to “GENERAL CHASSIS (1)” on page
4-1.
Front side cover
Refer to “GENERAL CHASSIS (2)” on page
4-3.
1 Rear side cover (left) 1
2 Rear side cover (right) 1
3 Storage box 1
4 Pin (seat) 1
5 Hinge (seat) 1
3
2
1
5
4
T
R
.
.
••
9 N m (0.9kgf
m, 6.5lb.ft)
T
R
.
.
••
9 N m (0.9kgf
m, 6.5lb.ft)
B63-F8197-EZ.book Page 6 Monday, January 23, 2017 4:12 PM
GENERAL CHASSIS (3)
4-7
Removing the rear fender
Order Job/Parts to remove Q’ty Remarks
1 Grab bar (left) 1
2 Grab bar (right) 1
3Tail cover 1
4 Rear fender 1 1
5 Rear fender 2 1
3
2
T
R
.
.
•
•
11 N m (1.1kgf
m, 8.0lb.ft)
T
R
.
.
•
•
4 N m (0.4kgf
m, 2.9lb.ft)
T
R
.
.
•
•
9 N m (0.9kgf
m, 6.5lb.ft)
T
R
.
.
••
9 N m (0.9kgf
m, 6.5lb.ft)
4
5
T
R
.
.
••
11 N m (1.1kgf
m, 8.0lb.ft)
1
B63-F8197-EZ.book Page 7 Monday, January 23, 2017 4:12 PM
GENERAL CHASSIS (3)
4-8
EAS31687
REMOVING THE REAR SIDE COVER
ASSEMBLY
The following procedure applies to both of the
rear side cover assembly.
1. Remove:
• Rear side cover assembly “1”
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Remove the screws.
b. Remove the projections “a” on the rear side
cover assembly from the holes “b” in the stor-
age box.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS31688
INSTALLING THE REAR SIDE COVER
ASSEMBLY
The following procedure applies to both of the
rear side cover assembly.
1. Install:
• Rear side cover assembly “1”
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Fit the projections “a” on the rear side cover
assembly into the holes “b” in the storage
box.
b. Install the screws, and then tighten the
screws to specification.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
a
b
1
b
a
T
R
.
.
Rear side cover assembly screw
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
1
a
b
a
B63-F8197-EZ.book Page 8 Monday, January 23, 2017 4:12 PM
GENERAL CHASSIS (4)
4-9
EAS20159
GENERAL CHASSIS (4)
Removing the front upper cowling assembly
Order Job/Parts to remove Q’ty Remarks
1 Front upper cowling assembly 1
2 Front upper cowling 1 1
3 Front upper cowling 2 1
2
1
3
B63-F8197-EZ.book Page 9 Monday, January 23, 2017 4:12 PM
GENERAL CHASSIS (4)
4-10
EAS31692
REMOVING THE FRONT UPPER COWLING
ASSEMBLY
1. Remove:
• Front upper cowling assembly “1”
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Remove the front upper cowling assembly
screw.
b. Remove the projections “a” on the front upper
cowling assembly from the holes “b” in the leg
shield and remove the projections “c” from
the holes “d” in the headlight unit.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS31693
INSTALLING THE FRONT UPPER COWLING
ASSEMBLY
1. Install:
• Front upper cowling assembly “1”
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Fit the projections “a” on the front upper cowl-
ing assembly into the holes “b” in the head-
light unit and fit the projections “c” into the
holes “d” in the leg shield.
b. Install the front upper cowling assembly
screw, and then tighten the screw to specifi-
cation.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS31694
DISASSEMBLING THE FRONT UPPER
COWLING ASSEMBLY
1. Disassemble:
• Front upper cowling “1”
• Front upper panel “2”
TIP
Remove the projections “a” on the front upper
cowling from the holes “b” in the front upper pan-
el, slide the panel in the direction shown in the il-
lustration, and remove the projections “c” on the
panel from the holes “d” in the cowling.
EAS31695
ASSEMBLING THE FRONT UPPER
COWLING ASSEMBLY
1. Assemble:
• Front upper panel “1”
• Front upper cowling “2”
1
d
c
b
a
T
R
.
.
Front upper cowling assembly
screw
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T
R
.
.
Front upper panel screw
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
1
d
c
b
a
1
2
B63-F8197-EZ.book Page 10 Monday, January 23, 2017 4:12 PM
GENERAL CHASSIS (4)
4-11
TIP
Slide the front upper panel in the direction
shown in the illustration, fit the projections “a” on
the panel into the holes “b” in the front upper
cowling, and fit the projections “c” on the cowling
into the holes “d” in the panel.
1
2
B63-F8197-EZ.book Page 11 Monday, January 23, 2017 4:12 PM
GENERAL CHASSIS (5)
4-12
EAS20193
GENERAL CHASSIS (5)
Removing the front cowling assembly
Order Job/Parts to remove Q’ty Remarks
Front upper cowling assembly
Refer to “GENERAL CHASSIS (4)” on page
4-9.
1 Front turn signal light (left) 1 Disconnect
2 Front turn signal light (right) 1 Disconnect
3 Headlight unit assembly 1 Disconnect
4 Front side cowling (left) 1
5
Front body cowling (left)
1
6
Front lower cowling
1
7
Front side cowling (right)
1
8 Front body cowling (right) 1
T
R
.
.
••
9 N m (0.9kgf m, 6.5lb.ft)
8
7
2
6
3
1
5
4
B63-F8197-EZ.book Page 12 Monday, January 23, 2017 4:12 PM
GENERAL CHASSIS (5)
4-13
EAS31278
REMOVING THE FRONT COWLING
ASSEMBLY
1. Remove:
• Front cowling assembly “1”
• Disconnect turn signal light coupler
• Disconnect head light coupler
• Disconnect auxiliary coupler
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Remove the front cowling assembly screws.
b. Pull the front cowling assembly forward to re-
move the projections “a” on the leg shield
from the holes “b” in the front cowling assem-
bly.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS31279
INSTALLING THE FRONT COWLING
ASSEMBLY
1. Install:
• Disconnect turn signal light coupler
• Disconnect head light coupler
• Disconnect auxiliary coupler
• Front cowling assembly “1”
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Fit the projections “a” on the leg shield into
the holes “b” in the front cowling assembly.
b. Install the front cowling assembly screws,
and then tighten the screws to specification.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS31696
REMOVING THE FRONT SIDE COWLING
The following procedure applies to both of the
front side cowling.
1. Remove:
• Front side cowling “1”
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Removing the front side cowling screws.
b. Remove the projections “a” on the front side
cowling from the holes “b” in the front lower
cowling.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
1
b
a
T
R
.
.
Front cowling assembly screw
(M5 6)
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
Front cowling assembly bolt
10 N·m (1.0 kgf·m, 7.2 lb·ft)
1
b
a
b
a
1
B63-F8197-EZ.book Page 13 Monday, January 23, 2017 4:12 PM
GENERAL CHASSIS (5)
4-14
EAS31697
INSTALLING THE FRONT SIDE COWLING
The following procedure applies to both of the
front side cowling.
1. Install:
• Front side cowling “1”
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Fit the projections “a” on the front side cowl-
ing into the holes “b” in the front lower cowl-
ing.
b. Install the front side cowling screws, and then
tighten the screws to specification.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
REMOVING THE FRONT BODY COWLING
1. Remove:
• Front body cowling “1”
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Remove the front body cowling screws.
b. Pull the front body cowling forward to remove
the projections “a” on the front cowling as-
sembly from the holes “b” in the front body
cowling.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
INSTALLING THE FRONT BODY COWLING
1. Install:
• Front body cowling “1”
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Fit the projections “a” on the front body cowl-
ing into the holes “b” in the front cowling as-
sembly.
T
R
.
.
Front side cowling screw
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
b
a
1
1
a
b
B63-F8197-EZ.book Page 14 Monday, January 23, 2017 4:12 PM
GENERAL CHASSIS (5)
4-15
b. Install the front body cowling screws and then
tighten the screws to specitification.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS31698
INSTALLING THE FRONT TURN SIGNAL
LIGHT
The following procedure applies to both of the
front turn signal light.
1. Install:
• Turn signal light “1”
TIP
Tighten the turn signal light screw in the proper
tightening sequence as shown.
T
R
.
.
Front body cowling screw
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T
R
.
.
Turn signal light screw
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
1
a
b
1
B63-F8197-EZ.book Page 15 Monday, January 23, 2017 4:12 PM
GENERAL CHASSIS (6)
4-16
EAS20158
GENERAL CHASSIS (6)
Removing the footrest board assembly
Order Job/Parts to remove Q’ty Remarks
Front upper cowling assembly
Refer to “GENERAL CHASSIS (4)” on page
4-9.
Front cowling assembly
Refer to “GENERAL CHASSIS (5)” on page
4-12.
1 Footrest board assembly (right) 1
2 Front lower cover (right) 1
3 Footrest board mat (right) 1
4 Footrest board (right) 1
5 Footrest board assembly (left) 1
6 Footrest board mat (left) 1
7 Front lower cover (left) 1
8 Footrest board (left) 1
6
2
1
8
7
5
4
3
T
R
.
.
•
•
7 N m (0.7kgf
m, 5.1lb.ft)
T
R
.
.
••
4 N m (0.4kgf
m, 2.9lb.ft)
T
R
.
.
••
4 N m (0.4kgf
m, 2.9lb.ft)
T
R
.
.
••
7 N m (0.7kgf m, 5.1lb.ft)
B63-F8197-EZ.book Page 16 Monday, January 23, 2017 4:12 PM
GENERAL CHASSIS (6)
4-17
EAS31690
INSTALLING THE FOOTREST BOARD
1. Install:
• Footrest board “1”
TIP
Make sure that the projection “a” on the frame
fits into the hole “b” in the footrest board assem-
bly.
EAS31691
INSTALLING THE LOWER MOLE COVER
1. Install:
• Lower mole cover “1”
TIP
Make sure that the projections “a” on the center
lower cover fit into the holes “b” in the bottom
cover.
T
R
.
.
Footrest board assembly bolt
10 N·m (1.0 kgf·m, 7.2 lb·ft)
1
b
a
1
b
a
B63-F8197-EZ.book Page 17 Monday, January 23, 2017 4:12 PM
GENERAL CHASSIS (7)
4-18
EAS20194
GENERAL CHASSIS (7)
Removing the leg shield
Order Job/Parts to remove Q’ty Remarks
Battery
Refer to “GENERAL CHASSIS (1)” on page
4-1.
Front side covers
Refer to “GENERAL CHASSIS (2)” on page
4-3.
Seat assembly
Refer to “GENERAL CHASSIS (3)” on page
4-6.
Storage box
Refer to “GENERAL CHASSIS (3)” on page
4-6.
Front cowling assembly
Refer to “GENERAL CHASSIS (5)” on page
4-12.
1
Center lower cover
1
2
Side cover (left)
1
3 Side cover (right) 1
4 Center cover assembly 1
5 Fuel tank cover 1
6 Center cover 1
7
Leg shield
1
1
2
4
5
6
7
3
T
R
.
.
•
•
7 N m (0.7kgf
m, 5.1lb.ft)
T
R
.
.
••
9 N m (0.9kgf
m, 6.5lb.ft)
T
R
.
.
••
9 N m (0.9kgf
m, 6.5lb.ft)
B63-F8197-EZ.book Page 18 Monday, January 23, 2017 4:12 PM
GENERAL CHASSIS (7)
4-19
EAS31689
INSTALLING THE CENTER LOWER COVER
1. Install:
• Center lower cover “1”
TIP
• Fit the end of the fuel tank overflow hose “2”
into the hole “a” in the center lower cover.
• Fit the hole “b” in the center lower cover over
the hook “c” on the frame.
1
2
b
a
c
e
d
B63-F8197-EZ.book Page 19 Monday, January 23, 2017 4:12 PM
FRONT WHEEL
4-20
EAS20028
FRONT WHEEL
Removing the front wheel and brake disc
Order Job/Parts to remove Q’ty Remarks
1 Front brake hose guide 1
2
Front brake caliper 1
3 Front wheel sensor 1
4
Front wheel axle nut 1
5 Front wheel axle 1
6 Collar 2
7 Front wheel 1
8 Front wheel sensor rotor 1
9 Front brake disc 1
1
a
b
a
1
2
1
a
b
c
d
e
7 N
•
m (0.7 kgf
•
m, 5.1 lb
•
ft)
8 N
•
m (0.8 kgf
•
m, 5.8 lb
•
ft)
23 N
•
m (2.3 kgf
•
m, 17 lb
•
ft)
35 N
•
m (3.5 kgf
•
m, 25 lb
•
ft)
26 N
•
m (2.6 kgf
•
m, 19 lb
•
ft)
B63-F8197-EZ.book Page 20 Monday, January 23, 2017 4:12 PM
FRONT WHEEL
4-21
Disassembling the front wheel
Order Job/Parts to remove Q’ty Remarks
1Oil seal 2
2 Wheel bearing 2
3Spacer 1
B63-F8197-EZ.book Page 21 Monday, January 23, 2017 4:12 PM
FRONT WHEEL
4-22
EAS30145
REMOVING THE FRONT WHEEL
NOTICE
ECA20981
• Keep any type of magnets (including mag-
netic pick-up tools, magnetic screwdrivers,
etc.) away from the front wheel sensor or
front wheel sensor rotor; otherwise, the
sensor or rotor may be damaged, resulting
in improper performance of the ABS sys-
tem.
• Do not drop the front wheel sensor rotor or
subject it to shocks.
• If any solvent gets on the front wheel sen-
sor rotor, wipe it off immediately.
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:
• Front brake caliper
NOTICE
ECA21830
Do not apply the brake lever when removing
the brake caliper.
3. Elevate:
• Front wheel
TIP
Place the vehicle on a suitable stand so that the
front wheel is elevated.
EAS30146
DISASSEMBLING THE FRONT WHEEL
1. Remove:
• Oil seals
• Wheel bearings
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Clean the surface of the front wheel hub.
b. Remove the oil seals “1” with a flat-head
screwdriver.
TIP
To prevent damaging the wheel, place a rag “2”
between the screwdriver and the wheel surface.
c. Remove the wheel bearings “3” with a gener-
al bearing puller.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS30147
CHECKING THE FRONT WHEEL
1. Check:
• Wheel axle
Roll the wheel axle on a flat surface.
Bends Replace.
WARNING
EWA13460
Do not attempt to straighten a bent wheel
axle.
2. Check:
•Tire
• Front wheel
Damage/wear Replace.
Refer to “CHECKING THE TIRES” on page
3-12 and “CHECKING THE WHEELS” on
page 3-12.
3. Measure:
• Radial wheel runout “1”
2
1
B63-F8197-EZ.book Page 22 Monday, January 23, 2017 4:12 PM
FRONT WHEEL
4-23
• Lateral wheel runout “2”
Over the specified limits Replace.
4. Check:
• Wheel bearings
Front wheel turns roughly or is loose Re-
place the wheel bearings.
• Oil seals
Damage/wear Replace.
EAS30155
MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR
NOTICE
ECA21070
• Handle the ABS components with care
since they have been accurately adjusted.
Keep them away from dirt and do not sub-
ject them to shocks.
• The front wheel sensor cannot be disas-
sembled. Do not attempt to disassemble it.
If faulty, replace with a new one.
• Keep any type of magnets (including mag-
netic pick-up tools, magnetic screwdrivers,
etc.) away from the front wheel sensor or
front wheel sensor rotor.
• Do not drop or shock the wheel sensor or
the wheel sensor rotor.
1. Check:
• Front wheel sensor “1”
Cracks/bends/distortion Replace.
Iron powder/dust Clean.
2. Check:
• Front wheel sensor rotor “1”
Cracks/damage/scratches Replace the
front wheel sensor rotor.
Iron powder/dust/solvent Clean.
TIP
When cleaning the wheel sensor rotor, be care-
ful not to damage the surface of the sensor rotor.
EAS30151
ASSEMBLING THE FRONT WHEEL
1. Lubricate:
• Oil seal lips
2. Install:
• Wheel bearings
• Oil seals
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Install the new wheel bearing (right side).
NOTICE
ECA18110
Do not contact the wheel bearing inner race
“1” or balls “2”. Contact should be made
only with the outer race “3”.
Radial wheel runout limit
1.0 mm (0.04 in)
Lateral wheel runout limit
1.0 mm (0.04 in)
1
2
Recommended lubricant
Lithium-soap-based grease
1
New
New
B63-F8197-EZ.book Page 23 Monday, January 23, 2017 4:12 PM
FRONT WHEEL
4-24
TIP
Use a socket “4” that matches the diameter of
the wheel bearing outer race.
b. Install the spacer.
c. Install the new wheel bearing (left side).
TIP
Place a suitable washer “1” between the socket
“2” and the bearing so that both the inner race
“3” and outer race “4” are pressed at the same
time, and then press the bearing until the inner
race makes contact with the spacer “5”.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS30152
ADJUSTING THE FRONT WHEEL STATIC
BALANCE
TIP
• After replacing the tire, wheel or both, the front
wheel static balance should be adjusted.
• Adjust the front wheel static balance with the
brake disc installed.
1. Remove:
• Balancing weight(s)
2. Find:
• Front wheel’s heavy spot
TIP
Place the front wheel on a suitable balancing
stand.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Spin the front wheel.
b. When the front wheel stops, put an “X
1
” mark
at the bottom of the wheel.
c. Turn the front wheel 90° so that the “X
1
” mark
is positioned as shown.
d. Release the front wheel.
e. When the wheel stops, put an “X
2
” mark at
the bottom of the wheel.
f. Repeat steps (c) through (e) several times
until all the marks come to rest at the same
spot.
g. The spot where all the marks come to rest is
the front wheel’s heavy spot “X”.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
3. Adjust:
• Front wheel static balance
TIP
• Install the balancing weights on the rim of the
brake disc side of the wheel.
• Install up to four balancing weights on the rim.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Install a balancing weight “1” onto the rim ex-
actly opposite the heavy spot “X”.
TIP
Start with the lightest weight.
B63-F8197-EZ.book Page 24 Monday, January 23, 2017 4:12 PM
FRONT WHEEL
4-25
b. Turn the front wheel 90° so that the heavy
spot is positioned as shown.
c. If the heavy spot does not stay in that posi-
tion, install a heavier weight.
d. Repeat steps (b) and (c) until the front wheel
is balanced.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
4. Check:
• Front wheel static balance
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Turn the front wheel and make sure it stays at
each position shown.
b. If the front wheel does not remain stationary
at all of the positions, rebalance it.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS30154
INSTALLING THE FRONT WHEEL (FRONT
BRAKE DISC)
1. Install:
• Front brake disc “1”
• Front wheel sensor rotor “2”
NOTICE
ECA21011
• Do not drop the wheel sensor rotor or sub-
ject it to shocks.
• If any solvent gets on the wheel sensor ro-
tor, wipe it off immediately.
• Replace the brake disc bolts and wheel
sensor rotor bolts with new ones.
TIP
• Install the brake disc with its chamfered side
“a” facing inward.
• Install the front wheel sensor rotor with the
stamped mark “b” facing away from the wheel.
• Tighten the bolts in stages.
2. Check:
• Front brake disc
Refer to “CHECKING THE FRONT BRAKE
DISC” on page 4-36.
3. Lubricate:
• Wheel axle
T
R
.
.
Front wheel sensor rotor bolt
8 N·m (0.8 kgf·m, 5.8 lb·ft)
Front brake disc bolt
23 N·m (2.3 kgf·m, 17 lb·ft)
Recommended lubricant
Lithium-soap-based grease
1
a
1
b
2
B63-F8197-EZ.book Page 25 Monday, January 23, 2017 4:12 PM
FRONT WHEEL
4-26
4. Install:
• Front wheel
• Collars
• Front wheel axle
TIP
Install the front wheel with the mark “a” on the
front tire pointing in the direction of wheel rota-
tion.
5. Tighten:
• Front wheel axle nut
NOTICE
ECA14140
Before tightening the wheel axle nut, push
down hard on the handlebar(s) several times
and check if the front fork rebounds smooth-
ly.
6. Install:
• Front wheel sensor
NOTICE
ECA21020
Make sure there are no foreign materials in
the front wheel sensor rotor and front wheel
sensor. Foreign materials cause damage to
the front wheel sensor rotor and front wheel
sensor.
TIP
• When installing the front wheel sensor, check
the wheel sensor lead for twists.
• To route the front wheel sensor lead, refer to
“CABLE ROUTING” on page 2-20.
7. Measure:
• Distance “a”
(between the front wheel sensor rotor “1” and
front wheel sensor “2”)
Out of specification Check the wheel bear-
ing for looseness, and the front wheel sensor
and sensor rotor installation conditions (war-
page caused by overtorque, wrong installa-
tion direction, rotor decentering, LOCTITE®
on the mounting surface of the rotor, defor-
mation caused by an impact during service
and caught foreign materials). If there is any
defective part, repair or replace the defective
part.
TIP
Measure the distance between the front wheel
sensor rotor and front wheel sensor in several
places in one rotation of the front wheel. Do not
turn the front wheel while the thickness gauge is
installed. This may damage the front wheel sen-
sor rotor and the front wheel sensor.
8. Install:
• Front brake caliper
• Front brake hose guide “1”
WARNING
EWA13500
Make sure the brake hose is routed properly.
T
R
.
.
Front wheel axle nut
26 N·m (2.6 kgf·m, 19 lb·ft)
T
R
.
.
Front wheel sensor bolt
7 N·m (0.7 kgf·m, 5.1 lb·ft)
a
Distance “a” (between the front
wheel sensor rotor and front
wheel sensor)
0.81–1.57 mm (0.032–0.062 in)
Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9
T
R
.
.
Front brake caliper bolt
35 N·m (3.5 kgf·m, 25 lb·ft)
Front brake hose guide bolt
7 N·m (0.7 kgf·m, 5.1 lb·ft)
2
1
a
B63-F8197-EZ.book Page 26 Monday, January 23, 2017 4:12 PM
FRONT WHEEL
4-27
TIP
While holding the front brake hose guide and
front wheel sensor lead holder so that the por-
tions “a” of the guide and holder contact the front
fork outer tube, tighten the bolts to specification.
1
a
B63-F8197-EZ.book Page 27 Monday, January 23, 2017 4:12 PM
REAR WHEEL
4-28
EAS22020
REAR WHEEL
Removing the rear wheel
Order Job/Parts to remove Q’ty Remarks
Place the vehicle on the centerstand so that
the rear wheel is elevated.
Muffler Refer to “ENGINE REMOVAL” on page 5-3.
1Rear arm 1
2 Rear wheel 1
3 Rear brake shoe assembly 1
1
2
3
.R.
95 N
•
m (9.5 kgf
•
m, 69 lb
•
ft)
B63-F8197-EZ.book Page 28 Monday, January 23, 2017 4:12 PM
REAR WHEEL
4-29
EAS22090
CHECKING THE REAR WHEEL
1. Check:
•Tire
• Rear wheel
Damage/wear Replace.
Refer to “CHECKING THE TIRES” on page
3-12 and “CHECKING THE WHEELS” on
page 3-12.
2. Measure:
• Radial wheel runout
• Lateral wheel runout
Refer to “CHECKING THE FRONT WHEEL”
on page 4-22.
EAS22150
ADJUSTING THE REAR WHEEL STATIC
BALANCE
TIP
After replacing the tire, wheel or both, the rear
wheel static balance should be adjusted.
1. Adjust:
• Rear wheel static balance
Refer to “ADJUSTING THE FRONT WHEEL
STATIC BALANCE” on page 4-24.
B63-F8197-EZ.book Page 29 Monday, January 23, 2017 4:12 PM
FRONT BRAKE
4-30
EAS20030
FRONT BRAKE
Removing the front brake pads
Order Job/Parts to remove Q’ty Remarks
1 Front brake caliper 1
2 Brake pad clip 2
3 Brake pad pin 1
4 Brake pad (inner) 1
5 Brake pad (outer) 1
6 Brake pad spring 1
7 Brake caliper bleed screw 1
6 N
•
m (0.6 kgf
•
m, 4.3 lb
•
ft)
4
5
6
2
3
1
7
.R
.
35 N
•
m (3.5 kgf
•
m, 25 lb
•
ft)
B63-F8197-EZ.book Page 30 Monday, January 23, 2017 4:12 PM
FRONT BRAKE
4-31
Removing the front brake master cylinder
Order Job/Parts to remove Q’ty Remarks
Upper handlebar cover assembly Refer to “HANDLEBAR” on page 4-55.
Brake fluid
Drain.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-11.
1 Brake master cylinder reservoir cap 1
2
Brake master cylinder reservoir diaphragm hold-
er
1
3 Brake master cylinder reservoir diaphragm 1
4 Front brake light switch connector 2 Disconnect.
5 Front brake light switch 1
6 Front brake lever pivot bolt/nut 1/1
7 Front brake lever 1
8
Front brake hose union bolt (master cylinder
side)
1
9 Brake hose gasket 2
6 N
•
m (0.6 kgf
•
m, 4.3 lb
•
ft)
1.1 N
•
m (0.11 kgf
•
m, 0.80 lb
•
ft)
29 N
•
m (2.9 kgf
•
m, 21 lb
•
ft)
6 N
•
m (0.6 kgf
•
m, 4.3 lb
•
ft)
1.5 N
•
m (0.15 kgf
•
m, 1.1 lb
•
ft)
10 N
•
m (1.0 kgf
•
m, 7.2 lb
•
ft)
B63-F8197-EZ.book Page 31 Monday, January 23, 2017 4:12 PM
FRONT BRAKE
4-32
Removing the front brake master cylinder
Order Job/Parts to remove Q’ty Remarks
10
Front brake hose (front brake master cylinder to
hydraulic unit)
1 Disconnect.
11 Front brake master cylinder holder 1
12 Front brake master cylinder assembly 1
6 N
•
m (0.6 kgf
•
m, 4.3 lb
•
ft)
1.1 N
•
m (0.11 kgf
•
m, 0.80 lb
•
ft)
29 N
•
m (2.9 kgf
•
m, 21 lb
•
ft)
6 N
•
m (0.6 kgf
•
m, 4.3 lb
•
ft)
1.5 N
•
m (0.15 kgf
•
m, 1.1 lb
•
ft)
10 N
•
m (1.0 kgf
•
m, 7.2 lb
•
ft)
12
11
10
B63-F8197-EZ.book Page 32 Monday, January 23, 2017 4:12 PM
FRONT BRAKE
4-33
Disassembling the front brake master cylinder
Order Job/Parts to remove Q’ty Remarks
1 Brake master cylinder kit 1
2 Brake master cylinder body 1
New
1
2
BF
BF
S
B63-F8197-EZ.book Page 33 Monday, January 23, 2017 4:12 PM
FRONT BRAKE
4-34
Removing the front brake caliper
Order Job/Parts to remove Q’ty Remarks
Brake fluid
Drain.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-11.
1 Front brake hose union bolt (brake caliper side) 1
2 Brake hose gasket 2
3
Front brake hose (hydraulic unit to front brake
caliper)
1 Disconnect.
4 Front brake caliper 1
1
2
4
3
29 N
•
m (2.9 kgf
•
m, 21 lb
•
ft)
35 N
•
m (3.5 kgf
•
m, 25 lb
•
ft)
B63-F8197-EZ.book Page 34 Monday, January 23, 2017 4:12 PM
FRONT BRAKE
4-35
Disassembling the front brake caliper
Order Job/Parts to remove Q’ty Remarks
1 Brake pad clip 2
2 Brake pad pin 1
3 Brake pad (inner) 1
4 Brake pad (outer) 1
5 Brake pad spring 1
6 Front brake caliper bracket 1
7 Brake caliper piston 1
8 Brake caliper piston dust seal 1
9 Brake caliper piston seal 1
10 Brake caliper bleed screw 1
11 Brake caliper body 1
11
10
9
5
1
2
3
6
New
8
7
New
4
BF
S
S
S
T.R.
S
6 N
•
m (0.6 kgf
•
m, 4.3 lb
•
ft)
B63-F8197-EZ.book Page 35 Monday, January 23, 2017 4:12 PM
FRONT BRAKE
4-36
EAS30168
INTRODUCTION
WARNING
EWA14101
Disc brake components rarely require disas-
sembly. Therefore, always follow these pre-
ventive measures:
• Never disassemble brake components un-
less absolutely necessary.
• If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reas-
sembly.
• Never use solvents on internal brake com-
ponents.
• Use only clean or new brake fluid for clean-
ing brake components.
• Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
• Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get im-
mediate medical attention.
EAS30169
CHECKING THE FRONT BRAKE DISC
1. Remove:
• Front wheel
Refer to “FRONT WHEEL” on page 4-20.
2. Check:
• Brake disc
Damage/galling Replace.
3. Measure:
• Brake disc runout
Out of specification Correct the brake disc
runout or replace the brake disc.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Place the vehicle on a suitable stand so that
the front wheel is elevated.
b. Before measuring the front brake disc runout,
turn the handlebar to the left or right to ensure
that the front wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
e. Measure the runout 1.5 mm (0.06 in) below
the edge of the brake disc.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
4. Measure:
• Brake disc thickness
Measure the brake disc thickness at a few dif-
ferent locations.
Out of specification Replace.
5. Adjust:
• Brake disc runout
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
NOTICE
ECA19150
Replace the brake disc bolts with new ones.
TIP
• Install the brake disc “1” with its chamfered
side “a” facing inward.
• Tighten the brake disc bolts in stages.
Brake disc runout limit (as mea-
sured on wheel)
0.15 mm (0.0059 in)
Brake disc thickness limit
3.5 mm (0.14 in)
T
R
.
.
Front brake disc bolt
23 N·m (2.3 kgf·m, 17 lb·ft)
LOCTITE®
B63-F8197-EZ.book Page 36 Monday, January 23, 2017 4:12 PM
FRONT BRAKE
4-37
d. Measure the brake disc runout.
e. If out of specification, repeat the adjustment
steps until the brake disc runout is within
specification.
f. If the brake disc runout cannot be brought
within specification, replace the brake disc.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
6. Install:
• Front wheel
Refer to “FRONT WHEEL” on page 4-20.
EAS30170
REPLACING THE FRONT BRAKE PADS
TIP
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disassem-
ble the brake caliper.
1. Measure:
• Brake pad wear limit “a”
Out of specification Replace the brake
pads as a set.
2. Install:
• Brake pad spring “1”
• Brake pads
TIP
Always install new brake pads, and new brake
pad spring, as a set.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Connect a clear plastic hose “1” tightly to the
bleed screw “2”. Put the other end of the hose
into an open container.
b. Loosen the bleed screw and push the brake
caliper piston into the brake caliper with your
finger.
c. Tighten the bleed screw.
d. Install new brake pad spring and new brake
pads.
TIP
The longer tangs “a” of the brake pad spring
must point in the direction of the brake caliper
piston.
Brake pad lining thickness (in-
ner)
4.4 mm (0.17 in)
Limit
0.8 mm (0.03 in)
Brake pad lining thickness (out-
er)
4.4 mm (0.17 in)
Limit
0.8 mm (0.03 in)
1
a
1
a
A
A. Inner
B. Outer
T
R
.
.
Brake caliper bleed screw
6 N·m (0.6 kgf·m, 4.3 lb·ft)
a
B
1
2
B63-F8197-EZ.book Page 37 Monday, January 23, 2017 4:12 PM
FRONT BRAKE
4-38
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
3. Install:
• Brake pad pin
• Brake pad clips
• Front brake caliper
• Front brake hose guide “1”
• Front brake caliper bolts
4. Check:
• Brake fluid level
Below the minimum level mark “a” Add the
specified brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-10.
5. Check:
• Brake lever operation
Soft or spongy feeling Bleed the brake sys-
tem.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-11.
EAS31328
REMOVING THE FRONT BRAKE CALIPER
TIP
Before removing the brake caliper, drain the
brake fluid from the entire brake system.
1. Remove:
• Brake hose union bolt “1”
• Brake hose gaskets “2”
• Front brake hose “3”
TIP
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
EAS30172
DISASSEMBLING THE FRONT BRAKE
CALIPER
1. Remove:
• Brake caliper piston “1”
• Brake caliper piston dust seal “2”
• Brake caliper piston seal “3”
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Blow compressed air into the brake hose joint
opening “a” to force out the piston from the
brake caliper “1”.
WARNING
EWA13550
• Cover the brake caliper piston with a rag.
Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
• Never try to pry out the brake caliper pis-
ton.
T
R
.
.
Front brake caliper bolt
35 N·m (3.5 kgf·m, 25 lb·ft)
a
1
1
a
1
3
1
2
1
2
3
B63-F8197-EZ.book Page 38 Monday, January 23, 2017 4:12 PM
FRONT BRAKE
4-39
b. Remove the brake caliper piston dust seal
and brake caliper piston seal.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS30173
CHECKING THE FRONT BRAKE CALIPER
1. Check:
• Brake caliper piston “1”
Rust/scratches/wear Replace the brake
caliper piston.
• Brake caliper cylinder “2”
Scratches/wear Replace the brake caliper
assembly.
• Brake caliper body “3”
Cracks/damage Replace the brake caliper
assembly.
• Brake fluid delivery passages
(brake caliper body)
Obstruction Blow out with compressed air.
WARNING
EWA17070
Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seal
and brake caliper piston seal.
2. Check:
• Brake caliper bracket
Cracks/damage Replace.
EAS30174
ASSEMBLING THE FRONT BRAKE CALIPER
WARNING
EWA13621
• Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake com-
ponents as they will cause the brake caliper
piston dust seals and brake caliper piston
seals to swell and distort.
• Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seals
and brake caliper piston seals.
EAS30934
INSTALLING THE FRONT BRAKE CALIPER
1. Install:
• Front brake caliper “1”
(temporarily)
• Brake hose gaskets “2”
• Front brake hose “3”
• Brake hose union bolt “4”
WARNING
EWA13531
Proper brake hose routing is essential to in-
sure safe vehicle operation.
Recommended brake component replacement
schedule
Brake pads If necessary
Piston seal Every two years
Piston dust seal Every two years
Brake hose Every four years
Brake fluid
Every two years and
whenever the brake is
disassembled
a
1
Specified brake fluid
YAMAHA GENUINE BRAKE
FLUID : DOT 3 or Dot 4
(GDR155)
YAMAHA GENUINE BRAKE
FLUID : Dot 4-Plus (GDR155-A)
T
R
.
.
Front brake hose union bolt
(brake caliper side)
29 N·m (2.9 kgf·m, 21 lb·ft)
1
2
3
New
B63-F8197-EZ.book Page 39 Monday, January 23, 2017 4:12 PM
FRONT BRAKE
4-40
NOTICE
ECA19080
When installing the brake hose onto the
brake caliper “1”, make sure the brake pipe
“a” passes between the projections “b” on
the brake caliper.
2. Remove:
• Front brake caliper
3. Install:
• Brake pad spring
• Brake pads
• Brake pad pin
• Brake pad clips
• Front brake caliper
• Front wheel sensor lead holder
• Front brake caliper bolts
Refer to “REPLACING THE FRONT BRAKE
PADS” on page 4-37.
4. Fill:
• Brake master cylinder reservoir
(with the specified amount of the specified
brake fluid)
WARNING
EWA13540
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake master cylinder reser-
voir. Water will significantly lower the boil-
ing point of the brake fluid and could cause
vapor lock.
NOTICE
ECA13540
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
5. Bleed:
• Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-11.
6. Check:
• Brake fluid level
Below the minimum level mark “a” Add the
specified brake fluid to the proper level.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-11.
7. Check:
• Brake lever operation
Soft or spongy feeling Bleed the brake sys-
tem.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-11.
EAS30179
REMOVING THE FRONT BRAKE MASTER
CYLINDER
TIP
Before removing the front brake master cylinder,
drain the brake fluid from the entire brake sys-
tem.
1. Remove:
• Brake hose union bolt “1”
• Brake hose gaskets “2”
• Front brake hose “3”
TIP
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
T
R
.
.
Front brake caliper bolt
35 N·m (3.5 kgf·m, 25 lb·ft)
Specified brake fluid
YAMAHA GENUINE BRAKE FLU-
ID: DOT 3 or DOT 4 (GDR155)
YAMAHA GENUINE BRAKE FLU-
ID: DOT 4-Plus (GDR155-A)
3
4
a
b
1
2
New
a
B63-F8197-EZ.book Page 40 Monday, January 23, 2017 4:12 PM
FRONT BRAKE
4-41
EAS30725
CHECKING THE FRONT BRAKE MASTER
CYLINDER
1. Check:
• Brake master cylinder
Damage/scratches/wear Replace.
• Brake fluid delivery passages
(brake master cylinder body)
Obstruction Blow out with compressed air.
2. Check:
• Brake master cylinder kit
Damage/scratches/wear Replace.
3. Check:
• Brake master cylinder reservoir “1”
• Brake master cylinder reservoir cap “2”
• Brake master cylinder reservoir diaphragm
holder “3”
• Brake master cylinder reservoir diaphragm
“4”
Damage/wear Replace.
4. Check:
• Front brake hose
Cracks/damage/wear Replace.
EAS30181
ASSEMBLING THE FRONT BRAKE MASTER
CYLINDER
WARNING
EWA13520
• Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake com-
ponents.
EAS30182
INSTALLING THE FRONT BRAKE MASTER
CYLINDER
1. Install:
• Brake master cylinder
• Brake master cylinder holder “1”
TIP
• Install the brake master cylinder holder with the
“UP” mark “a” facing up.
• First, tighten the upper bolt, then the lower bolt.
2. Install:
• Brake hose gaskets “1”
• Front brake hose “2”
• Brake hose union bolt “3”
WARNING
EWA13531
Proper brake hose routing is essential to in-
sure safe vehicle operation.
TIP
• Make sure that the distance “a” between the
brake hose and the handlebar “4” is 40–44 mm
(1.57–1.73 in) as shown in the illustration.
• Turn the handlebar to the left and right to make
sure the brake hose does not touch other parts
(e.g., wire harness, cables, leads). Correct if
necessary.
1
3
2
1
3
2
4
Specified brake fluid
YAMAHA GENUINE BRAKE
FLUID: DOT 3 or DOT 4 (GDR155)
YAMAHA GENUINE BRAKE
FLUID: DOT 4-Plus (GDR155-A)
T
R
.
.
Front brake master cylinder hold-
er bolt
10 N·m (1.0 kgf·m, 7.2 lb·ft)
T
R
.
.
Front brake hose union bolt
(master cylinder side)
29 N·m (2.9 kgf·m, 21 lb·ft)
1
a
up
New
B63-F8197-EZ.book Page 41 Monday, January 23, 2017 4:12 PM
FRONT BRAKE
4-42
3. Fill:
• Brake master cylinder reservoir
(with the specified amount of the specified
brake fluid)
WARNING
EWA13540
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake master cylinder reser-
voir. Water will significantly lower the boil-
ing point of the brake fluid and could cause
vapor lock.
NOTICE
ECA13540
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
4. Bleed:
• Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-11.
5. Check:
• Brake fluid level
Below the minimum level mark “a” Add the
specified brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-10.
6. Check:
• Brake lever operation
Soft or spongy feeling Bleed the brake sys-
tem.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-11.
Specified brake fluid
YAMAHA GENUINE BRAKE
FLUID: DOT 3 or DOT 4 (GDR155)
YAMAHA GENUINE BRAKE
FLUID: DOT 4-Plus (GDR155-A)
a
4
2
3
1
New
a
B63-F8197-EZ.book Page 42 Monday, January 23, 2017 4:12 PM
REAR BRAKE
4-43
EAS5P03037
REAR BRAKE
Disassembling the brake shoe
Order Job/Parts to remove Q’ty Remarks
Rear wheel Refer to “REAR WHEEL” on page 4-28.
1 Brake shoe 2
2 Brake shoe spring 2
3 Rear brake cable adjusting nut 1
4 Compression spring 1
5 Rear brake cable assembly 1
6
Pin
1
7
Brake camshaft lever
1
8
Washer
1
9
Brake shoe wear indicator
1
10
Brake camshaft
1
5
4
6
9
3
7
8
10
2
2
1
T
R
.
.
••
7 N m (0.7kgf m, 5.1lb.ft)
T
R
.
.
••
•
95 N m (9.5kgf m, 69 lb ft)
B63-F8197-EZ.book Page 43 Monday, January 23, 2017 4:12 PM
REAR BRAKE
4-44
EAS5P03038
REMOVING THE REAR BRAKE
1. Remove:
• Brake shoes “1”
• Brake shoe spring “2”
2. Remove:
• Adjusting nut “1”
• Rear brake cable “2”
•Pin “3”
• Brake camshaft lever bolt “4”
• Brake camshaft lever “5”
3. Remove:
• Wave washer “1”
• Brake shoe wear indicator “2”
4. Remove:
• Brake camshaft “1”
EAS5P03039
CHECKING THE REAR BRAKE SHOES
1. Check:
• Brake shoe lining
Glazed areas Repair.
Sand the glazed areas with coarse sandpa-
per.
TIP
After sanding the glazed areas, clean the brake
shoe with a cloth.
2. Measure:
• Brake shoe lining thickness “a”
Out of specification Replace.
2
1
4
5
1
3
2
1
2
Lining thickness
4.0 mm (0.16 in)
Limit
2.0 mm (0.08 in)
1
a
B63-F8197-EZ.book Page 44 Monday, January 23, 2017 4:12 PM
REAR BRAKE
4-45
WARNING
EWA3C11004
Do not allow oil or grease on the brake
shoes.
TIP
Replace the brake shoes as a set, if either is
worn to the wear limit.
3. Measure:
• Brake drum inside diameter “a”
Out of specification Replace the wheel.
4. Check:
• Brake drum inner surface
Oil deposits Clean.
Remove the oil with a rag soaked in lacquer
thinner or solvent.
Scratches Repair.
Lightly and evenly polish the scratches with
an emery cloth.
5. Check:
• Brake camshaft
Damage/wear Replace.
EAS5P03040
ASSEMBLING THE REAR BRAKE SHOE
PLATE
1. Install:
• Brake camshaft “1”
• Brake shoe wear indicator “2”
• Wave washer
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Install the brake camshaft so its punch mark
“a” is positioned as shown.
b. Align the projection “b” on the brake shoe
wear indicator with the notch in the brake
camshaft.
c. Check that the brake shoes are properly
positioned.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
WARNING
EWA5P03004
After installing the brake camshaft, remove
any excess grease.
2. Install:
• Brake camshaft lever “1”
TIP
Align the punch mark on the brake camshaft with
the mark on the brake camshaft lever positioned
as shown “a”.
3. Install:
• Brake shoe springs “1”
• Brake shoes
TIP
• Lubricate the pivot pin with a thin coat of sili-
cone grease.
• Do not to damage the springs during installa-
tion.
• Install the brake shoe springs as shown.
Brake drum inside diameter
130.0 mm (5.12 in)
Limit
131.0 mm (5.16 in)
a
T
R
.
.
Brake camshaft lever pinch bolt
7 N·m (0.7 kgf·m, 5.2 lb·ft)
1
b
2
a
1
a
New
B63-F8197-EZ.book Page 45 Monday, January 23, 2017 4:12 PM
REAR BRAKE
4-46
WARNING
EWA3C11005
Do not apply grease to the brake shoe lin-
ings.
EAS5P03041
CHECKING THE REAR BRAKE DRUM WEAR
LIMIT
TIP
After the new brake shoes are installed, the
brake drum inside diameter can be checked as
to whether it is within the wear limit “a” by means
of the brake drum wear indicator on the brake
shoe plate.
1. Check:
• Position at which to install the brake camshaft
lever
Reinstall the brake camshaft lever if its
installed position is out of specification.
2. Check:
• Brake pedal free play
If the free play is out of specification.
Refer to “ADJUSTING THE REAR DRUM
BRAKE” on page 3-10.
3. While pressing the brake pedal all the way
down, push the brake camshaft lever fully in
the arrow indicated direction and check that
the brake shoe wear indicator does not reach
the brake drum wear indicator.
Not reaching Still usable.
Reaching Replace the wheel.
B63-F8197-EZ.book Page 46 Monday, January 23, 2017 4:12 PM
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
4-47
EAS20032
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
Removing the hydraulic unit assembly
Order Job/Parts to remove Q’ty Remarks
Brake fluid
Drain.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-11.
Front cowling assembly
Refer to “GENERAL CHASSIS (5)” on page
4-15.
Front upper cowling assembly
Refer to “GENERAL CHASSIS (4)” on page
4-9.
1 ABS ECU coupler 1 Disconnect.
2
Front brake hose union bolt (hydraulic unit as-
sembly side)
2
3 Brake hose gasket 4
3
3
3
1
2
2
3
T
R
.
.
••
29 N m (2.5kgf
m, 21lb.ft)
T
R
.
.
••
7 N m (0.7kgf
m, 5.1lb.ft)
NEW
NEW
B63-F8197-EZ.book Page 47 Monday, January 23, 2017 4:12 PM
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
4-48
Removing the hydraulic unit assembly
Order Job/Parts to remove Q’ty Remarks
4
Front brake hose (front brake master cylinder to
hydraulic unit)
1 Disconnect.
5
Front brake hose (hydraulic unit to front brake
caliper)
1 Disconnect.
6 Hydraulic unit assembly 1
5
4
6
T
R
.
.
••
29 N m (2.5kgf
m, 21lb.ft)
T
R
.
.
••
7 N m (0.7kgf
m, 5.1lb.ft)
NEW
NEW
NEW
NEW
B63-F8197-EZ.book Page 48 Monday, January 23, 2017 4:12 PM
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
4-49
EAS30197
REMOVING THE HYDRAULIC UNIT
ASSEMBLY
NOTICE
ECA21091
Unless necessary, avoid removing and in-
stalling the brake hoses of the hydraulic unit
assembly.
WARNING
EWA13930
Refill with the same type of brake fluid that is
already in the system. Mixing fluids may re-
sult in a harmful chemical reaction, leading
to poor braking performance.
NOTICE
ECA18241
• Handle the ABS components with care
since they have been accurately adjusted.
Keep them away from dirt and do not sub-
ject them to shocks.
• Do not turn the main switch to “ON” when
removing the hydraulic unit assembly.
• Do not clean with compressed air.
• Do not reuse the brake fluid.
• Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
• Do not allow any brake fluid to contact the
couplers. Brake fluid may damage the cou-
plers and cause bad contacts.
• If the union bolts for the hydraulic unit as-
sembly have been removed, be sure to
tighten them to the specified torque and
bleed the brake system.
1. Disconnect:
• ABS ECU coupler “1”
2. Remove:
• Brake hoses
TIP
Do not operate the brake levers while removing
the brake hoses.
NOTICE
ECA14530
When removing the brake hoses, cover the
area around the hydraulic unit to catch any
spilt brake fluid. Do not allow the brake fluid
to contact other parts.
3. Remove:
• Hydraulic unit assembly “1”
TIP
• To avoid brake fluid leakage and to prevent for-
eign materials from entering the hydraulic unit
assembly, insert a rubber plug “a” or a bolt
(M10 1.25) into each brake hose union bolt
hole.
• When using a bolt, do not tighten the bolt until
the bolt head touches the hydraulic unit. Other-
wise, the brake hose union bolt seating surface
could be deformed.
EAS30198
CHECKING THE HYDRAULIC UNIT
ASSEMBLY
1. Check:
• Hydraulic unit assembly
Cracks/damage Replace the hydraulic unit
assembly and the brake hoses that are con-
nected to the assembly as a set.
EAS30200
INSTALLING THE HYDRAULIC UNIT
ASSEMBLY
1. Install:
• Hydraulic unit assembly
1
T
R
.
.
Hydraulic unit assembly bolt
7 N·m (0.7 kgf·m, 5.1 lb·ft)
1
a
B63-F8197-EZ.book Page 49 Monday, January 23, 2017 4:12 PM
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
4-50
NOTICE
ECA21110
Do not remove the rubber plugs or bolts
(M10 1.25) installed in the brake hose union
bolt holes before installing the hydraulic unit
assembly.
TIP
Do not allow any foreign materials to enter the
hydraulic unit assembly or the brake hoses
when installing the hydraulic unit assembly.
2. Remove:
• Rubber plugs or bolts (M10 1.25)
3. Install:
• Front brake hose (front brake master cylinder
to hydraulic unit) “1”
• Front brake hose (hydraulic unit to front brake
caliper) “2”
NOTICE
ECA21121
If the brake hose union bolt does not turn
easily, replace the hydraulic unit assembly,
brake hoses, and related parts as a set.
TIP
Position the pipe sections of the brake hoses at
a 30° angle from the line “a” as shown in the il-
lustration, and then tighten the brake hose union
bolts to specification.
4. Connect:
• ABS ECU coupler “1”
TIP
• Connect the ABS ECU coupler 1.
• Make sure that the ABS ECU coupler is con-
nected in the correct position.
5. Fill:
• Brake master cylinder reservoir
• Brake fluid reservoir
(with the specified amount of the specified
brake fluid)
WARNING
EWA13090
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
NOTICE
ECA13540
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
6. Bleed:
• Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-11.
T
R
.
.
Front brake hose union bolt
(hydraulic unit assembly side)
29 N·m (2.9 kgf·m, 21 lb·ft)
2
1
a
a
Specified brake fluid
YAMAHA GENUINE BRAKE
FLUID: DOT 3 or DOT 4 (GDR155)
YAMAHA GENUINE BRAKE
FLUID: DOT 4-Plus (GDR155-A)
1
B63-F8197-EZ.book Page 50 Monday, January 23, 2017 4:12 PM
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
4-51
7. Check the operation of the hydraulic unit ac-
cording to the brake levers response. (Refer
to “HYDRAULIC UNIT OPERATION TESTS”
on page 4-51.)
NOTICE
ECA14550
Always check the operation of the hydraulic
unit according to the brake lever response.
8. Delete the fault codes. (Refer to “[B-3] DE-
LETING THE FAULT CODES” on page
8-102.)
9. Perform a trial run. (Refer to “CHECKING
THE ABS WARNING LIGHT” on page 4-54.)
EAS30201
HYDRAULIC UNIT OPERATION TESTS
The reaction-force pulsating action generated in
the brake levers when the ABS is activated can
be tested when the vehicle is stopped.
The hydraulic unit operation can be tested using
the following two methods.
• Brake line routing confirmation: this test
checks the function of the ABS after the sys-
tem was disassembled, adjusted, or serviced.
• ABS reaction-force confirmation: this test gen-
erates the same reaction-force pulsating action
that is generated in the front brake lever when
the ABS is front activated.
Brake line routing confirmation
WARNING
EWA13120
Securely support the vehicle so that there is
no danger of it falling over.
TIP
• For the brake line routing confirmation, use the
diagnosis mode of the Yamaha diagnostic tool.
• Before performing the brake line routing confir-
mation, make sure that no malfunctions have
been detected in the ABS ECU and that the
wheels are not rotating.
1. Place the vehicle on a center stand.
2. Turn the main switch to “OFF”.
3. Open the seat.
4. Remove:
• Battery cover
Refer to “GENERAL CHASSIS (1)” on page
4-1.
5. Check:
• Battery voltage
Lower than 12.8 V Charge or replace the
battery.
TIP
If the battery voltage is lower than 12.8 V, charge
the battery, and then perform brake line routing
confirmation.
6. Removing the protective cap “1”, and then
connect the Yamaha diagnostic tool to the
Yamaha diagnostic tool coupler (4P).
7. Start the Yamaha diagnostic tool and display
the diagnosis mode screen.
8. Select code No. 2, “Brake line routing confir-
mation”.
9. Click “Action” “1”, and then operate the front
brake lever “2” simultaneously.
TIP
• The hydraulic unit operates 1 second after the
front brake lever operated and continues for
approximately 1 second.
• The operation of the hydraulic unit can be con-
firmed using the indicator.
On: The hydraulic unit is operating.
Battery voltage
Higher than 12.8 V
Yamaha diagnostic tool USB
90890-03250
Yamaha diagnostic tool (A/I)
90890-03252
1
B63-F8197-EZ.book Page 51 Monday, January 23, 2017 4:12 PM
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
4-52
Flashing: The conditions for operating the hy-
draulic unit have not been met.
Off: The front brake lever is not being
operated.
10.Check:
• Hydraulic unit operation
Click “Action”, a single pulse will be generat-
ed in the front brake lever “1”, operate only
once.
TIP
“ON” and “OFF” on the tool screen indicate
when the brakes are being applied and released
respectively.
NOTICE
ECA22080
• Check that the pulse is felt in the front
brake lever.
11.If the operation of the hydraulic unit is normal,
delete all of the fault codes.
ABS reaction-force confirmation
WARNING
EWA13120
Securely support the vehicle so that there is
no danger of it falling over.
TIP
• For the ABS reaction-force confirmation, use
the diagnosis mode of the Yamaha diagnostic
tool. For more information, refer to the opera-
tion manual of the Yamaha diagnostic tool.
• Before performing the ABS reaction-force con-
firmation, make sure that no malfunctions have
been detected in the ABS ECU and that the
wheels are not rotating.
1. Place the vehicle on a center stand.
2. Turn the main switch to “OFF”.
3. Open the seat.
4. Remove:
• Battery cover
Refer to “GENERAL CHASSIS (1)” on page
4-1.
5. Check:
• Battery voltage
Lower than 12.8 V Charge or replace the
battery.
TIP
If the battery voltage is lower than 12.8 V, charge
the battery, and then perform ABS reaction-
force confirmation.
1
2
1
Battery voltage
Higher than 12.8 V
B63-F8197-EZ.book Page 52 Monday, January 23, 2017 4:12 PM
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
4-53
6. Removing the protective cap “1”, and then
connect the Yamaha diagnostic tool to the
Yamaha diagnostic tool coupler (4P).
7. Start the Yamaha diagnostic tool and display
the diagnosis mode screen.
8. Select code No. 1, “ABS reaction-force con-
firmation”.
9. Click “Action” “1”, and then operate the front
brake lever “2” simultaneously.
TIP
• The hydraulic unit operates 1 second after the
front brake lever operated and continues for
approximately 1 second.
• The operation of the hydraulic unit can be con-
firmed using the indicator.
On: The hydraulic unit is operating.
Flashing: The conditions for operating the hy-
draulic unit have not been met.
Off: The front brake lever is not being operated.
10.A reaction-force pulsating action is generated
in the front brake lever “1” and continues for a
few seconds.
TIP
• The reaction-force pulsating action consists of
quick pulses.
• Be sure to continue operating the front brake
lever even after the pulsating action has
stopped.
• “ON” and “OFF” on the tool screen indicate
when the brakes are being applied and re-
leased respectively.
NOTICE
ECA22080
• Check that the pulse is felt in the front
brake lever.
• If the pulse is hardly felt in either the front
brake lever, check that the brake hoses and
brake pipes are connected correctly to the
hydraulic unit assembly.
Yamaha diagnostic tool USB
90890-03250
Yamaha diagnostic tool (A/I)
90890-03252
1
1
2
1
B63-F8197-EZ.book Page 53 Monday, January 23, 2017 4:12 PM
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
4-54
11.Turn the main switch to “OFF”.
12.Remove the Yamaha diagnostic tool from the
Yamaha diagnostic tool coupler, and then in-
stall the protective cap.
13.Turn the main switch to “ON”.
14.Check for brake fluid leakage around the hy-
draulic unit.
Brake fluid leakage Replace the hydraulic
unit, brake hoses, and related parts as a set.
15.If the operation of the hydraulic unit is normal,
delete all of the fault codes.
EAS30202
CHECKING THE ABS WARNING LIGHT
After all checks and servicing are completed, en-
sure that the ABS warning light goes off by walk-
ing the vehicle at a speed of faster than 10 km/h
(6 mph) or performing a trial run.
B63-F8197-EZ.book Page 54 Monday, January 23, 2017 4:12 PM
HANDLEBAR
4-55
EAS20033
HANDLEBAR
Removing the rear view mirror and handlebar cover
Order Job/Parts to remove Q’ty Remarks
1 Rear view mirror (left and right) 2
2 Front handlebar cover 1 1
3 Front handlebar cover 2 1
4 Rear handlebar cover 1
5 Left handlebar switch 1 Disconnect.
6 Right handlebar switch 1 Disconnect.
7 Meter assembly 1
8
Grip end (left and right) 2
9 Left handlebar grip 1
10
Throttle grip 1
10
1
61
8
7
2
3
4
5
8
9
B63-F8197-EZ.book Page 55 Monday, January 23, 2017 4:12 PM
HANDLEBAR
4-56
Removing the rear view mirror and handlebar cover
Order Job/Parts to remove Q’ty Remarks
11 Throttle cable housing 1
12 Throttle cable 1 Disconnect.
13 Front brake switch 1
14 Front brake lever 1
15 Brake hose 1
16 Front brake master cylinder holder 1
17 Handlebar 1
16
17
14
13
11
15
12
B63-F8197-EZ.book Page 56 Monday, January 23, 2017 4:12 PM
HANDLEBAR
4-57
EAS31622
REMOVING THE FRONT HANDLEBAR
COVER ASSEMBLY
1. Remove:
• Front handlebar cover assembly “1”
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Remove the quick fastener and front handle-
bar cover assembly screws.
b. Unhook the projections “a” on the front han-
dlebar cover assembly from the slots “b” in
the lower handlebar cover.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS31701
DISASSEMBLING THE FRONT HANDLEBAR
COVER ASSEMBLY
1. Disassemble:
• Front handlebar cover “1”
• Front handlebar cover “2”
TIP
Unhook the projections “a” on the front handle-
bar cover from the slots “b” in the front handlebar
cover.
EAS30203
REMOVING THE HANDLEBAR
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:
• Grip end
3. Remove:
• Handlebar grip “1”
TIP
Blow compressed air between the handlebar
and the handlebar grip, and gradually push the
grip off the handlebar.
EAS30204
CHECKING THE HANDLEBAR
1. Check:
• Handlebar
Bends/cracks/damage Replace.
WARNING
EWA13690
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.
EAS30205
INSTALLING THE HANDLEBAR
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there is
no danger of it falling over.
2. Install:
• Handlebar “1”
NOTICE
ECA18300
First, tighten the bolts on the front side of the
handlebar holder, and then on the rear side.
TIP
• Make sure that the projection “a” of the handle-
bar contacts the lower handlebar holder.
• The front handlebar holders should be installed
with the punch mark “b” facing forward.
a
1
b
2
1
a
a
b
b
T
R
.
.
Handlebar bolt
53 N·m (5.3 kgf·m, 38 lb·ft)
B63-F8197-EZ.book Page 57 Monday, January 23, 2017 4:12 PM
HANDLEBAR
4-58
3. Install:
• Handlebar switch (left) “1”
TIP
Align the projection “a” on the left handlebar
switch with the hole “b” in the rear handlebar
cover.
4. Install:
• Handlebar grip “1”
• Grip end (left) “2”
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Apply a thin coat of a rubber adhesive to the
left end of the handlebar.
b. Slide the handlebar grip over the left end of
the handlebar.
TIP
Make sure that the distance “a” between the end
of the left handlebar switch and the end of the
handlebar grip is 0 mm (0 in).
c. Wipe off any excess rubber adhesive with a
clean rag.
WARNING
EWA13700
Do not touch the handlebar grip until the rub-
ber adhesive has fully dried.
d. Install the left grip end.
TIP
There should be 1.0–3.0 mm (0.04–0.12 in) of
clearance “c” between the handlebar grip and
the grip end.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
5. Install:
• Handlebar switch (right) “1”
• Throttle cables “2”
• Throttle grip “3”
• Grip end (right) “4”
TIP
• Lubricate the end of the throttle cables and the
inside of the throttle grip with a thin coat of lith-
ium-soap-based grease.
• Align the projection “a” on the right handlebar
switch with the hole “b” in the rear handlebar
cover.
• There should be 1.0–3.0 mm (0.04–0.12 in) of
clearance “c” between the throttle grip and the
grip end.
1
a
b
1
1
a
T
R
.
.
Throttle cable holder bolt (han-
dlebar switch side)
3.5 N·m (0.35 kgf·m, 2.5 lb·ft)
a
2
2
1
1
B63-F8197-EZ.book Page 58 Monday, January 23, 2017 4:12 PM
HANDLEBAR
4-59
6. Install:
• Front brake master cylinder
• Front brake master cylinder holder “1”
TIP
• Install the brake master cylinder holder with the
“UP” mark “a” facing up.
• Align the edge “b” of the brake master cylinder
holder with the edge “c” of the stay on the han-
dlebar as shown in the illustration.
• First, tighten the upper bolt, then the lower bolt.
7. Adjust:
• Throttle grip free play
Refer to “CHECKING THE THROTTLE GRIP
OPERATION” on page 3-23.
EAS31702
ASSEMBLING THE FRONT HANDLEBAR
COVER ASSEMBLY
1. Assemble:
• Front handlebar cover “1”
• Front handlebar cover “2”
TIP
Fit the projections “a” on the front handlebar
cover into the slots “b” in the front handlebar
cover.
EAS31623
INSTALLING THE FRONT HANDLEBAR
COVER ASSEMBLY
1. Install:
• Front handlebar cover assembly “1”
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Fit the projections “a” on the front handlebar
cover into the slots “b” in the lower handlebar
cover.
b. Install the front handlebar cover assembly
screws and quick fasteners, and then tighten
the screws to specification.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
T
R
.
.
Front brake master cylinder
holder bolt
10 N·m (1.0 kgf·m, 7.2 lb·ft)
Throttle grip free play
3.0–5.0 mm (0.12–0.20 in)
2
3
3
4
1
b
a
c
LS
T
R
.
.
Upper handlebar cover assembly
screw
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
2
1
a
a
b
b
a
1
b
B63-F8197-EZ.book Page 59 Monday, January 23, 2017 4:12 PM
FRONT FORK
4-60
EAS20034
FRONT FORK
Removing the front fork legs
Order Job/Parts to remove Q’ty Remarks
The following procedure applies to both of
the front fork legs.
Front wheel Refer to “FRONT WHEEL” on page 4-20.
1 Front fender 1
2 Lower bracket pinch bolt 2
3Front fork leg 1
2
2
3
1
8 N
•
m (0.8 kgf
•
m, 5.8 lb
•
ft)
8 N
•
m (0.8 kgf
•
m, 5.8 lb
•
ft)
53 N
•
m (5.3 kgf
•
m, 3.8 lb
•
ft)
B63-F8197-EZ.book Page 60 Monday, January 23, 2017 4:12 PM
FRONT FORK
4-61
Disassembling the front fork legs
Order Job/Parts to remove Q’ty Remarks
The following procedure applies to both of
the front fork legs.
1 Front fork cap clip 1
2Front fork cap 1
3O-ring 1
4 Fork spring 1
5 Tip guard 1
6 Dust seal 1
7 Oil seal clip 1
8 Front fork damper rod bolt 1
9 Copper washer 1
10 Oil flow stopper 1
11 Damper rod 1
12 Rebound spring 1
13 Damper rod ring 1
14 Inner tube 1
15 Oil seal 1
16 Outer tube 1
23 N
•
m (2.3 kgf
•
m, 17 lb
•
ft)
10
13
1
2
3
4
5
6
7
11
12
14
15
16
9
8
B63-F8197-EZ.book Page 61 Monday, January 23, 2017 4:12 PM
FRONT FORK
4-62
EAS30206
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there is
no danger of it falling over.
TIP
Place the vehicle on a suitable stand so that the
front wheels are elevated.
2. Loosen:
• Lower bracket pinch bolts “1”
WARNING
EWA18000
Before loosening the lower bracket pinch
bolts, support the front fork leg.
EAS30207
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
NOTICE
ECA19110
• The front fork leg has a very sophisticated
internal construction, which are particular-
ly sensitive to foreign material.
• When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
1. Remove:
• Front fork cap clip “1”
• Front fork cap “2”
TIP
Push the front fork cap in the direction of the ar-
row shown in the illustration to remove the front
fork cap clip.
2. Drain:
• Fork oil
TIP
Stroke the outer tube several times while drain-
ing the fork oil.
3. Remove:
• Dust seal “1”
• Oil seal clip “2”
(with a flathead screwdriver)
NOTICE
ECA14180
Do not scratch the inner tube.
4. Remove:
• Front fork damper rod bolt “1”
• Copper washer
TIP
While holding the damper rod with the hexagon
bit socket (14 mm) “2” and T-handle “3”, loosen
the front fork damper rod bolt.
1
1
1
2
1
2
B63-F8197-EZ.book Page 62 Monday, January 23, 2017 4:12 PM
FRONT FORK
4-63
EAS30208
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Check:
• Inner tube
• Outer tube
Bends/damage/scratches Replace.
WARNING
EWA13650
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
2. Measure:
• Fork spring free length “a”
Out of specification Replace.
3. Check:
• Damper rod
Damage/wear Replace.
Obstruction Blow out all of the oil passag-
es with compressed air.
• Oil flow stopper
Damage Replace.
EAS30209
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
WARNING
EWA13660
• Make sure the oil levels in both front fork
legs are equal.
• Uneven oil levels can result in poor han-
dling and a loss of stability.
TIP
• When assembling the front fork leg, be sure to
replace the following parts:
–Front fork cap clip
–Oil seal
–Oil seal clip
–Dust seal
–Copper washer
–O-ring
• Before assembling the front fork leg, make
sure all of the components are clean.
1. Install:
• Damper rod ring “1”
• Damper rod “2”
• Rebound spring “3”
(in the inner tube “4”)
• Oil flow stopper “5”
NOTICE
ECA22740
Allow the damper rod to slide slowly down
the inner tube until it protrudes from the bot-
tom of the inner tube. Be careful not to dam-
age the inner tube.
TIP
Fit the damper rod ring into the damper rod
groove so that the side of the ring with the pro-
jections is facing in the direction shown in the il-
lustration.
T-handle
90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
Fork spring free length
282.1 mm (11.10 in)
Limit
276.0 mm (10.88 in)
2 31
a
2
1
B63-F8197-EZ.book Page 63 Monday, January 23, 2017 4:12 PM
FRONT FORK
4-64
2. Install:
• Oil seal “1”
(with the fork seal driver attachment “2” and
fork seal driver weight “3”)
NOTICE
ECA14220
Make sure the numbered side of the oil seal
faces up.
TIP
• Lubricate the outer surface of the inner tube
with fork oil.
• Before installing the oil seal, cover the top of
the front fork leg with a plastic bag to protect
the oil seal during installation.
3. Lubricate:
• Inner tube’s outer surface
4. Install:
• Inner tube
(in the outer tube)
5. Install:
• Copper washer
• Front fork damper rod bolt “1”
TIP
While holding the damper rod assembly with the
hexagon bit socket (14 mm) “2” and T-handle
“3”, tighten the front fork damper rod bolt.
6. Install:
• Oil seal clip “1”
TIP
Adjust the oil seal clip so that it fits into the outer
tube’s groove.
Fork seal driver weight
90890-01367
Replacement hammer
YM-A9409-7
Fork seal driver attachment (ø30)
90890-01400
21345
New
1
2
3
New
Recommended oil
Fork oil 10W or equivalent
T
R
.
.
Front fork damper rod bolt
23 N·m (2.3 kgf·m, 17 lb·ft)
LOCTITE®
T-handle
90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
New
2 31
New
1
New
B63-F8197-EZ.book Page 64 Monday, January 23, 2017 4:12 PM
FRONT FORK
4-65
7. Install:
• Dust seal “1”
(with the fork seal driver attachment “2” and
fork seal driver weight “3”)
8. Fill:
• Front fork leg
(with the specified amount of the recom-
mended fork oil)
NOTICE
ECA14230
• Be sure to use the recommended fork oil.
Other oils may have an adverse effect on
front fork performance.
• When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
9. After filling the front fork leg, slowly stroke the
inner tube “1” up and down (at least ten
times) to distribute the fork oil.
TIP
Be sure to stroke the inner tube slowly because
the fork oil may spurt out.
10.Before measuring the fork oil level, wait ten
minutes until the oil has settled and the air
bubbles have dispersed.
TIP
Be sure to bleed the front fork leg of any residual
air.
11.Measure:
• Front fork leg oil level “a”
(from the top of the inner tube, with the inner
tube fully compressed and without the fork
spring)
Out of specification Correct.
TIP
• While filling the front fork leg, keep it upright.
• After filling, slowly pump the front fork leg up
and down to distribute the fork oil.
12.Install:
• Fork spring “1”
• O-ring
• Front fork cap
• Front fork cap clip
TIP
Install the fork spring with its smaller pitch down-
ward.
Fork seal driver weight
90890-01367
Replacement hammer
YM-A9409-7
Fork seal driver attachment (ø30)
90890-01400
Recommended oil
Fork oil 10W or equivalent
Quantity
86.0 cm³ (2.91 US oz, 3.03
Imp.oz)
New
1
2
3
New
Level
78.0 mm (3.07 in)
1
New
New
B63-F8197-EZ.book Page 65 Monday, January 23, 2017 4:12 PM
FRONT FORK
4-66
EAS30210
INSTALLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Remove:
• Front side cover
• Refer to “GENERAL CHASSIS (2)” on page
4-3.
2. Install:
• Front fork leg “1”
Temporarily tighten the lower bracket pinch
bolts.
TIP
Make sure the inner tube end is flush with the top
of the lower bracket.
3. Tighten:
• Lower bracket pinch bolts “1”
TIP
Tighten the lower bracket pinch bolts to specifi-
cation twice. Tighten the upper and lower bolts
alternately, starting with the upper bolts.
T
R
.
.
Lower bracket pinch bolt
53 N·m (5.3 kgf·m, 38 lb·ft)
1
1
1
1
B63-F8197-EZ.book Page 66 Monday, January 23, 2017 4:12 PM
STEERING HEAD
4-67
EAS20035
STEERING HEAD
Removing the lower bracket
* Loosen the lower ring nut 1/4 of a turn, and then tighten it to specification.
Order Job/Parts to remove Q’ty Remarks
Front side covers
Refer to “GENERAL CHASSIS (2)” on page
4-3.
Center lower cover
Refer to “GENERAL CHASSIS (6)” on page
4-16.
Front upper cowling assembly
Refer to “GENERAL CHASSIS (4)” on page
4-9.
Front wheel Refer to “FRONT WHEEL” on page 4-20.
Handlebar Refer to “HANDLEBAR” on page 4-55.
Front fork legs Refer to “FRONT FORK” on page 4-60.
1 Handlebar bracket 1
2 Horn connector 2 Disconnect.
3Horn 1
4 Horn bracket 1
5 Front brake hose holder 1
17
18
16
19
2
1
3
4
5
6
7
8
9
10
11
12
13
20
14
15
16 N
•
m (1.6 kgf
•
m, 12 lb
•
ft)
38 N
•
m (3.8 kgf
•
m, 27 lb
•
ft)
75 N
•
m (7.5 kgf
•
m, 54 lb
•
ft)
7 N
•
m (0.7 kgf
•
m, 5.1 lb
•
ft)
7 N
•
m (0.7 kgf
•
m, 5.1 lb
•
ft)
53 N
•
m (5.3 kgf
•
m, 38 lb
•
ft)
B63-F8197-EZ.book Page 67 Monday, January 23, 2017 4:12 PM
STEERING HEAD
4-68
Removing the lower bracket
* Loosen the lower ring nut 1/4 of a turn, and then tighten it to specification.
Order Job/Parts to remove Q’ty Remarks
6 Ring nut cover 1
7 Upper ring nut 1
8 Lock washer 1
9 Center ring nut 1
10 Rubber washer 1
11 Lower ring nut 1
12 Lower bracket 1
13 Bearing cover 1
14 Upper bearing inner race 1
15 Upper bearing 1
16 Lower bearing 1
17 Lower bearing inner race 1
18 Dust seal 1
19 Lower bearing outer race 1
20 Upper bearing outer race 1
17
18
16
19
2
1
3
4
5
6
7
8
9
10
11
12
13
20
14
15
16 N
•
m (1.6 kgf
•
m, 12 lb
•
ft)
38 N
•
m (3.8 kgf
•
m, 27 lb
•
ft)
75 N
•
m (7.5 kgf
•
m, 54 lb
•
ft)
7 N
•
m (0.7 kgf
•
m, 5.1 lb
•
ft)
7 N
•
m (0.7 kgf
•
m, 5.1 lb
•
ft)
53 N
•
m (5.3 kgf
•
m, 38 lb
•
ft)
B63-F8197-EZ.book Page 68 Monday, January 23, 2017 4:12 PM
STEERING HEAD
4-69
EAS30213
REMOVING THE LOWER BRACKET
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:
• Ring nut cover
• Upper ring nut “1”
• Lock washer
• Center ring nut
• Rubber washer
• Lower ring nut
• Lower bracket
WARNING
EWA13730
Securely support the lower bracket so that
there is no danger of it falling.
TIP
Remove the upper ring nut and lower ring nut
with the steering nut wrench “2”.
EAS30214
CHECKING THE STEERING HEAD
1. Wash:
• Bearings
• Bearing races
2. Check:
• Bearings
• Bearing races
Damage/pitting Replace the bearings and
bearing races as a set.
3. Replace:
• Bearings
• Bearing races
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Remove the bearing races from the steering
head pipe “1” with a long rod “2” and hammer.
b. Remove the bearing race “3” from the lower
bracket with a floor chisel “4” and hammer.
c. Install a new dust seal and new bearing rac-
es.
NOTICE
ECA14270
If the bearing race is not installed properly,
the steering head pipe could be damaged.
TIP
• Always replace the bearings and bearing races
as a set.
• Whenever the steering head is disassembled,
replace the dust seal.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
4. Check:
• Lower bracket
(along with the steering stem)
Bends/cracks/damage Replace.
EAS30216
INSTALLING THE STEERING HEAD
1. Install:
• Upper bearing “1”
• Lower bearing
• Lower bearing dust seal
Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472
Recommended cleaning solvent
Kerosene
2
1
B63-F8197-EZ.book Page 69 Monday, January 23, 2017 4:12 PM
STEERING HEAD
4-70
TIP
• Apply lithium-soap-based grease to each part.
• Be sure to install the upper bearing so that the
marks “a” on the bearing are facing upward.
2. Install:
• Lower ring nut “1”
• Rubber washer “2”
• Center ring nut “3”
• Lock washer “4”
• Upper ring nut “5”
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-14.
3. Install:
• Front brake hose holder “1”
TIP
While holding the front brake hose holder so that
the holder contacts the projection “a” on the low-
er bracket, tighten the bolt to specification.
4. Install:
• Horn bracket “1”
• Horn “2”
TIP
While holding the horn so that the horn contacts
the portion “a” of the horn bracket, tighten the
bolt to specification.
5. Install:
• Handlebar bracket “1”
TIP
Align the slots “a” in the lower bracket with the
pin “b” on the handlebar bracket.
T
R
.
.
Front brake hose holder bolt
7 N·m (0.7 kgf·m, 5.1 lb·ft)
a
1
5
3
2
1
4
1
a
T
R
.
.
Horn bracket bolt
7 N·m (0.7 kgf·m, 5.1 lb·ft)
Horn bolt
7 N·m (0.7 kgf·m, 5.1 lb·ft)
T
R
.
.
Handlebar bracket nut
53 N·m (5.3 kgf·m, 38 lb·ft)
1
2
1
1
b
a
B63-F8197-EZ.book Page 70 Monday, January 23, 2017 4:12 PM
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM
4-71
EAS20189
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM
Removing the rear shock absorber assemblies and swingarm
Order Job/Parts to remove Q’ty Remarks
Muffler Refer to “ENGINE REMOVAL” on page 5-3.
Radiator cover Refer to “RADIATOR” on page 6-1.
1 Rear wheel axle nut 1
2 Rear shock absorber assembly 2
3 Swingarm assembly 1
1
3
2
.R.
•••
23 N m (2.3 kgf m, 17 lb ft)
.R
.
•••
23 N m (2.3 kgf m, 17 lb ft)
.R.
•••
95 N m (9.5 kgf m, 69 lb ft)
.R.
•••
57 N m (5.7 kgf m, 41 lb ft)
2
New
New
LS
LS
.R.
•••
23 N m (2.3 kgf m, 17 lb ft)
chapterbody4 Page 71 Tuesday, January 24, 2017 2:21 PM
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM
4-72
Removing the rear shock absorber assemblies and swingarm
Order Job/Parts to remove Q’ty Remarks
4Spacer 1
5
Oil seal 1
6Circlip 1
7 Bearing 1
8
Bush rear shock absorber
1
9 Swingarm 1
10 Collar 1
6
7
.R.
•••
23 N m (2.3 kgf m, 17 lb ft)
.R
.
•••
23 N m (2.3 kgf m, 17 lb ft)
.R.
•••
95 N m (9.5 kgf m, 69 lb ft)
.R.
•••
57 N m (5.7 kgf m, 41 lb ft)
4
5
2
New
New
LS
LS
.R
.
•••
23 N m (2.3 kgf m, 17 lb ft)
8
9
5
10
chapterbody4 Page 72 Tuesday, January 24, 2017 2:21 PM
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM
4-73
EAS31228
REMOVING THE SWINGARM
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there is
no danger of it falling over.
TIP
Place the vehicle on the centerstand so that the
rear wheel is elevated.
2. Remove:
• Rear wheel axle nut “1”
• Rear shock absorber assembly lower bolt
(right side)
• Swingarm mounting bolt (lower side) “3”
• Swingarm mounting bolt (upper side) “4”
3. Remove:
• Swingarm
EAS31229
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Check:
• Rear shock absorber rod
Bends/damage Replace the rear shock
absorber assembly.
• Rear shock absorber assembly
Oil leaks Replace the rear shock absorber
assembly.
•Spring
Damage/wear Replace the rear shock ab-
sorber assembly.
• Bushings
Damage/wear Replace the rear shock ab-
sorber assembly.
•Bolts
Bends/damage/wear Replace.
EAS31230
CHECKING THE SWINGARM
1. Check:
• Swingarm
Bends/cracks/damage Replace.
2. Check:
• Spacer
• Collar
• Oil seal
• Circlip
• Bearing
Damage/wear Replace.
EAS31231
INSTALLING THE SWINGARM
1. Lubricate:
• Oil seal lips
2. Assemble:
• Bearing “1”
• Circlip “2”
• Oil seals “3”
• Collar “4”
• Spacer “5”
(to the swingarm “6”)
TIP
• Install the oil seal until it is flush with the sur-
face “a” of the swingarm.
• Install the oil seal until it is flush with the sur-
face “b” of the swingarm.
1
2
3
4
Recommended lubricant
Lithium-soap-based grease
New
New
1
2
3
3
4
6
5
chapterbody4 Page 73 Tuesday, January 24, 2017 2:21 PM
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM
4-74
3. Install:
• Swingarm assembly “1”
• Rear wheel axle nut “2”
(temporarily tighten)
• Swingarm mounting bolt (upper side) “3”
(temporarily tighten)
• Swingarm mounting bolt (lower side) “4”
(temporarily tighten)
4. Tighten:
• Rear wheel axle nut “2”
• Swingarm mounting bolt (upper side) “3”
• Swingarm mounting bolt (lower side) “4”
TIP
Tighten the rear wheel axle nut “2”, then the
swingarm mounting bolts “3”, “4”.
5. Install:
• Rear shock absorber assemblies “5”
TIP
Tighten the rear shock absorber assembly nuts
and bolts temporarily, and then tighten them to
specification.
T
R
.
.
Rear wheel axle nut
95 N·m (9.5 kgf·m, 69 lb·ft)
Swingarm mounting bolt
57 N·m (5.7 kgf·m, 41 lb·ft)
T
R
.
.
Rear shock absorber assembly
nut
23 N·m (2.3 kgf·m, 41 lb·ft)
Rear shock absorber assembly
bolt
23 N·m (2.3 kgf·m, 41 lb·ft)
2
5
1
4
3
B63-F8197-EZ.book Page 74 Monday, January 23, 2017 4:12 PM
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM
4-75
B63-F8197-EZ.book Page 75 Monday, January 23, 2017 4:12 PM
5
ENGINE
ENGINE INSPECTION .................................................................................... 5-1
MEASURING THE COMPRESSION PRESSURE....................................5-1
ENGINE REMOVAL ........................................................................................ 5-3
INSTALLING THE ENGINE....................................................................... 5-7
CONNECTING THE LEADS .....................................................................5-8
INSTALLING THE MUFFLER ...................................................................5-8
CYLINDER HEAD............................................................................................ 5-9
REMOVING THE CYLINDER HEAD.......................................................5-13
CHECKING THE CYLINDER HEAD .......................................................5-13
CHECKING THE CAMSHAFT SPROCKET............................................5-14
CHECKING THE TIMING CHAIN TENSIONER......................................5-14
CHECKING THE DECOMPRESSION SYSTEM.....................................5-15
CHECKING THE VVA SOLENOID..........................................................5-15
INSTALLING THE CYLINDER HEAD .....................................................5-15
CAMSHAFT ...................................................................................................5-18
REMOVING THE CAMSHAFT ................................................................5-19
CHECKING THE CAMSHAFT.................................................................5-19
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........5-20
INSTALLING THE CAMSHAFT AND ROCKER ARMS ..........................5-20
VALVES AND VALVE SPRINGS.................................................................. 5-22
REMOVING THE VALVES......................................................................5-23
CHECKING THE VALVES AND VALVE GUIDES ..................................5-23
CHECKING THE VALVE SEATS ............................................................5-25
CHECKING THE VALVE SPRINGS........................................................5-26
INSTALLING THE VALVES ....................................................................5-27
CYLINDER AND PISTON.............................................................................. 5-29
REMOVING THE PISTON ......................................................................5-30
CHECKING THE CYLINDER AND PISTON ...........................................5-30
CHECKING THE PISTON RINGS...........................................................5-31
CHECKING THE PISTON PIN ................................................................5-32
CHECKING THE TIMING CHAIN GUIDE (EXHAUST SIDE) .................5-32
INSTALLING THE PISTON AND CYLINDER .........................................5-32
B63-F8197-EZ.book Page 1 Monday, January 23, 2017 4:12 PM
V-BELT AUTOMATIC TRANSMISSION .......................................................5-34
REMOVING THE PRIMARY SHEAVE....................................................5-37
REMOVING THE SECONDARY SHEAVE .............................................5-37
DISASSEMBLING THE SECONDARY SHEAVE....................................5-37
CHECKING THE CLUTCH HOUSING ....................................................5-38
CHECKING THE CLUTCH SHOES ........................................................5-38
CHECKING THE V-BELT........................................................................5-38
CHECKING THE PRIMARY SHEAVE ....................................................5-38
CHECKING THE PRIMARY SHEAVE WEIGHTS...................................5-39
CHECKING THE PRIMARY SHEAVE SLIDERS ....................................5-39
CHECKING THE SECONDARY SHEAVE ..............................................5-39
ASSEMBLING THE PRIMARY SHEAVE ................................................5-39
ASSEMBLING THE SECONDARY SHEAVE..........................................5-39
INSTALLING THE PRIMARY SHEAVE,
V-BELT AND SECONDARY SHEAVE ...................................................5-40
STARTER GENERATOR .............................................................................. 5-43
REMOVING THE STARTER GENERATOR ...........................................5-44
INSTALLING THE STARTER GENERATOR..........................................5-44
OIL PUMP......................................................................................................5-45
CHECKING THE OIL STRAINER ...........................................................5-47
CHECKING THE OIL PUMP ...................................................................5-47
ASSEMBLING THE OIL PUMP...............................................................5-47
TRANSMISSION............................................................................................5-48
CHECKING THE TRANSMISSION .........................................................5-50
INSTALLING THE TRANSMISSION .......................................................5-50
CRANKSHAFT .............................................................................................. 5-51
DISASSEMBLING THE CRANKCASE....................................................5-53
REMOVING THE CRANKSHAFT ASSEMBLY .......................................5-53
CHECKING THE CRANKSHAFT ASSEMBLY........................................5-53
CHECKING THE CRANKCASE ..............................................................5-54
CHECKING THE BEARING ....................................................................5-54
CHECKING THE OIL PUMP DRIVE GEAR ............................................5-54
INSTALLING THE CRANKSHAFT ..........................................................5-54
ASSEMBLING THE CRANKCASE..........................................................5-55
INSTALLING THE CENTERSTAND .......................................................5-55
B63-F8197-EZ.book Page 2 Monday, January 23, 2017 4:12 PM
ENGINE INSPECTION
5-1
EAS20041
ENGINE INSPECTION
EAS30249
MEASURING THE COMPRESSION
PRESSURE
TIP
Insufficient compression pressure will result in a
loss of performance.
1. Measure:
• Valve clearance
Out of specification Adjust.
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-5.
2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Remove:
• Front side cover assembly (right)
Refer to “GENERAL CHASSIS (2)” on page
4-3.
• Footrest board (right)
Refer to “GENERAL CHASSIS (6)” on page
4-16.
4. Disconnect:
• Spark plug cap
5. Remove:
• Spark plug
NOTICE
ECA20470
Before removing the spark plug, use com-
pressed air to blow away any dirt accumulat-
ed in the spark plug well to prevent it from
falling into the cylinder.
6. Install:
• Compression gauge “1”
• Extension “2”
7. Measure:
• Compression pressure
Out of specification Refer to steps (c) and
(d).
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Turn the main switch to “ON”.
b. With the throttle wide open, crank the engine
until the reading on the compression gauge
stabilizes.
WARNING
EWA12960
To prevent sparking, ground the spark plug
lead before cranking the engine.
c. If the compression pressure is above the
maximum specification, check the cylinder
head, valve surfaces and piston crown for
carbon deposits.
Carbon deposits Eliminate.
d. If the compression pressure is below the min-
imum specification, pour a teaspoonful of en-
gine oil into the spark plug bore and measure
again.
Refer to the following table.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
8. Install:
• Spark plug “1”
Compression gauge
90890-03081
Engine compression tester
YU-33223
Extension
90890-04136
2
1
Standard compression pressure
(at sea level)
1800 kPa/860 r/min (18.0
kgf/cm²/860 r/min, 256.0 psi/
860 r/min)
Minimum–Maximum
1570–2020 kPa/860 r/min
(15.7–20.2 kgf/cm²/860 r/min,
223.3–287.3 psi/860 r/min)
Compression pressure (with oil applied into the
cylinder)
Reading Diagnosis
Higher than without oil
Piston ring(s) wear or
damage Repair.
Same as without oil
Piston, valves, cylinder
head gasket or piston
ring(s) possibly defec-
tive Repair.
T
R
.
.
Spark plug
13 N·m (1.3 kgf·m, 9.4 lb·ft)
B63-F8197-EZ.book Page 1 Monday, January 23, 2017 4:12 PM
ENGINE INSPECTION
5-2
TIP
When tightening the spark plug, make sure that
the inside “a” of the spark plug wrench “2” does
not contact the portion “b” of the spark plug.
9. Connect:
• Spark plug cap
TIP
To route the spark plug lead, refer to “CON-
NECTING THE LEADS” on page 5-8.
10.Install:
• Footrest board (right)
Refer to “GENERAL CHASSIS (6)” on page
4-16.
• Front side cover assembly (right)
Refer to “GENERAL CHASSIS (2)” on page
4-3.
a
b
2
1
B63-F8197-EZ.book Page 2 Monday, January 23, 2017 4:12 PM
ENGINE REMOVAL
5-3
EAS20042
ENGINE REMOVAL
Removing the muffler
Order Job/Parts to remove Q’ty Remarks
1 Muffler protector 1
2 Muffler 1
3 Exhaust gasket 1
1
2
3
B63-F8197-EZ.book Page 3 Monday, January 23, 2017 4:12 PM
ENGINE REMOVAL
5-4
Disconnecting the leads
Order Job/Parts to remove Q’ty Remarks
Engine oil
Drain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-17.
Coolant
Drain.
Refer to “CHANGING THE COOLANT” on
page 3-19.
Battery
Refer to “GENERAL CHASSIS (1)” on page
4-1.
Front side covers
Refer to “GENERAL CHASSIS (2)” on page
4-3.
Rear side cover assembly
Refer to “GENERAL CHASSIS (3)” on page
4-6.
Storage box
Refer to “GENERAL CHASSIS (3)” on page
4-6.
Air filter case Refer to “AIR FILTER CASE” on page 7-7.
V-belt case air duct
Refer to “V-BELT AUTOMATIC TRANSMIS-
SION” on page 5-34.
Fuel injector Refer to “FUEL INJECTOR” on page 7-5.
Throttle body Refer to “THROTTLE BODY” on page 7-10.
Rear brake caple Refer to “REAR BRAKE” on page 4-43.
1
2
3
4
5
6
7
8
9
10
B63-F8197-EZ.book Page 4 Monday, January 23, 2017 4:12 PM
ENGINE REMOVAL
5-5
Disconnecting the leads
Order Job/Parts to remove Q’ty Remarks
Muffler Refer to “ENGINE REMOVAL” on page 5-3.
Rear wheel Refer to “REAR WHEEL” on page 4-28
1 Coolant temperature sensor coupler 1 Disconnect.
2 Crankshaft position sensor coupler 1 Disconnect.
3 Starter generator lead coupler 1 Disconnect.
4 Ignition coil coupler 1 Disconnect.
5 Engine ground lead 1 Disconnect.
6 Module sensor coupler 1 Disconnect.
7 ISC unit couler 1 Disconnect.
8 VVA (variable valve actuator) solenoid coupler 1 Disconnect.
9
O
2
sensor coupler
1
Disconnect.
10 Injector coupler 1 Disconnect.
1
2
3
4
5
6
7
8
9
10
B63-F8197-EZ.book Page 5 Monday, January 23, 2017 4:12 PM
ENGINE REMOVAL
5-6
Removing the engine
Order Job/Parts to remove Q’ty Remarks
1 Rear shock absorber assembly 2
2 Engine bracket bolt 1
3 Damper 2
4Spacer 1
5 Engine bracket 1
6 Collar 2
7Pin 2
8Engine
1
8
1
2
6
7
3
3
4
5
B63-F8197-EZ.book Page 6 Monday, January 23, 2017 4:12 PM
ENGINE REMOVAL
5-7
EAS23720
INSTALLING THE ENGINE
1. Install:
• Stopper “1”
• Collars “2”
• Engine bracket “3”
• Engine bracket bolt/nut (center) “4”
• Engine bracket bolt/nut (rear) “5”
• Engine bracket bolt/nut (front) “6”
TIP
Follow the installation procedure below to prop-
erly function the engine mount.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Temporarily put the stopper “1” and collar “2”
on the engine assembly “8”.
b. Temporarily install the engine bracket
bolt/nut (center) “4” and route the ø4 pin “10”
through the hole of the engine bracket bolt
(rear) and the hole of the inner collar.
c. Tighten the engine bracket nut (center) from
the right side first, then the left side.
d. Remove the ø4 pin, insert the engine bracket
bolt (rear) “5”, and then tighten the nut “5”.
e. Temporarily install the engine bracket
bolt/nut (front) “6”.
7. Engine assembly
8. Frame complete
B. Front
4
3
6
8
5
7
4
B
5
1
4
6
2
1
2
5
A-A
T
R
.
.
Engine bracket nut (center)
54 N·m (5.4 kgf·m, 39 lb·ft)
T
R
.
.
Engine bracket nut (rear)
27 N·m (2.7 kgf·m, 20 lb·ft)
8
1
2
4
10
1
10
3
5
B63-F8197-EZ.book Page 7 Monday, January 23, 2017 4:12 PM
ENGINE REMOVAL
5-8
f. Tighten the rear shock absorber lower bolt
“7”, lift the rear tire up using the centerstand,
and then tighten the engine bracket nut (front)
“6”.
g. Remove the centerstand and then make sure
that the stopper “1” is not touching the engine
assembly “8”.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS31717
CONNECTING THE LEADS
1. Connect:
• Engine ground lead “1”
TIP
Make sure that the engine ground lead terminal
“a” contacts the stopper “b” on the crankcase.
2. Connect:
• Spark plug cap “1”
TIP
Route the spark plug lead between the VVA
(variable valve actuator) solenoid “2” and the
water pump inlet hose “3”. Make sure that the
spark plug lead does not contact the VVA (vari-
able valve actuator) solenoid or water pump inlet
hose.
EAS31588
INSTALLING THE MUFFLER
1. Install:
• Exhaust gaskets “1”
(to the cylinder head)
TIP
Install the exhaust gasket with its projections “a”
facing toward the cylinder head.
T
R
.
.
Rear shock absorber lower bolt
23 N·m (2.3 kgf·m, 17 lb·ft)
T
R
.
.
Engine bracket nut (front)
50 N·m (5.0 kgf·m, 36 lb·ft)
T
R
.
.
Engine ground lead bolt
7 N·m (0.7 kgf·m, 5.1 lb·ft)
6
6
7
8
1
1
b
a
2
1
3
New
New
a
a
1
B63-F8197-EZ.book Page 8 Monday, January 23, 2017 4:12 PM
EAS20044
CYLINDER HEAD
Removing the cylinder head
* Apply Yamaha bond No.1215 (90890-85505).
Order Job/Parts to remove Q’ty Remarks
Battery
Refer to “GENERAL CHASSIS (1)” on page
4-1.
Front side covers
Refer to “GENERAL CHASSIS (2)” on page
4-3.
Fuel tank cover
Refer to “GENERAL CHASSIS (7)” on page
4-18.
Storage box
Refer to “GENERAL CHASSIS (3)” on page
4-6.
Center lower cover
Refer to “GENERAL CHASSIS (6)” on page
4-16.
Coolant
Drain.
Refer to “CHANGING THE COOLANT” on
page 3-19.
Muffler Refer to “ENGINE REMOVAL” on page 5-3.
Radiator Refer to “RADIATOR” on page 6-1.
Thermostat assembly Refer to “THERMOSTAT” on page 6-4.
Water pump Refer to “WATER PUMP” on page 6-6.
Fuel tank Refer to “FUEL TANK” on page 7-1.
15 N
•
m (1.5 kgf
•
m, 11 lb
•
ft)
10 N
•
m (1.0 kgf
•
m, 7.2 lb
•
ft)
13 N
•
m (1.3 kgf
•
m, 9.4 lb
•
ft)
25 N
•
m (2.5 kgf
•
m, 18 lb
•
ft)
30 N
•
m (3.0 kgf
•
m, 22 lb
•
ft)
24 N
•
m (2.4 kgf
•
m, 17 lb
•
ft)
10 N
•
m (1.0 kgf
•
m, 7.2 lb
•
ft)
7 N
•
m (0.7 kgf
•
m, 5.1 lb
•
ft)
10 N
•
m (1.0 kgf
•
m, 7.2 lb
•
ft)
4.0 N
•
m (0.40 kgf
•
m, 2.9 lb
•
ft)
10 N
•
m (1.0 kgf
•
m, 7.2 lb
•
ft)
7 N
•
m (0.7 kgf
•
m, 5.1 lb
•
ft)
CYLINDER HEAD
5-9
B63-F8197-EZ.book Page 9 Monday, January 23, 2017 4:12 PM
CYLINDER HEAD
5-10
Removing the cylinder head
* Apply Yamaha bond No.1215 (90890-85505).
Order Job/Parts to remove Q’ty Remarks
Air filter case Refer to “AIR FILTER CASE” on page 7-7.
Fuel injector Refer to “FUEL INJECTOR” on page 7-5.
Intake manifold Refer to “THROTTLE BODY” on page 7-10.
1 Spark plug cap 1 Disconnect.
2 Spark plug 1
3
O
2
sensor coupler
1 Disconnect.
4
O
2
sensor
1
TIP
Remove the O
2
sensor only when neces-
sary.
5 Coolant temperature sensor coupler 1 Disconnect.
15 N
•
m (1.5 kgf
•
m, 11 lb
•
ft)
10 N
•
m (1.0 kgf
•
m, 7.2 lb
•
ft)
13 N
•
m (1.3 kgf
•
m, 9.4 lb
•
ft)
25 N
•
m (2.5 kgf
•
m, 18 lb
•
ft)
30 N
•
m (3.0 kgf
•
m, 22 lb
•
ft)
24 N
•
m (2.4 kgf
•
m, 17 lb
•
ft)
10 N
•
m (1.0 kgf
•
m, 7.2 lb
•
ft)
7 N
•
m (0.7 kgf
•
m, 5.1 lb
•
ft)
10 N
•
m (1.0 kgf
•
m, 7.2 lb
•
ft)
4.0 N
•
m (0.40 kgf
•
m, 2.9 lb
•
ft)
10 N
•
m (1.0 kgf
•
m, 7.2 lb
•
ft)
7 N
•
m (0.7 kgf
•
m, 5.1 lb
•
ft)
1
2
5
3
4
B63-F8197-EZ.book Page 10 Monday, January 23, 2017 4:12 PM
CYLINDER HEAD
5-11
Removing the cylinder head
* Apply Yamaha bond No.1215 (90890-85505).
Order Job/Parts to remove Q’ty Remarks
6 Coolant temperature sensor 1
7 VVA (variable valve actuator) solenoid coupler 1 Disconnect.
8 VVA (variable valve actuator) solenoid 1
9 VVA (variable valve actuator) solenoid gasket 1
10 VVA (variable valve actuator) solenoid rod 1
11 Fuel hose holder 1
12 Cylinder head breather hose 1
13 Cylinder head cover 1
14 Cylinder head cover gasket 1
15 Dowel pin 2
15 N
•
m (1.5 kgf
•
m, 11 lb
•
ft)
10 N
•
m (1.0 kgf
•
m, 7.2 lb
•
ft)
13 N
•
m (1.3 kgf
•
m, 9.4 lb
•
ft)
25 N
•
m (2.5 kgf
•
m, 18 lb
•
ft)
30 N
•
m (3.0 kgf
•
m, 22 lb
•
ft)
24 N
•
m (2.4 kgf
•
m, 17 lb
•
ft)
10 N
•
m (1.0 kgf
•
m, 7.2 lb
•
ft)
7 N
•
m (0.7 kgf
•
m, 5.1 lb
•
ft)
10 N
•
m (1.0 kgf
•
m, 7.2 lb
•
ft)
4.0 N
•
m (0.40 kgf
•
m, 2.9 lb
•
ft)
10 N
•
m (1.0 kgf
•
m, 7.2 lb
•
ft)
7 N
•
m (0.7 kgf
•
m, 5.1 lb
•
ft)
7
6
15
8
9
10
12
14
15
11
13
B63-F8197-EZ.book Page 11 Monday, January 23, 2017 4:12 PM
CYLINDER HEAD
5-12
Removing the cylinder head
* Apply Yamaha bond No.1215 (90890-85505).
Order Job/Parts to remove Q’ty Remarks
16 Cylinder head cover breather plate 1
17 Cylinder head cover breather plate gasket 1
18 Oil seal 1
19 Timing chain tensioner plug 1
20 Timing chain tensioner 1
21 Timing chain tensioner gasket 1
22 Camshaft sprocket bolt 1
23 Camshaft sprocket 1
24 Decompression cam 1
25 Cylinder head 1
26 Cylinder head gasket 1
27 Dowel pin 2
28 Engine oil check bolt 1
15 N
•
m (1.5 kgf
•
m, 11 lb
•
ft)
10 N
•
m (1.0 kgf
•
m, 7.2 lb
•
ft)
13 N
•
m (1.3 kgf
•
m, 9.4 lb
•
ft)
25 N
•
m (2.5 kgf
•
m, 18 lb
•
ft)
30 N
•
m (3.0 kgf
•
m, 22 lb
•
ft)
24 N
•
m (2.4 kgf
•
m, 17 lb
•
ft)
10 N
•
m (1.0 kgf
•
m, 7.2 lb
•
ft)
7 N
•
m (0.7 kgf
•
m, 5.1 lb
•
ft)
10 N
•
m (1.0 kgf
•
m, 7.2 lb
•
ft)
4.0 N
•
m (0.40 kgf
•
m, 2.9 lb
•
ft)
10 N
•
m (1.0 kgf
•
m, 7.2 lb
•
ft)
7 N
•
m (0.7 kgf
•
m, 5.1 lb
•
ft)
22
23
24
25
27
27
26
28
21
20
19
16
17
18
B63-F8197-EZ.book Page 12 Monday, January 23, 2017 4:12 PM
CYLINDER HEAD
5-13
EAS30276
REMOVING THE CYLINDER HEAD
1. Align:
• “I” mark “a” on the AC magneto rotor
(with the match mark “b” on the right crank-
case)
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Turn the crankshaft clockwise.
b. When the piston is at TDC on the compres-
sion stroke, align the “I” mark “c” on the cam-
shaft sprocket with the match mark “d” on the
camshaft stopper plate.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
2. Loosen:
• Camshaft sprocket bolt “1”
TIP
Use the camshaft wrench “2” and loosen the
camshaft sprocket bolt.
3. Remove:
• Cylinder head
TIP
• Loosen the bolts and nuts in the proper se-
quence as shown.
• Loosen each bolt and nuts 1/2 of a turn at a
time. After all of the bolts and nuts are fully
loosened, remove them.
EAS30277
CHECKING THE CYLINDER HEAD
1. Eliminate:
• Combustion chamber carbon deposits
(with a rounded scraper)
TIP
Do not use a sharp instrument to avoid damag-
ing or scratching:
• Spark plug bore threads
• Valve seats
2. Check:
• Cylinder head
Damage/scratches Replace.
• Cylinder head water jacket
Mineral deposits/rust Eliminate.
3. Measure:
• Cylinder head warpage
Out of specification Resurface the cylinder
head.
Camshaft wrench
90890-04162
Camshaft wrench
YM-04162
b
a
d
c
1
2
Warpage limit
0.05 mm (0.0020 in)
3
5
2
4
6
1
2
×
4
×
B63-F8197-EZ.book Page 13 Monday, January 23, 2017 4:12 PM
CYLINDER HEAD
5-14
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Place a straightedge “1” and a thickness
gauge “2” across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylinder
head as follows.
d. Place 400–600 grit wet sandpaper on the sur-
face plate and resurface the cylinder head
using a figure-eight sanding pattern.
TIP
To ensure an even surface, rotate the cylinder
head several times.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS31232
CHECKING THE CAMSHAFT SPROCKET
1. Check:
• Camshaft sprocket
More than 1/4 tooth wear “a” Replace the
camshaft sprocket, timing chain and crank-
shaft as a set.
EAS30279
CHECKING THE TIMING CHAIN TENSIONER
1. Check:
• Timing chain tensioner
Cracks/damage Replace.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Remove the timing chain tensioner plug.
b. While lightly pressing the timing chain ten-
sioner rod by hand, turn the tensioner rod ful-
ly clockwise with a thin screwdriver “1”.
c. While holding the timing chain tensioner rod
in place with your hand, turn the screwdriver
counterclockwise, remove the screwdriver,
and slowly release the timing chain tensioner
rod.
d. Make sure that the timing chain tensioner rod
comes out of the timing chain tensioner hous-
ing smoothly. If there is rough movement, re-
place the timing chain tensioner.
1
2
a. 1/4 tooth
b. Correct
1. Timing chain roller
2. Camshaft sprocket
1
B63-F8197-EZ.book Page 14 Monday, January 23, 2017 4:12 PM
CYLINDER HEAD
5-15
e. Install the timing chain tensioner plug.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS30280
CHECKING THE DECOMPRESSION SYSTEM
1. Check:
• Decompression system
TIP
• Check that the decompression lever moves
smoothly.
• Check that the operating range “a” of the de-
compression lever is the same as the range
shown in the illustration.
EAS31624
CHECKING THE VVA SOLENOID
1. Check:
• VVA (variable valve actuator) solenoid “1”
Cracks/damage Replace.
EAS30282
INSTALLING THE CYLINDER HEAD
1. Tighten:
• Cylinder head nuts “1”
• Cylinder head bolts “2”
TIP
• Lubricate the cylinder head nuts and washers
with molybdenum disulfide grease.
• Tighten the cylinder head nuts and bolts in the
proper tightening sequence as shown and
torque them in two stages.
2. Install:
• Decompression cam “1”
• Camshaft sprocket “2”
• Timing chain
• Camshaft sprocket bolt
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Turn the crankshaft clockwise.
b. Align the “I” mark “a” on the AC magneto rotor
with the match mark “b” on the right crank-
case.
c. Install the decompression cam.
d. Install the timing chain onto the camshaft
sprocket, then the camshaft sprocket onto
the camshaft, and then finger tighten the
camshaft sprocket bolt.
NOTICE
ECA20600
Do not turn the crankshaft when installing
the camshaft sprocket to avoid damage or
improper valve timing.
TIP
• Fit the pin on the decompression cam into the
slot “c” in the decompression lever on the cam-
shaft sprocket.
• Align the “I” mark “d” on the camshaft sprocket
with the match mark “e” on the camshaft stop-
per plate.
a. 20.88°
T
R
.
.
Cylinder head nut
24 N·m (2.4 kgf·m, 17 lb·ft)
Cylinder head bolt
10 N·m (1.0 kgf·m, 7.2 lb·ft)
a
1
4
2
5
3
1
6
22
11
2
×
4
×
b
a
B63-F8197-EZ.book Page 15 Monday, January 23, 2017 4:12 PM
CYLINDER HEAD
5-16
e. While holding the camshaft, temporarily tight-
en the camshaft sprocket bolt.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
3. Install:
• Timing chain tensioner gasket
• Timing chain tensioner
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Remove the timing chain tensioner plug.
b. While lightly pressing the timing chain ten-
sioner rod by hand, turn the tensioner rod ful-
ly clockwise with a thin screwdriver “1”.
TIP
Make sure that the tensioner rod has been fully
turned clockwise.
c. Install the gasket and the timing chain ten-
sioner “2” onto the cylinder.
WARNING
EWA17620
Always use a new gasket.
TIP
• Install the timing chain tensioner gasket so that
the tabs “a” on the gasket are protruding in the
directions shown in the illustration.
• Apply Yamaha bond No. 1215 to the threads of
the timing chain tensioner bolts.
d. Turn the timing chain tensioner rod counter-
clockwise with a thin screwdriver “1”, make
sure it releases, and then install the timing
chain tensioner plug.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
4. Turn:
• Crankshaft
(several turns clockwise)
5. Check:
• “I” mark “a”
Make sure the “I” mark “a” on the AC magne-
to rotor is aligned with the match mark “b” on
the right crankcase.
• “I” mark “c”
Make sure the “I” mark “c” on the camshaft
sprocket is aligned with the match mark “d”
on the camshaft stopper plate.
Out of alignment Correct.
Refer to the installation steps above.
Yamaha bond No. 1215
90890-85505
(Three bond No.1215®)
e
1
c
d
2
New
1
T
R
.
.
Timing chain tensioner bolt
10 N·m (1.0 kgf·m, 7.2 lb·ft)
a
a
2
1
b
a
B63-F8197-EZ.book Page 16 Monday, January 23, 2017 4:12 PM
CYLINDER HEAD
5-17
6. Tighten:
• Camshaft sprocket bolt “1”
NOTICE
ECA20610
Be sure to tighten the camshaft sprocket bolt
to the specified torque to avoid the possibil-
ity of the bolt coming loose and damaging
the engine.
TIP
Tighten the camshaft sprocket bolt with the cam-
shaft wrench “2”.
7. Measure:
• Valve clearance
Out of specification Adjust.
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-5.
8. Install:
• Oil seal “1”
(into the cylinder head cover “2”)
TIP
Install the oil seal so that it is facing in the direc-
tion shown in the illustration. Press the oil seal
into the cylinder head cover using a suitable di-
ameter socket “3”.
9. Install:
• VVA (variable valve actuator) solenoid “1”
TIP
While holding the VVA (variable valve actuator)
solenoid so that it is contacting the cylinder head
cover “2”, tighten the bolts to specification.
T
R
.
.
Camshaft sprocket bolt
30 N·m (3.0 kgf·m, 22 lb·ft)
Camshaft wrench
90890-04162
Camshaft wrench
YM-04162
d
c
1
2
T
R
.
.
VVA (variable valve actuator)
solenoid bolt
10 N·m (1.0 kgf·m, 7.2 lb·ft)
1
2
3
1
2
B63-F8197-EZ.book Page 17 Monday, January 23, 2017 4:12 PM
CAMSHAFT
5-18
EAS20043
CAMSHAFT
Removing the rocker arms and camshaft
Order Job/Parts to remove Q’ty Remarks
Cylinder head Refer to “CYLINDER HEAD” on page 5-9.
1 Camshaft stopper plate 1
2 Locknut 4
3 Camshaft assembly 1
4 Bearing 1
5 Rocker arm shaft 2
6 Exhaust rocker arm 1
7 Adjusting screw (exhaust side) 2
8Plate 1
9Spring 1
10 Intake rocker arm 1 1
11 Intake rocker arm stopper pin 1
12 Spring 1
13 Intake rocker arm 2 1
14 Adjusting screw (intake side) 2
5
5
4
3
8
2
14
14
1
6
11
12
13
9
7
2
7
2
10
E
E
E
E
M
M
M
M
M
M
M
M
New
New
T.R.
T.R.
T.R.
7 N
•
m (0.7 kgf
•
m, 5.1 lb
•
ft)
8 N
•
m (0.8 kgf
•
m, 5.8 lb
•
ft)
7 N
•
m (0.7 kgf
•
m, 5.1 lb
•
ft)
B63-F8197-EZ.book Page 18 Monday, January 23, 2017 4:12 PM
CAMSHAFT
5-19
EAS30256
REMOVING THE CAMSHAFT
1. Loosen:
• Adjusting screws (intake/exhaust)
2. Remove:
• Camshaft assembly “1”
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Align the holes “a” in intake rocker arm 1 “2”
and intake rocker arm 2 “3”, and then push
the intake rocker arm stopper pin “4” in the di-
rection of the arrow shown in the illustration.
b. While pushing intake rocker arm 1 “2” and in-
take rocker arm 2 “3” in the direction of the ar-
row shown in the illustration, remove the
camshaft assembly using a slide hammer
bolt “5” and weight “6”.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS30257
CHECKING THE CAMSHAFT
1. Check:
• Camshaft lobes
Blue discoloration/pitting/scratches Re-
place the camshaft.
2. Measure:
• Camshaft lobe dimensions “a” and “b”
Out of specification Replace the camshaft.
3. Measure:
• Camshaft runout
Out of specification Replace the camshaft.
Slide hammer bolt
90890-01085
Slide hammer bolt 8 mm
YU-01083-2
Weight
90890-01084
Weight
YU-01083-3
a
2
3
4
1
6
3
5
2
Camshaft lobe dimensions
Lobe height (Intake)
32.211–32.311 mm (1.2681–
1.2721 in)
Limit
32.111 mm (1.2642 in)
Lobe height (Intake high speed)
32.587–32.687 mm (1.2830–
1.2869 in)
Limit (High speed)
32.487 mm (1.2790 in)
Lobe height (Exhaust)
29.420–29.520 mm (1.1583–
1.1622 in)
Limit
29.320 mm (1.1543 in)
Camshaft runout limit
0.030 mm (0.0012 in)
B63-F8197-EZ.book Page 19 Monday, January 23, 2017 4:12 PM
CAMSHAFT
5-20
4. Check:
• Camshaft oil passage
Obstruction Blow out with compressed air.
EAS30259
CHECKING THE ROCKER ARMS AND
ROCKER ARM SHAFTS
The following procedure applies to all of the
rocker arms and rocker arm shafts.
1. Check:
• Rocker arm
• Rocker arm roller “1”
Damage/wear Replace.
2. Check:
• Rocker arm shaft
Blue discoloration/excessive wear/pit-
ting/scratches Replace or check the lubri-
cation system.
3. Measure:
• Rocker arm inside diameter “a”
Out of specification Replace.
4. Measure:
• Rocker arm shaft outside diameter “a”
Out of specification Replace.
5. Calculate:
• Rocker-arm-to-rocker-arm-shaft clearance
TIP
Calculate the clearance by subtracting the rock-
er arm shaft outside diameter from the rocker
arm inside diameter.
Out of specification Replace the defective
part(s).
EAS30270
INSTALLING THE CAMSHAFT AND ROCKER
ARMS
1. Lubricate:
• Camshaft assembly
Rocker arm inside diameter
9.985–10.000 mm (0.3931–
0.3937 in)
Limit
10.015 mm (0.3943 in)
1
11
Rocker arm shaft outside diame-
ter
9.966–9.976 mm (0.3924–0.3928
in)
Limit
9.935 mm (0.3911 in)
Rocker-arm-to-rocker-arm-shaft
clearance
0.009–0.034 mm (0.0004–0.0013
in)
Limit
0.080 mm (0.0032 in)
a
B63-F8197-EZ.book Page 20 Monday, January 23, 2017 4:12 PM
CAMSHAFT
5-21
2. Lubricate:
• Rocker arms
• Rocker arm shafts
•Spring
• Intake rocker arm stopper pin
3. Install:
• Spring “1”
TIP
Install the spring so that the ends “a” of the
spring are positioned at the locations shown in
the illustration.
4. Install:
• Camshaft assembly “1”
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Align the holes “a” in intake rocker arm 1 “2”
and intake rocker arm 2 “3”, and then push
the intake rocker arm stopper pin “4” in the di-
rection of the arrow shown in the illustration.
b. While pushing intake rocker arm 1 “2” and in-
take rocker arm 2 “3” in the direction of the ar-
row shown in the illustration, install the
camshaft assembly.
TIP
Install the camshaft with the punch mark “a” fac-
ing upward.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
5. Install:
• Camshaft stopper plate
TIP
Before installing the camshaft stopper plate,
make sure that the slots “a” in the rocker arm
shafts “2” are parallel with the edge “b” of the cyl-
inder head and that the camshaft stopper plate
bolt holes in the cylinder head and rocker arm
shafts are aligned.
Recommended lubricant
Camshaft
Molybdenum disulfide oil
Camshaft bearing
Engine oil
Recommended lubricant
Rocker arm shaft
Intake rocker arm stopper pin
Molybdenum disulfide oil
Spring
Rocker arm roller
Engine oil
a
1
a
2
3
4
T
R
.
.
Camshaft stopper plate bolt
(M5
16)
8 N·m (0.8 kgf·m, 5.8 lb·ft)
Camshaft stopper plate bolt
(M6
14)
8 N·m (0.8 kgf·m, 5.8 lb·ft)
a
3
2
a
2
b
a
B63-F8197-EZ.book Page 21 Monday, January 23, 2017 4:12 PM
VALVES AND VALVE SPRINGS
5-22
EAS20045
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 5-9.
Camshaft/Rocker arms Refer to “CAMSHAFT” on page 5-18.
1 Valve cotter 8
2 Valve spring retainer 4
3Valve spring 4
4 Intake valve 2
5Exhaust valve 2
6 Valve stem seal 4
7 Valve spring seat 4
8Valve guide 4
M
M
M
E
E
New
New
New
1
2
3
6
7
8
5
New
2
3
4
8
1
6
7
B63-F8197-EZ.book Page 22 Monday, January 23, 2017 4:12 PM
VALVES AND VALVE SPRINGS
5-23
EAS30283
REMOVING THE VALVES
The following procedure applies to all of the
valves and related components.
TIP
Before removing the internal parts of the cylinder
head (e.g., valves, valve springs, valve seats),
make sure the valves properly seal.
1. Check:
• Valve sealing
Leakage at the valve seat Check the valve
face, valve seat, and valve seat width.
Refer to “CHECKING THE VALVE SEATS”
on page 5-25.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Pour a clean solvent “a” into the intake and
exhaust ports.
b. Check that the valves properly seal.
TIP
There should be no leakage at the valve seat “1”.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
2. Remove:
• Valve cotters “1”
TIP
Remove the valve cotters by compressing the
valve spring with the valve spring compressor
and the valve spring compressor attachment “2”.
3. Remove:
• Valve spring retainer “1”
• Valve spring “2”
•Valve “3”
• Valve stem seal “4”
• Valve spring seat “5”
TIP
Identify the position of each part very carefully so
that it can be reinstalled in its original place.
EAS30284
CHECKING THE VALVES AND VALVE
GUIDES
The following procedure applies to all of the
valves and valve guides.
1. Measure:
• Valve-stem-to-valve-guide clearance
Out of specification Replace the valve
guide.
Valve spring compressor
90890-04019
Valve spring compressor
YM-04019
Valve spring compressor attach-
ment
90890-04108
Valve spring compressor adapt-
er 22 mm
YM-04108
Valve-stem-to-valve-guide clearance =
Valve guide inside diameter “a” -
Valve stem diameter “b”
1
2
1
2
4
3
5
B63-F8197-EZ.book Page 23 Monday, January 23, 2017 4:12 PM
VALVES AND VALVE SPRINGS
5-24
2. Replace:
• Valve guide
TIP
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100 °C (212 °F) in an oven.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Remove the valve guide with the valve guide
remover “1”.
b. Install the new valve guide with the valve
guide installer “2” and valve guide remover
“1”.
c. After installing the valve guide, bore the valve
guide with the valve guide reamer “3” to ob-
tain the proper valve-stem-to-valve-guide
clearance.
TIP
After replacing the valve guide, reface the valve
seat.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
3. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
Valve-stem-to-valve-guide clear-
ance (intake)
0.010–0.037 mm (0.0004–0.0015
in)
Limit
0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clear-
ance (exhaust)
0.025–0.052 mm (0.0010–0.0020
in)
Limit
0.110 mm (0.0043 in)
New
Valve guide position
9.9–10.3 mm (0.39–0.41 in)
a. Valve guide position
Valve guide remover (ø5)
90890-04097
Valve guide remover (5.0 mm)
YM-04097
Valve guide installer (ø5)
90890-04098
Valve guide installer (5.0 mm)
YM-04098
Valve guide reamer (ø5)
90890-04099
Valve guide reamer (5.0 mm)
YM-04099
3
B63-F8197-EZ.book Page 24 Monday, January 23, 2017 4:12 PM
VALVES AND VALVE SPRINGS
5-25
4. Check:
• Valve face
Pitting/wear Grind the valve face.
• Valve stem end
Mushroom shape or diameter larger than the
body of the valve stem Replace the valve.
5. Measure:
• Valve stem runout
Out of specification Replace the valve.
TIP
• When installing a new valve, always replace
the valve guide.
• If the valve is removed or replaced, always re-
place the valve stem seal.
EAS30285
CHECKING THE VALVE SEATS
The following procedure applies to all of the
valves and valve seats.
1. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
2. Check:
• Valve seat
Pitting/wear Replace the cylinder head.
3. Measure:
• Valve seat width “a”
Out of specification Replace the cylinder
head.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Apply Blue layout fluid “b” onto the valve face.
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
d. Measure the valve seat width.
TIP
Where the valve seat and valve face contacted
one another, the blue layout fluid will have been
removed.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
4. Lap:
• Valve face
• Valve seat
TIP
After replacing the cylinder head or replacing the
valve and valve guide, the valve seat and valve
face should be lapped.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Apply a coarse lapping compound “a” to the
valve face.
NOTICE
ECA13790
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
Valve stem runout
0.010 mm (0.0004 in)
Valve seat contact width (intake)
0.90–1.20 mm (0.0354–0.0472 in)
Limit
1.7 mm (0.068 in)
Valve seat contact width (ex-
haust)
0.90–1.20 mm (0.0354–0.0472 in)
Limit
1.7 mm (0.068 in)
B63-F8197-EZ.book Page 25 Monday, January 23, 2017 4:12 PM
VALVES AND VALVE SPRINGS
5-26
b. Apply molybdenum disulfide oil onto the
valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve
seat are evenly polished, and then clean off
all of the lapping compound.
TIP
For the best lapping results, lightly tap the valve
seat while rotating the valve back and forth be-
tween your hands.
e. Apply a fine lapping compound to the valve
face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from the
valve face and valve seat.
g. Apply blue layout fluid “b” onto the valve face.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
j. Measure the valve seat width again. If the
valve seat width is out of specification, reface
and lap the valve seat.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS30286
CHECKING THE VALVE SPRINGS
The following procedure applies to all of the
valve springs.
1. Measure:
• Valve spring free length “a”
Out of specification Replace the valve
spring.
2. Measure:
• Compressed valve spring force “a”
Out of specification Replace the valve
spring.
Free length (intake)
33.81 mm (1.33 in)
Limit
32.11 mm (1.26 in)
Free length (exhaust)
33.81 mm (1.33 in)
Limit
32.11 mm (1.26 in)
Installed compression spring
force (intake)
139.50–160.50 N (14.22–
16.37 kgf, 31.36–36.08 lbf)
Installed compression spring
force (exhaust)
139.50–160.50 N (14.22–
16.37 kgf, 31.36–36.08 lbf)
Installed length (intake)
28.90 mm (1.14 in)
Installed length (exhaust)
28.90 mm (1.14 in)
B63-F8197-EZ.book Page 26 Monday, January 23, 2017 4:12 PM
VALVES AND VALVE SPRINGS
5-27
3. Measure:
• Valve spring tilt “a”
Out of specification Replace the valve
spring.
EAS30288
INSTALLING THE VALVES
The following procedure applies to all of the
valves and related components.
• Valve stem end
(with an oil stone)
4. Lubricate:
• Valve stem “1”
• Valve stem seal “2”
(with the recommended lubricant)
5. Install:
• Valve spring seat “1”
• Valve stem seal “2”
•Valve “3”
• Valve spring “4”
• Valve spring retainer “5”
(into the cylinder head)
TIP
• Make sure each valve is installed in its original
place.
• Install the valve springs with the larger pitch “a”
facing up.
6. Install:
• Valve cotters “1”
b. Installed length
Spring tilt (intake)
1.7 mm (0.068 in)
Spring tilt (exhaust)
1.7 mm (0.068 in)
Recommended lubricant
Molybdenum disulfide oil
Recommended lubricant
Engine oil
b. Smaller pitch
E
New
5
4
2
3
1
New
B63-F8197-EZ.book Page 27 Monday, January 23, 2017 4:12 PM
VALVES AND VALVE SPRINGS
5-28
TIP
Install the valve cotters by compressing the
valve spring with the valve spring compressor
and the valve spring compressor attachment “2”.
7. To secure the valve cotters onto the valve
stem, lightly tap the valve tip with a soft-face
hammer.
NOTICE
ECA13800
Hitting the valve tip with excessive force
could damage the valve.
Valve spring compressor
90890-04019
Valve spring compressor
YM-04019
Valve spring compressor attach-
ment
90890-04108
Valve spring compressor adapt-
er 22 mm
YM-04108
1
2
B63-F8197-EZ.book Page 28 Monday, January 23, 2017 4:12 PM
CYLINDER AND PISTON
5-29
EAS20046
CYLINDER AND PISTON
Removing the cylinder and piston
Order Job/Parts to remove Q’ty Remarks
Cylinder head Refer to “CYLINDER HEAD” on page 5-9.
1 Timing chain guide (exhaust side) 1
2 Cylinder 1
3 Cylinder gasket 1
4 Dowel pin 2
5 Piston pin clip 2
6Piston pin 1
7Piston 1
8Top ring 1
9 2nd ring 1
10 Oil ring 1
11 Coolant drain bolt (cylinder side) 1
10 N
•
m (1.0 kgf
•
m, 7.2 lb
•
ft)
B63-F8197-EZ.book Page 29 Monday, January 23, 2017 4:12 PM
CYLINDER AND PISTON
5-30
EAS30289
REMOVING THE PISTON
1. Remove:
• Piston pin clips “1”
• Piston pin “2”
• Piston “3”
NOTICE
ECA13810
Do not use a hammer to drive the piston pin
out.
TIP
• Before removing the piston pin clips, cover the
crankcase opening with a clean rag to prevent
them from falling into the crankcase.
• Before removing the piston pin, deburr the pis-
ton pin clip groove and the piston pin bore ar-
ea. If both areas are deburred and the piston
pin is still difficult to remove, remove it with the
piston pin puller set “4”.
2. Remove:
• Top ring
• 2nd ring
• Oil ring
TIP
When removing a piston ring, open the end gap
with your fingers and lift the other side of the ring
over the piston crown.
EAS30291
CHECKING THE CYLINDER AND PISTON
1. Check:
• Piston wall
• Cylinder wall
Vertical scratches Rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
2. Measure:
• Piston-to-cylinder clearance
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Measure cylinder bore “C” with the cylinder
bore gauge.
TIP
Measure cylinder bore “C” by taking side-to-side
and front-to-back measurements of the cylinder.
Then, find the average of the measurements.
Piston pin puller set
90890-01304
Piston pin puller
YU-01304
1
2
3
Bore
58.000–58.010 mm
(2.2835–2.2839 in)
Taper limit
0.050 mm (0.0020 in)
Out of round limit
0.050 mm (0.0020 in)
“C” = maximum of D
1
- D
2
“T” = maximum of D
1
or D
2
- maximum of D
5
or
D
6
“R” = maximum of D
1
, D
3
or D
5
- minimum of D
2
,
D
4
or D
6
B63-F8197-EZ.book Page 30 Monday, January 23, 2017 4:12 PM
CYLINDER AND PISTON
5-31
b. If out of specification, rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
c. Measure piston skirt diameter D “a” with the
micrometer.
d. If out of specification, replace the piston and
piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
f. If out of specification, rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS30292
CHECKING THE PISTON RINGS
1. Measure:
• Piston ring side clearance
Out of specification Replace the piston
and piston rings as a set.
TIP
Before measuring the piston ring side clearance,
eliminate any carbon deposits from the piston
ring grooves and piston rings.
2. Install:
• Piston ring
(into the cylinder)
TIP
Use the piston crown to level the position ring
near the bottom of the cylinder where the cylin-
der wear is lowest.
3. Measure:
• Piston ring end gap
Out of specification Replace the piston
ring.
TIP
The oil ring expander spacer end gap cannot be
measured. If the oil ring rail gap is excessive, re-
place all three piston rings.
b. 6.0 mm (0.24 in) from the bottom edge of the
piston
Piston
Diameter
57.962–57.985 mm
(2.2820–2.2829 in)
Piston-to-cylinder clearance =
Cylinder bore “C” -
Piston skirt diameter “D”
Piston-to-cylinder clearance
0.015–0.048 mm
(0.0006–0.0019 in)
Piston ring
Top ring
Ring side clearance
0.030–0.065 mm
(0.0012–0.0026 in)
Limit
0.115 mm (0.0045 in)
2nd ring
Ring side clearance
0.020–0.055 mm
(0.0008–0.0022 in)
Limit
0.115 mm (0.0045 in)
B63-F8197-EZ.book Page 31 Monday, January 23, 2017 4:12 PM
CYLINDER AND PISTON
5-32
EAS30293
CHECKING THE PISTON PIN
1. Check:
• Piston pin
Blue discoloration/grooves Replace the
piston pin, and then check the lubrication sys-
tem.
2. Measure:
• Piston pin outside diameter “a”
Out of specification Replace the piston pin.
3. Measure:
• Piston pin bore diameter “b”
Out of specification Replace the piston.
4. Calculate:
• Piston-pin-to-piston-pin-bore clearance
Out of specification Replace the piston pin
and piston as a set.
EAS30290
CHECKING THE TIMING CHAIN GUIDE
(EXHAUST SIDE)
1. Check:
• Timing chain guide (exhaust side)
Damage/wear Replace.
EAS30294
INSTALLING THE PISTON AND CYLINDER
1. Install:
• Lower oil ring rail “1”
• Oil ring expander “2”
Piston ring
Top ring
End gap (installed)
0.10–0.25 mm
(0.0039–0.0098 in)
Limit
0.50 mm (0.0197 in)
2nd ring
End gap (installed)
0.35–0.50 mm
(0.0138–0.0197 in)
Limit
0.85 mm (0.0335 in)
a. Bottom of cylinder
b. Upper of cylinder
Piston pin outside diameter
13.995–14.000 mm
(0.5510–0.5512 in)
Limit
13.975 mm (0.5502 in)
a
b
Piston pin bore inside diameter
14.002–14.013 mm
(0.5513–0.5517 in)
Limit
14.043 mm (0.5529 in)
Piston-pin-to-piston-pin-bore clearance =
Piston pin bore diameter “b” -
Piston pin outside diameter “a”
Piston-pin-to-piston-pin-bore
clearance
0.002–0.018 mm
(0.0001–0.0007 in)
B63-F8197-EZ.book Page 32 Monday, January 23, 2017 4:12 PM
CYLINDER AND PISTON
5-33
• Upper oil ring rail “3”
• 2nd ring “4”
• Top ring “5”
TIP
Be sure to install the piston rings so that the
manufacturer marks face up.
2. Install:
• Piston “1”
• Piston pin “2”
• Piston pin clips “3”
TIP
• Apply engine oil to the piston pin.
• Make sure the punch mark “a” on the piston
points towards the exhaust side of the cylinder.
• Before installing the piston pin clips, cover the
crankcase opening with a clean rag to prevent
the clips from falling into the crankcase.
• When installing a piston pin clip, make sure
that the clip ends “b” are positioned away from
the cutout “c” in the piston as shown in the illus-
tration.
3. Lubricate:
•Piston
• Piston rings
• Cylinder
(with the recommended lubricant)
4. Offset:
• Piston ring end gaps
5. Install:
• Dowel pins
• Cylinder gasket
• Cylinder “1”
TIP
• While holding the piston “2” with one hand, in-
stall the cylinder with the other hand.
• Pass the timing chain and timing chain guide
(intake side) through the timing chain cavity.
5
4
3
2
1
New
New
1
a
2
3
1
3
2
b
c
New
Recommended lubricant
Engine oil
a. Top ring
b. 2nd ring
c. Upper oil ring rail
d. Oil ring expander
e. Lower oil ring rail
A. Exhaust side
45˚ 45˚
45˚ 45˚
135˚
A
ed
c
ba
New
1
2
B63-F8197-EZ.book Page 33 Monday, January 23, 2017 4:12 PM
V-BELT AUTOMATIC TRANSMISSION
5-34
EAS20050
V-BELT AUTOMATIC TRANSMISSION
Removing the V-belt case
Order Job/Parts to remove Q’ty Remarks
Air filter case Refer to “AIR FILTER CASE” on page 7-7.
1 V-belt case air filter element cover 1
2 V-belt case air filter element 1
3 V-belt case air filter element support 1
4 V-belt case 1
5Gasket 1
6 Dowel pin 2
(2)
NEW
NEW
NEW
T
R
.
.
•
•
10 N m (1.0kgf m, 7.2lb.ft)
T
R
.
.
••
7 N m (0.7kgf
m, 5.1lb.ft)
6
5
4
3
2
1
B63-F8197-EZ.book Page 34 Monday, January 23, 2017 4:12 PM
V-BELT AUTOMATIC TRANSMISSION
5-35
Removing the V-belt, primary sheave and secondary sheave
Order Job/Parts to remove Q’ty Remarks
1 Primary fixed sheave nut 1
2 Conical spring washer 1
3Washer 1
4 Primary fixed sheave 1
5V-belt 1
6 Collar 1
7 Primary sliding sheave 1
8 Primary sheave weight 6
9Cam 1
10 Slider 3
11 Clutch housing nut 1
12 Clutch housing 1
13 Secondary sheave assembly 1
49 N
•
m (4.9 kgf
•
m, 35 lb
•
ft)
45 N
•
m (4.5 kgf
•
m, 33 lb
•
ft)
B63-F8197-EZ.book Page 35 Monday, January 23, 2017 4:12 PM
V-BELT AUTOMATIC TRANSMISSION
5-36
Disassembling the secondary sheave
* Apply Shell dolium grease R®.
Order Job/Parts to remove Q’ty Remarks
1 Secondary sheave nut 1
2 Clutch carrier assembly 1
3 Compression spring 1
4 Spring seat 1
5 Guide pin 3
6 Collar 3
7 Secondary sliding sheave 1
8O-ring 2
9Oil seal 2
10 Bearing 1
11 Circlip 1
12 Bearing 1
13 Secondary fixed sheave 1
*
*
*
New
New
New
New
1
2
4
9
10
11
12
13
5
9
7
8
3
6
T.R.
55 N
•
m (5.5 kgf
•
m, 40 lb
•
ft)
B63-F8197-EZ.book Page 36 Monday, January 23, 2017 4:12 PM
V-BELT AUTOMATIC TRANSMISSION
5-37
EAS30310
REMOVING THE PRIMARY SHEAVE
1. Remove:
• Primary fixed sheave nut “1”
• Conical spring washer
• Washer
• Primary fixed sheave “2”
TIP
While holding the primary fixed sheave with the
rotor holding tool “3”, loosen the primary fixed
sheave nut.
EAS30311
REMOVING THE SECONDARY SHEAVE
1. Remove:
• Clutch housing nut “1”
• Clutch housing “2”
TIP
While holding the clutch housing with the rotor
holding tool “3”, loosen the clutch housing nut.
2. Loosen:
• Secondary sheave nut “1”
NOTICE
ECA21820
Do not remove the secondary sheave nut at
this stage.
TIP
While holding the secondary sheave with the ro-
tor holding tool “2”, loosen the secondary
sheave nut one full turn with the socket wrench
“3”.
EAS30312
DISASSEMBLING THE SECONDARY
SHEAVE
1. Remove:
• Secondary sheave nut “1”
TIP
Install the sheave spring compressor “2” and
sheave fixed block “3” onto the secondary
sheave as shown. Then, compress the spring,
and remove the secondary sheave nut.
Rotor holding tool
90890-01235
Universal magneto and rotor
holder
YU-01235
Rotor holding tool
90890-01701
3
2
1
1
3
2
Rotor holding tool
90890-01701
Socket wrench (39 mm)
90890-01493
Sheave spring compressor
90890-04134
Sheave spring compressor
YM-04134
Sheave fixed block
90890-04135
Sheave fixed bracket
YM-04135
3
2
1
B63-F8197-EZ.book Page 37 Monday, January 23, 2017 4:12 PM
V-BELT AUTOMATIC TRANSMISSION
5-38
EAS30313
CHECKING THE CLUTCH HOUSING
1. Check:
• Clutch housing
Damage/wear Replace.
2. Measure:
• Clutch housing inside diameter “a”
Out of specification Replace the clutch
housing.
EAS30314
CHECKING THE CLUTCH SHOES
The following procedure applies to all of the
clutch shoes.
1. Check:
• Clutch shoe
Damage/wear Replace the clutch shoes
and springs as a set.
Glazed areas Sand with coarse sandpa-
per.
TIP
After sanding the glazed areas, clean the clutch
with a cloth.
2. Measure:
• Clutch shoe thickness “a”
Out of specification Replace the clutch
shoes and springs as a set.
EAS30315
CHECKING THE V-BELT
1. Check:
• V-belt “1”
Cracks/damage/wear Replace.
Grease/oil Clean the primary and second-
ary sheave.
2. Measure:
• V-belt width “a”
Out of specification Replace.
EAS30316
CHECKING THE PRIMARY SHEAVE
1. Check:
• Primary sliding sheave
• Primary fixed sheave
• Collar
Cracks/damage/wear Replace the primary
sliding sheave, primary fixed sheave, and
collar as a set.
Clutch housing inside diameter
125.0 mm (4.92 in)
Limit
125.5 mm (4.94 in)
1
2
3
a
Clutch shoe thickness
4.0 mm (0.16 in)
Limit
2.5 mm (0.10 in)
V-belt width
24.1 mm (0.95 in)
Limit
21.7 mm (0.85 in)
a
a
aa
a
a
B63-F8197-EZ.book Page 38 Monday, January 23, 2017 4:12 PM
V-BELT AUTOMATIC TRANSMISSION
5-39
EAS30317
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 “a”
Out of specification Replace.
EAS31233
CHECKING THE PRIMARY SHEAVE
SLIDERS
1. Check:
• Primary sheave slider
Cracks/damage/wear Replace.
EAS30319
CHECKING THE SECONDARY SHEAVE
1. Check:
• Secondary fixed sheave
• Secondary sliding sheave
Cracks/damage/wear Replace the sec-
ondary fixed and sliding sheaves as a set.
2. Check:
• Torque cam groove “a”
Damage/wear Replace the secondary
fixed and sliding sheaves as a set.
3. Check:
• Guide pin “1”
Damage/wear Replace the secondary
fixed and sliding sheaves as a set.
4. Check:
• Spring free length
Out of specification Replace the spring.
EAS30320
ASSEMBLING THE PRIMARY SHEAVE
1. Clean:
• Primary fixed sheave
• Primary sliding sheave
• Primary sheave weights
•Cam
EAS30321
ASSEMBLING THE SECONDARY SHEAVE
1. Lubricate:
• Secondary sliding sheave inner surface
• Oil seals “1”
(with the recommended lubricant)
TIP
Do not apply grease to the inner surface “a” of
the secondary fixed sheave “2”. If any grease
gets on the inner surface of the secondary fixed
sheave, be sure to wipe it off thoroughly.
Weight outside diameter
20.0 mm (0.79 in)
Limit
19.5 mm (0.77 in)
Compression spring free length
116.4 mm (4.58 in)
Limit
104.8 mm (4.12 in)
Recommended lubricant
Shell dolium grease R®
a
1
B63-F8197-EZ.book Page 39 Monday, January 23, 2017 4:12 PM
V-BELT AUTOMATIC TRANSMISSION
5-40
2. Install:
• Oil seals
• Secondary sliding sheave “1”
TIP
Install the secondary sliding sheave onto the
secondary fixed sheave “2” with the oil seal
guide “3”.
3. Install:
• Guide pins “1”
4. Lubricate:
• Guide pin grooves “a”
• O-rings “2”
(with the recommended lubricant)
5. Install:
• Spring seat
• Compression spring
• Clutch carrier assembly
• Secondary sheave nut “1”
TIP
• Install the sheave spring compressor “2” and
sheave fixed block “3” onto the secondary
sheave as shown. Then, compress the spring,
and install the secondary sheave nut.
• Install the secondary sheave nut “1” with its ta-
pered side facing the clutch carrier.
EAS31234
INSTALLING THE PRIMARY SHEAVE,
V-BELT AND SECONDARY SHEAVE
1. Install:
• Secondary sheave assembly
TIP
Before installing the secondary sheave assem-
bly, check that there is no grease on the splines
“a” of the primary drive gear. If there is any
grease on the splines, be sure to wipe it off thor-
oughly.
2. Tighten:
• Secondary sheave nut “1”
Oil seal guide (37 mm)
90890-04177
Recommended lubricant
Shell dolium grease R®
*
*
2
a
1
1
New
1
3
2
New
a
1
2
New
Sheave spring compressor
90890-04134
Sheave spring compressor
YM-04134
Sheave fixed block
90890-04135
Sheave fixed bracket
YM-04135
1
2
3
a
B63-F8197-EZ.book Page 40 Monday, January 23, 2017 4:12 PM
V-BELT AUTOMATIC TRANSMISSION
5-41
TIP
While holding the secondary sheave with the ro-
tor holding tool “2”, tighten the secondary
sheave nut with the socket wrench “3”.
3. Install:
• Clutch housing “1”
• Clutch housing nut “2”
TIP
While holding the clutch housing with the rotor
holding tool “3”, tighten the clutch housing nut.
4. Install:
• Primary sliding sheave assembly “1”
TIP
When installing the primary sliding sheave as-
sembly, hold the cam to prevent the primary
sheave weights from falling out of the primary
sliding sheave.
5. Install:
• V-belt “1”
NOTICE
ECA21720
Do not allow grease to come in contact with
the V-belt.
TIP
• Install the V-belt with the printed arrow mark on
the V-belt facing in the direction shown in the il-
lustration.
• Install the V-belt onto the primary sheave side.
6. Install:
• Primary fixed sheave “1”
• Washer
• Conical spring washer “2”
• Primary fixed sheave nut
NOTICE
ECA21730
Do not allow grease to contact the primary
sheave assembly.
TIP
• Apply lithium-soap-based grease to the prima-
ry fixed sheave nut side of the conical spring
washer and to the threaded portion of the
crankshaft.
T
R
.
.
Secondary sheave nut
55 N·m (5.5 kgf·m, 40 lb·ft)
Rotor holding tool
90890-01701
Socket wrench (39 mm)
90890-01493
T
R
.
.
Clutch housing nut
45 N·m (4.5 kgf·m, 33 lb·ft)
Rotor holding tool
90890-01701
2
3
1
2
3
1
1
1
B63-F8197-EZ.book Page 41 Monday, January 23, 2017 4:12 PM
V-BELT AUTOMATIC TRANSMISSION
5-42
• Install the conical spring washer with the mark
“a” facing outward.
• Install the V-belt in the primary sheave (when
the pulley is at its widest position) and in the
secondary sheave (when the pulley is at its
narrowest position), and make sure the V-belt
is tight.
7. Tighten:
• Primary fixed sheave nut “1”
TIP
While holding the primary fixed sheave with the
rotor holding tool “2”, tighten the primary fixed
sheave nut.
T
R
.
.
Primary fixed sheave nut
49 N·m (4.9 kgf·m, 35 lb·ft)
Rotor holding tool
90890-01701
Universal magneto and rotor
holder
YU-01235
2
a
1
2
1
B63-F8197-EZ.book Page 42 Monday, January 23, 2017 4:12 PM
STARTER GENERATOR
5-43
EAS20190
STARTER GENERATOR
Removing the starter generator assembly
Order Job/Parts to remove Q’ty Remarks
Coolant
Drain.
Refer to “CHANGING THE COOLANT” on
page 3-19.
Battery
Refer to “GENERAL CHASSIS (1)” on page
4-1.
Front side cover (right)
Refer to “GENERAL CHASSIS (2)” on page
4-3.
Radiator fan Refer to “RADIATOR” on page 6-1
1
Crankshaft position sensor coupler
/Starter generator coupler
1/1 Disconnect.
2 Starter generator rotor nut 1
3 Starter generator rotor 1
4 Woodruff key 1
5
Starter generator/
Crankshaft position sensor
1
5
3
4
2
1
LT
LT
70 N
•
m (7.0 kgf
•
m, 51 lb
•
ft)
T.R.
10 N
•
m (1.0 kgf
•
m, 7.2 lb
•
ft)
T.R.
B63-F8197-EZ.book Page 43 Monday, January 23, 2017 4:12 PM
STARTER GENERATOR
5-44
EAS31239
REMOVING THE STARTER GENERATOR
1. Remove:
• Starter generator rotor nut “1”
• Washer
TIP
While holding the starter generator rotor “2” with
the rotor holding tool “3”, loosen the starter gen-
erator rotor nut.
2. Remove:
• Starter generator rotor “1”
(with the flywheel puller “2”)
• Woodruff key
NOTICE
ECA21740
To protect the end of the crankshaft, place an
appropriate sized socket between the fly-
wheel puller center bolt and the crankshaft.
EAS31240
INSTALLING THE STARTER GENERATOR
1. Install:
• Woodruff key
• Starter generator rotor
• Washer
• Starter generator rotor nut
TIP
• Clean the tapered portion of the crankshaft and
the starter generator rotor hub.
• When installing the starter generator rotor,
make sure the woodruff key is properly seated
in the keyway of the crankshaft.
2. Tighten:
• Starter generator rotor nut “1”
TIP
While holding the starter generator rotor “2” with
the rotor holding tool “3”, tighten the starter gen-
erator rotor nut.
Rotor holding tool
90890-01235
Universal magneto and rotor
holder
YU-01235
Flywheel puller
90890-01189
Flywheel puller
YM-01189
3
1
2
2
1
T
R
.
.
Starter generator rotor nut
70 N·m (7.0 kgf·m, 51 lb·ft)
Rotor holding tool
90890-01235
Universal magneto and rotor
holder
YU-01235
3
1
2
B63-F8197-EZ.book Page 44 Monday, January 23, 2017 4:12 PM
OIL PUMP
5-45
EAS20054
OIL PUMP
Removing the oil pump
* Apply Yamaha bond No. 1215 (90890-85505).
Order Job/Parts to remove Q’ty Remarks
V-Belt automatic transmission
Refer to “V-BELT AUTOMATIC TRANSMIS-
SION” on page 5-34.
1Oil seal 1
2Oil pump cover 1
3Gasket 1
4 Dowel pin 2
5 Oil pump assembly 1
5
3
4
2
1
LS
T
R
.
.
••
4 N m (0.4kgf
m, 2.9lb.ft)
NEW
B63-F8197-EZ.book Page 45 Monday, January 23, 2017 4:12 PM
OIL PUMP
5-46
Disassembling the oil pump
Order Job/Parts to remove Q’ty Remarks
1 Oil pump housing cover 1
2Pin 1
3 Oil pump driven gear 1
4 Oil pump rotor assembly 1
5 Oil pump inner rotor 1
6 Oil pump outer rotor 1
7 Oil pump housing 1
T.R.
E
3
7
2
5
6
4
1
E
1.0 N
•
m (0.10 kgf
•
m, 0.72 lb
•
ft)
B63-F8197-EZ.book Page 46 Monday, January 23, 2017 4:12 PM
OIL PUMP
5-47
EAS30340
CHECKING THE OIL STRAINER
1. Check:
• Oil strainer
Damage Replace.
Contaminants Clean with solvent.
EAS30337
CHECKING THE OIL PUMP
1. Check:
• Oil pump drive gear
• Oil pump driven gear
• Oil pump housing
• Oil pump housing cover
Cracks/damage/wear Replace the oil
pump.
2. Measure:
• Inner-rotor-to-outer-rotor-tip clearance “a”
• Outer-rotor-to-oil-pump-housing clearance
“b”
Out of specification Replace the oil pump.
3. Check:
• Oil pump operation
Rough movement Repeat steps (1) and
(2) or replace the oil pump.
EAS30342
ASSEMBLING THE OIL PUMP
1. Lubricate:
• Inner rotor
• Outer rotor
• Oil pump shaft
2. Install:
• Oil pump housing “1”
• Oil pump outer rotor “2”
• Oil pump inner rotor “3”
• Oil pump driven gear “4”
•Pin “5”
• Oil pump housing cover
TIP
When installing the inner rotor, align the pin in
the oil pump driven gear with the groove “a” in
the inner rotor.
3. Check:
• Oil pump operation
Refer to “CHECKING THE OIL PUMP” on
page 5-47.
1. Inner rotor
2. Outer rotor
3. Oil pump housing
Inner-rotor-to-outer-rotor-tip
clearance
0.150 mm (0.0059 in)
Limit
0.23 mm (0.0091 in)
Outer-rotor-to-oil-pump-housing
clearance
0.13–0.18 mm (0.0051–0.0071 in)
Limit
0.22 mm (0.0086 in)
Recommended lubricant
Engine oil
T
R
.
.
Oil pump housing cover screw
1.0 N·m (0.10 kgf·m, 0.72 lb·ft)
5
3
4
2
1
a
B63-F8197-EZ.book Page 47 Monday, January 23, 2017 4:12 PM
TRANSMISSION
5-48
EAS20062
TRANSMISSION
Removing the transmission
Order Job/Parts to remove Q’ty Remarks
Muffler Refer to “ENGINE REMOVAL” on page 5-3.
Radiator cover Refer to “RADIATOR” on page 6-1.
Secondary sheave assembly
Refer to “V-BELT AUTOMATIC TRANSMIS-
SION” on page 5-34.
Swingarm Refer to “REAR WHEEL” on page 4-28.
Rear wheel Refer to “REAR WHEEL” on page 4-28.
1 Final transmission oil filler cap 1
2 Final transmission oil drain bolt 1
3 Transmission case cover 1
4 Transmission case cover gasket 1
5 Dowel pin 2
E
2
5
4
1
3
New
New
New
New
New
E
E
E
E
LS
LS
B63-F8197-EZ.book Page 48 Monday, January 23, 2017 4:12 PM
TRANSMISSION
5-49
Removing the transmission
Order Job/Parts to remove Q’ty Remarks
6 Main axle assembly 1
7 Primary driven gear 1
8 Main axle 1
9Drive axle 1
10 1st wheel gear 1
11 Circlip 1
12 Primary drive gear 1
13 Oil seal 2
14 Bearing 6
14
6
7
8
14
12
14
14
13
9
11
10
14
New
E
New
New
New
New
E
E
E
LS
LS
New
E
B63-F8197-EZ.book Page 49 Monday, January 23, 2017 4:12 PM
TRANSMISSION
5-50
EAS30433
CHECKING THE TRANSMISSION
1. Check:
• Transmission gears
Blue discoloration/pitting/wear Replace
the defective gear(s).
• Transmission gear dogs
Cracks/damage/rounded edges Replace
the defective gear(s).
2. Check:
• Transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect Reassemble the transmission
axle assemblies.
3. Check:
• Transmission gear movement
Rough movement Replace the defective
part(s).
EAS30438
INSTALLING THE TRANSMISSION
1. Install:
• Oil seal “1”
(to the transmission case cover “2”)
• Oil seal “3”
(to the right crankcase “4”)
2. Install:
• Circlip “1”
(to the drive axle “2”)
TIP
Install the circlip with its chamfered side facing
as shown.
3. Install:
• Primary driven gear “1”
(to the main axle “2”)
4. Install:
• Transmission case cover “1”
TIP
Tighten the transmission case cover bolts in the
proper tightening sequence as shown.
Installed depth “a”
21.7–21.8 mm (0.85–0.86 in)
Installed depth “b”
0.25–0.75 mm (0.01–0.03 in)
New
New
2
a
4
3
1
b
New
Primary driven gear installed
depth “a”
0.5–0.9 mm (0.020–0.035 in)
T
R
.
.
Transmission case cover bolt
20 N·m (2.0 kgf·m, 14 lb·ft)
1
2
1
2
New
New
1
2
a
1
1
2
4
5
6
7
3
8
B63-F8197-EZ.book Page 50 Monday, January 23, 2017 4:12 PM
CRANKSHAFT
5-51
EAS20061
CRANKSHAFT
Removing the crankshaft
Order Job/Parts to remove Q’ty Remarks
Engine Refer to “ENGINE REMOVAL” on page 5-3.
Cylinder head Refer to “CYLINDER HEAD” on page 5-9.
Piston
Refer to “CYLINDER AND PISTON” on page
5-29.
Secondary sheave assembly
Refer to “V-BELT AUTOMATIC TRANSMIS-
SION” on page 5-34.
Oil pump Refer to “OIL PUMP” on page 5-45.
1Dipstick 1
2 Centerstand spring 1
3 Centerstand shaft 1
(9)
1
3
2
E
LS
LS
LS
LS
New
New
B63-F8197-EZ.book Page 51 Monday, January 23, 2017 4:12 PM
CRANKSHAFT
5-52
Removing the crankshaft
Order Job/Parts to remove Q’ty Remarks
4 Dowel pin 2
5 Crankcase (left) 1
6 Crankcase (right) 1
7 Centerstand 1
8 Crankshaft assembly 1
(9)
4
6
4
8
5
E
LS
LS
LS
LS
New
New
7
B63-F8197-EZ.book Page 52 Monday, January 23, 2017 4:12 PM
CRANKSHAFT
5-53
EAS31241
DISASSEMBLING THE CRANKCASE
1. Remove:
• Crankcase bolts
TIP
Loosen each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern. After all of the
bolts are fully loosened, remove them.
2. Remove:
• Crankcase (left) “1”
NOTICE
ECA13900
Tap on one side of the crankcase with a soft-
face hammer. Tap only on reinforced por-
tions of the crankcase, not on the crankcase
mating surfaces. Work slowly and carefully
and make sure the crankcase halves sepa-
rate evenly.
EAS30414
REMOVING THE CRANKSHAFT ASSEMBLY
1. Remove:
• Crankshaft assembly “1”
TIP
• Remove the crankshaft assembly with the
crankcase separating tool “2” and M6 bolts “3”.
• Make sure that the crankcase separating tool
is centered over the crankshaft assembly.
NOTICE
ECA20630
• To protect the end of the crankshaft, place
an appropriate sized socket between the
crankcase separating tool bolt and the
crankshaft.
• Do not tap on the crankshaft.
EAS31242
CHECKING THE CRANKSHAFT ASSEMBLY
1. Measure:
• Crankshaft runout
Out of specification Replace the crank-
shaft assembly.
TIP
Turn the crankshaft slowly.
2. Measure:
• Big end side clearance
Out of specification Replace the crank-
shaft assembly.
1
Crankcase separating tool
90890-01135
Crankcase separator
YU-01135-B
Runout limit
0.030 mm (0.0012 in)
Big end side clearance
0.150–0.450 mm
(0.0059–0.0177 in)
B63-F8197-EZ.book Page 53 Monday, January 23, 2017 4:12 PM
CRANKSHAFT
5-54
3. Measure:
• Crankshaft width
Out of specification Replace the crank-
shaft assembly.
4. Check:
• Crankshaft sprocket “1”
Damage/wear Replace the crankshaft as-
sembly.
• Bearing “2”
Cracks/damage/wear Replace the crank-
shaft assembly.
EAS31243
CHECKING THE CRANKCASE
1. Thoroughly wash the crankcase halves in a
mild solvent.
2. Thoroughly clean all the gasket surfaces and
crankcase mating surfaces.
3. Check:
• Crankcase
Cracks/damage Replace.
EAS31244
CHECKING THE BEARING
1. Check:
• Bearing
Clean and lubricate the bearings, and then
rotate the inner race with your finger.
Rough movement Replace.
EAS31245
CHECKING THE OIL PUMP DRIVE GEAR
1. Check:
• Oil pump drive gear
Damage/wear Replace.
EAS30791
INSTALLING THE CRANKSHAFT
1. Install:
• Crankshaft assembly “1”
TIP
• Install the crankshaft assembly with the crank-
shaft installer pot “2”, crankshaft installer bolt
“3”, adapter “4”, and crankshaft installer spacer
“5”.
• Hold the connecting rod at top dead center
(TDC) with one hand while turning the nut of
the crankshaft installer bolt with the other. Turn
the crankshaft installer bolt until the crankshaft
assembly bottoms against the bearing.
Crank assembly width
51.45–51.50 mm (2.026–2.028 in)
2
1
Crankshaft installer pot
90890-01274
Installing pot
YU-90058
Crankshaft installer bolt
90890-01275
Bolt
YU-90060
Adapter (M12)
90890-01278
Adapter #3
YU-90063
Spacer (crankshaft installer)
90890-04081
Pot spacer
YM-91044
B63-F8197-EZ.book Page 54 Monday, January 23, 2017 4:12 PM
CRANKSHAFT
5-55
EAS31246
ASSEMBLING THE CRANKCASE
1. Thoroughly clean all the gasket mating sur-
faces and crankcase mating surfaces.
2. Apply:
• Sealant
(onto the crankcase mating surfaces)
TIP
Do not allow any sealant to come into contact
with the oil gallery.
3. Install:
• Crankcase (right)
(onto the crankcase (left))
• Crankcase bolts
TIP
• Thoroughly wipe off any sealant that protrudes
from between the left crankcase and the right
crankcase.
• Tighten the crankcase bolts in stages and in a
crisscross pattern.
EAS31247
INSTALLING THE CENTERSTAND
1. Install:
• Centerstand “1”
• Spring “2”
TIP
• Make sure that the hooked end “a” of the spring
is positioned to the outside.
• Make sure that the hooked end “b” of the spring
is positioned to the outside.
Yamaha bond No. 1215
90890-85505
(Three bond No.1215®)
T
R
.
.
Crankcase bolt
10 N·m (1.0 kgf·m, 7.2 lb·ft)
1
2
b
a
B63-F8197-EZ.book Page 55 Monday, January 23, 2017 4:12 PM
6
COOLING SYSTEM
RADIATOR ...................................................................................................... 6-1
CHECKING THE RADIATOR.................................................................... 6-3
INSTALLING THE RADIATOR.................................................................. 6-3
THERMOSTAT ................................................................................................ 6-4
CHECKING THE THERMOSTAT ASSEMBLY .........................................6-5
INSTALLING THE THERMOSTAT ASSEMBLY .......................................6-5
WATER PUMP................................................................................................. 6-6
DISASSEMBLING THE WATER PUMP....................................................6-8
CHECKING THE WATER PUMP ..............................................................6-8
ASSEMBLING THE WATER PUMP..........................................................6-8
INSTALLING THE WATER PUMP ............................................................ 6-8
B63-F8197-EZ.book Page 1 Monday, January 23, 2017 4:12 PM
RADIATOR
6-1
EAS20063
RADIATOR
Removing the radiator
Order Job/Parts to remove Q’ty Remarks
Coolant
Drain.
Refer to “CHANGING THE COOLANT” on
page 3-19.
Front side cover (right)
Refer to “GENERAL CHASSIS (2)” on page
4-3.
Footrest board assembly (right)/Bottom cover
Refer to “GENERAL CHASSIS (6)” on page
4-16.
1Radiator cover 1
2 Coolant reservoir breather hose 1
3 Coolant reservoir hose 1
4 Rear brake hose bracket 1
5 Rear brake hose holder (front side) 1
1
4
5
3
2
(4)
New
(5)
B63-F8197-EZ.book Page 1 Monday, January 23, 2017 4:12 PM
RADIATOR
6-2
Removing the radiator
Order Job/Parts to remove Q’ty Remarks
6 Coolant reservoir 1
7 Radiator inlet hose 1
8 Radiator outlet hose 1
9Radiator cap 1
10 Radiator 1
11 Radiator fan case 1
12 Radiator fan 1
11
9
12
8
10
6
7
(4)
New
(5)
B63-F8197-EZ.book Page 2 Monday, January 23, 2017 4:12 PM
RADIATOR
6-3
EAS30439
CHECKING THE RADIATOR
1. Check:
• Radiator fins
Obstruction Clean.
Apply compressed air to the rear of the radia-
tor.
Damage Repair or replace.
TIP
Straighten any flattened fins with a thin, flathead
screwdriver.
2. Check:
• Radiator hoses
• Coolant reservoir hose
Cracks/damage Replace.
3. Measure:
• Radiator cap valve opening pressure
Below the specified pressure Replace the
radiator cap.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Install the radiator cap tester “1” and radiator
cap tester adapter “2” to the radiator cap “3”.
b. Apply the specified pressure for ten seconds
and make sure there is no drop in pressure.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
4. Check:
• Radiator fan
Damage Replace.
EAS30440
INSTALLING THE RADIATOR
1. Fill:
• Cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-19.
2. Check:
• Cooling system
Leaks Repair or replace any faulty part.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Attach the radiator cap tester “1” to the radia-
tor.
b. Apply 196 kPa (1.96 kg/cm², 27.87 psi) of
pressure.
c. Measure the pressure to check its maintain-
ing applied pressure.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
3. Measure:
• Radiator cap opening pressure
Below the specified pressure Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-3.
Radiator cap valve opening pres-
sure
108.0–137.4 kPa (1.08–1.37
kgf/cm², 15.7–19.9 psi)
Radiator cap tester
90890-05375
1
2
3
Radiator cap tester
90890-05375
1
B63-F8197-EZ.book Page 3 Monday, January 23, 2017 4:12 PM
THERMOSTAT
6-4
EAS20065
THERMOSTAT
Removing the thermostat assembly
Order Job/Parts to remove Q’ty Remarks
Coolant
Drain.
Refer to “CHANGING THE COOLANT” on
page 3-19.
Front side cover (right)
Refer to “GENERAL CHASSIS (2)” on page
4-3.
Footrest board (right)
Refer to “GENERAL CHASSIS (6)” on page
4-16.
1 Radiator inlet hose 1 Disconnect.
2 Radiator outlet hose 1 Disconnect.
3 Water pump inlet hose 1 Disconnect.
4 Thermostat assembly 1
9 N
•
m (0.9 kgf
•
m, 6.5 lb
•
ft)
B63-F8197-EZ.book Page 4 Monday, January 23, 2017 4:12 PM
THERMOSTAT
6-5
EAS31248
CHECKING THE THERMOSTAT ASSEMBLY
1. Check:
• Thermostat “1”
Does not open at 74–78°C (165–172°F)
Replace.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Suspend the thermostat “1” in a container “2”
filled with water.
b. Slowly heat the water.
c. Place a thermometer “3” in the water.
d. While stirring the water “4”, observe the ther-
mostat and thermometer’s indicated temper-
ature.
e. Check the thermostat element position “5”.
Same level for the thermostat element upper
end and the hole lower line “a” at 90 °C (194
°F).
TIP
If the accuracy of the thermostat is in doubt, re-
place it. A faulty thermostat could cause serious
overheating or overcooling.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS30445
INSTALLING THE THERMOSTAT
ASSEMBLY
1. Fill:
• Cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-19.
2. Check:
• Cooling system
Leaks Repair or replace any faulty part.
Refer to “INSTALLING THE RADIATOR” on
page 6-3.
3. Measure:
• Radiator cap opening pressure
Below the specified pressure Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-3.
1
1
2
3
4
5
a
A. Fully closed
B. Fully open
B
A
74 – 78˚C
(165 – 172˚F)
90˚C
(194˚F)
7 mm
(0.28 in)
0.5 mm
(0.02 in)
B63-F8197-EZ.book Page 5 Monday, January 23, 2017 4:12 PM
WATER PUMP
6-6
EAS20066
WATER PUMP
Removing the water pump
Order Job/Parts to remove Q’ty Remarks
Coolant
Drain.
Refer to “CHANGING THE COOLANT” on
page 3-19.
Front side cover (left)
Refer to “GENERAL CHASSIS (2)” on page
4-3.
Footrest board (left)
Refer to “GENERAL CHASSIS (3)” on page
4-6.
1 Water pump inlet hose 1 Disconnect.
2 Water pump assembly 1
3 Dowel pin 2
10 N
•
m (1.0 kgf
•
m, 7.2 lb
•
ft)
B63-F8197-EZ.book Page 6 Monday, January 23, 2017 4:12 PM
WATER PUMP
6-7
Disassembling the water pump
Order Job/Parts to remove Q’ty Remarks
1 Water pump housing cover 1
2 Water pump housing gasket 1
3Circlip 1
4 Impeller shaft 1
5 Water pump seal 1
6 Bearing 1
7 Water pump housing 1
T
.R
.
T
.R
.
10 N
•
m (1.0 kgf
•
m, 7.2 lb
•
ft)
10 N
•
m (1.0 kgf
•
m, 7.2 lb
•
ft)
LS
New
New
New
New
1
2
5
4
6
7
3
B63-F8197-EZ.book Page 7 Monday, January 23, 2017 4:12 PM
WATER PUMP
6-8
EAS30446
DISASSEMBLING THE WATER PUMP
1. Remove:
• Water pump seal “1”
TIP
Remove the water pump seal from the inside of
the water pump housing “2”.
EAS30447
CHECKING THE WATER PUMP
1. Check:
• Water pump housing cover
• Water pump housing
• Impeller shaft
Cracks/damage/wear Replace.
EAS30448
ASSEMBLING THE WATER PUMP
1. Install:
• Water pump seal “1”
(into the water pump housing “2”)
TIP
Install the water pump seal with the special tools
to the specified depth as shown in the illustra-
tion.
2. Lubricate:
• Water pump seal
3. Install:
• Impeller shaft “1”
• Circlip
TIP
After installation, check that the impeller shaft ro-
tates smoothly.
EAS30449
INSTALLING THE WATER PUMP
1. Install:
• O-rings “1”
• Water pump assembly “2”
Installed depth of water pump
seal
0–0.5 mm (0–0.02 in)
Mechanical seal installer
90890-04145
Middle driven shaft bearing driv-
er
90890-04058
Middle drive bearing installer 40
& 50 mm
YM-04058
1
2
New
A. Push down
3. Mechanical seal installer
4. Middle driven shaft bearing driver
a. Installed depth of water pump seal
Recommended lubricant
Lithium-soap-based grease
1
3
A
4
2
New
1
2
a
New
1
New
B63-F8197-EZ.book Page 8 Monday, January 23, 2017 4:12 PM
WATER PUMP
6-9
TIP
• Align the projection “a” on the impeller shaft
with the slit “b” on the camshaft sprocket bolt.
• Lubricate the O-ring with a thin coat of lithium-
soap-based grease.
2. Fill:
• Cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-19.
3. Check:
• Cooling system
Leaks Repair or replace any faulty part.
Refer to “INSTALLING THE RADIATOR” on
page 6-3.
4. Measure:
• Radiator cap opening pressure
Below the specified pressure Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-3.
T
R
.
.
Water pump assembly bolt
10 N·m (1.0 kgf·m, 7.2 lb·ft)
1
b
a
2
New
LS
B63-F8197-EZ.book Page 9 Monday, January 23, 2017 4:12 PM
7
FUEL SYSTEM
FUEL TANK..................................................................................................... 7-1
REMOVING THE FUEL TANK .................................................................. 7-2
REMOVING THE FUEL PUMP .................................................................7-2
REMOVING THE FUEL FILTER ............................................................... 7-2
CHECKING THE FUEL PUMP BODY.......................................................7-2
CHECKING THE FUEL FILTER................................................................7-2
INSTALLING THE FUEL FILTER.............................................................. 7-2
INSTALLING THE FUEL PUMP................................................................ 7-3
INSTALLING THE FUEL TANK.................................................................7-3
CHECKING THE FUEL PRESSURE ........................................................7-3
FUEL INJECTOR............................................................................................. 7-5
REMOVING THE FUEL HOSE ................................................................. 7-6
CHECKING THE FUEL INJECTOR .......................................................... 7-6
INSTALLING THE FUEL INJECTOR ........................................................ 7-6
INSTALLING THE FUEL HOSE ................................................................ 7-6
AIR FILTER CASE ..........................................................................................7-7
INSTALLING THE AIR FILTER CASE ......................................................7-9
THROTTLE BODY.........................................................................................7-10
REMOVING THE THROTTLE BODY......................................................7-12
CHECKING THE THROTTLE BODY ......................................................7-12
CLEANING THE ISC (IDLE SPEED CONTROL)
UNIT AND THROTTLE BODY ...............................................................7-12
REPLACING THE THROTTLE BODY ....................................................7-14
INSTALLING THE THROTTLE BODY ....................................................7-15
B63-F8197-EZ.book Page 1 Monday, January 23, 2017 4:12 PM
FUEL TANK
7-1
EAS20067
FUEL TANK
Removing the fuel tank
Order Job/Parts to remove Q’ty Remarks
Front side covers
Refer to “GENERAL CHASSIS (2)” on page
4-3.
Fuel tank cover
Refer to “GENERAL CHASSIS (7)” on page
4-18.
1 Fuel tank cap 1
2 Fuel tank overflow tray 1
3 Fuel tank overflow hose 1
4 Fuel sender coupler 1 Disconnect.
5 Fuel pump coupler 1 Disconnect.
6 Fuel hose 1 Disconnect.
7 Fuel tank 1
8 Fuel pump bracket 1
9 Fuel pump 1
10 Fuel pump gasket 1
11 Fuel filter 1
3
1
2
7
6
11
10
9
8
5
4
B63-F8197-EZ.book Page 1 Monday, January 23, 2017 4:12 PM
FUEL TANK
7-2
EAS30450
REMOVING THE FUEL TANK
1. Extract the fuel in the fuel tank through the
fuel tank cap with a pump.
2. Disconnect:
• Fuel sender coupler
• Fuel pump coupler
• Fuel hose
WARNING
EWA18020
Cover the fuel hose connection with a cloth
when disconnecting it. Residual pressure in
the fuel lines could cause fuel to spurt out
when removing the hose.
NOTICE
ECA20020
Although the fuel has been removed from
the fuel tank, be careful when removing the
fuel hose, since there may be fuel remaining
in it.
TIP
• To remove the fuel hose from the fuel pump,
slide the fuel hose connector cover “1” on the
end of the hose in the direction of the arrow
shown, and then remove the hose.
• Before removing the hose, place a few rags in
the area under where it will be removed.
3. Remove:
• Fuel tank
EAS30451
REMOVING THE FUEL PUMP
1. Remove:
• Fuel pump
NOTICE
ECA14721
• Do not drop the fuel pump or give it a
strong shock.
• Do not touch the base section of the fuel
sender.
EAS31376
REMOVING THE FUEL FILTER
1. Remove:
• Fuel filter “1”
TIP
Remove the projections “a” on the fuel pump
from the holes “b” in the fuel filter and slide the
fuel filter in the direction of the arrow shown to
remove it.
EAS30454
CHECKING THE FUEL PUMP BODY
1. Check:
• Fuel pump body
Obstruction Clean.
Cracks/damage Replace fuel pump as-
sembly.
EAS31249
CHECKING THE FUEL FILTER
1. Check:
• Fuel filter
Damage Replace.
Contaminants Clean with solvent.
EAS31377
INSTALLING THE FUEL FILTER
1. Install:
• Fuel filter “1”
TIP
Fit the projections “a” on the fuel pump into the
holes “b” in the fuel filter and slide the fuel filter
in the direction of the arrow shown to install it.
1
a
a
b
1
a
a
b
1
B63-F8197-EZ.book Page 2 Monday, January 23, 2017 4:12 PM
FUEL TANK
7-3
EAS30456
INSTALLING THE FUEL PUMP
1. Install:
• Fuel pump gasket “1”
• Fuel pump
• Fuel pump bracket
TIP
• Do not damage the installation surfaces of the
fuel tank when installing the fuel pump.
• Always use a new fuel pump gasket.
• The gasket lip “a” shall face toward the fuel
pump.
• Align the projections “b” (two locations) on the
fuel pump gasket with the slots “c” in the fuel
pump.
• Align the projection “d” on the fuel pump with
the slot in the fuel pump bracket.
• Tighten the fuel pump bolts in the proper tight-
ening sequence as shown.
EAS30457
INSTALLING THE FUEL TANK
1. Install:
• Fuel tank “1”
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Temporarily install the fuel tank.
TIP
Make sure that the flanges of the fuel tank bolts
“2” do not contact the fuel tank.
b. Install the fuel tank overflow tray and fuel tank
cover “3”. To install the fuel tank cover, refer
to “GENERAL CHASSIS (3)” on page 4-6.
c. Tighten the fuel tank bolts to specification.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
2. Install:
• Fuel hose
NOTICE
ECA17500
When installing the fuel hose, make sure that
it is securely connected, and that the fuel
hose connector cover on the fuel hose is in
the correct position, otherwise the fuel hose
will not be properly installed.
TIP
• Install the fuel hose securely onto the fuel
pump until a distinct “click” is heard.
• To install the fuel hose, slide the fuel hose con-
nector cover “1” on each end of the hose in the
direction of the arrow shown.
EAS30703
CHECKING THE FUEL PRESSURE
1. Remove:
• Front side cover assembly (left)
Refer to “GENERAL CHASSIS (2)” on page
4-3.
T
R
.
.
Fuel pump bracket bolt
4.0 N·m (0.40 kgf·m, 2.9 lb·ft)
New
1
b
c
a
New
d
4
2
3
1
T
R
.
.
Fuel tank bolt
9 N·m (0.9 kgf·m, 6.5 lb·ft)
3
1
2
2
1
B63-F8197-EZ.book Page 3 Monday, January 23, 2017 4:12 PM
FUEL TANK
7-4
• Footrest board (right)
Refer to “GENERAL CHASSIS (6)” on page
4-16.
2. Check:
• Pressure regulator operation
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Disconnect the fuel hose from the fuel pump.
WARNING
EWA18020
Cover the fuel hose connection with a cloth
when disconnecting it. Residual pressure in
the fuel lines could cause fuel to spurt out
when removing the hose.
NOTICE
ECA20020
Although the fuel has been removed from
the fuel tank, be careful when removing the
fuel hose, since there may be fuel remaining
in it.
TIP
Before removing the hose, place a few rags in
the area under where it will be removed.
b. Connect the pressure gauge “1” and fuel
pressure adapter “2” to the fuel hose “3”.
c. Start the engine.
d. Measure the fuel pressure.
Faulty Replace the fuel pump.
e. Connect the fuel hose.
Refer to “INSTALLING THE FUEL TANK” on
page 7-3.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
3. Install:
• Footrest board (left)
Refer to “GENERAL CHASSIS (6)” on page
4-16.
• Front side cover assembly (left)
Refer to “GENERAL CHASSIS (2)” on page
4-3.
Pressure gauge
90890-03153
Pressure gauge
YU-03153
Fuel pressure adapter 6.3mm
90890-03227
Fuel line pressure at idling
220–300 kPa (2.2–3.0 kgf/cm²,
31.9–43.5 psi)
YAM AH
1
3
2
B63-F8197-EZ.book Page 4 Monday, January 23, 2017 4:12 PM
FUEL INJECTOR
7-5
EAS20191
FUEL INJECTOR
Removing the fuel injector
Order Job/Parts to remove Q’ty Remarks
Battery
Refer to “GENERAL CHASSIS (1)” on page
4-1.
Front side covers
Refer to “GENERAL CHASSIS (7)” on page
4-18.
Fuel tank cover
Refer to “GENERAL CHASSIS (3)” on page
4-6.
Storage box
Refer to “GENERAL CHASSIS (3)” on page
4-6.
Center lower cover
Refer to “GENERAL CHASSIS (6)” on page
4-16.
1 Fuel hose 1
2 Fuel injector coupler 1 Disconnect.
3 Fuel injector 1
4 Fuel injector adaptor 1
10 N
•
m (1.0 kgf
•
m, 7.2 lb
•
ft)
B63-F8197-EZ.book Page 5 Monday, January 23, 2017 4:12 PM
FUEL INJECTOR
7-6
EAS31250
REMOVING THE FUEL HOSE
1. Disconnect:
• Fuel hose
WARNING
EWA17610
Cover fuel hose connections with a cloth
when disconnecting them. Residual pres-
sure in the fuel lines could cause fuel to
spurt out when removing the hoses.
NOTICE
ECA20020
Although the fuel has been removed from
the fuel tank, be careful when removing the
fuel hose, since there may be fuel remaining
in it.
TIP
• To remove the fuel hose from the fuel injector,
slide the fuel hose connector cover “1” on the
end of the hose in the direction of the arrow
shown, and then remove the hose.
• Before removing the hose, place a few rags in
the area under where it will be removed.
EAS31251
CHECKING THE FUEL INJECTOR
1. Check:
• Injector
Obstruction Replace and check the fuel
pump/fuel supply system.
Deposit Replace.
Damage Replace.
2. Check:
• Injector resistance
Refer to “CHECKING THE FUEL INJEC-
TOR” on page 7-6.
EAS31617
INSTALLING THE FUEL INJECTOR
1. Install:
• Fuel injector adaptor “1”
• O-ring “2”
(to the fuel injector)
• Fuel injector “3”
TIP
• Lubricate the O-ring with engine oil.
• Align the projection “a” on the fuel injector
adapter with the hole “b” in the intake manifold.
• Align the projection “c” on the fuel injector with
the hole “d” in the fuel injector adapter.
EAS31253
INSTALLING THE FUEL HOSE
1. Install:
• Fuel hose
NOTICE
ECA17500
When installing the fuel hose, make sure that
it is securely connected, and that the fuel
hose connector cover on the fuel hose is in
the correct position, otherwise the fuel hose
will not be properly installed.
TIP
• Install the fuel hose securely onto the fuel in-
jector until a distinct “click” is heard.
• To install the fuel hose onto the fuel injector,
slide the fuel hose connector cover “1” on the
end of the hose in the direction of the arrow
shown.
1
New
T
R
.
.
Fuel injector bolt
10 N·m (1.0 kgf·m, 7.2 lb·ft)
New
3
2
1
a
b
c
d
1
B63-F8197-EZ.book Page 6 Monday, January 23, 2017 4:12 PM
AIR FILTER CASE
7-7
EAS20068
AIR FILTER CASE
Removing the air filter case
Order Job/Parts to remove Q’ty Remarks
Battery
Refer to “GENERAL CHASSIS (1)” on page
4-1.
Front side covers
Refer to “GENERAL CHASSIS (2)” on page
4-3.
Fuel tank cover
Refer to “GENERAL CHASSIS (7)” on page
4-18.
Storage box
Refer to “GENERAL CHASSIS (3)” on page
4-6.
1 Air filter case cover 1
2 Air filter case duct cover 1
3 Air filter case duct 1
4 Air filter element 1
5 Transmission case breather hose 1
5
4
1
2
3
B63-F8197-EZ.book Page 7 Monday, January 23, 2017 4:12 PM
AIR FILTER CASE
7-8
Removing the air filter case
Order Job/Parts to remove Q’ty Remarks
6 Cylinder head breather hose 1 Disconnect.
7 Air filter case joint clamp screw 1 Loosen.
8 Air filter case 1
9 Air filter check hose 1
10 Air filter case joint 1
11 Hose 1
9
6
7
8
11
10
B63-F8197-EZ.book Page 8 Monday, January 23, 2017 4:12 PM
AIR FILTER CASE
7-9
EAS31618
INSTALLING THE AIR FILTER CASE
1. Install:
• Hose “1”
(to the air filter case joint “2”)
•Clamp “3”
TIP
• Apply Three bond 1521 “4” onto the mating
surfaces of the hose and air filter case joint.
• Align the slot “a” on the air filter case joint with
the projection “b” in the hose.
2. Install:
• Air filter case joint “1”
(to the air filter case “2”)
TIP
• Apply Three Bond 1521 “3” onto the mating
surfaces of the air filter case joint and air filter
case.
• Fit the projection “a” on the air filter case joint
between the projections “b” on the air filter
case.
3. Install:
• Air filter case joint clamp “1”
(to the air filter case joint “2”)
TIP
Align the projection “a” on the air filter case joint
with the slot “b” in the air filter case joint clamp.
4. Install:
• Air filter case duct “1”
TIP
Fit the projection “a” on the air filter case duct be-
tween the projections “b” on the air filter case
cover “2”.
T
R
.
.
Air filter case joint clamp screw
2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
2
1
3
a
b
1
3
4
2
a
b
1
2
a
b
b
a
1
2
B63-F8197-EZ.book Page 9 Monday, January 23, 2017 4:12 PM
THROTTLE BODY
7-10
EAS20070
THROTTLE BODY
Removing the throttle body
Order Job/Parts to remove Q’ty Remarks
Battery
Refer to “GENERAL CHASSIS (1)” on page
4-1.
Front side covers
Refer to “GENERAL CHASSIS (2)” on page
4-3.
Fuel tank cover
Refer to “GENERAL CHASSIS (7)” on page
4-18.
Storage box
Refer to “GENERAL CHASSIS (3)” on page
4-6.
Center lower cover
Refer to “GENERAL CHASSIS (6)” on page
4-16.
Air filter case joint Refer to “AIR FILTER CASE” on page 7-7.
Fuel injector Refer to “FUEL INJECTOR” on page 7-5.
1 ISC (Idle Speed Control) unit coupler 1 Disconnect.
2 Throttle body sensor assembly coupler 1 Disconnect.
NEW
NEW
T
R
.
.
•
•
10 N m (1.0kgf
m, 7.2lb.ft)
T
R
.
.
••
10 N m (1.0kgf
m, 7.2lb.ft)
T
R
.
.
••
7 N m (0.7kgf
m, 5.1lb.ft)
T
R
.
.
•
•
7 N m (0.7kgf
m, 5.1lb.ft)
1
2
M
LS
NEW
B63-F8197-EZ.book Page 10 Monday, January 23, 2017 4:12 PM
THROTTLE BODY
7-11
Removing the throttle body
Order Job/Parts to remove Q’ty Remarks
3 Throttle cable 2 Disconnect.
4 Throttle cable holder 1
5 Throttle body 1 Loosen.
6 Intake manifold 1
7 ISC (Idle Speed Control) unit holder 1
8 ISC (Idle Speed Control) unit 1
9Spring 1
NEW
NEW
T
R
.
.
••
10 N m (1.0kgf m, 7.2lb.ft)
T
R
.
.
••
10 N m (1.0kgf m, 7.2lb.ft)
T
R
.
.
••
7 N m (0.7kgf m, 5.1lb.ft)
T
R
.
.
••
7 N m (0.7kgf m, 5.1lb.ft)
7
8
9
6
4
3
5
M
LS
NEW
chapterbody7 Page 11 Wednesday, January 4, 2017 3:51 PM
THROTTLE BODY
7-12
EAS30979
REMOVING THE THROTTLE BODY
1. Remove:
• Throttle body
NOTICE
ECA20500
Do not remove the throttle body sensor as-
sembly from the throttle body.
EAS30479
CHECKING THE THROTTLE BODY
TIP
Before checking the throttle body, check the fol-
lowing items:
• Valve clearance
• Spark plug
• Air filter element
• Intake manifold
• Fuel hose
• Exhaust system
• Cylinder head breather hose
WARNING
EWA18030
If the throttle body is subjected to strong
shocks or dropped during, replace it.
1. Check:
• Throttle body
Cracks/damage Replace the throttle body.
2. Check:
• Butterfly valve
Damage/scratches/wear Replace the
throttle body.
NOTICE
ECA21770
Do not adjust the stop screw “1”.
EAS31254
CLEANING THE ISC (IDLE SPEED
CONTROL) UNIT AND THROTTLE BODY
1. Remove the throttle body from the vehicle.
TIP
Before removing the throttle body, disconnect
the throttle cables and couplers.
2. Remove:
•Screw “1”
• ISC (Idle Speed Control) unit holder “2”
• ISC (Idle Speed Control) unit “3”
NOTICE
ECA21780
Because the force of the spring may push
out the ISC unit unexpectedly, be sure to
hold the ISC unit when removing the compo-
nents.
3. Remove:
•Spring “1”
• O-ring “2”
4. Check:
• ISC (Idle Speed Control) unit
Plunger “1” does not rotate smoothly/plunger
rotates together with the motor shaft “2”
Replace.
5. Check:
•Spring
Damage/bent Replace.
6. Clean:
• Area “a” of the ISC unit
1
1
2
3
2
1
2
1
B63-F8197-EZ.book Page 12 Monday, January 23, 2017 4:12 PM
THROTTLE BODY
7-13
• Areas “b” and “c” of the throttle body
Clogs or foreign materials cannot be re-
moved Replace.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Use a rag soaked in the recommended clean-
ing agent to wipe off any deposits and foreign
materials.
NOTICE
ECA21790
• Be sure to use the recommended cleaning
agent.
• Do not spray the cleaning agent directly
onto the ISC unit or throttle body and do
not immerse them in the cleaning agent.
• To prevent scratching the components, do
not use a brush, metal file, or other abra-
sive tool.
• Do not clean with compressed air.
• Do not allow the removed deposits or for-
eign materials to adhere to the sealing sur-
faces of the O-ring.
• Do not scratch or deform the ISC valve or
air passage; otherwise, poor starting per-
formance, an unstable engine idling speed,
or uncontrollable engine speed could re-
sult.
• Do not clean any areas other than the areas
“a”, “b”, and “c”. If the cleaning agent en-
ters the ISC unit or throttle body, thorough-
ly wipe it off.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
7. Adjust the ISC unit plunger to the specified
distance “a” from the motor assembly body.
8. Install:
•Spring
• O-ring “1”
• ISC (Idle Speed Control) unit “2”
NOTICE
ECA21800
• Do not use the ISC unit if it was dropped.
• Do not allow water to enter the ISC unit and
do not allow foreign materials to adhere to
the assembly.
• Do not touch the terminals of the coupler
directly.
• Because the force of the spring may push
out the ISC unit unexpectedly, be sure to
hold the motor assembly when installing
the components.
TIP
• Install the new O-ring until it contacts the raised
portion of the ISC unit body.
• When installing the ISC unit, be sure to align
the oval portion “a” of the ISC unit with the oval
hole “b” in the throttle body.
Recommended cleaning agent
Yamaha oil & brake cleaner
a
b
c
Distance “a”
0.0–3.0 mm (0.0–0.12 in)
a
New
B63-F8197-EZ.book Page 13 Monday, January 23, 2017 4:12 PM
THROTTLE BODY
7-14
9. Install:
• ISC (Idle Speed Control) unit holder “1”
•Screw
TIP
Align the slot “a” in the ISC unit holder with the
projection “b” on the ISC unit “2”.
10.Install the throttle body to the vehicle.
11.Reset:
• ISC learning valves
Use the diagnostic code number “67”.
Refer to “SELF-DIAGNOSTIC FUNCTION
AND DIAGNOSTIC CODE TABLE” on page
9-5.
• ISC valve position
Use the diagnostic code number “54”.
Refer to “SELF-DIAGNOSTIC FUNCTION
AND DIAGNOSTIC CODE TABLE” on page
9-5.
12.Place the vehicle on the centerstand so that
the rear wheel is elevated.
13.Check:
• Engine idling speed
Start the engine, warm it up, and then mea-
sure the engine idling speed. Within specifi-
cation Service is finished.
Out of specification Replace the throttle
body.
Refer to “REPLACING THE THROTTLE
BODY” on page 7-14.
EAS31160
REPLACING THE THROTTLE BODY
1. Remove the throttle body from the vehicle.
2. Install a new throttle body to the vehicle.
3. Reset:
• ISC learning valves
Use the diagnostic code number “67”.
Refer to “SELF-DIAGNOSTIC FUNCTION
AND DIAGNOSTIC CODE TABLE” on page
9-5.
• ISC valve position
Use the diagnostic code number “54”
Refer to “SELF-DIAGNOSTIC FUNCTION
AND DIAGNOSTIC CODE TABLE” on page
9-5.
4. Place the vehicle on the centerstand so that
the rear wheel is elevated.
5. Check:
• Engine idling speed
Start the engine, warm it up, and then mea-
sure the engine idling speed.
T
R
.
.
ISC (Idle Speed Control) unit
holder screw
5 N·m (0.5 kgf·m, 3.6 lb·ft)
New
1
2
a
b
1
2
a
b
Yamaha diagnostic tool USB
90890-03250
Yamaha diagnostic tool (A/I)
90890-03252
Engine idling speed
1500–1700 r/min
Yamaha diagnostic tool USB
90890-03250
Yamaha diagnostic tool (A/I)
90890-03252
Engine idling speed
1500–1700 r/min
B63-F8197-EZ.book Page 14 Monday, January 23, 2017 4:12 PM
THROTTLE BODY
7-15
EAS30980
INSTALLING THE THROTTLE BODY
1. Install:
• Throttle body
TIP
Align the projection “a” on the O-ring with the slot
“b” in the throttle body.
T
R
.
.
Throttle body bolt
10 N·m (1.0 kgf·m, 7.2 lb·ft)
b
a
B63-F8197-EZ.book Page 15 Monday, January 23, 2017 4:12 PM
8
ELECTRICAL SYSTEM
IGNITION SYSTEM .........................................................................................8-1
CIRCUIT DIAGRAM (GDR155).................................................................8-1
CIRCUIT DIAGRAM (GDR155-A) .............................................................8-3
TROUBLESHOOTING ..............................................................................8-5
ELECTRIC STARTING SYSTEM .................................................................... 8-7
CIRCUIT DIAGRAM (GDR155).................................................................8-7
CIRCUIT DIAGRAM (GDR155-A) .............................................................8-9
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ........................8-11
TROUBLESHOOTING ............................................................................8-12
STOP AND START SYSTEM (GDR155-A)...................................................8-15
CIRCUIT DIAGRAM ................................................................................8-15
STOP AND START SYSTEM OPERATION ...........................................8-17
TROUBLESHOOTING ............................................................................8-18
CHARGING SYSTEM....................................................................................8-21
CIRCUIT DIAGRAM (GDR155)...............................................................8-21
CIRCUIT DIAGRAM (GDR155-A) ...........................................................8-23
TROUBLESHOOTING ............................................................................8-25
LIGHTING SYSTEM ......................................................................................8-27
CIRCUIT DIAGRAM (GDR155)...............................................................8-27
CIRCUIT DIAGRAM (GDR155-A) ...........................................................8-29
TROUBLESHOOTING ............................................................................8-31
SIGNALING SYSTEM ...................................................................................8-33
CIRCUIT DIAGRAM (GDR155)...............................................................8-33
CIRCUIT DIAGRAM (GDR155-A) ...........................................................8-35
TROUBLESHOOTING ............................................................................8-37
FUEL INJECTION SYSTEM.......................................................................... 8-41
CIRCUIT DIAGRAM (GDR155)...............................................................8-41
CIRCUIT DIAGRAM (GDR155-A) ...........................................................8-43
SGCU SELF-DIAGNOSTIC FUNCTION .................................................8-45
TROUBLESHOOTING METHOD............................................................8-45
YAMAHA DIAGNOSTIC TOOL ...............................................................8-46
TROUBLESHOOTING DETAILS ............................................................8-47
FUEL PUMP SYSTEM...................................................................................8-73
CIRCUIT DIAGRAM (GDR155)...............................................................8-73
CIRCUIT DIAGRAM (GDR155-A) ...........................................................8-75
TROUBLESHOOTING ............................................................................8-77
B63-F8197-EZ.book Page 1 Monday, January 23, 2017 4:12 PM
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)......................................8-79
CIRCUIT DIAGRAM ................................................................................8-79
ABS COUPLER LOCATION CHART ......................................................8-81
MAINTENANCE OF THE ABS ECU .......................................................8-83
ABS TROUBLESHOOTING OUTLINE....................................................8-83
BASIC INSTRUCTIONS FOR TROUBLESHOOTING ............................8-84
BASIC PROCESS FOR TROUBLESHOOTING .....................................8-85
[A] CHECKING THE ABS WARNING LIGHT..........................................8-86
[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON.............8-86
[A-2] ALL INDICATOR LIGHTS FAIL TO COME ON ..............................8-86
[A-3] THE ABS WARNING LIGHT COMES ON ......................................8-86
[A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE
(The select unit screen does not appear.) ..............................................8-87
[A-5] ABS ECU AND SGCU FAIL TO COMMUNICATE
(Cannot connect due to a tool error.)......................................................8-87
[B-1] MALFUNCTION ARE CURRENTLY DETECTED ..........................8-87
[B-2] DIAGNOSIS USING THE FAULT CODES .....................................8-87
[B-3] DELETING THE FAULT CODES..................................................8-102
[C-1] FINAL CHECK ..............................................................................8-102
SMART KEY SYSTEM (GDR155-A)...........................................................8-105
CIRCUIT DIAGRAM ..............................................................................8-105
TROUBLESHOOTING ..........................................................................8-107
SMART KEY SYSTEM SELF-DIAGNOSIS...........................................8-111
SMART KEY SYSTEM EMERGENCY MODE ......................................8-112
REGISTERING A SMART KEY.............................................................8-114
DISABLING A SMART KEY ..................................................................8-115
DISABLING THE POWER-ON ALARM.................................................8-117
REPLACEMENT PARTS LIST ..............................................................8-117
ELECTRICAL COMPONENTS....................................................................8-119
CHECKING THE SWITCHES ...............................................................8-120
CHECKING THE BULBS AND BULB SOCKETS .................................8-123
CHECKING THE FUSES ......................................................................8-124
REPLACING THE SGCU (starter generator control unit)......................8-124
CHECKING AND CHARGING THE BATTERY.....................................8-124
CHECKING THE RELAYS ....................................................................8-128
CHECKING THE TURN SIGNAL RELAY .............................................8-128
CHECKING THE DIODE (GDR155-A) ..................................................8-129
CHECKING THE IGNITION SPARK GAP.............................................8-129
CHECKING THE SPARK PLUG CAP ...................................................8-130
CHECKING THE IGNITION COIL .........................................................8-130
CHECKING THE STARTER GENERATOR..........................................8-131
CHECKING THE FUEL SENDER .........................................................8-131
CHECKING THE COOLANT TEMPERATURE SENSOR.....................8-132
CHECKING THE FUEL INJECTOR ......................................................8-132
CHECKING THE VVA SOLENOID........................................................8-133
CHECKING THE SMART KEY BATTERY (GDR155-A) .......................8-133
CHECKING THE BUZZER (GDR155-A) ...............................................8-133
CHECKING THE MAIN SWITCH SOLENOID (GDR155-A)..................8-134
B63-F8197-EZ.book Page 2 Monday, January 23, 2017 4:12 PM
B63-F8197-EZ.book Page 3 Monday, January 23, 2017 4:12 PM
IGNITION SYSTEM
8-1
EAS20072
IGNITION SYSTEM
EAS30490
CIRCUIT DIAGRAM (GDR155)
ON
OPEN
OFF
LOCK
L
PUSH
R
ON
OFF
HI
LO
PUSH
FREE
PUSH
FREE
B
W/R
Br
R
G/W
Br
R/Y
R
R
Br/R
R/W,B r
B/W,B
(B)
Br/R
R
Y/R
Br
R/B
RWG
R/YR/L
R/W
(B)
B/LG/R
(B)
B/L
Y L
P/WBr/W
Gy/R
(B)
B
(B)
(B)
G/Y
W/R
B/Y
O
P
O/B
G
B/W
W/L
Ch
Sb Y
B
/
L
Br/B
R/B
Gy
B/L
W/B
L
W/Y
R
Br/W
B
P/WR/W
L/Y
B/L
G/R
Y/LB/R
Gy/R
L/B
R/L
W
B
Y/BY/R
GWR
G
L/Y
W/R
Br/B
W/L
W/B
(B)
W/R
W/LBr/B
W/Y
B/L
W/B
(B)
(B)
P
G/Y
Sb Gy
Br
(B)
O/B
(Gy)
G
Ch
B/W
R
Y/L Y/L
(B)
R
B/Y
(Gy)
G
B/W
R/L
W
W
B
B/YBr
(B)
BB
Br B
BBr
B
B
(L)
L/Y
B
(L)
Br
Br/W
(R)
L
Y/R
B/Y
L/B
B
L/W
(R)
Br
G
(L)
Dg
Ch
Br/W
(R)
Y
L
(R)
L/B
Y
(L)
Br/W
Ch
Dg
(B)
B
Dg
Ch
(B)
Ch
Dg
B
P
B
P
B
Br
B
L
B
L
Y
B
(B)
YBr
B
Br
Y/B
R
Y
BChDg
Y/L
B/W
G
(Gy)
Y
G
B
GY
Y/B
Br
R
R
R
B
B
R
Br/R
Br
Br
R
B
Br/R
B/W
Br/R
Br/R
RBr
Br
Br Br
Br
Br
Br
Br
Br
Br
R
R
R
R
R
RR
RR
R
B
B
B
BBBB
B
B
B
BBBB
G/W
G/W
R/Y
Br
R/W
R/B
Y/R
Br/R
Br/R
W/R
W/R
R/W
R/Y
R/W
R/L
P/W
Br/W
Gy/RGy/R
L/B
L/Y
G/R
B/L
G/R
B/L
B/L
L
B
Y
P/W
Br/W
B/L
L
Y
W
R
R
W/R
W/L
W/B
W/Y
Br/B
B/L
G/Y
Gy
Sb
O/B
B/Y B/Y
R
G
B/W
Ch
Y/LY/LY/L
R
B/W
R/B
Y/R
Y/B
Y/B
B/R
B/R
B/W
O
G
O
Br
P
G
W
R/L
W
R/L
B
W
B/Y
B/Y
B/Y
L/BL/B
B/Y
B/Y
B
B
B
B
Br
Br
Br
Br
Br
Br
P
PL
Br/W
Br/W
DgCh
Ch
Ch
Ch Ch
Dg
Ch Dg
YBr Br
B
B
BB
B
LL
B
Ch Dg
Dg
Dg Dg
BY
Y
Y
Y
YG
L/B
Br
Br Br
B/YB/Y
Y
W/R
W/L
W/B
W/Y
Br/B
B/L
L/Y
G/Y
Gy
Sb
O/B
Br
Ch
P
G
B
B
B
B/W
G
W
R
G
L/Y
B
L/B
G
L/W
L
B
Y/R
B/Y
Br
Br
Br Br
B
B
B
B
B
Br
G
L
G
B
B
B
B
B
Br Br
Br
Y/B
B
Y/B
B/W
Y/L
RChDgY
Br G
B
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
25
26
27
28
29
30
31
32
33
34
35 35
63
24
3637
38
39
40 41 42 43 44 45
46
47
48
49 50 51
52
53
54 5556575859
6061
62
B63-F8197-EZ.book Page 1 Monday, January 23, 2017 4:12 PM
8-2
IGNITION SYSTEM
1. Battery
2. Main fuse
5. Ignition fuse
10.Main switch
16.Sidestand switch
25.SGCU (starter generator control unit)
26.Crankshaft position sensor
27.Ignition coil
28.Spark plug
35.Engine ground 2
62.Frame ground
63.Engine ground 1
B63-F8197-EZ.book Page 2 Monday, January 23, 2017 4:12 PM
IGNITION SYSTEM
8-3
EASB631001
CIRCUIT DIAGRAM (GDR155-A)
ON
OPEN
OFF
LOCK
L
PUSH
R
ON
OFF
HI
LO
PUSH
FREE
PUSH
FREE
ON
OFF
B
W/R
B
B/Y
B
L
R/W
B
(B)
R/W
B
(B)
Br
R
G/W
Br
R/Y
R
(B)
ChB
L/Y
R/BY/L
G/W
Dg
R/W
Br
W/R
B/Y
R
R/B
R
R
Br/R
R/W,B r
B/W,B
B
R
(B)
Br/R
R
Y/R
Br
R/B
RWG
R/YR/L
R/W
(B)
B/LG/R
(B)
B/L
Y L
P/WBr/W
Gy/R
(B)
B
(B)
(B)
G/Y
W/R
B/Y
O
P
O/B
G
B/W
W/L
Ch
Sb Y
B
/
L
Br/B
R/B
Gy
B/L
W/B
L
W/Y
R
Br/W
B
P/WR/W
L/B
B/L
G/R
Y/LB/R
Gy/R
L/Y
W/G
W
B
Y/BY/R
GWR
G
L/Y
W/R
Br/B
W/L
W/B
(B)
W/R
W/LBr/B
W/Y
B/L
W/B
(B)
(B)
P
G/Y
Sb Gy
Br
(B)
O/B
(Gy)
G
Ch
B/W
R
Y/L Y/L
(B)
R
B/Y
(Gy)
G
B/W
LG
W
B
L/RL/B
RB
R
L/RL/BY/L
B/W
R/LB/Y
Br
W/L
LGWB
B/Y
Br
(B)
BB
Br B
BBr
B
B
(L)
L/Y
B
(L)
Br
Br/W
Br/B
Br/W
(R)
L
Y/R
B/Y
L/B
(B)
B
W/G
B
L/W
(B)
B/W
Y/W
(R)
Br
G
(L)
Dg
Ch
Br/W
(R)
Y
L
(R)
L/B
Y
(L)
Br/B
Ch
Dg
(B)
B
Dg
Ch
(B)
Ch
Dg
B
P
B
P
B
Br
B
L
B
L
Y
B
(B)
YBr
B
Br
W/R
Y/B
R
Y
BCh
W/L
Dg
Y/L
B/W
G
(Gy)
Y
G
B
GY
Y/B
R
Br
BrBr
Br
Br
R
R
RR
BB
B
R
G/W
Br/R
R
Br
Br Br
Br
Br
R
RR
R
R
B
R
B
Br/R
B/W
Br/R
Br/R
RBr
Br
R/B
R
R
R
Br
Br Br
Br
Br
Br
Br
Br
Br
R
R
R
R
R
RR
RR
G/W
R
B
L
B
B
B
B
B
B
BBBB
B
BBBB
BBBBBB
B
G/W
R/W
R/Y
B/Y
Br
R/W
L/Y
W/R
R/W
R/B
Y/R
Br/R
Br/R
R/B
Dg
Ch
B
Y/L
G/W
B/Y
Br
W/R
W/R
R/L
R/W
R/Y
R/W
R/L
P/W
W/G
Br/W
Gy/RGy/R
L/B
L/Y
G/R
B/L
G/R
B/L
B/L
L
W
B
Y
P/W
Br/W
B/L
L
Y
W
R
R
W/R
W/L
W/B
W/Y
Br/B
B/L
G/Y
Gy
Sb
O/B
B/Y B/Y
R
G
B/W
Ch
Y/LY/LY/L
R
B/W
R/B
L/BL/B
L/RL/R
Y/R
Y/B
Y/B
B/R
B/R
B/W
B/W
O
G
O
Br
P
G
G
L
B
W
G
WBr
R
R/L
W/L
B/Y
B/YB/Y
B/Y
B/Y
L/BL/B
W/GW/G
B/Y
B/Y
B
B
B
B
Br
Br
Br
Br
Br
Br
P
PL
Br/W
Br/W
Br/B
Br/B
DgCh
Ch
Ch
Ch Ch
Ch
Dg
Ch Dg
YBr Br
B
B
BB
B
LL
B
Ch Dg
Dg
Dg Dg
Dg
BY
Y
Y
Y
YG
Br/WL/B
Br
Br Br
B/YB/Y
Y
L
B
B/WY/L
R
B
W/R
W/L
W/B
W/Y
Br/B
B/L
L/Y
G/Y
Gy
Sb
O/B
Br
Ch
P
G
B
B
B
B/W
G
W
R
G
Y/L
Y/L
Y/LY/L
L/YL/Y
L/Y
L/Y
B
B
L/B
G
B/WL/W
L
Y/W
B
Y/R
W/GB/Y
Br
Br
Br Br
B
B
B
B
B
Br
G
L
G
B
B
B
B
B
Br Br
Br
Y/B
B
Y/B
W/RB/W
Y/L
RChDgY
Br G
B
W/L
1
2
3
4
5
6
7
8
9
10
11
12
13
14
16
15
17
18
19
20
21
22 23 24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43 43
78 78
44
45
46
4748
49
50
51 52 53 54 55 56 57 58 59
60
61
62
63
64
65 66
67
68
69 7071727374
7576
77
B63-F8197-EZ.book Page 3 Monday, January 23, 2017 4:12 PM
8-4
IGNITION SYSTEM
1. Battery
5. Main fuse
10.Ignition fuse
14.Main switch
25.Sidestand switch
33.SGCU (starter generator control unit)
34.Crankshaft position sensor
35.Ignition coil
36.Spark plug
43.Engine ground 2
77.Frame ground
78.Engine ground 1
B63-F8197-EZ.book Page 4 Monday, January 23, 2017 4:12 PM
IGNITION SYSTEM
8-5
EAS30492
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP
• Before troubleshooting, remove the following part(s):
1. Battery cover
2. Front side covers
3. Fuel tank cover
4. Storage box
5. Front cowling assembly
NG
OK
NG
OK
NG
OK
OK
NG
NG
OK
NG
OK
NG
OK
NG
OK
1. Check the fuses.
(Main and ignition)
Refer to “CHECKING THE FUS-
ES” on page 8-124.
Replace the fuse(s).
2. Check the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 8-124.
• Clean the battery terminals.
• Recharge or replace the battery.
3. Check the spark plug.
Refer to “CHECKING THE SPARK
PLUG” on page 3-4.
Re-gap or replace the spark plug.
4. Check the ignition spark gap.
Refer to “CHECKING THE IGNI-
TION SPARK GAP” on page 8-129.
Ignition system is OK.
5. Check the spark plug cap.
Refer to “CHECKING THE SPARK
PLUG CAP” on page 8-130.
Replace the spark plug cap.
6. Check the ignition coil.
Refer to “CHECKING THE IGNI-
TION COIL” on page 8-130.
Replace the ignition coil.
7. Check the main switch.
Refer to “CHECKING THE
SWITCHES” on page 8-120.
Replace the main switch.
8. Check the sidestand switch.
Refer to “CHECKING THE
SWITCHES” on page 8-120.
Replace the sidestand switch.
B63-F8197-EZ.book Page 5 Monday, January 23, 2017 4:12 PM
8-6
IGNITION SYSTEM
NG
OK
9. Check the entire ignition system
wiring.
Refer to “CIRCUIT DIAGRAM
(GDR155)” on page 8-1 or refer to
“CIRCUIT DIAGRAM (GDR155-A)”
on page 8-3.
Properly connect or replace the wire har-
ness.
Replace the starter generator assem-
bly or the SGCU. Refer to “REPLAC-
ING THE SGCU (starter generator
control unit)” on page 8-124.
B63-F8197-EZ.book Page 6 Monday, January 23, 2017 4:12 PM
ELECTRIC STARTING SYSTEM
8-7
EAS20073
ELECTRIC STARTING SYSTEM
EAS30493
CIRCUIT DIAGRAM (GDR155)
ON
OPEN
OFF
LOCK
L
PUSH
R
ON
OFF
HI
LO
PUSH
FREE
PUSH
FREE
B
W/R
Br
R
G/W
Br
R/Y
R
R
Br/R
R/W,B r
B/W,B
(B)
Br/R
R
Y/R
Br
R/B
RWG
R/YR/L
R/W
(B)
B/LG/R
(B)
B/L
Y L
P/WBr/W
Gy/R
(B)
B
(B)
(B)
G/Y
W/R
B/Y
O
P
O/B
G
B/W
W/L
Ch
Sb Y
B
/
L
Br/B
R/B
Gy
B/L
W/B
L
W/Y
R
Br/W
B
P/WR/W
L/Y
B/L
G/R
Y/LB/R
Gy/R
L/B
R/L
W
B
Y/BY/R
GWR
G
L/Y
W/R
Br/B
W/L
W/B
(B)
W/R
W/LBr/B
W/Y
B/L
W/B
(B)
(B)
P
G/Y
Sb Gy
Br
(B)
O/B
(Gy)
G
Ch
B/W
R
Y/L Y/L
(B)
R
B/Y
(Gy)
G
B/W
R/L
W
W
B
B/YBr
(B)
BB
Br B
BBr
B
B
(L)
L/Y
B
(L)
Br
Br/W
(R)
L
Y/R
B/Y
L/B
B
L/W
(R)
Br
G
(L)
Dg
Ch
Br/W
(R)
Y
L
(R)
L/B
Y
(L)
Br/W
Ch
Dg
(B)
B
Dg
Ch
(B)
Ch
Dg
B
P
B
P
B
Br
B
L
B
L
Y
B
(B)
YBr
B
Br
Y/B
R
Y
BChDg
Y/L
B/W
G
(Gy)
Y
G
B
GY
Y/B
Br
R
R
R
B
B
R
Br/R
Br
Br
R
B
Br/R
B/W
Br/R
Br/R
RBr
Br
Br Br
Br
Br
Br
Br
Br
Br
R
R
R
R
R
RR
RR
R
B
B
B
BBBB
B
B
B
BBBB
G/W
G/W
R/Y
Br
R/W
R/B
Y/R
Br/R
Br/R
W/R
W/R
R/W
R/Y
R/W
R/L
P/W
Br/W
Gy/RGy/R
L/B
L/Y
G/R
B/L
G/R
B/L
B/L
L
B
Y
P/W
Br/W
B/L
L
Y
W
R
R
W/R
W/L
W/B
W/Y
Br/B
B/L
G/Y
Gy
Sb
O/B
B/Y B/Y
R
G
B/W
Ch
Y/LY/LY/L
R
B/W
R/B
Y/R
Y/B
Y/B
B/R
B/R
B/W
O
G
O
Br
P
G
W
R/L
W
R/L
B
W
B/Y
B/Y
B/Y
L/BL/B
B/Y
B/Y
B
B
B
B
Br
Br
Br
Br
Br
Br
P
PL
Br/W
Br/W
DgCh
Ch
Ch
Ch Ch
Dg
Ch Dg
YBr Br
B
B
BB
B
LL
B
Ch Dg
Dg
Dg Dg
BY
Y
Y
Y
YG
L/B
Br
Br Br
B/YB/Y
Y
W/R
W/L
W/B
W/Y
Br/B
B/L
L/Y
G/Y
Gy
Sb
O/B
Br
Ch
P
G
B
B
B
B/W
G
W
R
G
L/Y
B
L/B
G
L/W
L
B
Y/R
B/Y
Br
Br
Br Br
B
B
B
B
B
Br
G
L
G
B
B
B
B
B
Br Br
Br
Y/B
B
Y/B
B/W
Y/L
RChDgY
Br G
B
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
25
26
27
28
29
30
31
32
33
34
35 35
63
24
3637
38
39
40 41 42 43 44 45
46
47
48
49 50 51
52
53
54 5556575859
6061
62
B63-F8197-EZ.book Page 7 Monday, January 23, 2017 4:12 PM
8-8
ELECTRIC STARTING SYSTEM
1. Battery
2. Main fuse
3. Fuel injection system fuse
5. Ignition fuse
7. Signaling system fuse
10.Main switch
11.Main relay
12.Starter charge relay
13.Handlebar switch (right)
15.Start switch
16.Sidestand switch
17.Starter generator
25.SGCU (starter generator control unit)
26.Crankshaft position sensor
35.Engine ground 2
36.Rear brake light switch
37.Front brake light switch
62.Frame ground
63.Engine ground 1
B63-F8197-EZ.book Page 8 Monday, January 23, 2017 4:12 PM
ELECTRIC STARTING SYSTEM
8-9
EASB631002
CIRCUIT DIAGRAM (GDR155-A)
ON
OPEN
OFF
LOCK
L
PUSH
R
ON
OFF
HI
LO
PUSH
FREE
PUSH
FREE
ON
OFF
B
W/R
B
B/Y
B
L
R/W
B
(B)
R/W
B
(B)
Br
R
G/W
Br
R/Y
R
(B)
ChB
L/Y
R/BY/L
G/W
Dg
R/W
Br
W/R
B/Y
R
R/B
R
R
Br/R
R/W,B r
B/W,B
B
R
(B)
Br/R
R
Y/R
Br
R/B
RWG
R/YR/L
R/W
(B)
B/LG/R
(B)
B/L
Y L
P/WBr/W
Gy/R
(B)
B
(B)
(B)
G/Y
W/R
B/Y
O
P
O/B
G
B/W
W/L
Ch
Sb Y
B
/
L
Br/B
R/B
Gy
B/L
W/B
L
W/Y
R
Br/W
B
P/WR/W
L/B
B/L
G/R
Y/LB/R
Gy/R
L/Y
W/G
W
B
Y/BY/R
GWR
G
L/Y
W/R
Br/B
W/L
W/B
(B)
W/R
W/LBr/B
W/Y
B/L
W/B
(B)
(B)
P
G/Y
Sb Gy
Br
(B)
O/B
(Gy)
G
Ch
B/W
R
Y/L Y/L
(B)
R
B/Y
(Gy)
G
B/W
LG
W
B
L/RL/B
RB
R
L/RL/BY/L
B/W
R/LB/Y
Br
W/L
LGWB
B/Y
Br
(B)
BB
Br B
BBr
B
B
(L)
L/Y
B
(L)
Br
Br/W
Br/B
Br/W
(R)
L
Y/R
B/Y
L/B
(B)
B
W/G
B
L/W
(B)
B/W
Y/W
(R)
Br
G
(L)
Dg
Ch
Br/W
(R)
Y
L
(R)
L/B
Y
(L)
Br/B
Ch
Dg
(B)
B
Dg
Ch
(B)
Ch
Dg
B
P
B
P
B
Br
B
L
B
L
Y
B
(B)
YBr
B
Br
W/R
Y/B
R
Y
BCh
W/L
Dg
Y/L
B/W
G
(Gy)
Y
G
B
GY
Y/B
R
Br
BrBr
Br
Br
R
R
RR
BB
B
R
G/W
Br/R
R
Br
Br Br
Br
Br
R
RR
R
R
B
R
B
Br/R
B/W
Br/R
Br/R
RBr
Br
R/B
R
R
R
Br
Br Br
Br
Br
Br
Br
Br
Br
R
R
R
R
R
RR
RR
G/W
R
B
L
B
B
B
B
B
B
BBBB
B
BBBB
BBBBBB
B
G/W
R/W
R/Y
B/Y
Br
R/W
L/Y
W/R
R/W
R/B
Y/R
Br/R
Br/R
R/B
Dg
Ch
B
Y/L
G/W
B/Y
Br
W/R
W/R
R/L
R/W
R/Y
R/W
R/L
P/W
W/G
Br/W
Gy/RGy/R
L/B
L/Y
G/R
B/L
G/R
B/L
B/L
L
W
B
Y
P/W
Br/W
B/L
L
Y
W
R
R
W/R
W/L
W/B
W/Y
Br/B
B/L
G/Y
Gy
Sb
O/B
B/Y B/Y
R
G
B/W
Ch
Y/LY/LY/L
R
B/W
R/B
L/BL/B
L/RL/R
Y/R
Y/B
Y/B
B/R
B/R
B/W
B/W
O
G
O
Br
P
G
G
L
B
W
G
WBr
R
R/L
W/L
B/Y
B/YB/Y
B/Y
B/Y
L/BL/B
W/GW/G
B/Y
B/Y
B
B
B
B
Br
Br
Br
Br
Br
Br
P
PL
Br/W
Br/W
Br/B
Br/B
DgCh
Ch
Ch
Ch Ch
Ch
Dg
Ch Dg
YBr Br
B
B
BB
B
LL
B
Ch Dg
Dg
Dg Dg
Dg
BY
Y
Y
Y
YG
Br/WL/B
Br
Br Br
B/YB/Y
Y
L
B
B/WY/L
R
B
W/R
W/L
W/B
W/Y
Br/B
B/L
L/Y
G/Y
Gy
Sb
O/B
Br
Ch
P
G
B
B
B
B/W
G
W
R
G
Y/L
Y/L
Y/LY/L
L/YL/Y
L/Y
L/Y
B
B
L/B
G
B/WL/W
L
Y/W
B
Y/R
W/GB/Y
Br
Br
Br Br
B
B
B
B
B
Br
G
L
G
B
B
B
B
B
Br Br
Br
Y/B
B
Y/B
W/RB/W
Y/L
RChDgY
Br G
B
W/L
1
2
3
4
5
6
7
8
9
10
11
12
13
14
16
15
17
18
19
20
21
22 23 24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43 43
78 78
44
45
46
4748
49
50
51 52 53 54 55 56 57 58 59
60
61
62
63
64
65 66
67
68
69 7071727374
7576
77
B63-F8197-EZ.book Page 9 Monday, January 23, 2017 4:12 PM
8-10
ELECTRIC STARTING SYSTEM
1. Battery
5. Main fuse
8. Fuel injection system fuse
10.Ignition fuse
12.Signaling system fuse
14.Main switch
19.Main relay
20.Starter charge relay
21.Handlebar switch (right)
23.Start switch
25.Sidestand switch
26.Starter generator
33.SGCU (starter generator control unit)
34.Crankshaft position sensor
43.Engine ground 2
47.Rear brake light switch
48.Front brake light switch
77.Frame ground
78.Engine ground 1
B63-F8197-EZ.book Page 10 Monday, January 23, 2017 4:12 PM
ELECTRIC STARTING SYSTEM
8-11
EAS30494
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION
If the main switch is turned to “ON” and the start switch “ ” is pushed, the starter generator can only
operate if at least one of the following conditions is met:
• The front brake lever is pulled to the handlebar (the front brake light switch is closed) and the side-
stand is up (the sidestand switch is closed).
• The rear brake lever is pulled to the handlebar (the rear brake light switch is closed) and the sidestand
is up (the sidestand switch is closed).
11 12
13
14
15
10
1
4
6
5
8
2
7
9
3
1. Battery
2. Main fuse
3. Main switch
4. Ignition fuse
5. Fuel injection system fuse
6. Main relay
7. Starter charge relay
8. Signaling system fuse
9. Rear brake light switch
10. Front brake light switch
11. Start switch
12. Sidestand switch
13. SGCU (starter generator control unit)
14. Starter generator
15. Crankshaft position sensor
B63-F8197-EZ.book Page 11 Monday, January 23, 2017 4:12 PM
8-12
ELECTRIC STARTING SYSTEM
EAS30495
TROUBLESHOOTING
The starter generator fails to turn.
TIP
• Before troubleshooting, remove the following part(s):
1. Battery cover
2. Front side covers
3. Fuel tank cover
4. Storage box
5. Front cowling assembly
NG
OK
NG
OK
NG
OK
NG
OK
NG
OK
NG
OK
NG
OK
1. Check the fuses.
(Main, ignition, fuel injection sys-
tem, and signaling system)
Refer to “CHECKING THE FUS-
ES” on page 8-124.
Replace the fuse(s).
2. Check the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 8-124.
• Clean the battery terminals.
• Recharge or replace the battery.
3. Check the starter generator.
Refer to “CHECKING THE START-
ER GENERATOR” on page 8-131.
Replace the starter generator assembly.
4. Check the main relay.
Refer to “CHECKING THE RE-
LAYS” on page 8-128.
Replace the main relay.
5. Check the starter charge relay.
Refer to “CHECKING THE RE-
LAYS” on page 8-128.
Replace the starter charge relay.
6. Check the main switch.
Refer to “CHECKING THE
SWITCHES” on page 8-120.
Replace the main switch.
7. Check the sidestand switch.
Refer to “CHECKING THE
SWITCHES” on page 8-120.
Replace the sidestand switch.
B63-F8197-EZ.book Page 12 Monday, January 23, 2017 4:12 PM
ELECTRIC STARTING SYSTEM
8-13
NG
OK
NG
OK
NG
OK
8. Check the start switch.
Refer to “CHECKING THE
SWITCHES” on page 8-120.
The start switch is faulty. Replace the right
handlebar switch.
9. Check the brake light switches.
(Front and rear)
Refer to “CHECKING THE
SWITCHES” on page 8-120.
Replace the brake light switch(es).
10.Check the entire starting system
wiring.
Refer to “CIRCUIT DIAGRAM
(GDR155)” on page 8-7 or refer to
“CIRCUIT DIAGRAM (GDR155-A)”
on page 8-9.
Properly connect or replace the wire har-
ness.
Replace the starter generator assem-
bly or SGCU. Refer to “REPLACING
THE SGCU (starter generator control
unit)” on page 8-124.
B63-F8197-EZ.book Page 13 Monday, January 23, 2017 4:12 PM
8-14
ELECTRIC STARTING SYSTEM
B63-F8197-EZ.book Page 14 Monday, January 23, 2017 4:12 PM
STOP AND START SYSTEM (GDR155-A)
8-15
EASB631003
STOP AND START SYSTEM (GDR155-A)
EASB631004
CIRCUIT DIAGRAM
ON
OPEN
OFF
LOCK
L
PUSH
R
ON
OFF
HI
LO
PUSH
FREE
PUSH
FREE
ON
OFF
B
W/R
B
B/Y
B
L
R/W
B
(B)
R/W
B
(B)
Br
R
G/W
Br
R/Y
R
(B)
ChB
L/Y
R/BY/L
G/W
Dg
R/W
Br
W/R
B/Y
R
R/B
R
R
Br/R
R/W,B r
B/W,B
B
R
(B)
Br/R
R
Y/R
Br
R/B
RWG
R/YR/L
R/W
(B)
B/LG/R
(B)
B/L
Y L
P/WBr/W
Gy/R
(B)
B
(B)
(B)
G/Y
W/R
B/Y
O
P
O/B
G
B/W
W/L
Ch
Sb Y
B
/
L
Br/B
R/B
Gy
B/L
W/B
L
W/Y
R
Br/W
B
P/WR/W
L/B
B/L
G/R
Y/LB/R
Gy/R
L/Y
W/G
W
B
Y/BY/R
GWR
G
L/Y
W/R
Br/B
W/L
W/B
(B)
W/R
W/LBr/B
W/Y
B/L
W/B
(B)
(B)
P
G/Y
Sb Gy
Br
(B)
O/B
(Gy)
G
Ch
B/W
R
Y/L Y/L
(B)
R
B/Y
(Gy)
G
B/W
LG
W
B
L/RL/B
RB
R
L/RL/BY/L
B/W
R/LB/Y
Br
W/L
LGWB
B/Y
Br
(B)
BB
Br B
BBr
B
B
(L)
L/Y
B
(L)
Br
Br/W
Br/B
Br/W
(R)
L
Y/R
B/Y
L/B
(B)
B
W/G
B
L/W
(B)
B/W
Y/W
(R)
Br
G
(L)
Dg
Ch
Br/W
(R)
Y
L
(R)
L/B
Y
(L)
Br/B
Ch
Dg
(B)
B
Dg
Ch
(B)
Ch
Dg
B
P
B
P
B
Br
B
L
B
L
Y
B
(B)
YBr
B
Br
W/R
Y/B
R
Y
BCh
W/L
Dg
Y/L
B/W
G
(Gy)
Y
G
B
GY
Y/B
R
Br
BrBr
Br
Br
R
R
RR
BB
B
R
G/W
Br/R
R
Br
Br Br
Br
Br
R
RR
R
R
B
R
B
Br/R
B/W
Br/R
Br/R
RBr
Br
R/B
R
R
R
Br
Br Br
Br
Br
Br
Br
Br
Br
R
R
R
R
R
RR
RR
G/W
R
B
L
B
B
B
B
B
B
BBBB
B
BBBB
BBBBBB
B
G/W
R/W
R/Y
B/Y
Br
R/W
L/Y
W/R
R/W
R/B
Y/R
Br/R
Br/R
R/B
Dg
Ch
B
Y/L
G/W
B/Y
Br
W/R
W/R
R/L
R/W
R/Y
R/W
R/L
P/W
W/G
Br/W
Gy/RGy/R
L/B
L/Y
G/R
B/L
G/R
B/L
B/L
L
W
B
Y
P/W
Br/W
B/L
L
Y
W
R
R
W/R
W/L
W/B
W/Y
Br/B
B/L
G/Y
Gy
Sb
O/B
B/Y B/Y
R
G
B/W
Ch
Y/LY/LY/L
R
B/W
R/B
L/BL/B
L/RL/R
Y/R
Y/B
Y/B
B/R
B/R
B/W
B/W
O
G
O
Br
P
G
G
L
B
W
G
WBr
R
R/L
W/L
B/Y
B/YB/Y
B/Y
B/Y
L/BL/B
W/GW/G
B/Y
B/Y
B
B
B
B
Br
Br
Br
Br
Br
Br
P
PL
Br/W
Br/W
Br/B
Br/B
DgCh
Ch
Ch
Ch Ch
Ch
Dg
Ch Dg
YBr Br
B
B
BB
B
LL
B
Ch Dg
Dg
Dg Dg
Dg
BY
Y
Y
Y
YG
Br/WL/B
Br
Br Br
B/YB/Y
Y
L
B
B/WY/L
R
B
W/R
W/L
W/B
W/Y
Br/B
B/L
L/Y
G/Y
Gy
Sb
O/B
Br
Ch
P
G
B
B
B
B/W
G
W
R
G
Y/L
Y/L
Y/LY/L
L/YL/Y
L/Y
L/Y
B
B
L/B
G
B/WL/W
L
Y/W
B
Y/R
W/GB/Y
Br
Br
Br Br
B
B
B
B
B
Br
G
L
G
B
B
B
B
B
Br Br
Br
Y/B
B
Y/B
W/RB/W
Y/L
RChDgY
Br G
B
W/L
1
2
3
4
5
6
7
8
9
10
11
12
13
14
16
15
17
18
19
20
21
22 23 24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43 43
78 78
44
45
46
4748
49
50
51 52 53 54 55 56 57 58 59
60
61
62
63
64
65 66
67
68
69 7071727374
7576
77
B63-F8197-EZ.book Page 15 Monday, January 23, 2017 4:12 PM
8-16
STOP AND START SYSTEM (GDR155-A)
1. Battery
4. ABS control unit fuse
5. Main fuse
8. Fuel injection system fuse
10.Ignition fuse
14.Main switch
20.Starter charge relay
21.Handlebar switch (right)
24.Stop and Start System switch
25.Sidestand switch
26.Starter generator
27.Coolant temperature sensor
28.Throttle body sensor assembly
31.Throttle position sensor
33.SGCU (starter generator control unit)
34.Crankshaft position sensor
42.Yamaha diagnostic tool coupler
43.Engine ground 2
44.Front wheel sensor
46.ABS ECU
49.Meter assembly
50.Multi-function meter
57.Stop and Start System indicator light
77.Frame ground
78.Engine ground 1
B63-F8197-EZ.book Page 16 Monday, January 23, 2017 4:12 PM
STOP AND START SYSTEM (GDR155-A)
8-17
EASB631005
STOP AND START SYSTEM OPERATION
If the main switch is turned to “ON” and the Stop and Start System switch is set to “ON” (both switches
are closed), the following functions operate when the conditions for each function are met.
Engine stop function:
When all of the following conditions are met, this function cuts off the fuel after 5 seconds (or 0 seconds
depending on the circumstances) to stop the engine.
• Vehicle speed: stopped
• Engine speed: idling
• Throttle valve: fully closed
• Coolant temperature: 70°C or more
• Operating condition: vehicle has traveled at a speed of more than 10 km/h after the engine was started
TIP
The engine stop function may not operate when the vehicle is traveling at a speed of 10 km/h or less,
such as when traveling in heavy traffic. This, however, does not indicate a malfunction.
Engine start function:
When all of the following conditions are met, this function restarts the engine.
• Sidestand: UP
• Throttle valve: opened
14
15
16
1918
11
17
12
10
1
45
8
2
7
9
3
13
6
1. Battery
2. Main fuse
3. Main switch
4. ABS control unit fuse
5. Ignition fuse
6. Fuel injection system fuse
7. Starter charge relay
8. Yamaha diagnostic tool coupler
9. Multi-function meter
10. Stop and Start System indicator light
11. SGCU (starter generator control unit)
12. Starter generator
13. Crankshaft position sensor
14. Coolant temperature sensor
15. Throttle position sensor
16. Front wheel sensor
17. ABS ECU
18. Sidestand switch
19. Stop and Start System switch
B63-F8197-EZ.book Page 17 Monday, January 23, 2017 4:12 PM
8-18
STOP AND START SYSTEM (GDR155-A)
EASB631006
TROUBLESHOOTING
• The engine stop function does not operate.
• The engine start function does not operate.
• The Stop and Start System indicator light fails to come on.
TIP
• Before troubleshooting, remove the following part(s):
1. Battery cover
2. Front side covers
3. Fuel tank cover
4. Storage box
5. Front cowling assembly
NG
OK
NG
OK
NG
OK
NG
OK
NG
OK
1. Check the fuses.
(Main, ignition, fuel injection sys-
tem, and ABS control unit)
Refer to “CHECKING THE FUS-
ES” on page 8-124.
Replace the fuse(s).
2. Check the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 8-124.
• Clean the battery terminals.
• Recharge or replace the battery.
3. Check the main switch.
Refer to “CHECKING THE
SWITCHES” on page 8-120.
Replace the main switch.
4. Check the Stop and Start System
switch.
Refer to “CHECKING THE
SWITCHES” on page 8-120.
The Stop and Start System switch is faulty.
Replace the right handlebar switch.
5. Check the entire starting system
wiring.
Refer to “CIRCUIT DIAGRAM” on
page 8-15.
Properly connect or replace the wire har-
ness.
Check the condition of each of the
Stop and Start System circuits. Refer
to “Checking the Stop and Start Sys-
tem”.
B63-F8197-EZ.book Page 18 Monday, January 23, 2017 4:12 PM
STOP AND START SYSTEM (GDR155-A)
8-19
Checking the Stop and Start System
The engine stop function does not operate.
NG
OK
NG
OK
NG
OK
NG
OK
TIP
Replace the wire harness if there is an open or short circuit.
• Between front speed sensor coupler and ABS ECU coupler.
(Green–Green)
(Blue–Blue)
• Between ABS ECU coupler and SGCU coupler.
(White–White)
The engine start function does not operate.
NG
OK
NG
OK
1. Check the coolant temperature sen-
sor.
Refer to “CHECKING THE COOL-
ANT TEMPERATURE SENSOR”
on page 8-132.
Replace the coolant temperature sensor.
2. Check the throttle position sensor.
The throttle position sensor is faulty. Re-
place the throttle body assembly.
3. Check the front wheel sensor. Replace the front wheel sensor.
4. Check the entire wiring.
Refer to TIP.
Properly connect or replace the wiring har-
ness.
Replace the SGCU or ABS ECU. Re-
fer to “REPLACING THE SGCU (start-
er generator control unit)” on page
8-124.
1. Check the side stand switch.
Refer to “CHECKING THE
SWITCHES” on page 8-120.
Replace the side stand switch.
2. Check the starter generator.
Refer to “CHECKING THE START-
ER GENERATOR” on page 8-131.
Replace the starter generator assembly.
B63-F8197-EZ.book Page 19 Monday, January 23, 2017 4:12 PM
8-20
STOP AND START SYSTEM (GDR155-A)
NG
OK
NG
OK
NG
OK
The Stop and Start System indicator light fails to come on.
NG
OK
TIP
Replace the wire harness if there is an open or short circuit.
• Between SGCU coupler and meter assembly coupler.
(Yellow/Blue–Yellow/Blue)
3. Check the start charge relay.
Refer to “CHECKING THE RE-
LAYS” on page 8-128.
Replace the start charge relay.
4. Check the throttle position sensor.
The throttle position sensor is faulty. Re-
place the throttle body assembly.
5. Check the entire Stop and Start
System wiring.
Refer to “CIRCUIT DIAGRAM” on
page 8-15.
Properly connect or replace the wiring har-
ness.
Replace the starter generator assem-
bly or the SGCU. Refer to “REPLAC-
ING THE SGCU (starter generator
control unit)” on page 8-124.
1. Check the entire wiring.
Refer to TIP.
Properly connect or replace the wiring har-
ness.
Replace the SGCU or meter assembly.
Refer to “REPLACING THE SGCU
(starter generator control unit)” on
page 8-124.
B63-F8197-EZ.book Page 20 Monday, January 23, 2017 4:12 PM
CHARGING SYSTEM
8-21
EAS20074
CHARGING SYSTEM
EAS30496
CIRCUIT DIAGRAM (GDR155)
ON
OPEN
OFF
LOCK
L
PUSH
R
ON
OFF
HI
LO
PUSH
FREE
PUSH
FREE
B
W/R
Br
R
G/W
Br
R/Y
R
R
Br/R
R/W,B r
B/W,B
(B)
Br/R
R
Y/R
Br
R/B
RWG
R/YR/L
R/W
(B)
B/LG/R
(B)
B/L
Y L
P/WBr/W
Gy/R
(B)
B
(B)
(B)
G/Y
W/R
B/Y
O
P
O/B
G
B/W
W/L
Ch
Sb Y
B
/
L
Br/B
R/B
Gy
B/L
W/B
L
W/Y
R
Br/W
B
P/WR/W
L/Y
B/L
G/R
Y/LB/R
Gy/R
L/B
R/L
W
B
Y/BY/R
GWR
G
L/Y
W/R
Br/B
W/L
W/B
(B)
W/R
W/LBr/B
W/Y
B/L
W/B
(B)
(B)
P
G/Y
Sb Gy
Br
(B)
O/B
(Gy)
G
Ch
B/W
R
Y/L Y/L
(B)
R
B/Y
(Gy)
G
B/W
R/L
W
W
B
B/YBr
(B)
BB
Br B
BBr
B
B
(L)
L/Y
B
(L)
Br
Br/W
(R)
L
Y/R
B/Y
L/B
B
L/W
(R)
Br
G
(L)
Dg
Ch
Br/W
(R)
Y
L
(R)
L/B
Y
(L)
Br/W
Ch
Dg
(B)
B
Dg
Ch
(B)
Ch
Dg
B
P
B
P
B
Br
B
L
B
L
Y
B
(B)
YBr
B
Br
Y/B
R
Y
BChDg
Y/L
B/W
G
(Gy)
Y
G
B
GY
Y/B
Br
R
R
R
B
B
R
Br/R
Br
Br
R
B
Br/R
B/W
Br/R
Br/R
RBr
Br
Br Br
Br
Br
Br
Br
Br
Br
R
R
R
R
R
RR
RR
R
B
B
B
BBBB
B
B
B
BBBB
G/W
G/W
R/Y
Br
R/W
R/B
Y/R
Br/R
Br/R
W/R
W/R
R/W
R/Y
R/W
R/L
P/W
Br/W
Gy/RGy/R
L/B
L/Y
G/R
B/L
G/R
B/L
B/L
L
B
Y
P/W
Br/W
B/L
L
Y
W
R
R
W/R
W/L
W/B
W/Y
Br/B
B/L
G/Y
Gy
Sb
O/B
B/Y B/Y
R
G
B/W
Ch
Y/LY/LY/L
R
B/W
R/B
Y/R
Y/B
Y/B
B/R
B/R
B/W
O
G
O
Br
P
G
W
R/L
W
R/L
B
W
B/Y
B/Y
B/Y
L/BL/B
B/Y
B/Y
B
B
B
B
Br
Br
Br
Br
Br
Br
P
PL
Br/W
Br/W
DgCh
Ch
Ch
Ch Ch
Dg
Ch Dg
YBr Br
B
B
BB
B
LL
B
Ch Dg
Dg
Dg Dg
BY
Y
Y
Y
YG
L/B
Br
Br Br
B/YB/Y
Y
W/R
W/L
W/B
W/Y
Br/B
B/L
L/Y
G/Y
Gy
Sb
O/B
Br
Ch
P
G
B
B
B
B/W
G
W
R
G
L/Y
B
L/B
G
L/W
L
B
Y/R
B/Y
Br
Br
Br Br
B
B
B
B
B
Br
G
L
G
B
B
B
B
B
Br Br
Br
Y/B
B
Y/B
B/W
Y/L
RChDgY
Br G
B
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
25
26
27
28
29
30
31
32
33
34
35 35
63
24
3637
38
39
40 41 42 43 44 45
46
47
48
49 50 51
52
53
54 5556575859
6061
62
B63-F8197-EZ.book Page 21 Monday, January 23, 2017 4:12 PM
8-22
CHARGING SYSTEM
1. Battery
2. Main fuse
5. Ignition fuse
10.Main switch
11.Main relay
12.Starter charge relay
17.Starter generator
25.SGCU (starter generator control unit)
26.Crankshaft position sensor
35.Engine ground 2
63.Engine ground 1
B63-F8197-EZ.book Page 22 Monday, January 23, 2017 4:12 PM
CHARGING SYSTEM
8-23
EASB631007
CIRCUIT DIAGRAM (GDR155-A)
ON
OPEN
OFF
LOCK
L
PUSH
R
ON
OFF
HI
LO
PUSH
FREE
PUSH
FREE
ON
OFF
B
W/R
B
B/Y
B
L
R/W
B
(B)
R/W
B
(B)
Br
R
G/W
Br
R/Y
R
(B)
ChB
L/Y
R/BY/L
G/W
Dg
R/W
Br
W/R
B/Y
R
R/B
R
R
Br/R
R/W,B r
B/W,B
B
R
(B)
Br/R
R
Y/R
Br
R/B
RWG
R/YR/L
R/W
(B)
B/LG/R
(B)
B/L
Y L
P/WBr/W
Gy/R
(B)
B
(B)
(B)
G/Y
W/R
B/Y
O
P
O/B
G
B/W
W/L
Ch
Sb Y
B
/
L
Br/B
R/B
Gy
B/L
W/B
L
W/Y
R
Br/W
B
P/WR/W
L/B
B/L
G/R
Y/LB/R
Gy/R
L/Y
W/G
W
B
Y/BY/R
GWR
G
L/Y
W/R
Br/B
W/L
W/B
(B)
W/R
W/LBr/B
W/Y
B/L
W/B
(B)
(B)
P
G/Y
Sb Gy
Br
(B)
O/B
(Gy)
G
Ch
B/W
R
Y/L Y/L
(B)
R
B/Y
(Gy)
G
B/W
LG
W
B
L/RL/B
RB
R
L/RL/BY/L
B/W
R/LB/Y
Br
W/L
LGWB
B/Y
Br
(B)
BB
Br B
BBr
B
B
(L)
L/Y
B
(L)
Br
Br/W
Br/B
Br/W
(R)
L
Y/R
B/Y
L/B
(B)
B
W/G
B
L/W
(B)
B/W
Y/W
(R)
Br
G
(L)
Dg
Ch
Br/W
(R)
Y
L
(R)
L/B
Y
(L)
Br/B
Ch
Dg
(B)
B
Dg
Ch
(B)
Ch
Dg
B
P
B
P
B
Br
B
L
B
L
Y
B
(B)
YBr
B
Br
W/R
Y/B
R
Y
BCh
W/L
Dg
Y/L
B/W
G
(Gy)
Y
G
B
GY
Y/B
R
Br
BrBr
Br
Br
R
R
RR
BB
B
R
G/W
Br/R
R
Br
Br Br
Br
Br
R
RR
R
R
B
R
B
Br/R
B/W
Br/R
Br/R
RBr
Br
R/B
R
R
R
Br
Br Br
Br
Br
Br
Br
Br
Br
R
R
R
R
R
RR
RR
G/W
R
B
L
B
B
B
B
B
B
BBBB
B
BBBB
BBBBBB
B
G/W
R/W
R/Y
B/Y
Br
R/W
L/Y
W/R
R/W
R/B
Y/R
Br/R
Br/R
R/B
Dg
Ch
B
Y/L
G/W
B/Y
Br
W/R
W/R
R/L
R/W
R/Y
R/W
R/L
P/W
W/G
Br/W
Gy/RGy/R
L/B
L/Y
G/R
B/L
G/R
B/L
B/L
L
W
B
Y
P/W
Br/W
B/L
L
Y
W
R
R
W/R
W/L
W/B
W/Y
Br/B
B/L
G/Y
Gy
Sb
O/B
B/Y B/Y
R
G
B/W
Ch
Y/LY/LY/L
R
B/W
R/B
L/BL/B
L/RL/R
Y/R
Y/B
Y/B
B/R
B/R
B/W
B/W
O
G
O
Br
P
G
G
L
B
W
G
WBr
R
R/L
W/L
B/Y
B/YB/Y
B/Y
B/Y
L/BL/B
W/GW/G
B/Y
B/Y
B
B
B
B
Br
Br
Br
Br
Br
Br
P
PL
Br/W
Br/W
Br/B
Br/B
DgCh
Ch
Ch
Ch Ch
Ch
Dg
Ch Dg
YBr Br
B
B
BB
B
LL
B
Ch Dg
Dg
Dg Dg
Dg
BY
Y
Y
Y
YG
Br/WL/B
Br
Br Br
B/YB/Y
Y
L
B
B/WY/L
R
B
W/R
W/L
W/B
W/Y
Br/B
B/L
L/Y
G/Y
Gy
Sb
O/B
Br
Ch
P
G
B
B
B
B/W
G
W
R
G
Y/L
Y/L
Y/LY/L
L/YL/Y
L/Y
L/Y
B
B
L/B
G
B/WL/W
L
Y/W
B
Y/R
W/GB/Y
Br
Br
Br Br
B
B
B
B
B
Br
G
L
G
B
B
B
B
B
Br Br
Br
Y/B
B
Y/B
W/RB/W
Y/L
RChDgY
Br G
B
W/L
1
2
3
4
5
6
7
8
9
10
11
12
13
14
16
15
17
18
19
20
21
22 23 24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43 43
78 78
44
45
46
4748
49
50
51 52 53 54 55 56 57 58 59
60
61
62
63
64
65 66
67
68
69 7071727374
7576
77
B63-F8197-EZ.book Page 23 Monday, January 23, 2017 4:12 PM
8-24
CHARGING SYSTEM
1. Battery
5. Main fuse
10.Ignition fuse
14.Main switch
19.Main relay
20.Starter charge relay
26.Starter generator
33.SGCU (starter generator control unit)
34.Crankshaft position sensor
43.Engine ground 2
78.Engine ground 1
B63-F8197-EZ.book Page 24 Monday, January 23, 2017 4:12 PM
CHARGING SYSTEM
8-25
EAS30497
TROUBLESHOOTING
The battery is not being charged.
TIP
• Before troubleshooting, remove the following part(s):
1. Battery cover
2. Front side covers
3. Fuel tank cover
4. Storage box
5. Front cowling assembly
NG
OK
NG
OK
NG
OK
NG
OK
NG
OK
NG
OK
1. Check the fuses.
(Main and ignition)
Refer to “CHECKING THE FUS-
ES” on page 8-124.
Replace the fuse(s).
2. Check the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 8-124.
• Clean the battery terminals.
• Recharge or replace the battery.
3. Check the starter generator.
Refer to “CHECKING THE START-
ER GENERATOR” on page 8-131.
Replace the starter generator assembly.
4. Check the main relay.
Refer to “CHECKING THE RE-
LAYS” on page 8-128.
Replace the main relay.
5. Check the starter charge relay.
Refer to “CHECKING THE RE-
LAYS” on page 8-128.
Replace the starter charge relay.
6. Check the main switch.
Refer to “CHECKING THE
SWITCHES” on page 8-120.
Replace the main switch.
B63-F8197-EZ.book Page 25 Monday, January 23, 2017 4:12 PM
8-26
CHARGING SYSTEM
NG
OK
7. Check the entire charging system
wiring.
Refer to “CIRCUIT DIAGRAM
(GDR155)” on page 8-21 or refer to
“CIRCUIT DIAGRAM (GDR155-A)”
on page 8-23.
Properly connect or replace the wire har-
ness.
Replace the starter generator assem-
bly or the SGCU. Refer to “REPLAC-
ING THE SGCU (starter generator
control unit)” on page 8-124.
B63-F8197-EZ.book Page 26 Monday, January 23, 2017 4:12 PM
LIGHTING SYSTEM
8-27
EAS20075
LIGHTING SYSTEM
EAS30498
CIRCUIT DIAGRAM (GDR155)
ON
OPEN
OFF
LOCK
L
PUSH
R
ON
OFF
HI
LO
PUSH
FREE
PUSH
FREE
B
W/R
Br
R
G/W
Br
R/Y
R
R
Br/R
R/W,B r
B/W,B
(B)
Br/R
R
Y/R
Br
R/B
RWG
R/YR/L
R/W
(B)
B/LG/R
(B)
B/L
Y L
P/WBr/W
Gy/R
(B)
B
(B)
(B)
G/Y
W/R
B/Y
O
P
O/B
G
B/W
W/L
Ch
Sb Y
B
/
L
Br/B
R/B
Gy
B/L
W/B
L
W/Y
R
Br/W
B
P/WR/W
L/Y
B/L
G/R
Y/LB/R
Gy/R
L/B
R/L
W
B
Y/BY/R
GWR
G
L/Y
W/R
Br/B
W/L
W/B
(B)
W/R
W/LBr/B
W/Y
B/L
W/B
(B)
(B)
P
G/Y
Sb Gy
Br
(B)
O/B
(Gy)
G
Ch
B/W
R
Y/L Y/L
(B)
R
B/Y
(Gy)
G
B/W
R/L
W
W
B
B/YBr
(B)
BB
Br B
BBr
B
B
(L)
L/Y
B
(L)
Br
Br/W
(R)
L
Y/R
B/Y
L/B
B
L/W
(R)
Br
G
(L)
Dg
Ch
Br/W
(R)
Y
L
(R)
L/B
Y
(L)
Br/W
Ch
Dg
(B)
B
Dg
Ch
(B)
Ch
Dg
B
P
B
P
B
Br
B
L
B
L
Y
B
(B)
YBr
B
Br
Y/B
R
Y
BChDg
Y/L
B/W
G
(Gy)
Y
G
B
GY
Y/B
Br
R
R
R
B
B
R
Br/R
Br
Br
R
B
Br/R
B/W
Br/R
Br/R
RBr
Br
Br Br
Br
Br
Br
Br
Br
Br
R
R
R
R
R
RR
RR
R
B
B
B
BBBB
B
B
B
BBBB
G/W
G/W
R/Y
Br
R/W
R/B
Y/R
Br/R
Br/R
W/R
W/R
R/W
R/Y
R/W
R/L
P/W
Br/W
Gy/RGy/R
L/B
L/Y
G/R
B/L
G/R
B/L
B/L
L
B
Y
P/W
Br/W
B/L
L
Y
W
R
R
W/R
W/L
W/B
W/Y
Br/B
B/L
G/Y
Gy
Sb
O/B
B/Y B/Y
R
G
B/W
Ch
Y/LY/LY/L
R
B/W
R/B
Y/R
Y/B
Y/B
B/R
B/R
B/W
O
G
O
Br
P
G
W
R/L
W
R/L
B
W
B/Y
B/Y
B/Y
L/BL/B
B/Y
B/Y
B
B
B
B
Br
Br
Br
Br
Br
Br
P
PL
Br/W
Br/W
DgCh
Ch
Ch
Ch Ch
Dg
Ch Dg
YBr Br
B
B
BB
B
LL
B
Ch Dg
Dg
Dg Dg
BY
Y
Y
Y
YG
L/B
Br
Br Br
B/YB/Y
Y
W/R
W/L
W/B
W/Y
Br/B
B/L
L/Y
G/Y
Gy
Sb
O/B
Br
Ch
P
G
B
B
B
B/W
G
W
R
G
L/Y
B
L/B
G
L/W
L
B
Y/R
B/Y
Br
Br
Br Br
B
B
B
B
B
Br
G
L
G
B
B
B
B
B
Br Br
Br
Y/B
B
Y/B
B/W
Y/L
RChDgY
Br G
B
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
25
26
27
28
29
30
31
32
33
34
35 35
63
24
3637
38
39
40 41 42 43 44 45
46
47
48
49 50 51
52
53
54 5556575859
6061
62
B63-F8197-EZ.book Page 27 Monday, January 23, 2017 4:12 PM
8-28
LIGHTING SYSTEM
1. Battery
2. Main fuse
5. Ignition fuse
6. Headlight fuse
10.Main switch
13.Handlebar switch (right)
14.Light switch
25.SGCU (starter generator control unit)
35.Engine ground 2
38.Meter assembly
42.Meter light
45.High beam indicator light
48.Handlebar switch (left)
49.Dimmer switch
52.License light
53.Tail/brake light assembly
55.Taillight
60.Headlight
61.Auxiliary light
62.Frame ground
63.Engine ground 1
B63-F8197-EZ.book Page 28 Monday, January 23, 2017 4:12 PM
LIGHTING SYSTEM
8-29
EASB631008
CIRCUIT DIAGRAM (GDR155-A)
ON
OPEN
OFF
LOCK
L
PUSH
R
ON
OFF
HI
LO
PUSH
FREE
PUSH
FREE
ON
OFF
B
W/R
B
B/Y
B
L
R/W
B
(B)
R/W
B
(B)
Br
R
G/W
Br
R/Y
R
(B)
ChB
L/Y
R/BY/L
G/W
Dg
R/W
Br
W/R
B/Y
R
R/B
R
R
Br/R
R/W,B r
B/W,B
B
R
(B)
Br/R
R
Y/R
Br
R/B
RWG
R/YR/L
R/W
(B)
B/LG/R
(B)
B/L
Y L
P/WBr/W
Gy/R
(B)
B
(B)
(B)
G/Y
W/R
B/Y
O
P
O/B
G
B/W
W/L
Ch
Sb Y
B
/
L
Br/B
R/B
Gy
B/L
W/B
L
W/Y
R
Br/W
B
P/WR/W
L/B
B/L
G/R
Y/LB/R
Gy/R
L/Y
W/G
W
B
Y/BY/R
GWR
G
L/Y
W/R
Br/B
W/L
W/B
(B)
W/R
W/LBr/B
W/Y
B/L
W/B
(B)
(B)
P
G/Y
Sb Gy
Br
(B)
O/B
(Gy)
G
Ch
B/W
R
Y/L Y/L
(B)
R
B/Y
(Gy)
G
B/W
LG
W
B
L/RL/B
RB
R
L/RL/BY/L
B/W
R/LB/Y
Br
W/L
LGWB
B/Y
Br
(B)
BB
Br B
BBr
B
B
(L)
L/Y
B
(L)
Br
Br/W
Br/B
Br/W
(R)
L
Y/R
B/Y
L/B
(B)
B
W/G
B
L/W
(B)
B/W
Y/W
(R)
Br
G
(L)
Dg
Ch
Br/W
(R)
Y
L
(R)
L/B
Y
(L)
Br/B
Ch
Dg
(B)
B
Dg
Ch
(B)
Ch
Dg
B
P
B
P
B
Br
B
L
B
L
Y
B
(B)
YBr
B
Br
W/R
Y/B
R
Y
BCh
W/L
Dg
Y/L
B/W
G
(Gy)
Y
G
B
GY
Y/B
R
Br
BrBr
Br
Br
R
R
RR
BB
B
R
G/W
Br/R
R
Br
Br Br
Br
Br
R
RR
R
R
B
R
B
Br/R
B/W
Br/R
Br/R
RBr
Br
R/B
R
R
R
Br
Br Br
Br
Br
Br
Br
Br
Br
R
R
R
R
R
RR
RR
G/W
R
B
L
B
B
B
B
B
B
BBBB
B
BBBB
BBBBBB
B
G/W
R/W
R/Y
B/Y
Br
R/W
L/Y
W/R
R/W
R/B
Y/R
Br/R
Br/R
R/B
Dg
Ch
B
Y/L
G/W
B/Y
Br
W/R
W/R
R/L
R/W
R/Y
R/W
R/L
P/W
W/G
Br/W
Gy/RGy/R
L/B
L/Y
G/R
B/L
G/R
B/L
B/L
L
W
B
Y
P/W
Br/W
B/L
L
Y
W
R
R
W/R
W/L
W/B
W/Y
Br/B
B/L
G/Y
Gy
Sb
O/B
B/Y B/Y
R
G
B/W
Ch
Y/LY/LY/L
R
B/W
R/B
L/BL/B
L/RL/R
Y/R
Y/B
Y/B
B/R
B/R
B/W
B/W
O
G
O
Br
P
G
G
L
B
W
G
WBr
R
R/L
W/L
B/Y
B/YB/Y
B/Y
B/Y
L/BL/B
W/GW/G
B/Y
B/Y
B
B
B
B
Br
Br
Br
Br
Br
Br
P
PL
Br/W
Br/W
Br/B
Br/B
DgCh
Ch
Ch
Ch Ch
Ch
Dg
Ch Dg
YBr Br
B
B
BB
B
LL
B
Ch Dg
Dg
Dg Dg
Dg
BY
Y
Y
Y
YG
Br/WL/B
Br
Br Br
B/YB/Y
Y
L
B
B/WY/L
R
B
W/R
W/L
W/B
W/Y
Br/B
B/L
L/Y
G/Y
Gy
Sb
O/B
Br
Ch
P
G
B
B
B
B/W
G
W
R
G
Y/L
Y/L
Y/LY/L
L/YL/Y
L/Y
L/Y
B
B
L/B
G
B/WL/W
L
Y/W
B
Y/R
W/GB/Y
Br
Br
Br Br
B
B
B
B
B
Br
G
L
G
B
B
B
B
B
Br Br
Br
Y/B
B
Y/B
W/RB/W
Y/L
RChDgY
Br G
B
W/L
1
2
3
4
5
6
7
8
9
10
11
12
13
14
16
15
17
18
19
20
21
22 23 24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43 43
78 78
44
45
46
4748
49
50
51 52 53 54 55 56 57 58 59
60
61
62
63
64
65 66
67
68
69 7071727374
7576
77
B63-F8197-EZ.book Page 29 Monday, January 23, 2017 4:12 PM
8-30
LIGHTING SYSTEM
1. Battery
5. Main fuse
10.Ignition fuse
11.Headlight fuse
14.Main switch
21.Handlebar switch (right)
22.Light switch
33.SGCU (starter generator control unit)
43.Engine ground 2
49.Meter assembly
54.Meter light
59.High beam indicator light
63.Handlebar switch (left)
64.Dimmer switch
67.License light
68.Tail/brake light assembly
70.Taillight
75.Headlight
76.Auxiliary light
77.Frame ground
78.Engine ground 1
B63-F8197-EZ.book Page 30 Monday, January 23, 2017 4:12 PM
LIGHTING SYSTEM
8-31
EAS30499
TROUBLESHOOTING
Any of the following fail to light: headlight, high beam indicator light, taillight, auxiliary lights, license light
or meter light.
TIP
• Before troubleshooting, remove the following part(s):
1. Battery cover
2. Front side covers
3. Storage box
4. Front cowling assembly
5. Handlebar cover assembly
NG
OK
NG
OK
NG
OK
NG
OK
NG
OK
NG
OK
1. Check the condition of each bulb
and bulb socket.
Refer to “CHECKING THE BULBS
AND BULB SOCKETS” on page
8-123.
Replace the bulb(s) and bulb socket(s).
2. Check the fuses.
(Main, ignition, and headlight)
Refer to “CHECKING THE FUS-
ES” on page 8-124.
Replace the fuse(s).
3. Check the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 8-124.
• Clean the battery terminals.
• Recharge or replace the battery.
4. Check the main switch.
Refer to “CHECKING THE
SWITCHES” on page 8-120.
Replace the main switch.
5. Check the light switch.
Refer to “CHECKING THE
SWITCHES” on page 8-120.
The light switch is faulty. Replace the right
handlebar switch.
6. Check the dimmer switch.
Refer to “CHECKING THE
SWITCHES” on page 8-120.
The dimmer switch is faulty. Replace the
left handlebar switch.
B63-F8197-EZ.book Page 31 Monday, January 23, 2017 4:12 PM
8-32
LIGHTING SYSTEM
NG
OK
7. Check the entire lighting system
wiring.
Refer to “CIRCUIT DIAGRAM
(GDR155)” on page 8-27 or refer to
“CIRCUIT DIAGRAM (GDR155-A)”
on page 8-29.
Properly connect or replace the wire har-
ness.
Replace the SGCU, meter assembly,
tail/brake light assembly or headlight
unit. Refer to “REPLACING THE
SGCU (starter generator control unit)”
on page 8-124.
B63-F8197-EZ.book Page 32 Monday, January 23, 2017 4:12 PM
SIGNALING SYSTEM
8-33
EAS20076
SIGNALING SYSTEM
EAS30500
CIRCUIT DIAGRAM (GDR155)
ON
OPEN
OFF
LOCK
L
PUSH
R
ON
OFF
HI
LO
PUSH
FREE
PUSH
FREE
B
W/R
Br
R
G/W
Br
R/Y
R
R
Br/R
R/W,B r
B/W,B
(B)
Br/R
R
Y/R
Br
R/B
RWG
R/YR/L
R/W
(B)
B/LG/R
(B)
B/L
Y L
P/WBr/W
Gy/R
(B)
B
(B)
(B)
G/Y
W/R
B/Y
O
P
O/B
G
B/W
W/L
Ch
Sb Y
B
/
L
Br/B
R/B
Gy
B/L
W/B
L
W/Y
R
Br/W
B
P/WR/W
L/Y
B/L
G/R
Y/LB/R
Gy/R
L/B
R/L
W
B
Y/BY/R
GWR
G
L/Y
W/R
Br/B
W/L
W/B
(B)
W/R
W/LBr/B
W/Y
B/L
W/B
(B)
(B)
P
G/Y
Sb Gy
Br
(B)
O/B
(Gy)
G
Ch
B/W
R
Y/L Y/L
(B)
R
B/Y
(Gy)
G
B/W
R/L
W
W
B
B/YBr
(B)
BB
Br B
BBr
B
B
(L)
L/Y
B
(L)
Br
Br/W
(R)
L
Y/R
B/Y
L/B
B
L/W
(R)
Br
G
(L)
Dg
Ch
Br/W
(R)
Y
L
(R)
L/B
Y
(L)
Br/W
Ch
Dg
(B)
B
Dg
Ch
(B)
Ch
Dg
B
P
B
P
B
Br
B
L
B
L
Y
B
(B)
YBr
B
Br
Y/B
R
Y
BChDg
Y/L
B/W
G
(Gy)
Y
G
B
GY
Y/B
Br
R
R
R
B
B
R
Br/R
Br
Br
R
B
Br/R
B/W
Br/R
Br/R
RBr
Br
Br Br
Br
Br
Br
Br
Br
Br
R
R
R
R
R
RR
RR
R
B
B
B
BBBB
B
B
B
BBBB
G/W
G/W
R/Y
Br
R/W
R/B
Y/R
Br/R
Br/R
W/R
W/R
R/W
R/Y
R/W
R/L
P/W
Br/W
Gy/RGy/R
L/B
L/Y
G/R
B/L
G/R
B/L
B/L
L
B
Y
P/W
Br/W
B/L
L
Y
W
R
R
W/R
W/L
W/B
W/Y
Br/B
B/L
G/Y
Gy
Sb
O/B
B/Y B/Y
R
G
B/W
Ch
Y/LY/LY/L
R
B/W
R/B
Y/R
Y/B
Y/B
B/R
B/R
B/W
O
G
O
Br
P
G
W
R/L
W
R/L
B
W
B/Y
B/Y
B/Y
L/BL/B
B/Y
B/Y
B
B
B
B
Br
Br
Br
Br
Br
Br
P
PL
Br/W
Br/W
DgCh
Ch
Ch
Ch Ch
Dg
Ch Dg
YBr Br
B
B
BB
B
LL
B
Ch Dg
Dg
Dg Dg
BY
Y
Y
Y
YG
L/B
Br
Br Br
B/YB/Y
Y
W/R
W/L
W/B
W/Y
Br/B
B/L
L/Y
G/Y
Gy
Sb
O/B
Br
Ch
P
G
B
B
B
B/W
G
W
R
G
L/Y
B
L/B
G
L/W
L
B
Y/R
B/Y
Br
Br
Br Br
B
B
B
B
B
Br
G
L
G
B
B
B
B
B
Br Br
Br
Y/B
B
Y/B
B/W
Y/L
RChDgY
Br G
B
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
25
26
27
28
29
30
31
32
33
34
35 35
63
24
3637
38
39
40 41 42 43 44 45
46
47
48
49 50 51
52
53
54 5556575859
6061
62
B63-F8197-EZ.book Page 33 Monday, January 23, 2017 4:12 PM
8-34
SIGNALING SYSTEM
1. Battery
2. Main fuse
5. Ignition fuse
7. Signaling system fuse
10.Main switch
11.Main relay
18.Coolant temperature sensor
24.Front wheel sensor
25.SGCU (starter generator control unit)
32.Fuel sender
34.Yamaha diagnostic tool coupler
35.Engine ground 2
36.Rear brake light switch
37.Front brake light switch
38.Meter assembly
39.Multi-function meter
40.Coolant temperature warning light
43.Turn signal indicator light (left)
44.Turn signal indicator light (right)
46.Turn signal relay
47.Horn
48.Handlebar switch (left)
50.Horn switch
51.Turn signal switch
53.Tail/brake light assembly
54.Brake light
56.Rear turn signal light (right)
57.Rear turn signal light (left)
58.Front turn signal light (right)
59.Front turn signal light (left)
62.Frame ground
63.Engine ground 1
B63-F8197-EZ.book Page 34 Monday, January 23, 2017 4:12 PM
SIGNALING SYSTEM
8-35
EASB631009
CIRCUIT DIAGRAM (GDR155-A)
ON
OPEN
OFF
LOCK
L
PUSH
R
ON
OFF
HI
LO
PUSH
FREE
PUSH
FREE
ON
OFF
B
W/R
B
B/Y
B
L
R/W
B
(B)
R/W
B
(B)
Br
R
G/W
Br
R/Y
R
(B)
ChB
L/Y
R/BY/L
G/W
Dg
R/W
Br
W/R
B/Y
R
R/B
R
R
Br/R
R/W,B r
B/W,B
B
R
(B)
Br/R
R
Y/R
Br
R/B
RWG
R/YR/L
R/W
(B)
B/LG/R
(B)
B/L
Y L
P/WBr/W
Gy/R
(B)
B
(B)
(B)
G/Y
W/R
B/Y
O
P
O/B
G
B/W
W/L
Ch
Sb Y
B
/
L
Br/B
R/B
Gy
B/L
W/B
L
W/Y
R
Br/W
B
P/WR/W
L/B
B/L
G/R
Y/LB/R
Gy/R
L/Y
W/G
W
B
Y/BY/R
GWR
G
L/Y
W/R
Br/B
W/L
W/B
(B)
W/R
W/LBr/B
W/Y
B/L
W/B
(B)
(B)
P
G/Y
Sb Gy
Br
(B)
O/B
(Gy)
G
Ch
B/W
R
Y/L Y/L
(B)
R
B/Y
(Gy)
G
B/W
LG
W
B
L/RL/B
RB
R
L/RL/BY/L
B/W
R/LB/Y
Br
W/L
LGWB
B/Y
Br
(B)
BB
Br B
BBr
B
B
(L)
L/Y
B
(L)
Br
Br/W
Br/B
Br/W
(R)
L
Y/R
B/Y
L/B
(B)
B
W/G
B
L/W
(B)
B/W
Y/W
(R)
Br
G
(L)
Dg
Ch
Br/W
(R)
Y
L
(R)
L/B
Y
(L)
Br/B
Ch
Dg
(B)
B
Dg
Ch
(B)
Ch
Dg
B
P
B
P
B
Br
B
L
B
L
Y
B
(B)
YBr
B
Br
W/R
Y/B
R
Y
BCh
W/L
Dg
Y/L
B/W
G
(Gy)
Y
G
B
GY
Y/B
R
Br
BrBr
Br
Br
R
R
RR
BB
B
R
G/W
Br/R
R
Br
Br Br
Br
Br
R
RR
R
R
B
R
B
Br/R
B/W
Br/R
Br/R
RBr
Br
R/B
R
R
R
Br
Br Br
Br
Br
Br
Br
Br
Br
R
R
R
R
R
RR
RR
G/W
R
B
L
B
B
B
B
B
B
BBBB
B
BBBB
BBBBBB
B
G/W
R/W
R/Y
B/Y
Br
R/W
L/Y
W/R
R/W
R/B
Y/R
Br/R
Br/R
R/B
Dg
Ch
B
Y/L
G/W
B/Y
Br
W/R
W/R
R/L
R/W
R/Y
R/W
R/L
P/W
W/G
Br/W
Gy/RGy/R
L/B
L/Y
G/R
B/L
G/R
B/L
B/L
L
W
B
Y
P/W
Br/W
B/L
L
Y
W
R
R
W/R
W/L
W/B
W/Y
Br/B
B/L
G/Y
Gy
Sb
O/B
B/Y B/Y
R
G
B/W
Ch
Y/LY/LY/L
R
B/W
R/B
L/BL/B
L/RL/R
Y/R
Y/B
Y/B
B/R
B/R
B/W
B/W
O
G
O
Br
P
G
G
L
B
W
G
WBr
R
R/L
W/L
B/Y
B/YB/Y
B/Y
B/Y
L/BL/B
W/GW/G
B/Y
B/Y
B
B
B
B
Br
Br
Br
Br
Br
Br
P
PL
Br/W
Br/W
Br/B
Br/B
DgCh
Ch
Ch
Ch Ch
Ch
Dg
Ch Dg
YBr Br
B
B
BB
B
LL
B
Ch Dg
Dg
Dg Dg
Dg
BY
Y
Y
Y
YG
Br/WL/B
Br
Br Br
B/YB/Y
Y
L
B
B/WY/L
R
B
W/R
W/L
W/B
W/Y
Br/B
B/L
L/Y
G/Y
Gy
Sb
O/B
Br
Ch
P
G
B
B
B
B/W
G
W
R
G
Y/L
Y/L
Y/LY/L
L/YL/Y
L/Y
L/Y
B
B
L/B
G
B/WL/W
L
Y/W
B
Y/R
W/GB/Y
Br
Br
Br Br
B
B
B
B
B
Br
G
L
G
B
B
B
B
B
Br Br
Br
Y/B
B
Y/B
W/RB/W
Y/L
RChDgY
Br G
B
W/L
1
2
3
4
5
6
7
8
9
10
11
12
13
14
16
15
17
18
19
20
21
22 23 24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43 43
78 78
44
45
46
4748
49
50
51 52 53 54 55 56 57 58 59
60
61
62
63
64
65 66
67
68
69 7071727374
7576
77
B63-F8197-EZ.book Page 35 Monday, January 23, 2017 4:12 PM
8-36
SIGNALING SYSTEM
1. Battery
4. ABS control unit fuse
5. Main fuse
10.Ignition fuse
12.Signaling system fuse
14.Main switch
19.Main relay
27.Coolant temperature sensor
33.SGCU (starter generator control unit)
40.Fuel sender
42.Yamaha diagnostic tool coupler
43.Engine ground 2
44.Front wheel sensor
46.ABS ECU
47.Rear brake light switch
48.Front brake light switch
49.Meter assembly
50.Multi-function meter
51.Coolant temperature warning light
55.Turn signal indicator light (left)
56.Turn signal indicator light (right)
60.Turn signal relay
61.Diode
62.Horn
63.Handlebar switch (left)
65.Horn switch
66.Turn signal switch
68.Tail/brake light assembly
69.Brake light
71.Rear turn signal light (right)
72.Rear turn signal light (left)
73.Front turn signal light (right)
74.Front turn signal light (left)
77.Frame ground
78.Engine ground 1
B63-F8197-EZ.book Page 36 Monday, January 23, 2017 4:12 PM
SIGNALING SYSTEM
8-37
EAS30501
TROUBLESHOOTING
• Any of the following fail to light: turn signal lights, brake light, warning lights or indicator lights.
• The horn fails to sound.
• The fuel meter fails to come on.
• The speedometer fails to operate.
• The instantaneous fuel consumption meter fails to operation.
TIP
• Before troubleshooting, remove the following part(s):
1. Battery cover
2. Front side covers
3. Fuel tank cover
4. Storage box
5. Front cowling assembly
6. Handlebar cover assembly
NG
OK
NG
OK
NG
OK
NG
OK
NG
OK
1. Check the fuses.
(Main, ignition, signaling system,
and ABS control unit)
Refer to “CHECKING THE FUS-
ES” on page 8-124.
Replace the fuse(s).
2. Check the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 8-124.
• Clean the battery terminals.
• Recharge or replace the battery.
3. Check the main switch.
Refer to “CHECKING THE
SWITCHES” on page 8-120.
Replace the main switch.
4. Check the main relay.
Refer to “CHECKING THE RE-
LAYS” on page 8-128.
Replace the main relay.
5. Check the entire signaling system
wiring.
Refer to “CIRCUIT DIAGRAM
(GDR155)” on page 8-33 or refer to
“CIRCUIT DIAGRAM (GDR155-A)”
on page 8-35.
Properly connect or replace the wire har-
ness.
Check the condition of each of the sig-
naling system circuits. Refer to
“Checking the signaling system”.
B63-F8197-EZ.book Page 37 Monday, January 23, 2017 4:12 PM
8-38
SIGNALING SYSTEM
Checking the signaling system
The horn fails to sound.
NG
OK
NG
OK
The brake light fails to come on.
NG
OK
NG
OK
NG
OK
The turn signal light, turn signal indicator light or both fail to blink.
NG
OK
NG
OK
1. Check the horn switch.
Refer to “CHECKING THE
SWITCHES” on page 8-120.
The horn switch is faulty. Replace the left
handlebar switch.
2. Check the entire signaling system
wiring.
Refer to “CIRCUIT DIAGRAM
(GDR155)” on page 8-33 or refer to
“CIRCUIT DIAGRAM (GDR155-A)”
on page 8-35.
Properly connect or replace the wire har-
ness.
Replace the horn.
1. Check the front brake light switch.
Refer to “CHECKING THE
SWITCHES” on page 8-120.
Replace the front brake light switch.
2. Check the rear brake light switch.
Refer to “CHECKING THE
SWITCHES” on page 8-120.
Replace the rear brake light switch.
3. Check the entire signaling system
wiring.
Refer to “CIRCUIT DIAGRAM
(GDR155)” on page 8-33 or refer to
“CIRCUIT DIAGRAM (GDR155-A)”
on page 8-35.
Properly connect or replace the wire har-
ness.
Replace the tail/brake light assembly.
1. Check the turn signal light bulbs
and sockets.
Refer to “CHECKING THE BULBS
AND BULB SOCKETS” on page
8-123.
Replace the turn signal light bulb, socket or
both.
2. Check the turn signal switch.
Refer to “CHECKING THE
SWITCHES” on page 8-120.
The turn signal switch is faulty. Replace
the left handlebar switch.
B63-F8197-EZ.book Page 38 Monday, January 23, 2017 4:12 PM
SIGNALING SYSTEM
8-39
NG
OK
NG
OK
NG
OK
The coolant temperature warning light fails to come on.
NG
OK
NG
OK
The fuel meter fails to come on.
NG
OK
3. Check the turn signal relay.
Refer to “CHECKING THE TURN
SIGNAL RELAY” on page 8-128.
Replace the turn signal relay.
4. Check the diode (GDR155-A).
Refer to “CHECKING THE DIODE
(GDR155-A)” on page 8-129.
Replace the diode.
5. Check the entire signaling system
wiring.
Refer to “CIRCUIT DIAGRAM
(GDR155)” on page 8-33 or refer to
“CIRCUIT DIAGRAM (GDR155-A)”
on page 8-35.
Properly connect or replace the wire har-
ness.
Replace the meter assembly.
1. Check the coolant temperature sen-
sor.
Refer to “CHECKING THE COOL-
ANT TEMPERATURE SENSOR”
on page 8-132.
Replace the coolant temperature sensor.
2. Check the entire signaling system
wiring.
Refer to “CIRCUIT DIAGRAM
(GDR155)” on page 8-33 or refer to
“CIRCUIT DIAGRAM (GDR155-A)”
on page 8-35.
Properly connect or replace the wire har-
ness.
Replace the meter assembly or
SGCU. Refer to “REPLACING THE
SGCU (starter generator control unit)”
on page 8-124.
1. Check the fuel sender.
Refer to “CHECKING THE FUEL
SENDER” on page 8-131.
Replace the fuel pump.
B63-F8197-EZ.book Page 39 Monday, January 23, 2017 4:12 PM
8-40
SIGNALING SYSTEM
NG
OK
The speedometer, instantaneous fuel consumption meter fails to operate.
NG
OK
NG
OK
TIP
Replace the wire harness if there is an open or short circuit.
• Between front speed sensor coupler and SGCU coupler. (GDR155)
(White–White)
(Red/Blue–Red/Blue)
• Between front speed sensor coupler and ABS ECU coupler. (GDR155-A)
(Green–Green)
(Blue–Blue)
• Between ABS ECU coupler and SGCU coupler. (GDR155-A)
(White–White)
• Between SGCU coupler and meter assembly coupler.
(Yellow/Blue–Yellow/Blue)
2. Check the entire signaling system
wiring.
Refer to “CIRCUIT DIAGRAM
(GDR155)” on page 8-33.
Properly connect or replace the wire har-
ness.
Replace the meter assembly.
1. Check the front wheel sensor.
Refer to “MAINTENANCE OF THE
FRONT WHEEL SENSOR AND
SENSOR ROTOR” on page 4-23.
Replace the front wheel sensor.
2. Check the entire wiring.
Refer to TIP.
Properly connect or replace the wiring har-
ness.
Replace the SGCU, ABS ECU
(GDR155-A), or meter assembly. Re-
fer to “REPLACING THE SGCU (start-
er generator control unit)” on page
8-124.
B63-F8197-EZ.book Page 40 Monday, January 23, 2017 4:12 PM
FUEL INJECTION SYSTEM
8-41
EAS20078
FUEL INJECTION SYSTEM
EAS30504
CIRCUIT DIAGRAM (GDR155)
ON
OPEN
OFF
LOCK
L
PUSH
R
ON
OFF
HI
LO
PUSH
FREE
PUSH
FREE
B
W/R
Br
R
G/W
Br
R/Y
R
R
Br/R
R/W,B r
B/W,B
(B)
Br/R
R
Y/R
Br
R/B
RWG
R/YR/L
R/W
(B)
B/LG/R
(B)
B/L
Y L
P/WBr/W
Gy/R
(B)
B
(B)
(B)
G/Y
W/R
B/Y
O
P
O/B
G
B/W
W/L
Ch
Sb Y
B
/
L
Br/B
R/B
Gy
B/L
W/B
L
W/Y
R
Br/W
B
P/WR/W
L/Y
B/L
G/R
Y/LB/R
Gy/R
L/B
R/L
W
B
Y/BY/R
GWR
G
L/Y
W/R
Br/B
W/L
W/B
(B)
W/R
W/LBr/B
W/Y
B/L
W/B
(B)
(B)
P
G/Y
Sb Gy
Br
(B)
O/B
(Gy)
G
Ch
B/W
R
Y/L Y/L
(B)
R
B/Y
(Gy)
G
B/W
R/L
W
W
B
B/YBr
(B)
BB
Br B
BBr
B
B
(L)
L/Y
B
(L)
Br
Br/W
(R)
L
Y/R
B/Y
L/B
B
L/W
(R)
Br
G
(L)
Dg
Ch
Br/W
(R)
Y
L
(R)
L/B
Y
(L)
Br/W
Ch
Dg
(B)
B
Dg
Ch
(B)
Ch
Dg
B
P
B
P
B
Br
B
L
B
L
Y
B
(B)
YBr
B
Br
Y/B
R
Y
BChDg
Y/L
B/W
G
(Gy)
Y
G
B
GY
Y/B
Br
R
R
R
B
B
R
Br/R
Br
Br
R
B
Br/R
B/W
Br/R
Br/R
RBr
Br
Br Br
Br
Br
Br
Br
Br
Br
R
R
R
R
R
RR
RR
R
B
B
B
BBBB
B
B
B
BBBB
G/W
G/W
R/Y
Br
R/W
R/B
Y/R
Br/R
Br/R
W/R
W/R
R/W
R/Y
R/W
R/L
P/W
Br/W
Gy/RGy/R
L/B
L/Y
G/R
B/L
G/R
B/L
B/L
L
B
Y
P/W
Br/W
B/L
L
Y
W
R
R
W/R
W/L
W/B
W/Y
Br/B
B/L
G/Y
Gy
Sb
O/B
B/Y B/Y
R
G
B/W
Ch
Y/LY/LY/L
R
B/W
R/B
Y/R
Y/B
Y/B
B/R
B/R
B/W
O
G
O
Br
P
G
W
R/L
W
R/L
B
W
B/Y
B/Y
B/Y
L/BL/B
B/Y
B/Y
B
B
B
B
Br
Br
Br
Br
Br
Br
P
PL
Br/W
Br/W
DgCh
Ch
Ch
Ch Ch
Dg
Ch Dg
YBr Br
B
B
BB
B
LL
B
Ch Dg
Dg
Dg Dg
BY
Y
Y
Y
YG
L/B
Br
Br Br
B/YB/Y
Y
W/R
W/L
W/B
W/Y
Br/B
B/L
L/Y
G/Y
Gy
Sb
O/B
Br
Ch
P
G
B
B
B
B/W
G
W
R
G
L/Y
B
L/B
G
L/W
L
B
Y/R
B/Y
Br
Br
Br Br
B
B
B
B
B
Br
G
L
G
B
B
B
B
B
Br Br
Br
Y/B
B
Y/B
B/W
Y/L
RChDgY
Br G
B
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
25
26
27
28
29
30
31
32
33
34
35 35
63
24
3637
38
39
40 41 42 43 44 45
46
47
48
49 50 51
52
53
54 5556575859
6061
62
B63-F8197-EZ.book Page 41 Monday, January 23, 2017 4:12 PM
8-42
FUEL INJECTION SYSTEM
1. Battery
2. Main fuse
3. Fuel injection system fuse
5. Ignition fuse
10.Main switch
16.Sidestand switch
18.Coolant temperature sensor
19.Throttle body sensor assembly
20.Intake air pressure sensor
21.Intake air temperature sensor
22.Throttle position sensor
23.O
2
sensor
24.Front wheel sensor
25.SGCU (starter generator control unit)
26.Crankshaft position sensor
27.Ignition coil
28.Spark plug
29.ISC (idle speed control) unit
30.Injector
31.Fuel pump
33.VVA (variable valve actuator) solenoid
34.Yamaha diagnostic tool coupler
35.Engine ground 2
38.Meter assembly
39.Multi-function meter
41.Engine trouble warning light
62.Frame ground
63.Engine ground 1
B63-F8197-EZ.book Page 42 Monday, January 23, 2017 4:12 PM
FUEL INJECTION SYSTEM
8-43
EASB631010
CIRCUIT DIAGRAM (GDR155-A)
ON
OPEN
OFF
LOCK
L
PUSH
R
ON
OFF
HI
LO
PUSH
FREE
PUSH
FREE
ON
OFF
B
W/R
B
B/Y
B
L
R/W
B
(B)
R/W
B
(B)
Br
R
G/W
Br
R/Y
R
(B)
ChB
L/Y
R/BY/L
G/W
Dg
R/W
Br
W/R
B/Y
R
R/B
R
R
Br/R
R/W,Br
B/W,B
B
R
(B)
Br/R
R
Y/R
Br
R/B
RWG
R/YR/L
R/W
(B)
B/LG/R
(B)
B/L
Y L
P/WBr/W
Gy/R
(B)
B
(B)
(B)
G/Y
W/R
B/Y
O
P
O/B
G
B/W
W/L
Ch
Sb Y
B
/
L
Br/B
R/B
Gy
B/L
W/B
L
W/Y
R
Br/W
B
P/WR/W
L/B
B/L
G/R
Y/LB/R
Gy/R
L/Y
W/G
W
B
Y/BY/R
GWR
G
L/Y
W/R
Br/B
W/L
W/B
(B)
W/R
W/LBr/B
W/Y
B/L
W/B
(B)
(B)
P
G/Y
Sb Gy
Br
(B)
O/B
(Gy)
G
Ch
B/W
R
Y/L Y/L
(B)
R
B/Y
(Gy)
G
B/W
LG
W
B
L/RL/B
RB
R
L/RL/BY/L
B/W
R/LB/Y
Br
W/L
LGWB
B/YBr
(B)
BB
Br B
BBr
B
B
(L)
L/Y
B
(L)
Br
Br/W
Br/B
Br/W
(R)
L
Y/R
B/Y
L/B
(B)
B
W/G
B
L/W
(B)
B/W
Y/W
(R)
Br
G
(L)
Dg
Ch
Br/W
(R)
Y
L
(R)
L/B
Y
(L)
Br/B
Ch
Dg
(B)
B
Dg
Ch
(B)
Ch
Dg
B
P
B
P
B
Br
B
L
B
L
Y
B
(B)
YBr
B
Br
W/R
Y/B
R
Y
BCh
W/L
Dg
Y/L
B/W
G
(Gy)
Y
G
B
GY
Y/B
R
Br
BrBr
Br
Br
R
R
RR
BB
B
R
G/W
Br/R
R
Br
Br Br
Br
Br
R
RR
R
R
B
R
B
Br/R
B/W
Br/R
Br/R
RBr
Br
R/B
R
R
R
Br
Br Br
Br
Br
Br
Br
Br
Br
R
R
R
R
R
RR
RR
G/W
R
B
L
B
B
B
B
B
B
BBBB
B
BBBB
BBBBBB
B
G/W
R/W
R/Y
B/Y
Br
R/W
L/Y
W/R
R/W
R/B
Y/R
Br/R
Br/R
R/B
Dg
Ch
B
Y/L
G/W
B/Y
Br
W/R
W/R
R/L
R/W
R/Y
R/W
R/L
P/W
W/G
Br/W
Gy/RGy/R
L/B
L/Y
G/R
B/L
G/R
B/L
B/L
L
W
B
Y
P/W
Br/W
B/L
L
Y
W
R
R
W/R
W/L
W/B
W/Y
Br/B
B/L
G/Y
Gy
Sb
O/B
B/Y B/Y
R
G
B/W
Ch
Y/LY/LY/L
R
B/W
R/B
L/BL/B
L/RL/R
Y/R
Y/B
Y/B
B/R
B/R
B/W
B/W
O
G
O
Br
P
G
G
L
B
W
G
WBr
R
R/L
W/L
B/Y
B/YB/Y
B/Y
B/Y
L/BL/B
W/GW/G
B/Y
B/Y
B
B
B
B
Br
Br
Br
Br
Br
Br
P
PL
Br/W
Br/W
Br/B
Br/B
DgCh
Ch
Ch
Ch Ch
Ch
Dg
Ch Dg
YBr Br
B
B
BB
B
LL
B
Ch Dg
Dg
Dg Dg
Dg
BY
Y
Y
Y
YG
Br/WL/B
Br
Br Br
B/YB/Y
Y
L
B
B/WY/L
R
B
W/R
W/L
W/B
W/Y
Br/B
B/L
L/Y
G/Y
Gy
Sb
O/B
Br
Ch
P
G
B
B
B
B/W
G
W
R
G
Y/L
Y/L
Y/LY/L
L/YL/Y
L/Y
L/Y
B
B
L/B
G
B/WL/W
L
Y/W
B
Y/R
W/GB/Y
Br
Br
Br Br
B
B
B
B
B
Br
G
L
G
B
B
B
B
B
Br Br
Br
Y/B
B
Y/B
W/RB/W
Y/L
RChDgY
Br G
B
W/L
1
2
3
4
5
6
7
8
9
10
11
12
13
14
16
15
17
18
19
20
21
22 23 24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43 43
78 78
44
45
46
4748
49
50
51 52 53 54 55
56 57 58 59
60
61
62
63
64
65 66
67
68
69 7071727374
7576
77
B63-F8197-EZ.book Page 43 Monday, January 23, 2017 4:12 PM
8-44
FUEL INJECTION SYSTEM
1. Battery
4. ABS control unit fuse
5. Main fuse
8. Fuel injection system fuse
10.Ignition fuse
14.Main switch
25.Sidestand switch
27.Coolant temperature sensor
28.Throttle body sensor assembly
29.Intake air pressure sensor
30.Intake air temperature sensor
31.Throttle position sensor
32.O
2
sensor
33.SGCU (starter generator control unit)
34.Crankshaft position sensor
35.Ignition coil
36.Spark plug
37.ISC (idle speed control) unit
38.Injector
39.Fuel pump
41.VVA (variable valve actuator) solenoid
42.Yamaha diagnostic tool coupler
43.Engine ground 2
44.Front wheel sensor
46.ABS ECU
49.Meter assembly
50.Multi-function meter
53.Engine trouble warning light
77.Frame ground
78.Engine ground 1
B63-F8197-EZ.book Page 44 Monday, January 23, 2017 4:12 PM
FUEL INJECTION SYSTEM
8-45
EAS30505
SGCU SELF-DIAGNOSTIC FUNCTION
The SGCU 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. Once a malfunction has been detected, a fault code
number is stored in the memory of the SGCU.
• To inform the rider that the fuel injection system is not functioning, the engine trouble warning light
flashes while the start switch is being pushed to start the engine.
• If a malfunction is detected in the system by the self-diagnostic function, the SGCU provides an ap-
propriate substitute characteristic operation, and alerts the rider of the detected malfunction by illumi-
nating the engine trouble warning light.
• After the engine has been stopped, the lowest fault code number appears on the meter display. This
number remains stored in the memory of the SGCU until it is deleted.
Engine trouble warning light indication and fuel injection system operation
* The warning light flashes when any one of the following conditions is present and the start switch is
pushed:
Checking the engine trouble warning light
The engine trouble warning light comes on for around 2 seconds after the main switch has been set to
“ON” and it comes on while the start switch is being pushed. If the warning light does not come on under
these conditions, the warning light (LED) may be defective.
SGCU detects an abnormal signal from a sensor
If the SGCU detects an abnormal signal from a sensor while the vehicle is being driven, the SGCU il-
luminates the engine trouble warning light and provides the engine with alternate operating instructions
that are appropriate for the type of malfunction.
When an abnormal signal is received from a sensor, the SGCU processes the specified values that are
programmed for each sensor in order to provide the engine with alternate operating instructions that
enable the engine to continue operating or stop operating, depending on the conditions.
EAS30506
TROUBLESHOOTING METHOD
The engine operation is not normal and the engine trouble warning light comes on.
1. Check:
• Fault code number
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼▼▼
a. Check the fault code number displayed on the computer.
b. Identify the faulty system with the fault code number.
Warning light indication SGCU operation Fuel injection operation Vehicle operation
Flashing*
Warning provided when
unable to start engine
Operation stopped Cannot be operated
Remains on Malfunction detected
Operated with substitute
characteristics in accor-
dance with the descrip-
tion of the malfunction
Can or cannot be operat-
ed depending on the fault
code
12: Crankshaft position sensor 50:
SGCU internal malfunction
(memory check error)
39:
Fuel injector
(short circuit)
B63-F8197-EZ.book Page 45 Monday, January 23, 2017 4:12 PM
8-46
FUEL INJECTION SYSTEM
c. Identify the probable cause of the malfunction.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲ ▲▲▲▲
2. Check and repair the probable cause of the malfunction.
3. Perform the reinstatement action for the fuel injection system.
Refer to “Confirmation of service completion” in the appropriate table in “TROUBLESHOOTING DE-
TAILS” on page 8-47.
4. Set the main switch to “OFF”, then to “ON” again, and then check that no fault code number is dis-
played.
TIP
If another fault code number is displayed, repeat steps (1) to (4) until no fault code number is displayed.
5. Erase the malfunction history in the diagnostic mode. Refer to “Sensor operation table (Diagnostic
code No. 62)”.
TIP
Turning the main switch to “OFF” will not erase the malfunction history.
The engine operation is not normal, but the engine trouble warning light does not come on.
1. Check the operation of the following sensors and actuators in the diagnostic mode. Refer to “TROU-
BLESHOOTING DETAILS” on page 8-47.
If a malfunction is detected in the sensors or actuators, repair or replace all faulty parts.
If no malfunction is detected in the sensors and actuators, check and repair the inner parts of the
engine.
EAS30951
YAMAHA DIAGNOSTIC TOOL
This model uses the Yamaha diagnostic tool to identify malfunctions.
For information about using the Yamaha diagnostic tool, refer to the operation manual that is included
with the tool.
Connecting the Yamaha diagnostic tool
Disconnect the Yamaha diagnostic tool coupler “1”, and then connect the Yamaha diagnostic tool “2”
to the coupler.
Fault code No. No fault code No.
Check and repair. Refer to “TROUBLESHOOTING
DETAILS” on page 8-47.
Monitor the operation of the sensors and actuators in
the diagnostic mode. Refer to “TROUBLESHOOT-
ING DETAILS” on page 8-47 and “SELF-DIAGNOS-
TIC FUNCTION AND DIAGNOSTIC CODE TABLE”
on page 9-5.
Check and repair.
01: Throttle position sensor signal (throttle angle)
30: Ignition coil
36: Fuel injector
Yamaha diagnostic tool USB
90890-03250
Yamaha diagnostic tool (A/I)
90890-03252
B63-F8197-EZ.book Page 46 Monday, January 23, 2017 4:12 PM
FUEL INJECTION SYSTEM
8-47
EAS30508
TROUBLESHOOTING DETAILS
This section describes the measures per fault code number displayed on the computer. Check and ser-
vice the items or components that are the probable cause of the malfunction following the order given.
Fault code No.:
Fault code number displayed on the computer when the engine failed to work normally.
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. Refer to “SELF-DIAGNOS-
TIC FUNCTION AND DIAGNOSTIC CODE TABLE” on page 9-5.
Fault code No. 12
1
2
Fault code No. 12
Item
Crankshaft position sensor: no normal signals are received from the
crankshaft position sensor.
Fail-safe system
Unable to start engine
Unable to drive vehicle
Diagnostic code No. —
Tool display —
Procedure —
Item
Probable cause of malfunc-
tion and check
Maintenance job
Confirmation of service com-
pletion
1 Connection of crankshaft posi-
tion sensor coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Crank the engine.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 2.
2 Connection of SGCU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Crank the engine.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 3.
B63-F8197-EZ.book Page 47 Monday, January 23, 2017 4:12 PM
8-48
FUEL INJECTION SYSTEM
Fault code No. 13
NOTICE
ECA20500
Do not remove the throttle body sensor assembly from the throttle body.
TIP
If fault code numbers “13” and “14” are both indicated, take the actions specified for fault code number
“13” first.
3 Wire harness continuity. Open or short circuit Replace
the wire harness.
Between crankshaft position
sensor coupler and SGCU cou-
pler.
White/Red–White/Red
White/Blue–White/Blue
White/Black–White/Black
White/Yellow–White/Yellow
Brown/Black–Brown/Black
Black/Blue–Black/Blue
Crank the engine.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 4.
4 Installed condition of crankshaft
position sensor.
Check for looseness or pinch-
ing.
Improperly installed sensor
Reinstall or replace the starter
generator assembly.
Refer to “STARTER GENERA-
TOR” on page 5-43.
Crank the engine.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 5.
5 Defective crankshaft position
sensor.
Replace the starter generator
assembly.
Crank the engine.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 6.
6 Malfunction in SGCU. Replace the SGCU.
Refer to “REPLACING THE
SGCU (starter generator control
unit)” on page 8-124.
Fault code No. 12
Item
Crankshaft position sensor: no normal signals are received from the
crankshaft position sensor.
Fault code No. 13
Item Intake air pressure sensor: open or short circuit detected.
Fail-safe system
Able to start engine
Able to drive vehicle
Diagnostic code No. 03
Tool display Displays the intake air pressure.
Procedure
Operate the throttle while pushing the start switch “ ”. (If the display val-
ue changes, the performance is OK.)
Item
Probable cause of malfunc-
tion and check
Maintenance job
Confirmation of service com-
pletion
B63-F8197-EZ.book Page 48 Monday, January 23, 2017 4:12 PM
FUEL INJECTION SYSTEM
8-49
1 Connection of throttle body sen-
sor assembly coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 2.
2 Connection of SGCU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 3.
3 Connection of sub-wire har-
ness coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 4.
4 Wire harness continuity. Open or short circuit Replace
the wire harness.
Between throttle body sensor
assembly coupler and SGCU
coupler.
Black/Blue–Black/Blue
Pink/White–Pink/White
Blue–Blue
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 5.
5 Installed condition of throttle
body sensor assembly.
Check for looseness or pinch-
ing.
Improperly installed sensor
Replace the throttle body.
Refer to “THROTTLE BODY” on
page 7-10.
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 6.
Fault code No. 13
Item Intake air pressure sensor: open or short circuit detected.
B63-F8197-EZ.book Page 49 Monday, January 23, 2017 4:12 PM
8-50
FUEL INJECTION SYSTEM
Fault code No. 14
NOTICE
ECA20500
Do not remove the throttle body sensor assembly from the throttle body.
TIP
If fault code numbers “13” and “14” are both indicated, take the actions specified for fault code number
“13” first.
6 Defective intake air pressure
sensor.
Execute the diagnostic mode.
(Code No. 03)
When engine is stopped:
Atmospheric pressure at the
current altitude and weather
conditions is indicated.
At sea level: Approx. 101 kPa
(757.6 mmHg, 29.8 inHg)
1000 m (3300 ft) above sea lev-
el: Approx. 90 kPa (675.1
mmHg, 26.6 inHg)
2000 m (6700 ft) above sea lev-
el: Approx. 80 kPa (600.0
mmHg, 23.6 inHg)
3000 m (9800 ft) above sea lev-
el: Approx. 70 kPa (525.0
mmHg, 20.7 inHg)
When engine is cranking: Make
sure that the indication value
changes.
The value does not change
when engine is cranking. Re-
place the throttle body if defec-
tive.
Refer to “THROTTLE BODY” on
page 7-10.
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 7.
7 Malfunction in SGCU. Replace the SGCU.
Refer to “REPLACING THE
SGCU (starter generator control
unit)” on page 8-124.
Fault code No. 13
Item Intake air pressure sensor: open or short circuit detected.
Fault code No. 14
Item
Intake air pressure sensor: system malfunction (clogged hole or de-
tached).
Fail-safe system
Able to start engine
Able to drive vehicle
Diagnostic code No. 03
Tool display Displays the intake air pressure.
Procedure
Operate the throttle while pushing the start switch “ ”. (If the display val-
ue changes, the performance is OK.)
Item
Probable cause of malfunc-
tion and check
Maintenance job
Confirmation of service com-
pletion
B63-F8197-EZ.book Page 50 Monday, January 23, 2017 4:12 PM
FUEL INJECTION SYSTEM
8-51
Fault code No. 15
NOTICE
ECA20500
Do not remove the throttle body sensor assembly from the throttle body.
1 Installed condition of throttle
body sensor assembly.
Check for looseness or pinch-
ing.
Improperly installed sensor
Replace the throttle body.
Refer to “THROTTLE BODY” on
page 7-10.
Start the engine and let it idle for
approximately 5 seconds.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 2.
2 Defective intake air pressure
sensor.
Execute the diagnostic mode.
(Code No. 03)
When engine is stopped:
Atmospheric pressure at the
current altitude and weather
conditions is indicated.
At sea level: Approx. 101 kPa
(757.6 mmHg, 29.8 inHg)
1000 m (3300 ft) above sea lev-
el: Approx. 90 kPa (675.1
mmHg, 26.6 inHg)
2000 m (6700 ft) above sea lev-
el: Approx. 80 kPa (600.0
mmHg, 23.6 inHg)
3000 m (9800 ft) above sea lev-
el: Approx. 70 kPa (525.0
mmHg, 20.7 inHg)
When engine is cranking: Make
sure that the indication value
changes.
The value does not change
when engine is cranking. Re-
place the throttle body if defec-
tive.
Refer to “THROTTLE BODY” on
page 7-10.
Fault code No. 14
Item
Intake air pressure sensor: system malfunction (clogged hole or de-
tached).
Fault code No. 15
Item Throttle position sensor: open or short circuit detected.
Fail-safe system
Able to start engine
Able to drive vehicle
Diagnostic code No. 01
Tool display
Throttle position sensor signal
• 13–21 (fully closed position)
• 97–107 (fully open position)
Procedure
• Check with throttle valves fully closed.
• Check with throttle valves fully open.
Item
Probable cause of malfunc-
tion and check
Maintenance job
Confirmation of service com-
pletion
B63-F8197-EZ.book Page 51 Monday, January 23, 2017 4:12 PM
8-52
FUEL INJECTION SYSTEM
1 Connection of throttle body sen-
sor assembly coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 2.
2 Connection of SGCU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 3.
3 Connection of sub-wire har-
ness coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 4.
4 Wire harness continuity. Open or short circuit Replace
the wire harness.
Between throttle body sensor
assembly coupler and SGCU
coupler.
Black/Blue–Black/Blue
Yellow–Yellow
Blue–Blue
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 5.
5 Installed condition of throttle
body sensor assembly.
Check for looseness or pinch-
ing.
Improperly installed sensor
Replace the throttle body.
Refer to “THROTTLE BODY” on
page 7-10.
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 6.
6 Defective throttle position sen-
sor.
Check throttle position sensor
signal.
Execute the diagnostic mode.
(Code No. 01)
When the throttle valves are ful-
ly closed:
A value of 13–21 is indicated.
When throttle valves are fully
open:
A value of 97–107 is indicated.
An indicated value is out of the
specified range Replace the
throttle body if defective.
Refer to “THROTTLE BODY” on
page 7-10.
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 7.
7 Malfunction in SGCU. Replace the SGCU.
Refer to “REPLACING THE
SGCU (starter generator control
unit)” on page 8-124.
Fault code No. 15
Item Throttle position sensor: open or short circuit detected.
B63-F8197-EZ.book Page 52 Monday, January 23, 2017 4:12 PM
FUEL INJECTION SYSTEM
8-53
Fault code No. 16
NOTICE
ECA20500
Do not remove the throttle body sensor assembly from the throttle body.
Fault code No. 21
TIP
Perform this procedure when the engine is cold.
Fault code No. 16
Item Throttle position sensor: stuck throttle position sensor is detected.
Fail-safe system
Able to start engine
Able to drive vehicle
Diagnostic code No. 01
Tool display
Throttle position sensor signal
• 13–21 (fully closed position)
• 97–107 (fully open position)
Procedure
• Check with throttle valves fully closed.
• Check with throttle valves fully open.
Item
Probable cause of malfunc-
tion and check
Maintenance job
Confirmation of service com-
pletion
1 Installed condition of throttle
body sensor assembly.
Check for looseness or pinch-
ing.
Improperly installed sensor
Replace the throttle body.
Refer to “THROTTLE BODY” on
page 7-10.
Turn the main switch to “ON”
and then open and close the
throttle valves.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 2.
2 Defective throttle position sen-
sor.
Execute the diagnostic mode.
(Code No. 01)
When the throttle valves are ful-
ly closed:
A value of 13–21 is indicated.
When throttle valves are fully
open:
A value of 97–107 is indicated.
An indicated value is out of the
specified range Replace the
throttle body.
Refer to “THROTTLE BODY” on
page 7-10.
Turn the main switch to “ON”
and then open and close the
throttle valves.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 3.
3 Malfunction in SGCU. Replace the SGCU.
Refer to “REPLACING THE
SGCU (starter generator control
unit)” on page 8-124.
Fault code No. 21
Item Coolant temperature sensor: open or short circuit detected.
Fail-safe system
Able to start engine
Able to drive vehicle
Diagnostic code No. 06
Tool display
When engine is cold: Displays temperature closer to air temperature.
When engine is hot: Displays current coolant temperature.
B63-F8197-EZ.book Page 53 Monday, January 23, 2017 4:12 PM
8-54
FUEL INJECTION SYSTEM
Procedure
Compare the actually measured coolant temperature with the computer
display value.
Item
Probable cause of malfunc-
tion and check
Maintenance job
Confirmation of service com-
pletion
1 Connection of coolant tempera-
ture sensor coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 2.
2 Connection of SGCU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 3.
3 Wire harness continuity. Open or short circuit Replace
the wire harness.
Between coolant temperature
sensor coupler and SGCU cou-
pler.
Green/Red–Green/Red
Black/Blue–Black/Blue
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 4.
4 Installed condition of coolant
temperature sensor.
Check for looseness or pinch-
ing.
Improperly installed sensor
Reinstall or replace the sensor.
Refer to “CYLINDER HEAD” on
page 5-9.
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 5.
5 Defective coolant temperature
sensor.
Execute the diagnostic mode.
(Code No. 06)
When engine is cold:
Displayed temperature is close
to the ambient temperature.
The displayed temperature is
not close to the ambient temper-
ature Check the coolant tem-
perature sensor.
Replace if defective.
Refer to “CHECKING THE
COOLANT TEMPERATURE
SENSOR” on page 8-132.
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 6.
6 Malfunction in SGCU. Replace the SGCU.
Refer to “REPLACING THE
SGCU (starter generator control
unit)” on page 8-124.
Fault code No. 21
Item Coolant temperature sensor: open or short circuit detected.
B63-F8197-EZ.book Page 54 Monday, January 23, 2017 4:12 PM
FUEL INJECTION SYSTEM
8-55
Fault code No. 22
NOTICE
ECA20500
Do not remove the throttle body sensor assembly from the throttle body.
TIP
Perform this procedure when the engine is cold.
Fault code No. 22
Item Intake air temperature sensor: open or short circuit detected.
Fail-safe system
Able to start engine
Able to drive vehicle
Diagnostic code No. 05
Tool display Displays the intake air temperature.
Procedure
When engine is cold: Displays temperature closer to air temperature
When engine is hot: Air temperature + approx. 20 °C (68 °F)
Item
Probable cause of malfunc-
tion and check
Maintenance job
Confirmation of service com-
pletion
1 Connection of throttle body sen-
sor assembly coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 2.
2 Connection of SGCU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 3.
3 Wire harness continuity. Open or short circuit Replace
the wire harness.
Between throttle body sensor
assembly coupler and SGCU
coupler.
Black/Blue–Black/Blue
Brown/White–Brown/White
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 4.
4 Installed condition of throttle
body sensor assembly.
Check for looseness or pinch-
ing.
Improperly installed sensor
Replace the throttle body.
Refer to “THROTTLE BODY” on
page 7-10.
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 5.
5 Defective intake air tempera-
ture sensor.
Execute the diagnostic mode.
(Code No. 05)
When engine is cold:
Displayed temperature is close
to the ambient temperature.
The displayed temperature is
not close to the ambient temper-
ature. Replace the throttle
body if defective.
Refer to “THROTTLE BODY” on
page 7-10.
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 6.
B63-F8197-EZ.book Page 55 Monday, January 23, 2017 4:12 PM
8-56
FUEL INJECTION SYSTEM
Fault code No. 24
6 Malfunction in SGCU. Replace the SGCU.
Refer to “REPLACING THE
SGCU (starter generator control
unit)” on page 8-124.
Fault code No. 22
Item Intake air temperature sensor: open or short circuit detected.
Fault code No. 24
Item
O
2
sensor: no normal signals are received from the O
2
sensor.
Fail-safe system
Able to start engine
Able to drive vehicle
Diagnostic code No. —
Tool display —
Procedure —
Item
Probable cause of malfunc-
tion and check
Maintenance job
Confirmation of service com-
pletion
1 Installed condition of O
2
sensor.
Check for looseness or pinch-
ing.
Improperly installed sensor
Replace the sensor.
Refer to “ENGINE REMOVAL”
on page 5-3.
Start the engine, warm it up,
and then race it, or execute the
diagnostic mode. (Code No. 62)
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 2.
2 Connection of O
2
sensor cou-
pler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Start the engine, warm it up,
and then race it, or execute the
diagnostic mode. (Code No. 62)
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 3.
3 Connection of SGCU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Start the engine, warm it up,
and then race it, or execute the
diagnostic mode. (Code No. 62)
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 4.
4 Wire harness continuity. Open or short circuit Replace
the wire harness.
Between O
2
sensor coupler and
SGCU coupler.
Gray/Red–Gray/Red
Start the engine, warm it up,
and then race it, or execute the
diagnostic mode. (Code No. 62)
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 5.
5 Check fuel pressure. Refer to “CHECKING THE
FUEL PRESSURE” on page
7-3.
Start the engine, warm it up,
and then race it, or execute the
diagnostic mode. (Code No. 62)
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 6.
B63-F8197-EZ.book Page 56 Monday, January 23, 2017 4:12 PM
FUEL INJECTION SYSTEM
8-57
Fault code No. 37
TIP
• If fault code numbers “37” and “46” are both indicated, take the actions specified for fault code number
“46” first.
• If fault code numbers “37” and “42” are both indicated, take the actions specified for fault code number
“42” first.
• If fault code numbers “37” and “61” are both indicated, take the actions specified for fault code number
“61” first.
6 Defective O
2
sensor. Check the O
2
sensor.
Replace if defective.
Refer to “ENGINE REMOVAL”
on page 5-3.
Start the engine, warm it up,
and then race it, or execute the
diagnostic mode. (Code No. 62)
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 7.
7 Malfunction in SGCU. Replace the SGCU.
Refer to “REPLACING THE
SGCU (starter generator control
unit)” on page 8-124.
Fault code No. 24
Item
O
2
sensor: no normal signals are received from the O
2
sensor.
Fault code No. 37
Item
A
Component other than ISC (idle speed control) unit is defec-
tive (ISC operating sound is heard).
B
Defective ISC (idle speed control) unit (ISC operating sound is
not heard).
Fail-safe system
Able to start engine
Able to drive vehicle
Diagnostic code No. 54
Actuation
Fully closes the ISC valve, and then opens the valve. This operation
takes approximately 3 seconds.
Procedure The ISC unit vibrates when the ISC valve operates.
Item
Probable cause of malfunc-
tion and check
Maintenance job
Confirmation of service com-
pletion
A-1 Locate the malfunction. Execute the diagnostic mode.
(Code No. 54)
Fully closes the ISC (idle speed
control) valve, and then opens
the valve. This operation takes
approximately 3 seconds.
ISC operating sound is heard
Go to item A-2.
ISC operating sound is not
heard Go to item B-2 for the
defective ISC (idle speed con-
trol) unit.
A-2 Incorrect front wheel sensor sig-
nal.
Check the front wheel sensor.
Execute the diagnostic mode.
(Code No. 07)
Rotate the front wheel by hand
and check that the indicated val-
ue increases.
Value does not increase Go
to fault code No. 42.
Start the engine and let it idle for
approximately 10 seconds.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item A-3.
B63-F8197-EZ.book Page 57 Monday, January 23, 2017 4:12 PM
8-58
A-3 Throttle valve does not fully
close due to malfunction in
throttle cables.
Check the throttle grip free play.
Refer to “CHECKING THE
THROTTLE GRIP OPERA-
TION” on page 3-23.
Start the engine and let it idle for
approximately 10 seconds.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item A-4.
A-4 Air leak from the throttle body. Check the throttle body.
Refer to “CHECKING THE
THROTTLE BODY” on page 7-
12.
Start the engine and let it idle for
approximately 10 seconds.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item A-5.
A-5 Air leak from the ISC (idle speed
control) unit.
Improperly installed ISC (idle
speed control) unit Reinstall
the ISC (idle speed control) unit.
Check the intake air passages
for air leaks.
Start the engine and let it idle for
approximately 10 seconds.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item A-6.
A-6 The air volume for the throttle
body and ISC (idle speed con-
trol) unit is excessive.
Clean the throttle body and ISC
(idle speed control) unit.
Refer to “CLEANING THE ISC
(IDLE SPEED CONTROL) UNIT
AND THROTTLE BODY” on
page 7-12.
Start the engine and let it idle for
approximately 10 seconds.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item A-7.
A-7 ISC (idle speed control) unit is
not moving correctly.
Replace the ISC (idle speed
control) unit.
Refer to “CLEANING THE ISC
(IDLE SPEED CONTROL) UNIT
AND THROTTLE BODY” on
page 7-12.
Start the engine and let it idle for
approximately 10 seconds.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item A-8.
A-8 Malfunction in SGCU. Replace the SGCU.
Refer to “REPLACING THE
SGCU (starter generator control
unit)” on page 8-124.
Fault code No. 37
Item
A
Component other than ISC (idle speed control) unit is defec-
tive (ISC operating sound is heard).
B
Defective ISC (idle speed control) unit (ISC operating sound is
not heard).
Fail-safe system
Able to start engine
Able to drive vehicle
Diagnostic code No. 54
Actuation
Fully closes the ISC valve, and then opens the valve. This operation
takes approximately 3 seconds.
Procedure The ISC unit vibrates when the ISC valve operates.
Fault code No. 37
Item
A
Component other than ISC (idle speed control) unit is defec-
tive (ISC operating sound is heard).
B
Defective ISC (idle speed control) unit (ISC operating sound is
not heard).
FUEL INJECTION SYSTEM
chapterbody8 Page 58 Monday, January 23, 2017 4:34 PM
FUEL INJECTION SYSTEM
8-59
Item
Probable cause of malfunc-
tion and check
Maintenance job
Confirmation of service com-
pletion
B-1 Locate the malfunction. Execute the diagnostic mode.
(Code No. 54)
Fully closes the ISC (idle speed
control) valve, and then opens
the valve. This operation takes
approximately 3 seconds.
ISC operating sound is heard
Go to item A-2 for the compo-
nent other than ISC (idle speed
control) unit is defective.
ISC operating sound is not
heard Go to item B-2.
B-2 Connection of ISC (idle speed
control) unit coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Execute the diagnostic mode.
(Code No. 54)
ISC operating sound is heard
Go to item B-9 and delete the
fault code.
ISC operating sound is not
heard Go to item B-3.
B-3 Connection of SGCU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Execute the diagnostic mode.
(Code No. 54)
ISC operating sound is heard
Go to item B-9 and delete the
fault code.
ISC operating sound is not
heard Go to item B-4.
B-4 Wire harness continuity. Open or short circuit Replace
the wire harness.
Between ISC (idle speed con-
trol) unit coupler and SGCU
coupler.
Pink–Pink
Green/Yellow–Green/Yellow
Gray–Gray
Sky blue–Sky blue
Execute the diagnostic mode.
(Code No. 54)
ISC operating sound is heard
Go to item B-9 and delete the
fault code.
ISC operating sound is not
heard Go to item B-5.
B-5 Installed condition of ISC (idle
speed control) unit.
Check for looseness or pinch-
ing.
Improperly installed ISC (idle
speed control) unit Reinstall
the ISC (idle speed control) unit.
Check the intake air passages
for air leaks.
Execute the diagnostic mode.
(Code No. 54)
ISC operating sound is heard
Go to item B-9 and delete the
fault code.
ISC operating sound is not
heard Go to item B-6.
B-6 Battery malfunction Check the battery voltage.
Refer to “CLEANING THE ISC
(IDLE SPEED CONTROL) UNIT
AND THROTTLE BODY” on
page 7-12.
Execute the diagnostic mode.
(Code No. 54)
ISC operating sound is heard
Go to item B-9 and delete the
fault code.
ISC operating sound is not
heard Go to item B-7.
Fault code No. 37
Item
A
Component other than ISC (idle speed control) unit is defec-
tive (ISC operating sound is heard).
B
Defective ISC (idle speed control) unit (ISC operating sound is
not heard).
B63-F8197-EZ.book Page 59 Monday, January 23, 2017 4:12 PM
8-60
FUEL INJECTION SYSTEM
Fault code No. 39
B-7 ISC (idle speed control) unit is
not moving correctly.
Replace the ISC (idle speed
control) unit.
Refer to “CLEANING THE ISC
(IDLE SPEED CONTROL) UNIT
AND THROTTLE BODY” on
page 7-12.
Execute the diagnostic mode.
(Code No. 54)
ISC operating sound is heard
Go to item B-9 and delete the
fault code.
ISC operating sound is not
heard Go to item B-8.
B-8 Malfunction in SGCU. Replace the SGCU.
Refer to “REPLACING THE
SGCU (starter generator control
unit)” on page 8-124.
Execute the diagnostic mode.
(Code No. 54)
Return the ISC (idle speed con-
trol) valve to the initial opening
position.
B-9 Delete the fault code. Start the engine and let it idle for
approximately 10 seconds.
Check that the fault code num-
ber is not displayed.
Fault code No. 37
Item
A
Component other than ISC (idle speed control) unit is defec-
tive (ISC operating sound is heard).
B
Defective ISC (idle speed control) unit (ISC operating sound is
not heard).
Fault code No. 39
Item Fuel injector: open or short circuit detected.
Fail-safe system
Unable to start engine.
Unable to drive vehicle.
Diagnostic code No. 36
Actuation
Actuates fuel injector five times at one-second intervals.
The “ ” and “CHECK” indicator on the Yamaha diagnostic tool screen
comes on each time the fuel injector is actuated.
Procedure
Disconnect the fuel pump coupler. Check that fuel injector is actuated
five times by listening for the operating sound.
Item
Probable cause of malfunc-
tion and check
Maintenance job
Confirmation of service com-
pletion
1 Connection of fuel injector cou-
pler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Execute the diagnostic mode.
(Code No. 36)
Operating sound Go to item
7.
No operating sound Go to
item 2.
2 Defective fuel injector. Measure the fuel injector resis-
tance.
Replace if out of specification.
Refer to “CHECKING THE
FUEL INJECTOR” on page
8-132.
Execute the diagnostic mode.
(Code No. 36)
Operating sound Go to item
7.
No operating sound Go to
item 3.
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FUEL INJECTION SYSTEM
8-61
Fault code No. 42 (GDR155)
3 Connection of SGCU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Execute the diagnostic mode.
(Code No. 36)
Operating sound Go to item
7.
No operating sound Go to
item 4.
4 Connection of sub-wire har-
ness coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Execute the diagnostic mode.
(Code No. 36)
Operating sound Go to item
7.
No operating sound Go to
item 5.
5 Wire harness continuity. Open or short circuit Replace
the wire harness.
Between fuel injector coupler
and SGCU coupler.
Orange/Black–Orange/Black
Between fuel injector coupler
and main switch coupler.
Brown–Brown
Execute the diagnostic mode.
(Code No. 36)
Operating sound Go to item
7.
No operating sound Go to
item 6.
6 Malfunction in SGCU. Replace the SGCU.
Refer to “REPLACING THE
SGCU (starter generator control
unit)” on page 8-124.
7 Delete the fault code. Start the engine and let it idle for
approximately 5 seconds.
Check that the fault code num-
ber is not displayed.
Fault code No. 39
Item Fuel injector: open or short circuit detected.
Fault code No. 42
Item
Front wheel sensor: no normal signals are received from the front
wheel sensor.
Fail-safe system
Able to start engine
Able to drive vehicle
Diagnostic code No. 07
Tool display
Front wheel sensor pulse
0–999
Procedure
Check that the number increases when the front wheel is rotated. The
number is cumulative and does not reset each time the wheel is stopped.
Item
Probable cause of malfunc-
tion and check
Maintenance job
Confirmation of service com-
pletion
B63-F8197-EZ.book Page 61 Monday, January 23, 2017 4:12 PM
8-62
FUEL INJECTION SYSTEM
Fault code No. 42 (GDR155-A)
1 Connection of front wheel sen-
sor coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Turn the main switch to “ON”
and rotate the front wheel by
hand.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 2.
2 Connection of SGCU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Turn the main switch to “ON”
and rotate the front wheel by
hand.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 3.
3 Wire harness continuity. Open or short circuit Replace
the wire harness.
Between front wheel sensor
coupler and SGCU coupler.
White–White
Red/Blue–Red/Blue
Turn the main switch to “ON”
and rotate the front wheel by
hand.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 4.
4 Defective front wheel sensor. Installed condition of front wheel
sensor.
Check the front wheel sensor.
Execute the diagnostic mode.
(Code No. 07)
Front wheel stop: The pulse in-
tegrated value should be con-
stant.
Rotate the front wheel by hand
and check that the indicated val-
ue increases.
Value does not increase Re-
place the front wheel sensor.
Turn the main switch to “ON”
and rotate the front wheel by
hand.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 5.
5 Malfunction in SGCU. Replace the SGCU.
Refer to “REPLACING THE
SGCU (starter generator control
unit)” on page 8-124.
Fault code No. 42
Item
Front wheel sensor: no normal signals are received from the front
wheel sensor.
Fault code No. 42
Item
Front wheel sensor: no normal signals are received from the front
wheel sensor.
Fail-safe system
Able to start engine
Able to drive vehicle
Diagnostic code No. 07
Tool display
Front wheel sensor pulse
0–999
Procedure
Check that the number increases when the front wheel is rotated. The
number is cumulative and does not reset each time the wheel is stopped.
B63-F8197-EZ.book Page 62 Monday, January 23, 2017 4:12 PM
FUEL INJECTION SYSTEM
8-63
Item
Probable cause of malfunc-
tion and check
Maintenance job
Confirmation of service com-
pletion
1 Connection of front wheel sen-
sor coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Execute the diagnostic mode.
(Code No. 07)
Rotate the front wheel by hand
and check that the indicated val-
ue increases.
Value increases Go to item 7
and delete the fault code.
Value does not increase Go
to item 2.
2 Connection of ABS ECU cou-
pler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Execute the diagnostic mode.
(Code No. 07)
Rotate the front wheel by hand
and check that the indicated val-
ue increases.
Value increases Go to item 7
and delete the fault code.
Value does not increase Go
to item 3.
3 Connection of SGCU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Execute the diagnostic mode.
(Code No. 07)
Rotate the front wheel by hand
and check that the indicated val-
ue increases.
Value increases Go to item 7
and delete the fault code.
Value does not increase Go
to item 4.
4 Front wheel sensor lead conti-
nuity or detective front wheel
sensor.
Open or short circuit or detec-
tive front wheel sensor Re-
place the front wheel sensor.
Between front wheel sensor
coupler and ABS ECU coupler.
Green –Green
Blue–Blue
Between ABS ECU coupler and
SGCU coupler.
White–White
Execute the diagnostic mode.
(Code No. 07)
Rotate the front wheel by hand
and check that the indicated val-
ue increases.
Value increases Go to item 7
and delete the fault code.
Value does not increase Go
to item 5.
5 Malfunction in SGCU. Replace the SGCU.
Refer to “REPLACING THE
SGCU (starter generator control
unit)” on page 8-124.
Execute the diagnostic mode.
(Code No. 07)
Rotate the front wheel by hand
and check that the indicated val-
ue increases.
Value increases Go to item 7
and delete the fault code.
Value does not increase Go
to item 6.
6 Malfunction in ABS ECU. Replace the hydraulic unit as-
sembly.
Refer to “ABS (ANTI-LOCK
BRAKE SYSTEM)” on page
8-79.
Go to item 7 and delete the fault
code.
Fault code No. 42
Item
Front wheel sensor: no normal signals are received from the front
wheel sensor.
B63-F8197-EZ.book Page 63 Monday, January 23, 2017 4:12 PM
8-64
FUEL INJECTION SYSTEM
Fault code No. 44
Fault code No. 46
7 Turn the main switch to “ON”
and then rotate the front wheel
by hand.
Check that the fault code num-
ber is not displayed.
Fault code No. 42
Item
Front wheel sensor: no normal signals are received from the front
wheel sensor.
Fault code No. 44
Item
EEPROM fault code number: an error is detected while reading or
writing on EEPROM.
Fail-safe system
Able/Unable to start engine
Able/Unable to drive vehicle
Diagnostic code No. 60
Tool display
EEPROM fault code display
• 00 (no history): No malfunctions detected (If the self-diagnosis fault
code 44 is indicated, the SGCU is defective.)
• 11: ISC (idle speed control) learning is being carried out.
Procedure —
Item
Probable cause of malfunc-
tion and check
Maintenance job
Confirmation of service com-
pletion
1 Locate the malfunction Execute the diagnostic mode.
(Code No. 60)
00: Go to item 3.
11: Go to item 2.
2 “11” is indicated in diagnostic
mode (code No. 60). Flash
memory data error for ISC (idle
speed control) control values.
Turn the main switch to “OFF”. Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Repeat item 1. If the same
number is indicated, go to item
3.
3 Malfunction in SGCU. Replace the SGCU.
Refer to “REPLACING THE
SGCU (starter generator control
unit)” on page 8-124.
Fault code No. 46
Item Charging voltage is abnormal.
Fail-safe system
Able to start engine
Able to drive vehicle
Diagnostic code No. —
Tool display —
Procedure —
Item
Probable cause of malfunc-
tion and check
Maintenance job
Confirmation of service com-
pletion
B63-F8197-EZ.book Page 64 Monday, January 23, 2017 4:12 PM
FUEL INJECTION SYSTEM
8-65
Fault code No. 50
Fault code No. 61
1 Malfunction in charging system. Check the charging system.
Refer to “CHARGING SYSTEM”
on page 8-21.
Defective starter generator or
SGCU Replace.
Defective connection in the
charging system circuit Prop-
erly connect or replace the wire
harness.
Start the engine and let it idle for
approximately 5 seconds.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Repeat the maintenance job.
Fault code No. 46
Item Charging voltage is abnormal.
Fault code No. 50
Item
Faulty SGCU memory. (When this malfunction is detected in the
SGCU, the fault code number might not appear on the tool display.)
Fail-safe system
Unable to start engine
Unable to drive vehicle
Diagnostic code No. —
Tool display —
Procedure —
Item
Probable cause of malfunc-
tion and check
Maintenance job
Confirmation of service com-
pletion
1 Malfunction in SGCU. Replace the SGCU.
Refer to “REPLACING THE
SGCU (starter generator control
unit)” on page 8-124.
Turn the main switch to “ON”.
Check that the fault code num-
ber is not displayed.
Fault code No. 61
Item ISC (idle speed control) unit: open or short circuit detected.
Fail-safe system
Able to start engine
Able to drive vehicle
Diagnostic code No. –
Action –
Procedure –
Item
Probable cause of malfunc-
tion and check
Maintenance job
Confirmation of service com-
pletion
1 Connection of ISC unit coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Set the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 2.
B63-F8197-EZ.book Page 65 Monday, January 23, 2017 4:12 PM
8-66
FUEL INJECTION SYSTEM
Fault code No. 84
2 Connection of wire harness
SGCU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Set the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 3.
3 Wire harness continuity. Open or short circuit Replace
the wire harness.
Between ISC unit coupler and
SGCU coupler.
Pink–Pink
Green/Yellow–Green/Yellow
Gray–Gray
Sky blue–Sky blue
Set the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 4.
4 Faulty ISC unit operation. Execute the diagnostic mode.
(Code No. D54)
ISC unit operation sound is not
heard. Replace the ISC unit.
Refer to “CLEANING THE ISC
(IDLE SPEED CONTROL)
UNIT AND THROTTLE BODY”
on page 7-12.
Set the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 5.
5 Malfunction in SGCU Replace the SGCU.
Refer to “REPLACING THE
SGCU (starter generator control
unit)” on page 8-124.
Fault code No. 61
Item ISC (idle speed control) unit: open or short circuit detected.
Fault code No. 84
Item
VVA (variable valve actuator) solenoid: open or short circuit detect-
ed.
Fail-safe system
Able to start engine
Able to drive vehicle
Diagnostic code No. 45
Action
Actuates the VVA (variable valve actuator) solenoid five times at five-sec-
ond intervals. The “ ” and “CHECK” indicator on the Yamaha diagnos-
tic tool screen come on each time the VVA (variable valve actuator)
solenoid is actuated.
Procedure
Remove the VVA (variable valve actuator) solenoid from the cylinder
head, and then connect the VVA (variable valve actuator) solenoid cou-
pler.
Refer to “CYLINDER HEAD” on page 5-9.
Visually check that the VVA (variable valve actuator) solenoid is actuated
five times.
Item
Probable cause of malfunc-
tion and check
Maintenance job
Confirmation of service com-
pletion
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FUEL INJECTION SYSTEM
8-67
Fault code No. Er-1 (fault code display)
1 Connection of VVA (variable
valve actuator) solenoid coupler.
Check the locking condition of
the coupler. Disconnect the cou-
pler and check the pins (bent or
broken terminals and locking
condition of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Set the main switch to “ON”.
Start the engine and accelerate
to 6000 r/min.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 2.
2 Connection of wire harness
SGCU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Set the main switch to “ON”.
Start the engine and accelerate
to 6000 r/min.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 3.
3 Wire harness continuity. Open or short circuit Replace
the wire harness.
Between VVA (variable valve
actuator) solenoid coupler and
SGCU coupler.
Green–Green
Chocolate-Chocolate
Between engine ground and
SGCU coupler.
Black/Red–Black/Red
Set the main switch to “ON”.
Start the engine and accelerate
to 6000 r/min.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 4.
4 Defective VVA (variable valve
actuator) solenoid.
Measure the VVA (variable
valve actuator) solenoid resis-
tance.
Replace it out of specification.
Refer to “CHECKING THE VVA
SOLENOID” on page 8-133.
Set the main switch to “ON”.
Start the engine and accelerate
to 6000 r/min.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 5.
5 Malfunction in SGCU. Replace the SGCU.
Refer to “REPLACING THE
SGCU (starter generator control
unit)” on page 8-124.
Fault code No. 84
Item
VVA (variable valve actuator) solenoid: open or short circuit detect-
ed.
Fault code No. Er-1 (fault code display)
Item
SGCU (starter generator control unit) internal malfunction (output
signal error): signals cannot be transmitted between the SGCU and
the multi-function meter.
Fail-safe system
Able to start engine (unable when SGCU is malfunctioning)
Able to drive vehicle (unable when SGCU is malfunctioning)
Diagnostic code No. —
Tool display —
Procedure —
Item
Probable cause of malfunc-
tion and check
Maintenance job
Confirmation of service com-
pletion
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8-68
FUEL INJECTION SYSTEM
Fault code No. Er-2
1 Connection of meter assembly
coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 2.
2 Connection of wire harness
SGCU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 3.
3 Wire harness continuity. Open or short circuit Replace
the wire harness.
Between SGCU coupler and Ya-
maha diagnostic tool coupler.
Yellow/Blue–Yellow/Blue
Between Yamaha diagnostic
tool coupler and meter assem-
bly coupler.
Yellow/Blue–Yellow/Blue
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 4.
4 Defective meter assembly. Replace the meter assembly. Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 5.
5 Malfunction in SGCU. Replace the SGCU.
Refer to “REPLACING THE
SGCU (starter generator control
unit)” on page 8-124.
Fault code No. Er-1 (fault code display)
Item
SGCU (starter generator control unit) internal malfunction (output
signal error): signals cannot be transmitted between the SGCU and
the multi-function meter.
Fault code No. Er-2
Item
SGCU (starter generator control unit) internal malfunction (output
signal error): no signals are received from the SGCU within the spec-
ified duration.
Fail-safe system
Able to start engine
Able to drive vehicle
Diagnostic code No. —
Tool display —
Procedure —
Item
Probable cause of malfunc-
tion and check
Maintenance job
Confirmation of service com-
pletion
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FUEL INJECTION SYSTEM
8-69
Fault code No. Er-3
1 Connection of meter assembly
coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 2.
2 Connection of wire harness
SGCU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 3.
3 Wire harness continuity. Open or short circuit Replace
the wire harness.
Between SGCU coupler and Ya-
maha diagnostic tool coupler.
Yellow/Blue–Yellow/Blue
Between Yamaha diagnostic
tool coupler and meter assem-
bly coupler.
Yellow/Blue–Yellow/Blue
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 4.
4 Defective meter assembly. Replace the meter assembly. Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 5.
5 Malfunction in SGCU. Replace the SGCU.
Refer to “REPLACING THE
SGCU (starter generator control
unit)” on page 8-124.
Fault code No. Er-2
Item
SGCU (starter generator control unit) internal malfunction (output
signal error): no signals are received from the SGCU within the spec-
ified duration.
Fault code No. Er-3
Item
SGCU (starter generator control unit) internal malfunction (output
signal error): data from the SGCU cannot be received correctly.
Fail-safe system
Able to start engine
Able to drive vehicle
Diagnostic code No. —
Tool display —
Procedure —
Item
Probable cause of malfunc-
tion and check
Maintenance job
Confirmation of service com-
pletion
B63-F8197-EZ.book Page 69 Monday, January 23, 2017 4:12 PM
8-70
FUEL INJECTION SYSTEM
Fault code No. Er-4 (fault code display)
1 Connection of meter assembly
coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 2.
2 Connection of wire harness
SGCU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 3.
3 Wire harness continuity. Open or short circuit Replace
the wire harness.
Between SGCU coupler and Ya-
maha diagnostic tool coupler.
Yellow/Blue–Yellow/Blue
Between Yamaha diagnostic
tool coupler and meter assem-
bly coupler.
Yellow/Blue–Yellow/Blue
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 4.
4 Defective meter assembly. Replace the meter assembly. Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 5.
5 Malfunction in SGCU. Replace the SGCU.
Refer to “REPLACING THE
SGCU (starter generator control
unit)” on page 8-124.
Fault code No. Er-3
Item
SGCU (starter generator control unit) internal malfunction (output
signal error): data from the SGCU cannot be received correctly.
Fault code No. Er-4 (fault code display)
Item
SGCU (starter generator control unit) internal malfunction (input sig-
nal error): non-registered data has been received from the meter.
Fail-safe system
Able to start engine
Able to drive vehicle
Diagnostic code No. —
Tool display —
Procedure —
Item
Probable cause of malfunc-
tion and check
Maintenance job
Confirmation of service com-
pletion
B63-F8197-EZ.book Page 70 Monday, January 23, 2017 4:12 PM
FUEL INJECTION SYSTEM
8-71
1 Connection of meter assembly
coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 2.
2 Connection of wire harness
SGCU coupler.
Check the locking condition of
the coupler.
Disconnect the coupler and
check the pins (bent or broken
terminals and locking condition
of the pins).
Improperly connected Con-
nect the coupler securely or re-
place the wire harness.
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 3.
3 Wire harness continuity. Open or short circuit Replace
the wire harness.
Between SGCU coupler and Ya-
maha diagnostic tool coupler.
Yellow/Blue–Yellow/Blue
Between Yamaha diagnostic
tool coupler and meter assem-
bly coupler.
Yellow/Blue–Yellow/Blue
Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 4.
4 Defective meter assembly. Replace the meter assembly. Turn the main switch to “ON”.
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 5.
5 Malfunction in SGCU. Replace the SGCU.
Refer to “REPLACING THE
SGCU (starter generator control
unit)” on page 8-124.
Fault code No. Er-4 (fault code display)
Item
SGCU (starter generator control unit) internal malfunction (input sig-
nal error): non-registered data has been received from the meter.
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8-72
FUEL INJECTION SYSTEM
B63-F8197-EZ.book Page 72 Monday, January 23, 2017 4:12 PM
FUEL PUMP SYSTEM
8-73
EAS20081
FUEL PUMP SYSTEM
EAS30513
CIRCUIT DIAGRAM (GDR155)
ON
OPEN
OFF
LOCK
L
PUSH
R
ON
OFF
HI
LO
PUSH
FREE
PUSH
FREE
B
W/R
Br
R
G/W
Br
R/Y
R
R
Br/R
R/W,B r
B/W,B
(B)
Br/R
R
Y/R
Br
R/B
RWG
R/YR/L
R/W
(B)
B/LG/R
(B)
B/L
Y L
P/WBr/W
Gy/R
(B)
B
(B)
(B)
G/Y
W/R
B/Y
O
P
O/B
G
B/W
W/L
Ch
Sb Y
B
/
L
Br/B
R/B
Gy
B/L
W/B
L
W/Y
R
Br/W
B
P/WR/W
L/Y
B/L
G/R
Y/LB/R
Gy/R
L/B
R/L
W
B
Y/BY/R
GWR
G
L/Y
W/R
Br/B
W/L
W/B
(B)
W/R
W/LBr/B
W/Y
B/L
W/B
(B)
(B)
P
G/Y
Sb Gy
Br
(B)
O/B
(Gy)
G
Ch
B/W
R
Y/L Y/L
(B)
R
B/Y
(Gy)
G
B/W
R/L
W
W
B
B/YBr
(B)
BB
Br B
BBr
B
B
(L)
L/Y
B
(L)
Br
Br/W
(R)
L
Y/R
B/Y
L/B
B
L/W
(R)
Br
G
(L)
Dg
Ch
Br/W
(R)
Y
L
(R)
L/B
Y
(L)
Br/W
Ch
Dg
(B)
B
Dg
Ch
(B)
Ch
Dg
B
P
B
P
B
Br
B
L
B
L
Y
B
(B)
YBr
B
Br
Y/B
R
Y
BChDg
Y/L
B/W
G
(Gy)
Y
G
B
GY
Y/B
Br
R
R
R
B
B
R
Br/R
Br
Br
R
B
Br/R
B/W
Br/R
Br/R
RBr
Br
Br Br
Br
Br
Br
Br
Br
Br
R
R
R
R
R
RR
RR
R
B
B
B
BBBB
B
B
B
BBBB
G/W
G/W
R/Y
Br
R/W
R/B
Y/R
Br/R
Br/R
W/R
W/R
R/W
R/Y
R/W
R/L
P/W
Br/W
Gy/RGy/R
L/B
L/Y
G/R
B/L
G/R
B/L
B/L
L
B
Y
P/W
Br/W
B/L
L
Y
W
R
R
W/R
W/L
W/B
W/Y
Br/B
B/L
G/Y
Gy
Sb
O/B
B/Y B/Y
R
G
B/W
Ch
Y/LY/LY/L
R
B/W
R/B
Y/R
Y/B
Y/B
B/R
B/R
B/W
O
G
O
Br
P
G
W
R/L
W
R/L
B
W
B/Y
B/Y
B/Y
L/BL/B
B/Y
B/Y
B
B
B
B
Br
Br
Br
Br
Br
Br
P
PL
Br/W
Br/W
DgCh
Ch
Ch
Ch Ch
Dg
Ch Dg
YBr Br
B
B
BB
B
LL
B
Ch Dg
Dg
Dg Dg
BY
Y
Y
Y
YG
L/B
Br
Br Br
B/YB/Y
Y
W/R
W/L
W/B
W/Y
Br/B
B/L
L/Y
G/Y
Gy
Sb
O/B
Br
Ch
P
G
B
B
B
B/W
G
W
R
G
L/Y
B
L/B
G
L/W
L
B
Y/R
B/Y
Br
Br
Br Br
B
B
B
B
B
Br
G
L
G
B
B
B
B
B
Br Br
Br
Y/B
B
Y/B
B/W
Y/L
RChDgY
Br G
B
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
25
26
27
28
29
30
31
32
33
34
35 35
63
24
3637
38
39
40 41 42 43 44 45
46
47
48
49 50 51
52
53
54 5556575859
6061
62
B63-F8197-EZ.book Page 73 Monday, January 23, 2017 4:12 PM
8-74
FUEL PUMP SYSTEM
1. Battery
2. Main fuse
3. Fuel injection system fuse
5. Ignition fuse
10.Main switch
25.SGCU (starter generator control unit)
31.Fuel pump
35.Engine ground 2
63.Engine ground 1
B63-F8197-EZ.book Page 74 Monday, January 23, 2017 4:12 PM
FUEL PUMP SYSTEM
8-75
EASB631011
CIRCUIT DIAGRAM (GDR155-A)
ON
OPEN
OFF
LOCK
L
PUSH
R
ON
OFF
HI
LO
PUSH
FREE
PUSH
FREE
ON
OFF
B
W/R
B
B/Y
B
L
R/W
B
(B)
R/W
B
(B)
Br
R
G/W
Br
R/Y
R
(B)
ChB
L/Y
R/BY/L
G/W
Dg
R/W
Br
W/R
B/Y
R
R/B
R
R
Br/R
R/W,B r
B/W,B
B
R
(B)
Br/R
R
Y/R
Br
R/B
RWG
R/YR/L
R/W
(B)
B/LG/R
(B)
B/L
Y L
P/WBr/W
Gy/R
(B)
B
(B)
(B)
G/Y
W/R
B/Y
O
P
O/B
G
B/W
W/L
Ch
Sb Y
B
/
L
Br/B
R/B
Gy
B/L
W/B
L
W/Y
R
Br/W
B
P/WR/W
L/B
B/L
G/R
Y/LB/R
Gy/R
L/Y
W/G
W
B
Y/BY/R
GWR
G
L/Y
W/R
Br/B
W/L
W/B
(B)
W/R
W/LBr/B
W/Y
B/L
W/B
(B)
(B)
P
G/Y
Sb Gy
Br
(B)
O/B
(Gy)
G
Ch
B/W
R
Y/L Y/L
(B)
R
B/Y
(Gy)
G
B/W
LG
W
B
L/RL/B
RB
R
L/RL/BY/L
B/W
R/LB/Y
Br
W/L
LGWB
B/Y
Br
(B)
BB
Br B
BBr
B
B
(L)
L/Y
B
(L)
Br
Br/W
Br/B
Br/W
(R)
L
Y/R
B/Y
L/B
(B)
B
W/G
B
L/W
(B)
B/W
Y/W
(R)
Br
G
(L)
Dg
Ch
Br/W
(R)
Y
L
(R)
L/B
Y
(L)
Br/B
Ch
Dg
(B)
B
Dg
Ch
(B)
Ch
Dg
B
P
B
P
B
Br
B
L
B
L
Y
B
(B)
YBr
B
Br
W/R
Y/B
R
Y
BCh
W/L
Dg
Y/L
B/W
G
(Gy)
Y
G
B
GY
Y/B
R
Br
BrBr
Br
Br
R
R
RR
BB
B
R
G/W
Br/R
R
Br
Br Br
Br
Br
R
RR
R
R
B
R
B
Br/R
B/W
Br/R
Br/R
RBr
Br
R/B
R
R
R
Br
Br Br
Br
Br
Br
Br
Br
Br
R
R
R
R
R
RR
RR
G/W
R
B
L
B
B
B
B
B
B
BBBB
B
BBBB
BBBBBB
B
G/W
R/W
R/Y
B/Y
Br
R/W
L/Y
W/R
R/W
R/B
Y/R
Br/R
Br/R
R/B
Dg
Ch
B
Y/L
G/W
B/Y
Br
W/R
W/R
R/L
R/W
R/Y
R/W
R/L
P/W
W/G
Br/W
Gy/RGy/R
L/B
L/Y
G/R
B/L
G/R
B/L
B/L
L
W
B
Y
P/W
Br/W
B/L
L
Y
W
R
R
W/R
W/L
W/B
W/Y
Br/B
B/L
G/Y
Gy
Sb
O/B
B/Y B/Y
R
G
B/W
Ch
Y/LY/LY/L
R
B/W
R/B
L/BL/B
L/RL/R
Y/R
Y/B
Y/B
B/R
B/R
B/W
B/W
O
G
O
Br
P
G
G
L
B
W
G
WBr
R
R/L
W/L
B/Y
B/YB/Y
B/Y
B/Y
L/BL/B
W/GW/G
B/Y
B/Y
B
B
B
B
Br
Br
Br
Br
Br
Br
P
PL
Br/W
Br/W
Br/B
Br/B
DgCh
Ch
Ch
Ch Ch
Ch
Dg
Ch Dg
YBr Br
B
B
BB
B
LL
B
Ch Dg
Dg
Dg Dg
Dg
BY
Y
Y
Y
YG
Br/WL/B
Br
Br Br
B/YB/Y
Y
L
B
B/WY/L
R
B
W/R
W/L
W/B
W/Y
Br/B
B/L
L/Y
G/Y
Gy
Sb
O/B
Br
Ch
P
G
B
B
B
B/W
G
W
R
G
Y/L
Y/L
Y/LY/L
L/YL/Y
L/Y
L/Y
B
B
L/B
G
B/WL/W
L
Y/W
B
Y/R
W/GB/Y
Br
Br
Br Br
B
B
B
B
B
Br
G
L
G
B
B
B
B
B
Br Br
Br
Y/B
B
Y/B
W/RB/W
Y/L
RChDgY
Br G
B
W/L
1
2
3
4
5
6
7
8
9
10
11
12
13
14
16
15
17
18
19
20
21
22 23 24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43 43
78 78
44
45
46
4748
49
50
51 52 53 54 55 56 57 58 59
60
61
62
63
64
65 66
67
68
69 7071727374
7576
77
B63-F8197-EZ.book Page 75 Monday, January 23, 2017 4:12 PM
8-76
FUEL PUMP SYSTEM
1. Battery
5. Main fuse
8. Fuel injection system fuse
10.Ignition fuse
14.Main switch
33.SGCU (starter generator control unit)
39.Fuel pump
43.Engine ground 2
78.Engine ground 1
B63-F8197-EZ.book Page 76 Monday, January 23, 2017 4:12 PM
FUEL PUMP SYSTEM
8-77
EAS30514
TROUBLESHOOTING
If the fuel pump fails to operate.
TIP
• Before troubleshooting, remove the following part(s):
1. Battery cover
2. Front side covers
3. Footrest board assemblies
4. Fuel tank
NG
OK
NG
OK
NG
OK
NG
OK
NG
OK
1. Check the fuses.
(Main ignition, and fuel injection
system)
Refer to “CHECKING THE FUS-
ES” on page 8-124.
Replace the fuse(s).
2. Check the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 8-124.
• Clean the battery terminals.
• Recharge or replace the battery.
3. Check the main switch.
Refer to “CHECKING THE
SWITCHES” on page 8-120.
Replace the main switch.
4. Check the fuel pump.
Refer to “CHECKING THE FUEL
PRESSURE” on page 7-3.
Replace the fuel pump.
5. Check the entire fuel pump system
wiring.
Refer to “CIRCUIT DIAGRAM
(GDR155)” on page 8-73 or refer to
“CIRCUIT DIAGRAM (GDR155-A)”
on page 8-75.
Properly connect or replace the wiring har-
ness.
Replace the SGCU. Refer to “RE-
PLACING THE SGCU (starter genera-
tor control unit)” on page 8-124.
B63-F8197-EZ.book Page 77 Monday, January 23, 2017 4:12 PM
8-78
FUEL PUMP SYSTEM
B63-F8197-EZ.book Page 78 Monday, January 23, 2017 4:12 PM
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
8-79
EAS20085
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
EAS30843
CIRCUIT DIAGRAM
ON
OPEN
OFF
LOCK
L
PUSH
R
ON
OFF
HI
LO
PUSH
FREE
PUSH
FREE
ON
OFF
B
W/R
B
B/Y
B
L
R/W
B
(B)
R/W
B
(B)
Br
R
G/W
Br
R/Y
R
(B)
ChB
L/Y
R/BY/L
G/W
Dg
R/W
Br
W/R
B/Y
R
R/B
R
R
Br/R
R/W,B r
B/W,B
B
R
(B)
Br/R
R
Y/R
Br
R/B
RWG
R/YR/L
R/W
(B)
B/LG/R
(B)
B/L
Y L
P/WBr/W
Gy/R
(B)
B
(B)
(B)
G/Y
W/R
B/Y
O
P
O/B
G
B/W
W/L
Ch
Sb Y
B
/
L
Br/B
R/B
Gy
B/L
W/B
L
W/Y
R
Br/W
B
P/WR/W
L/B
B/L
G/R
Y/LB/R
Gy/R
L/Y
W/G
W
B
Y/BY/R
GWR
G
L/Y
W/R
Br/B
W/L
W/B
(B)
W/R
W/LBr/B
W/Y
B/L
W/B
(B)
(B)
P
G/Y
Sb Gy
Br
(B)
O/B
(Gy)
G
Ch
B/W
R
Y/L Y/L
(B)
R
B/Y
(Gy)
G
B/W
LG
W
B
L/RL/B
RB
R
L/RL/BY/L
B/W
R/LB/Y
Br
W/L
LGWB
B/Y
Br
(B)
BB
Br B
BBr
B
B
(L)
L/Y
B
(L)
Br
Br/W
Br/B
Br/W
(R)
L
Y/R
B/Y
L/B
(B)
B
W/G
B
L/W
(B)
B/W
Y/W
(R)
Br
G
(L)
Dg
Ch
Br/W
(R)
Y
L
(R)
L/B
Y
(L)
Br/B
Ch
Dg
(B)
B
Dg
Ch
(B)
Ch
Dg
B
P
B
P
B
Br
B
L
B
L
Y
B
(B)
YBr
B
Br
W/R
Y/B
R
Y
BCh
W/L
Dg
Y/L
B/W
G
(Gy)
Y
G
B
GY
Y/B
R
Br
BrBr
Br
Br
R
R
RR
BB
B
R
G/W
Br/R
R
Br
Br Br
Br
Br
R
RR
R
R
B
R
B
Br/R
B/W
Br/R
Br/R
RBr
Br
R/B
R
R
R
Br
Br Br
Br
Br
Br
Br
Br
Br
R
R
R
R
R
RR
RR
G/W
R
B
L
B
B
B
B
B
B
BBBB
B
BBBB
BBBBBB
B
G/W
R/W
R/Y
B/Y
Br
R/W
L/Y
W/R
R/W
R/B
Y/R
Br/R
Br/R
R/B
Dg
Ch
B
Y/L
G/W
B/Y
Br
W/R
W/R
R/L
R/W
R/Y
R/W
R/L
P/W
W/G
Br/W
Gy/RGy/R
L/B
L/Y
G/R
B/L
G/R
B/L
B/L
L
W
B
Y
P/W
Br/W
B/L
L
Y
W
R
R
W/R
W/L
W/B
W/Y
Br/B
B/L
G/Y
Gy
Sb
O/B
B/Y B/Y
R
G
B/W
Ch
Y/LY/LY/L
R
B/W
R/B
L/BL/B
L/RL/R
Y/R
Y/B
Y/B
B/R
B/R
B/W
B/W
O
G
O
Br
P
G
G
L
B
W
G
WBr
R
R/L
W/L
B/Y
B/YB/Y
B/Y
B/Y
L/BL/B
W/GW/G
B/Y
B/Y
B
B
B
B
Br
Br
Br
Br
Br
Br
P
PL
Br/W
Br/W
Br/B
Br/B
DgCh
Ch
Ch
Ch Ch
Ch
Dg
Ch Dg
YBr Br
B
B
BB
B
LL
B
Ch Dg
Dg
Dg Dg
Dg
BY
Y
Y
Y
YG
Br/WL/B
Br
Br Br
B/YB/Y
Y
L
B
B/WY/L
R
B
W/R
W/L
W/B
W/Y
Br/B
B/L
L/Y
G/Y
Gy
Sb
O/B
Br
Ch
P
G
B
B
B
B/W
G
W
R
G
Y/L
Y/L
Y/LY/L
L/YL/Y
L/Y
L/Y
B
B
L/B
G
B/WL/W
L
Y/W
B
Y/R
W/GB/Y
Br
Br
Br Br
B
B
B
B
B
Br
G
L
G
B
B
B
B
B
Br Br
Br
Y/B
B
Y/B
W/RB/W
Y/L
RChDgY
Br G
B
W/L
1
2
3
4
5
6
7
8
9
10
11
12
13
14
16
15
17
18
19
20
21
22 23 24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43 43
78 78
44
45
46
4748
49
50
51 52 53 54 55 56 57 58 59
60
61
62
63
64
65 66
67
68
69 7071727374
7576
77
B63-F8197-EZ.book Page 79 Monday, January 23, 2017 4:12 PM
8-80
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
1. Battery
2. ABS solenoid fuse
3. ABS motor fuse
4. ABS control unit fuse
5. Main fuse
9. Backup fuse
10.Ignition fuse
12.Signaling system fuse
14.Main switch
19.Main relay
33.SGCU (starter generator control unit)
42.Yamaha diagnostic tool coupler
43.Engine ground 2
44.Front wheel sensor
45.ABS test coupler
46.ABS ECU
47.Rear brake light switch
48.Front brake light switch
49.Meter assembly
50.Multi-function meter
52.ABS warning light
68.Tail/brake light assembly
69.Brake light
77.Frame ground
78.Engine ground 1
B63-F8197-EZ.book Page 80 Monday, January 23, 2017 4:12 PM
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
8-81
EAS30844
ABS COUPLER LOCATION CHART
LG
W
B
L/RL/B
RB
R
L/RL/BY/L
B/W
R/LB/Y
Br
W/L
LGWB
Br
W/R
Y/B
R
Y
BCh
W/L
Dg
Y/L
B/W
G
(Gy)
1
2
4
3
B63-F8197-EZ.book Page 81 Monday, January 23, 2017 4:12 PM
8-82
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
1. ABS ECU coupler
2. ABS test coupler
3. Meter assembly coupler
4. Front wheel sensor coupler
B63-F8197-EZ.book Page 82 Monday, January 23, 2017 4:12 PM
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
8-83
EAS30845
MAINTENANCE OF THE ABS ECU
Checking the ABS ECU
1. Check:
• Terminals “1” of the ABS ECU
Cracks/damages Replace the hydraulic unit assembly, brake hoses, and brake pipes that are
connected to the assembly as a set.
• Terminals “2” of the ABS ECU coupler
Connection defective, contaminated, come-off Correct or clean.
TIP
If the ABS ECU coupler is clogged with mud or dirt, clean with compressed air.
EAS30528
ABS TROUBLESHOOTING OUTLINE
This section describes the troubleshooting for the ABS in detail. Read this service manual carefully and
make sure you fully understand the information provided before repairing any malfunctions or perform-
ing service.
The ABS ECU (electronic control unit) has a self-diagnosis function. When failures occur in the system,
the ABS warning light on the meter assembly indicates a malfunction.
The following troubleshooting describes the problem identification and service method using the Yama-
ha diagnostic tool. For information about using the Yamaha diagnostic tool, refer to “[B-2] DIAGNOSIS
USING THE FAULT CODES” on page 8-87. For troubleshooting items other than the following items,
follow the normal service method.
WARNING
EWA16710
When maintenance or checks have been performed on components related to the ABS, be sure
to perform a final check before delivering the vehicle to the customer.
TIP
To final check, refer to “[C-1] FINAL CHECK” on page 8-102.
ABS operation when the ABS warning light comes on
1. The ABS warning light remains on ABS operates as a normal brake system.
• A malfunction was detected using the ABS self-diagnosis function.
• The ABS self-diagnosis has not been completed.
The ABS self-diagnosis starts when the main switch is turned to “ON” and finishes when the vehicle
has traveled at a speed of approximately 10 km/h (6 mi/h).
2. The ABS warning light comes on after the engine starts, and then goes off when the vehicle starts
moving (traveling at a speed of approximately 10 km/h (6 mi/h)). ABS operation is normal.
3. The ABS warning light flashes ABS operation is normal.
• Refer to “BASIC INSTRUCTIONS FOR TROUBLESHOOTING” on page 8-84.
1
2
B63-F8197-EZ.book Page 83 Monday, January 23, 2017 4:12 PM
8-84
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
Self-diagnosis and servicing
The ABS ECU has a self-diagnosis function. By utilizing this function, quick problem identification and
service are possible. Previous malfunctions can be checked since the ABS ECU also stores the mal-
function history.
The fault codes recorded in the ABS ECU can be checked using the Yamaha diagnostic tool. When the
service is finished, check the normal operation of the vehicle, and then delete the fault code(s). For in-
formation about deleting the fault codes, refer to “[B-3] DELETING THE FAULT CODES” on page
8-102. By deleting the fault codes stored in the ABS ECU memory, it is possible to pursue the cause
correctly if another malfunction occurs.
TIP
The ABS performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the
main switch was turned to “ON”. During this test, a “clicking” noise can be heard from front side, and if
the front brake lever is even slightly applied, a vibration can be felt at the lever, but these do not indicate
a malfunction.
Special precautions for handling and servicing a vehicle equipped with ABS
NOTICE
ECA18490
Care should be taken not to damage components by subjecting them to shocks or pulling on
them with too much force since the ABS components are precisely adjusted.
• The ABS ECU and hydraulic unit are united assemblies and cannot be disassembled.
• The malfunction history is stored in the memory of the ABS ECU. Delete the fault codes when the ser-
vice is finished. (This is because the past fault codes will be displayed again if another malfunction
occurs.)
EAS30529
BASIC INSTRUCTIONS FOR TROUBLESHOOTING
WARNING
EWA17420
• Perform the troubleshooting [A][B][C] in order. Be sure to follow the order since a wrong
diagnosis could result if the steps are followed in a different order or omitted.
• Use sufficiently charged regular batteries only.
[A] Malfunction check using the ABS warning light
[B] Use the Yamaha diagnostic tool and determine the location of the malfunction and the cause from
the recorded fault code.
Determine the cause of the malfunction from the condition and place where the malfunction occurred.
[C] Servicing the ABS
Execute the final check after disassembly and assembly.
Self-diagnosis using the ABS ECU
The ABS ECU performs a static check of the entire system when the main switch is turned to “ON”. It also
checks for malfunctions while the vehicle is ridden. Since all malfunctions are recorded after they are detect-
ed, it is possible to check the recorded malfunction data by utilizing the Yamaha diagnostic tool when the
ABS ECU has entered the self-diagnosis mode.
B63-F8197-EZ.book Page 84 Monday, January 23, 2017 4:12 PM
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
8-85
EAS30530
BASIC PROCESS FOR TROUBLESHOOTING
[A-1] Does only the ABS
warning light fail to
come on?
[A-2] Do all indicator lights
fail to come on?
The ABS warning light (LED)
is defective.
The wire harness is grounded
between the ABS ECU and the
meter assembly.
The meter assembly circuit is
defective.
The hydraulic unit assembly is
defective.
The main switch is defective.
The battery voltage is low.
The ignition fuse is blown.
The meter assembly circuit is
defective.
Ye s
Ye s
No
Return to [A].
Return to [A].
•
•
•
•
•
•
•
•
[A-3]
The ABS warning light comes
on.
Connect the Yamaha
diagnostic tool, and then
execute functional diagnosis.
Can the tool communicate with
the ABS ECU?
Return to [A].
[B-2] Diagnose by the fault
code.
[B-3] Delete the fault codes.
Return to [A].
[C-1] Perform the final checks.
Were all of the final checks
completed normally?
Finished.
Ye s
No
[A] Turn the main switch to “ ON ”,
and check the ABS warning
light.
Fails to
come on
Comes on
The ABS ECU coupler is
disconnected.
•
The wire harness is defective.
•
The hydraulic unit assembly
is defective.
•
The ABS solenoid fuse is blown.
Refer to “ Troubleshooting details
of fault code No. 31 ”.
•
Can communicate
[B-1] Check for ABS fault
codes in the screen for the
Execute fault diagnosis.
Yamaha diagnostic tool.
Are fault codes displayed on
the screen?
No
Ye s
The reaction force generated
during brake line routing
confirmation is incorrect.
The brake hoses and brake
pipes are not connected
correctly.
•
The malfunction is not
corrected.
•
There is a break in the wire
harness between the ABS ECU
and the meter assembly.
•
The ABS warning light does
not go off when the light is
checked.
The meter assembly circuit
is defective.
•
The ABS warning light circuit
in the hydraulic unit assembly
is defective.
•
Return to [A].
The connection with the Yamaha
diagnostic tool is defective.
•
Cannot communicate
The ABS control unit fuse is blown.
•
(Check that the ABS warning
light goes off during the ABS
warning light check.)
B63-F8197-EZ.book Page 85 Monday, January 23, 2017 4:12 PM
8-86
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
WARNING
EWA16710
When maintenance or checks have been performed on components related to the ABS, be sure
to perform a final check before delivering the vehicle to the customer.
TIP
To final check, refer to “[C-1] FINAL CHECK” on page 8-102.
EAS30531
[A] CHECKING THE ABS WARNING LIGHT
Turn the main switch to “ON”. (Do not start the engine.)
1. The ABS warning light does not come on.
• Only the ABS warning light fails to come on. [A-1]
• The ABS warning light and all other indicator lights fail to come on. [A-2]
2. The ABS warning light comes on. [A-3]
EAS30532
[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON
1. Check for a short circuit to the ground between the White/Blue terminal of the ABS ECU coupler and
White/Blue terminal of the meter assembly.
• If there is short circuit to the ground, the wire harness is defective. Replace the wire harness.
2. Disconnect the ABS ECU coupler and check that the ABS warning light comes on when the main
switch is turned to “ON”.
• If the ABS warning light does not come on, the meter assembly circuit (including the ABS warning
light [LED]) is defective. Replace the meter assembly.
• If the ABS warning light comes on, the ABS ECU is defective. Replace the hydraulic unit assembly.
EAS30964
[A-2] ALL INDICATOR LIGHTS FAIL TO COME ON
1. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES” on page 8-120.
• If there is no continuity, replace the main switch.
2. Battery
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-124.
• If the battery is defective, clean the battery terminals and recharge it, or replace the battery.
3. Ignition fuse
• Check the fuse for continuity.
Refer to “CHECKING THE FUSES” on page 8-124.
• If the ignition fuse is blown, replace the fuse.
4. Circuit
• Check the meter assembly circuit.
Refer to “CIRCUIT DIAGRAM” on page 8-79.
• If the meter assembly circuit is open, replace the wire harness.
EAS31162
[A-3] THE ABS WARNING LIGHT COMES ON
Connect the Yamaha diagnostic tool to the ABS test coupler and execute functional diagnosis. (For in-
formation about how to execute functional diagnosis, refer to the operation manual that is included with
the tool.)
Check that communication with the ABS ECU is possible.
• Only the ABS ECU fails to communicate. [A-4]
• ABS ECU and SGCU fail to communicate. [A-5]
• Communication is possible with the ABS ECU. [B-1] (The ABS is displayed on the select unit screen.)
B63-F8197-EZ.book Page 86 Monday, January 23, 2017 4:12 PM
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
8-87
EAS31163
[A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE (The select unit screen does not appear.)
1. ABS control unit fuse
• Check the ABS control unit fuse for continuity.
Refer to “CHECKING THE FUSES” on page 8-124.
• If the ABS control unit fuse is blown, replace the fuse.
2. ABS ECU coupler
• Check that the ABS ECU coupler is connected properly.
For information about connecting the ABS ECU coupler properly, refer to “INSTALLING THE HY-
DRAULIC UNIT ASSEMBLY” on page 4-49.
3. Wire harness
• Open circuit between the main switch and the ABS ECU, or between the ABS ECU and the ground.
Check for continuity between Brown terminal of the main switch coupler and Brown/White terminal
of the ABS ECU coupler.
Check for continuity between Black/White terminal of the ABS ECU coupler and the ground, and be-
tween the Black terminal of the ABS ECU coupler and ground.
If there is no continuity, the wire harness is defective. Replace the wire harness.
• Open circuit in the wire harness between the ABS ECU coupler and the ABS test coupler.
Check for continuity between Blue/Red terminal of the ABS ECU coupler and Blue/Red terminal of
the ABS test coupler. (CANH)
Check for continuity between Blue/Black terminal of the ABS ECU coupler and Blue/Black terminal
of the ABS test coupler. (CANL)
4. ABS ECU malfunction
Replace the hydraulic unit assembly.
EAS31164
[A-5] ABS ECU AND SGCU FAIL TO COMMUNICATE (Cannot connect due to a tool error.)
1. Yamaha diagnostic tool
Check that the Yamaha diagnostic tool is properly connected.
2. Wire harness
• Open circuit in the wire harness between the ABS ECU coupler and the ABS test coupler.
Check for continuity between Blue/Red terminal of the ABS ECU coupler and Blue/Red terminal of
the ABS test coupler. (CANH)
Check for continuity between Blue/Black terminal of the ABS ECU coupler and Blue/Black terminal
of the ABS test coupler. (CANL)
EAS31165
[B-1] MALFUNCTION ARE CURRENTLY DETECTED
When the Yamaha diagnostic tool is connected to the ABS test coupler, the fault codes will be displayed
on the computer screen.
• A fault code is displayed. [B-2]
• A fault code is not displayed. [C-1]
EAS31166
[B-2] DIAGNOSIS USING THE FAULT CODES
This model uses the Yamaha diagnostic tool to identify malfunctions.
For information about using the Yamaha diagnostic tool, refer to the operation manual that is included
with the tool.
Connecting the Yamaha diagnostic tool
Removing the battery cover. Refer to “GENERAL CHASSIS (1)” on page 4-1.
Yamaha diagnostic tool USB
90890-03250
Yamaha diagnostic tool (A/I)
90890-03252
B63-F8197-EZ.book Page 87 Monday, January 23, 2017 4:12 PM
8-88
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
Removing the protective cap “1”, and then connect the Yamaha diagnostic tool to the ABS test coupler.
Details about the displayed fault codes are shown in the following chart. Refer to this chart and check
the vehicle.
Once all the work is complete, delete the fault codes. [B-3]
TIP
Check the inspection points after terminating the connection with the Yamaha diagnostic tool and turn-
ing the main switch off.
Fault code table
TIP
Record all of the fault codes displayed and inspect the check points.
1
Fault code No. Item Symptom Check point
11*
25*
Front wheel sensor (intermit-
tent pulses or no pulses)
Front wheel sensor signal is
not received properly. (Puls-
es are not received or are re-
ceived intermittently while
the vehicle is traveling.)
• Foreign material adhered
around the front wheel sen-
sor
• Incorrect installation of the
front wheel
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective front wheel sen-
sor or incorrect installation
of the sensor
13*
26*
Front wheel sensor (abnor-
mal pulse period)
Front wheel sensor signal is
not received properly. (The
pulse period is abnormal
while the vehicle is traveling.)
• Foreign material adhered
around the front wheel sen-
sor
• Incorrect installation of the
front wheel
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective front wheel sen-
sor or incorrect installation
of the sensor
15 Front wheel sensor (open or
short circuit)
Open or short circuit is de-
tected in the front wheel sen-
sor.
• Defective coupler between
the front wheel sensor and
the hydraulic unit assembly
• Open or short circuit in the
wire harness between the
front wheel sensor and the
hydraulic unit assembly
• Defective front wheel sen-
sor or hydraulic unit as-
sembly
B63-F8197-EZ.book Page 88 Monday, January 23, 2017 4:12 PM
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
8-89
17*
45*
Front wheel sensor (missing
pulses)
Front wheel sensor signal is
not received properly. (Miss-
ing pulses are detected in
the signal while the vehicle is
traveling.)
• Foreign material adhered
around the front wheel sen-
sor
• Incorrect installation of the
front wheel
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective front wheel sen-
sor or incorrect installation
of the sensor
21 Hydraulic unit assembly (de-
fective solenoid drive circuit)
Solenoid drive circuit in the
hydraulic unit assembly is
open or short-circuited.
• Defective hydraulic unit as-
sembly
24 Brake light switch or brake
light
Brake light signal is not re-
ceived properly while the ve-
hicle is traveling. (Brake light
circuit, or front or rear brake
light switch circuit)
• Defective signaling system
(brake light or brake light
switch)
• Defective coupler between
the signaling system (brake
light or brake light switch)
and the hydraulic unit as-
sembly
• Open or short circuit in the
wire harness between the
signaling system (brake
light or brake light switch)
and the hydraulic unit as-
sembly
• Defective hydraulic unit as-
sembly
31 Hydraulic unit assembly (ab-
normal ABS solenoid power
supply)
Power is not supplied to the
solenoid circuit in the hy-
draulic unit assembly.
• Blown ABS solenoid fuse
• Defective coupler between
the battery and the hydrau-
lic unit assembly
• Open or short circuit in the
wire harness between the
battery and the hydraulic
unit assembly
• Defective hydraulic unit as-
sembly
32 Hydraulic unit assembly
(short circuit in ABS solenoid
power supply circuit)
Short circuit is detected in
the solenoid power supply
circuit in the hydraulic unit
assembly.
• Defective hydraulic unit as-
sembly
33 Hydraulic unit assembly (ab-
normal ABS motor power
supply)
Power is not supplied to the
motor circuit in the hydraulic
unit assembly.
• Blown ABS motor fuse
• Defective coupler between
the battery and the hydrau-
lic unit assembly
• Open or short circuit in the
wire harness between the
battery and the hydraulic
unit assembly
• Defective hydraulic unit as-
sembly
34 Hydraulic unit assembly
(short circuit in ABS motor
power supply circuit)
Short circuit is detected in
the motor power supply cir-
cuit in the hydraulic unit as-
sembly.
• Defective hydraulic unit as-
sembly
Fault code No. Item Symptom Check point
B63-F8197-EZ.book Page 89 Monday, January 23, 2017 4:12 PM
8-90
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
41 Front wheel ABS (intermit-
tent wheel speed pulses or
incorrect depressurization)
• Pulses from the front wheel
sensor are received inter-
mittently while the vehicle
is traveling.
• Front wheel will not recover
from the locking tendency
even though the signal is
transmitted from the ABS
ECU to reduce the hydrau-
lic pressure.
• Incorrect installation of the
front wheel sensor
• Incorrect rotation of the
front wheel
• Front brake dragging
• Defective hydraulic unit as-
sembly
43 Front wheel sensor (missing
pulses)
Front wheel sensor signal is
not received properly. (Miss-
ing pulses are detected in
the signal while the vehicle is
traveling.)
• Foreign material adhered
around the front wheel sen-
sor
• Incorrect installation of the
front wheel
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective front wheel sen-
sor or incorrect installation
of the sensor
51 Vehicle system power supply
(voltage of ABS ECU power
supply is high)
Power voltage supplied to
the ABS ECU in the hydrau-
lic unit assembly is too high.
• Defective battery
• Disconnected battery ter-
minal
• Defective charging system
52 Vehicle system power supply
(voltage of wheel sensor
power supply is high)
Power voltage supplied to
the wheel sensor is too high.
• Defective battery
• Disconnected battery ter-
minal
• Defective charging system
53 Vehicle system power supply
(voltage of ABS ECU power
supply is low)
Power voltage supplied to
the ABS ECU in the hydrau-
lic unit assembly is too low.
• Defective battery
• Defective coupler between
the battery and the hydrau-
lic unit assembly
• Open or short circuit in the
wire harness between the
battery and the hydraulic
unit assembly
• Defective charging system
54 Hydraulic unit assembly (de-
fective ABS solenoid and
ABS motor power supply cir-
cuits)
Abnormality is detected in
the solenoid or motor power
supply circuit in the hydraulic
unit assembly.
• Defective battery
• Defective coupler between
the battery and the hydrau-
lic unit assembly
• Open or short circuit in the
wire harness between the
battery and the hydraulic
unit assembly
• Defective charging system
• Defective hydraulic unit as-
sembly
55 Hydraulic unit assembly (de-
fective ABS ECU)
Abnormal data is detected in
the hydraulic unit assembly.
• Defective hydraulic unit as-
sembly
56 Hydraulic unit assembly (ab-
normal internal circuit.
Abnormality is detected in
the internal circuit in the hy-
draulic unit assembly.
• Defective hydraulic unit as-
sembly
Fault code No. Item Symptom Check point
B63-F8197-EZ.book Page 90 Monday, January 23, 2017 4:12 PM
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
8-91
* The fault code number varies according to the vehicle conditions.
Fault code No. 11, 25
TIP
If the rear wheel was rotated with the front wheel stopped, fault code No. 11 or 25 may be recorded.
63 Front wheel sensor power
supply (voltage of power
supply is low)
Power voltage supplied from
the ABS ECU to the front
wheel sensor is too low.
• Short circuit in the wire har-
ness between the front
wheel sensor and the hy-
draulic unit assembly
• Defective front wheel sen-
sor
• Defective hydraulic unit as-
sembly
95 K-Line communication K-Line data is not received
properly.
• Defective coupler in the K-
Line communication circuit
(SGCU, meter assembly,
and ABS ECU)
• Open or short circuit in the
wire harness in the K-Line
communication circuit
(SGCU, meter assembly,
and ABS ECU)
• Defective unit (SGCU or
meter assembly) connect-
ed to the K-Line communi-
cation circuit
• Defective hydraulic unit as-
sembly
Fault code No. Item Symptom Check point
Fault code No.
11
25
Item Front wheel sensor (intermittent pulses or no pulses)
Symptom
Front wheel sensor signal is not received properly. (Pulses are not re-
ceived or are received intermittently while the vehicle is traveling.)
Order Item/components and probable cause Check or maintenance job
1 Foreign material adhered around the front
wheel sensor
Check the surface of the sensor rotor and wheel sensor
for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.
2 Incorrect installation of the front wheel Check the components for looseness, distortion, and
bends.
Refer to “CHECKING THE FRONT WHEEL” on page
4-22.
3 Defective sensor rotor or incorrect instal-
lation of the rotor
Check the surface of the sensor rotor for damage.
Replace the sensor rotor if there is visible damage.
Refer to “MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR” on page 4-23.
4 Defective front wheel sensor or incorrect
installation of the sensor
Check the wheel sensor for damage and the installed
condition of the sensor. Repair or replace the wheel
sensor if necessary.
Refer to “MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR” on page 4-23.
B63-F8197-EZ.book Page 91 Monday, January 23, 2017 4:12 PM
8-92
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
Fault code No. 13, 26
TIP
• If the front brake ABS operates continuously for 20 seconds or more, fault code No. 26 will be record-
ed. If the front brake ABS operates continuously for 36 seconds or more, fault code No. 13 will be re-
corded.
• Vehicle possibly ridden on uneven roads.
Fault code No. 15
TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.
Fault code No.
13
26
Item Front wheel sensor (abnormal pulse period)
Symptom
Front wheel sensor signal is not received properly. (The pulse period
is abnormal while the vehicle is traveling.)
Order Item/components and probable cause Check or maintenance job
1 Foreign material adhered around the front
wheel sensor
Check the surface of the sensor rotor and wheel sensor
for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.
2 Incorrect installation of the front wheel Check the components for looseness, distortion, and
bends.
Refer to “CHECKING THE FRONT WHEEL” on page
4-22.
3 Defective sensor rotor or incorrect instal-
lation of the rotor
Check the surface of the sensor rotor for damage. Re-
place the sensor rotor if there is visible damage.
Refer to “MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR” on page 4-23.
4 Defective front wheel sensor or incorrect
installation of the sensor
Check the wheel sensor for damage and the installed
condition of the sensor. Repair or replace the wheel
sensor if necessary.
Refer to “MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR” on page 4-23.
Fault code No. 15
Item Front wheel sensor (open or short circuit)
Symptom Open or short circuit is detected in the front wheel sensor.
Order Item/components and probable cause Check or maintenance job
1 Defective coupler between the front wheel
sensor and the hydraulic unit assembly
• Check the coupler for any pins that may be pulled out.
• Check the locking condition of the coupler.
• If there is a malfunction, repair it and connect the cou-
pler securely.
See “TIP”.
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ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
8-93
2 Open or short circuit in the wire harness
between the front wheel sensor and the
hydraulic unit assembly
• Check for continuity between the Green terminal “1”
and the Green terminal “4” and between the Blue ter-
minal “2” and the Blue terminal “5”.
• If there is no continuity, the wire harness is defective.
Replace the wire harness.
• Check that there is no short circuit between the Green
terminal “1” and the Blue terminal “2” and between the
Green terminal “4” and the Blue terminal “5”.
• If there is short circuit, the wire harness is defective.
Replace the wire harness.
• Check that there is no short circuit between the
Black/White terminal “3” and the Green terminal “4”
and between the Black/White terminal “3” and the Blue
terminal “5”.
• If there is short circuit, the wire harness is defective.
Replace the wire harness.
6. ABS ECU
7. Front wheel sensor
3 Defective front wheel sensor or hydraulic
unit assembly
If the above items were performed and no malfunctions
were found, the wheel sensor or hydraulic unit assembly
is defective. Replace the wheel sensor or hydraulic unit
assembly.
Refer to “FRONT WHEEL” on page 4-20 and “ABS (AN-
TI-LOCK BRAKE SYSTEM)” on page 4-47.
Fault code No. 15
Item Front wheel sensor (open or short circuit)
Symptom Open or short circuit is detected in the front wheel sensor.
Order Item/components and probable cause Check or maintenance job
LG
W
B
R
L/RL/BY/L
B/W
R/LB/Y
Br
W/L
LGWB
4
6
7
5
2 1 3
B63-F8197-EZ.book Page 93 Monday, January 23, 2017 4:12 PM
8-94
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
Fault code No. 17, 45
TIP
If pulse gaps are detected when the vehicle is traveling at a speed of 30 km/h (19 mi/h) or more, fault
code No. 17 will be recorded. If the vehicle is traveling at a speed of 29 km/h (18 mi/h) or less, fault code
No. 45 will be recorded first and fault code No. 17 will be recorded if the condition continues.
Fault code No. 21
Fault code No. 24
Fault code No.
17
45
Item Front wheel sensor (missing pulses)
Symptom
Front wheel sensor signal is not received properly. (Missing pulses
are detected in the signal while the vehicle is traveling.)
Order Item/components and probable cause Check or maintenance job
1 Foreign material adhered around the front
wheel sensor
Check the surface of the sensor rotor and wheel sensor
for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.
2 Incorrect installation of the front wheel Check the components for looseness, distortion, and
bends.
Refer to “CHECKING THE FRONT WHEEL” on page
4-22.
3 Defective sensor rotor or incorrect instal-
lation of the rotor
Check the surface of the sensor rotor for damage.
Replace the sensor rotor if there is visible damage.
Refer to “MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR” on page 4-23.
4 Defective front wheel sensor or incorrect
installation of the sensor
Check the wheel sensor for damage and the installed
condition of the sensor. Repair or replace the wheel
sensor if necessary.
Refer to “MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR” on page 4-23.
Fault code No. 21
Item Hydraulic unit assembly (defective solenoid drive circuit)
Symptom
Solenoid drive circuit in the hydraulic unit assembly is open or short-
circuited.
Order Item/components and probable cause Check or maintenance job
1 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
4-47.
Fault code No. 24
Item Brake light switch or brake light
Symptom
Brake light signal is not received properly while the vehicle is travel-
ing (Brake light circuit, or front or rear brake light switch circuit).
Order Item/components and probable cause Check or maintenance job
1 Defective signaling system (brake light or
brake light switch)
Check the brake light switches.
Refer to “CHECKING THE SWITCHES” on page 8-120.
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ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
8-95
Fault code No. 31
TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.
2 Defective coupler between the signaling
system (brake light or brake light switch)
and the hydraulic unit assembly
• Check the coupler for any pins that may be pulled out.
• Check the locking condition of the coupler.
• If there is a malfunction, repair it and connect the cou-
pler securely.
3 Open or short circuit in the wire harness
between the signaling system (brake light
or brake light switch) and the hydraulic
unit assembly
• Between front brake light switch connector and rear
brake light switch connector.
(Black/Yellow–Black/Yellow)
• Between ABS ECU coupler and rear brake light switch
connector.
(Black/Yellow–Black/Yellow)
4 Defective hydraulic unit assembly If the above items were performed and no malfunctions
were found, replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
4-47.
Fault code No. 24
Item Brake light switch or brake light
Symptom
Brake light signal is not received properly while the vehicle is travel-
ing (Brake light circuit, or front or rear brake light switch circuit).
Order Item/components and probable cause Check or maintenance job
Fault code No. 31
Item Hydraulic unit assembly (abnormal ABS solenoid power supply)
Symptom
Power is not supplied to the solenoid circuit in the hydraulic unit as-
sembly.
Order Item/components and probable cause Check or maintenance job
1 Blown ABS solenoid fuse Check the ABS solenoid fuse. If the ABS solenoid fuse
is blown, replace the fuse and check the wire harness.
Refer to “CHECKING THE FUSES” on page 8-124.
2 Defective coupler between the battery
and the hydraulic unit assembly
• Check the locking condition of the coupler.
• If there is a malfunction, repair it and connect the cou-
pler securely.
See TIP.
3 Open or short circuit in the wire harness
between the battery and the hydraulic unit
assembly
• Replace if there is an open or short circuit.
• Between ABS ECU coupler and ABS solenoid fuse.
(Red–Red)
4 Defective hydraulic unit assembly If the above items were performed and no malfunctions
were found, replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
4-47.
B63-F8197-EZ.book Page 95 Monday, January 23, 2017 4:12 PM
8-96
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
Fault code No. 32
Fault code No. 33
TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.
Fault code No. 34
Fault code No. 32
Item
Hydraulic unit assembly (short circuit in ABS solenoid power supply
circuit)
Symptom
Short circuit is detected in the solenoid power supply circuit in the hy-
draulic unit assembly.
Order Item/components and probable cause Check or maintenance job
1 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)
(GDR155-A)” on page 4-47.
Fault code No. 33
Item Hydraulic unit assembly (abnormal ABS motor power supply)
Symptom
Power is not supplied to the motor circuit in the hydraulic unit assem-
bly.
Order Item/components and probable cause Check or maintenance job
1 Blown ABS motor fuse Check the ABS motor fuse. If the ABS motor fuse is
blown, replace the fuse and check the wire harness.
Refer to “CHECKING THE FUSES” on page 8-124.
2 Defective coupler between the battery
and the hydraulic unit assembly
• Check the coupler for any pins that may be pulled out.
• Check the locking condition of the coupler.
• If there is a malfunction, repair it and connect the cou-
pler securely.
See TIP.
3 Open or short circuit in the wire harness
between the battery and the hydraulic unit
assembly
• Replace if there is an open or short circuit.
• Between ABS ECU coupler and ABS motor fuse.
(Red/Blue–Red/Blue)
• Between ABS ECU coupler and ground.
(Black–Black)
4 Defective hydraulic unit assembly If the above items were performed and no malfunctions
were found, replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)
(GDR155-A)” on page 4-47.
Fault code No. 34
Item
Hydraulic unit assembly (short circuit in ABS motor power supply cir-
cuit)
Symptom
Short circuit is detected in the motor power supply circuit in the hy-
draulic unit assembly.
Order Item/components and probable cause Check or maintenance job
1 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)
(GDR155-A)” on page 4-47.
B63-F8197-EZ.book Page 96 Monday, January 23, 2017 4:12 PM
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
8-97
Fault code No. 41
Fault code No. 43
Fault code No. 41
Item
Front wheel ABS (intermittent wheel speed pulses or incorrect de-
pressurization)
Symptom
• Pulses from the front wheel sensor are received intermittently while
the vehicle is traveling.
• Front wheel will not recover from the locking tendency even though
the signal is transmitted from the ABS ECU to reduce the hydraulic
pressure.
Order Item/components and probable cause Check or maintenance job
1 Incorrect installation of the front wheel
sensor
Check the components for looseness, distortion, and
bends.
Refer to “CHECKING THE FRONT WHEEL” on page
4-22.
2 Incorrect rotation of the front wheel Check that there is no brake disc drag on the front wheel
and make sure that it rotates smoothly.
Refer to “CHECKING THE FRONT WHEEL” on page
4-22 and “CHECKING THE FRONT BRAKE DISC” on
page 4-36.
3 Front brake dragging Check that the brake fluid pressure is correctly transmit-
ted to the brake caliper when the brake lever is operated
and that the pressure decreases when the lever is re-
leased.
Refer to “CHECKING THE FRONT BRAKE DISC” on
page 4-36.
4 Defective hydraulic unit assembly If the above items were performed and no malfunctions
were found, replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)
(GDR155-A)” on page 4-47.
Fault code No. 43
Item Front wheel sensor (missing pulses)
Symptom
Front wheel sensor signal is not received properly. (Missing pulses
are detected in the signal while the vehicle is traveling.)
Order Item/components and probable cause Check or maintenance job
1 Foreign material adhered around the front
wheel sensor
Check the surface of the sensor rotor and wheel sensor
for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.
2 Incorrect installation of the front wheel Check the components for looseness, distortion, and
bends.
Refer to “CHECKING THE FRONT WHEEL” on page
4-22.
3 Defective sensor rotor or incorrect instal-
lation of the rotor
Check the surface of the sensor rotor for damage. Re-
place the sensor rotor if there is visible damage.
Refer to “MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR” on page 4-23.
4 Defective front wheel sensor or incorrect
installation of the sensor
Check the wheel sensor for damage and the installed
condition of the sensor. Repair or replace the wheel
sensor if necessary.
Refer to “MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR” on page 4-23.
B63-F8197-EZ.book Page 97 Monday, January 23, 2017 4:12 PM
8-98
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
Fault code No. 51
Fault code No. 52
Fault code No. 51
Item
Vehicle system power supply (voltage of ABS ECU power supply is
high)
Symptom
Power voltage supplied to the ABS ECU in the hydraulic unit assem-
bly is too high.
Order Item/components and probable cause Check or maintenance job
1 Defective battery Recharge or replace the battery.
Refer to “CHECKING AND CHARGING THE BATTERY”
on page 8-124.
2 Disconnected battery terminal Check the connection. Replace or reconnect the termi-
nal if necessary.
3 Defective charging system Check the charging system.
Refer to “CIRCUIT DIAGRAM (GDR155)” on page 8-21.
Fault code No. 52
Item
Vehicle system power supply (voltage of wheel sensor power supply
is high)
Symptom Power voltage supplied to the wheel sensor is too high.
Order Item/components and probable cause Check or maintenance job
1 Defective battery Recharge or replace the battery.
Refer to “CHECKING AND CHARGING THE BATTERY”
on page 8-124.
2 Disconnected battery terminal Check the connection. Replace or reconnect the termi-
nal if necessary.
3 Defective charging system Check the charging system.
Refer to “CIRCUIT DIAGRAM (GDR155)” on page 8-21.
B63-F8197-EZ.book Page 98 Monday, January 23, 2017 4:12 PM
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
8-99
Fault code No. 53
TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.
Fault code No. 54
TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.
Fault code No. 53
Item
Vehicle system power supply (voltage of ABS ECU power supply is
low)
Symptom
Power voltage supplied to the ABS ECU in the hydraulic unit assem-
bly is too low.
Order Item/components and probable cause Check or maintenance job
1 Defective battery Recharge or replace the battery.
Refer to “CHECKING AND CHARGING THE BATTERY”
on page 8-124.
2 Defective coupler between the battery
and the hydraulic unit assembly
• Check the coupler for any pins that may be pulled out.
• Check the locking condition of the coupler.
• If there is a malfunction, repair it and connect the cou-
pler securely.
See TIP.
3 Open or short circuit in the wire harness
between the battery and the hydraulic unit
assembly
• Replace if there is an open or short circuit.
• Between ABS ECU coupler and ABS control unit fuse.
(Brown–Brown)
4 Defective charging system Check the charging system.
Refer to “CIRCUIT DIAGRAM (GDR155)” on page 8-21.
Fault code No. 54
Item
Hydraulic unit assembly (defective ABS solenoid and ABS motor
power supply circuits)
Symptom
Abnormality is detected in the solenoid or motor power supply circuit
in the hydraulic unit assembly.
Order Item/components and probable cause Check or maintenance job
1 Defective battery Recharge or replace the battery.
Refer to “CHECKING AND CHARGING THE BATTERY”
on page 8-124.
2 Defective coupler between the battery
and the hydraulic unit assembly
• Check the coupler for any pins that may be pulled out.
• Check the locking condition of the coupler.
• If there is a malfunction, repair it and connect the cou-
pler securely.
See TIP.
3 Open or short circuit in the wire harness
between the battery and the hydraulic unit
assembly
• Replace if there is an open or short circuit.
• Between ABS ECU coupler and ABS motor fuse.
(Red/Blue–Red/Blue)
• Between ABS ECU coupler and ABS solenoid fuse.
(Red–Red)
4 Defective charging system Check the charging system.
Refer to “CHARGING SYSTEM” on page 8-21.
B63-F8197-EZ.book Page 99 Monday, January 23, 2017 4:12 PM
8-100
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
Fault code No. 55
Fault code No. 56
5 Defective hydraulic unit assembly If the above items were performed and no malfunctions
were found, replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)
(GDR155-A)” on page 4-47.
Fault code No. 54
Item
Hydraulic unit assembly (defective ABS solenoid and ABS motor
power supply circuits)
Symptom
Abnormality is detected in the solenoid or motor power supply circuit
in the hydraulic unit assembly.
Order Item/components and probable cause Check or maintenance job
Fault code No. 55
Item Hydraulic unit assembly (defective ABS ECU)
Symptom Abnormal data is detected in the hydraulic unit assembly.
Order Item/components and probable cause Check or maintenance job
1 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)
(GDR155-A)” on page 4-47.
Fault code No. 56
Item Hydraulic unit assembly (abnormal internal circuit)
Symptom
Abnormality is detected in the internal circuit in the hydraulic unit as-
sembly.
Order Item/components and probable cause Check or maintenance job
1 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)
(GDR155-A)” on page 4-47.
B63-F8197-EZ.book Page 100 Monday, January 23, 2017 4:12 PM
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
8-101
Fault code No. 63
Fault code No. 63
Item Front wheel sensor power supply (voltage of power supply is low)
Symptom
Power voltage supplied from the ABS ECU to the front wheel sensor is
too low.
Order Item/components and probable cause Check or maintenance job
1 Short circuit in the wire harness between
the front wheel sensor and the hydraulic
unit assembly
• Check that there is no short circuit between the Green
terminal “1” and the Blue terminal “2”.
• Check that there is no short circuit between the
Black/White terminal “3” and the Green terminal “1”.
• If there is a short circuit, the wire harness is defective.
Replace the wire harness.
4. ABS ECU
5. Front wheel sensor
2 Defective front wheel sensor • Check that there is no short circuit between the Black
terminal “1” and the White terminal “2”.
• If there is a short circuit, the wheel sensor is defective.
Repair or replace the wheel sensor.
3. ABS ECU
4. Front wheel sensor
3 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)
(GDR155-A)” on page 4-47.
LG
W
B
R
L/RL/BY/L
B/W
R/LB/Y
Br
W/L
LGWB
1
4
5
2
3
LG
W
B
R
L/RL/BY/L
B/W
R/LB/Y
Br
W/L
LGWB
2
3
4
1
B63-F8197-EZ.book Page 101 Monday, January 23, 2017 4:12 PM
8-102
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
Fault code No. 95
TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.
EAS31167
[B-3] DELETING THE FAULT CODES
To delete the fault codes, use the Yamaha diagnostic tool. For information about deleting the fault
codes, refer to the operation manual of the Yamaha diagnostic tool.
Check that all the displayed fault codes are deleted.
Connecting the Yamaha diagnostic tool
Remove the protective cap “1”, and then connect the Yamaha diagnostic tool to the coupler.
EAS31168
[C-1] FINAL CHECK
Check all the following items to complete the inspection.
If the process is not completed properly, start again from the beginning.
Fault code No. 95
Item K-Line communication
Symptom K-Line data is not received properly.
Order Item/components and probable cause Check or maintenance job
1 Defective coupler in the K-Line communi-
cation circuit (SGCU, meter assembly,
and ABS ECU)
• Check the coupler for any pins that may be pulled out.
• Check the locking condition of the coupler.
• If there is a malfunction, repair it and connect the cou-
pler securely.
See TIP.
2 Open or short circuit in the wire harness
in the K-Line communication circuit
(SGCU, meter assembly, and ABS ECU)
• Replace if there is open or short circuit.
• Between SGCU coupler, meter assembly coupler, and
ABS ECU coupler.
(Yellow/Blue–Yellow/Blue)
3 Defective unit (SGCU or meter assembly)
connected to the K-Line communication
circuit
Replace the SGCU or meter assembly.
Refer to “REPLACING THE SGCU (starter generator
control unit)” on page 8-124.
4 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)
(GDR155-A)” on page 4-47.
Yamaha diagnostic tool USB
90890-03250
Yamaha diagnostic tool (A/I)
90890-03252
1
B63-F8197-EZ.book Page 102 Monday, January 23, 2017 4:12 PM
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
8-103
Checking procedures
1. Check the brake fluid level in the front brake master cylinder reservoir.
Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-10.
2. Check the wheel sensor for proper installation.
Refer to “INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC)” on page 4-25.
3. Perform brake line routing confirmation.
Refer to “HYDRAULIC UNIT OPERATION TESTS” on page 4-51.
If it does not have reaction-force properly, the brake hose is not properly routed or connected.
4. Delete the fault codes.
Refer to “[B-3] DELETING THE FAULT CODES” on page 8-102.
5. Checking the ABS warning light.
Check that the ABS warning light goes off.
If the ABS warning light does not come on or if it does not go off, refer to “CHECKING THE ABS
WARNING LIGHT” on page 4-54.
If the ABS warning light does not turn off, the possible causes are following:
• The problem is not solved.
• Open circuit between the ABS ECU and the meter assembly.
Check for continuity between White/Blue terminal of the ABS ECU coupler and White/Blue terminal
of the meter assembly coupler.
• Malfunction in the meter assembly circuit.
• Malfunction in the ABS warning light circuit in the hydraulic unit assembly.
B63-F8197-EZ.book Page 103 Monday, January 23, 2017 4:12 PM
8-104
ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)
B63-F8197-EZ.book Page 104 Monday, January 23, 2017 4:12 PM
SMART KEY SYSTEM (GDR155-A)
8-105
EAS20201
SMART KEY SYSTEM (GDR155-A)
EAS31452
CIRCUIT DIAGRAM
ON
OPEN
OFF
LOCK
L
PUSH
R
ON
OFF
HI
LO
PUSH
FREE
PUSH
FREE
ON
OFF
B
W/R
B
B/Y
B
L
R/W
B
(B)
R/W
B
(B)
Br
R
G/W
Br
R/Y
R
(B)
ChB
L/Y
R/BY/L
G/W
Dg
R/W
Br
W/R
B/Y
R
R/B
R
R
Br/R
R/W,B r
B/W,B
B
R
(B)
Br/R
R
Y/R
Br
R/B
RWG
R/YR/L
R/W
(B)
B/LG/R
(B)
B/L
Y L
P/WBr/W
Gy/R
(B)
B
(B)
(B)
G/Y
W/R
B/Y
O
P
O/B
G
B/W
W/L
Ch
Sb Y
B
/
L
Br/B
R/B
Gy
B/L
W/B
L
W/Y
R
Br/W
B
P/WR/W
L/B
B/L
G/R
Y/LB/R
Gy/R
L/Y
W/G
W
B
Y/BY/R
GWR
G
L/Y
W/R
Br/B
W/L
W/B
(B)
W/R
W/LBr/B
W/Y
B/L
W/B
(B)
(B)
P
G/Y
Sb Gy
Br
(B)
O/B
(Gy)
G
Ch
B/W
R
Y/L Y/L
(B)
R
B/Y
(Gy)
G
B/W
LG
W
B
L/RL/B
RB
R
L/RL/BY/L
B/W
R/LB/Y
Br
W/L
LGWB
B/Y
Br
(B)
BB
Br B
BBr
B
B
(L)
L/Y
B
(L)
Br
Br/W
Br/B
Br/W
(R)
L
Y/R
B/Y
L/B
(B)
B
W/G
B
L/W
(B)
B/W
Y/W
(R)
Br
G
(L)
Dg
Ch
Br/W
(R)
Y
L
(R)
L/B
Y
(L)
Br/B
Ch
Dg
(B)
B
Dg
Ch
(B)
Ch
Dg
B
P
B
P
B
Br
B
L
B
L
Y
B
(B)
YBr
B
Br
W/R
Y/B
R
Y
BCh
W/L
Dg
Y/L
B/W
G
(Gy)
Y
G
B
GY
Y/B
R
Br
BrBr
Br
Br
R
R
RR
BB
B
R
G/W
Br/R
R
Br
Br Br
Br
Br
R
RR
R
R
B
R
B
Br/R
B/W
Br/R
Br/R
RBr
Br
R/B
R
R
R
Br
Br Br
Br
Br
Br
Br
Br
Br
R
R
R
R
R
RR
RR
G/W
R
B
L
B
B
B
B
B
B
BBBB
B
BBBB
BBBBBB
B
G/W
R/W
R/Y
B/Y
Br
R/W
L/Y
W/R
R/W
R/B
Y/R
Br/R
Br/R
R/B
Dg
Ch
B
Y/L
G/W
B/Y
Br
W/R
W/R
R/L
R/W
R/Y
R/W
R/L
P/W
W/G
Br/W
Gy/RGy/R
L/B
L/Y
G/R
B/L
G/R
B/L
B/L
L
W
B
Y
P/W
Br/W
B/L
L
Y
W
R
R
W/R
W/L
W/B
W/Y
Br/B
B/L
G/Y
Gy
Sb
O/B
B/Y B/Y
R
G
B/W
Ch
Y/LY/LY/L
R
B/W
R/B
L/BL/B
L/RL/R
Y/R
Y/B
Y/B
B/R
B/R
B/W
B/W
O
G
O
Br
P
G
G
L
B
W
G
WBr
R
R/L
W/L
B/Y
B/YB/Y
B/Y
B/Y
L/BL/B
W/GW/G
B/Y
B/Y
B
B
B
B
Br
Br
Br
Br
Br
Br
P
PL
Br/W
Br/W
Br/B
Br/B
DgCh
Ch
Ch
Ch Ch
Ch
Dg
Ch Dg
YBr Br
B
B
BB
B
LL
B
Ch Dg
Dg
Dg Dg
Dg
BY
Y
Y
Y
YG
Br/WL/B
Br
Br Br
B/YB/Y
Y
L
B
B/WY/L
R
B
W/R
W/L
W/B
W/Y
Br/B
B/L
L/Y
G/Y
Gy
Sb
O/B
Br
Ch
P
G
B
B
B
B/W
G
W
R
G
Y/L
Y/L
Y/LY/L
L/YL/Y
L/Y
L/Y
B
B
L/B
G
B/WL/W
L
Y/W
B
Y/R
W/GB/Y
Br
Br
Br Br
B
B
B
B
B
Br
G
L
G
B
B
B
B
B
Br Br
Br
Y/B
B
Y/B
W/RB/W
Y/L
RChDgY
Br G
B
W/L
1
2
3
4
5
6
7
8
9
10
11
12
13
14
16
15
17
18
19
20
21
22 23 24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43 43
78 78
44
45
46
4748
49
50
51 52 53 54 55 56 57 58 59
60
61
62
63
64
65 66
67
68
69 7071727374
7576
77
B63-F8197-EZ.book Page 105 Monday, January 23, 2017 4:12 PM
8-106
SMART KEY SYSTEM (GDR155-A)
1. Battery
5. Main fuse
6. Smart key system fuse
9. Backup fuse
10.Ignition fuse
14.Main switch
15.Request switch
16.Main switch solenoid
17.Smart key unit
18.Buzzer
25.Sidestand switch
33.SGCU (starter generator control unit)
42.Yamaha diagnostic tool coupler
43.Engine ground 2
49.Meter assembly
50.Multi-function meter
58.Smart key system indicator light
71.Rear turn signal light (right)
72.Rear turn signal light (left)
73.Front turn signal light (right)
74.Front turn signal light (left)
77.Frame ground
78.Engine ground 1
B63-F8197-EZ.book Page 106 Monday, January 23, 2017 4:12 PM
SMART KEY SYSTEM (GDR155-A)
8-107
EAS31453
TROUBLESHOOTING
Vehicle power does not turn on. (Meter light and tail/brake light do not come on.)
Engine does not start even though vehicle power is turned on.
Seat does not open. (Vehicle power is turned on.)
Fuel lid does not open. (Vehicle power is turned on.)
Answer back function does not operate.
TIP
Before troubleshooting, remove the following part(s):
1. Battery cover
2. Storage box
3. Front cowling assembly
Checking the vehicle power
NG
OK
NG
OK
NG
OK
NG
OK
NG
OK
1. Check the smart key.
The smart key indicator light
comes on when the smart key but-
ton is pushed.
Check the button cell battery.
Refer to “CHECKING THE SMART
KEY BATTERY (GDR155-A)” on
page 8-133.
Replace the button cell battery of the
smart key. Standard battery: CR2032
2. Check the fuses.
(Main, backup, ignition, and smart
key system)
Refer to “CHECKING THE FUS-
ES” on page 8-124.
Replace the fuse(s).
3. Check the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 8-124.
• Clean the battery terminals.
• Recharge or replace the battery.
4. Check the main switch and request
switch.
Refer to “CHECKING THE
SWITCHES” on page 8-120.
Replace the main switch.
5. Check the main switch solenoid.
Refer to “CHECKING THE MAIN
SWITCH SOLENOID (GDR155-A)”
on page 8-134.
Replace the main switch.
B63-F8197-EZ.book Page 107 Monday, January 23, 2017 4:12 PM
8-108
SMART KEY SYSTEM (GDR155-A)
NG
OK
Checking the smart key system
Before checking the smart key system, make sure that the smart key is located within the operating
range of the smart key system and that the key is turned on.
Vehicle power does not turn on. (Meter light and tail light do not come on.)
TIP
• Before performing this procedure, make sure that there are no sources of strong electromagnetic
waves in the vicinity. (Because the amount of electromagnetic waves will change if the vehicle is
moved a short distance, move the vehicle away from sources of strong electromagnetic waves before
performing the procedure.)
• Use the smart key that is registered to the vehicle.
NG
OK
Engine does not start even though vehicle power is turned on.
NO
YES
NG
OK
6. Check the entire smart key sys-
tem’s wiring.
Refer to “CIRCUIT DIAGRAM” on
page 8-105.
Properly connect or replace the wire har-
ness.
Replace the smart key unit.
1. Check the vehicle power.
Refer to “Checking the vehicle pow-
er”.
Repair or replace any defective parts.
• There are sources of strong electro-
magnetic waves in the vicinity
Move the vehicle.
• Smart key malfunction Register
and use a different smart key.
• Smart key unit malfunction Re-
place the smart key unit.
1. When the vehicle power is turned
on, the smart key system indicator
light “ ” flashes 4 times.
Refer to “SMART KEY SYSTEM
SELF-DIAGNOSIS” on page 8-111.
Check and repair the electric starting sys-
tem. Refer to “ELECTRIC STARTING
SYSTEM” on page 8-7.
2. Turn the main switch to “OFF”, and
then push the main switch and
check that it can be turned back to
“ON”.
Repair or replace any defective parts. Re-
fer to “Checking the vehicle power”.
B63-F8197-EZ.book Page 108 Monday, January 23, 2017 4:12 PM
SMART KEY SYSTEM (GDR155-A)
8-109
NG
OK
Seat does not open. (Vehicle power is turned on.)
NG
OK
Fuel lid does not open. (Vehicle power is turned on.)
NG
OK
Answer back function does not operate.
NG
OK
NG
OK
3. Check for continuity in the commu-
nication line between the SGCU
and the smart key unit (Yel-
low/Blue).
Replace the wire harness.
• Replace the SGCU.
Refer to “REPLACING THE SGCU
(starter generator control unit)” on
page 8-124.
• Replace the smart key unit.
1. Check the vehicle power.
Refer to “Checking the vehicle pow-
er”.
Repair or replace any defective parts.
• Check the mechanical components
of the lock for malfunctions. Repair or
replace any defective parts.
• Adjust or replace the seat lock cable.
1. Check the vehicle power.
Refer to “Checking the vehicle pow-
er”.
Repair or replace any defective parts.
• Check the mechanical components
of the lock for malfunctions. Repair or
replace any defective parts.
• Adjust or replace the fuel lid cable.
1. Check the vehicle power.
Refer to “Checking the vehicle pow-
er”.
Repair or replace any defective parts.
2. Check the buzzer operation.
Refer to “CHECKING THE BUZZ-
ER (GDR155-A)” on page 8-133.
Replace the buzzer.
B63-F8197-EZ.book Page 109 Monday, January 23, 2017 4:12 PM
SMART KEY SYSTEM (GDR155-A)
8-111
EAS31534
SMART KEY SYSTEM SELF-DIAGNOSIS
The smart key system is equipped with a self-diagnostic function. If a malfunction is detected in the sys-
tem, the malfunction will be indicated by the flash pattern of the smart key system indicator light “ ”.
TIP
The smart key system indicator light “ ” comes on for about 2 seconds when the vehicle power is on.
If one of the following malfunctions is detected, the indicator light starts flashing.
* The running detection error
If the smart key is dropped or can no longer be recognized while the vehicle is traveling. If the vehicle
travels while the smart key cannot be recognized, the smart key system indicator light “ ” flashes in
0.15-second intervals.
The vehicle can be ridden, but the vehicle power cannot be turned off.
Although a forced shutdown can be performed to turn off the vehicle power (the main switch is
pushed for 4 times within 2 seconds while the smart key system indicator light “ ” is flashing in 0.15-
second intervals), the vehicle power cannot be turned back on.
Communication error between the SGCU and the smart key unit
If a communication error between the SGCU and the smart key unit is detected, the following fault code
numbers will be displayed on the meter to indicate the location of the malfunction.
Item Flash pattern
Flashing time/number
of flashes
Malfunction and check
point
Low voltage of smart
key button cell battery
a.LED on
b.LED off
20 (seconds)
Replace the button cell
battery of the smart key.
Refer to “SMART KEY
SYSTEM (GDR155-A)”
on page 8-105.
Vehicle power off verifi-
cation error
a.LED on
b.LED off
30 (seconds)
The smart key cannot
be recognized.
Check that there are no
sources of strong elec-
tromagnetic waves in
the vicinity, the smart
key is not lost, and the
battery is not dis-
charged.
Running detection er-
ror*
a.LED on
b.LED off
Flashes continuously
until the error is re-
solved.
The smart key cannot
be recognized.
Check that there are no
sources of strong elec-
tromagnetic waves in
the vicinity, the smart
key is not lost, and the
battery is not dis-
charged.
• SGCU communica-
tion error
• Data error
• SGCU malfunction
a.LED on
b.LED off
Flashes continuously
until the error is re-
solved./flashes 4 times
in a repeating cycle
Check the wire harness.
Check the SGCU.
Check the smart key
unit.
0.5
(s)
0.5
(s)
a
b
0.15
(s)
0.15
(s)
a
b
0.15
(s)
0.15
(s)
a
b
0.3
(s)
0.3
(s)
1.0
(s)
a
b
B63-F8197-EZ.book Page 111 Monday, January 23, 2017 4:12 PM
8-112
SMART KEY SYSTEM (GDR155-A)
TIP
These fault code numbers are not stored in the memory of the SGCU. Note all of the displayed fault
code numbers, and then check the vehicle.
EAS31535
SMART KEY SYSTEM EMERGENCY MODE
If the smart key is lost or if it cannot be used due a discharged battery or malfunction, this mode can be
used to turn on the smart key system.
TIP
The emergency mode operation will be canceled if the respective steps are not carried out within the
time set for each operation.
Fault code
No.
Device that de-
tected the mal-
function
Symptom Cause
Check or maintenance
job
51 Smart key unit Communication error
between the smart key
and the smart key unit.
Radio wave noise inter-
ference.
• Lock condition in the
smart key
• Defective smart key
• Defective smart key
unit
Perform the checks and
maintenance job for
“Engine does not start
even though vehicle
power is turned on.”
53 Smart key unit Communication error
between the SGCU and
the smart key unit.
Radio wave noise inter-
ference or disconnect-
ed lead.
• Obstruction due to ra-
dio wave noise
• Disconnection in the
wire harness
• Defective SGCU
• Defective smart key
unit
Perform the checks and
maintenance job for
“Engine does not start
even though vehicle
power is turned on.”
54 Smart key unit Codes transmitted be-
tween the SGCU and
the smart key unit do
not match.
Radio wave noise inter-
ference or disconnect-
ed lead.
• Obstruction due to ra-
dio wave noise.
• Disconnection in the
wire harness
• Defective SGCU
(when the SGCU or
smart key unit is re-
placed with a unit
from a different vehi-
cle)
• Defective smart key
unit
Perform the checks and
maintenance job for
“Engine does not start
even though vehicle
power is turned on.”
56 SGCU Unidentified code is re-
ceived.
Radio wave noise inter-
ference or disconnect-
ed lead.
• Obstruction due to ra-
dio wave noise
• Disconnection in the
wire harness
• Defective SGCU
• Defective smart key
unit
Perform the checks and
maintenance job for
“Engine does not start
even though vehicle
power is turned on.”
B63-F8197-EZ.book Page 112 Monday, January 23, 2017 4:12 PM
SMART KEY SYSTEM (GDR155-A)
8-113
1. Stop the vehicle in a safe place and turn the main switch to “OFF”.
2. Push the main switch for 5 seconds until the smart key system indicator light flashes once, then re-
lease it. Repeat two more times. The smart key system indicator light “1” will come on for 3 seconds
to indicate the transition to emergency mode.
3. After the smart key system indicator light “ ” goes off, use the main switch to enter the smart key
identification number “1” located inside the smart key case (open the smart key case as shown) or
the identification number “2” located on the identification number card. (Refer to the following proce-
dure on how to input the identification number.)
4. The input identification number is indicated by the number of flashes of the smart key system indi-
cator light “ ” while the main switch is pushed.
For example, if the smart key identification number is 123456:
Push and hold the main switch.
The smart key system indicator light “ ” will start to flash.
1
868588
868588
21
B63-F8197-EZ.book Page 113 Monday, January 23, 2017 4:12 PM
8-114
SMART KEY SYSTEM (GDR155-A)
Release the main switch after the smart key system indicator light “ ” flashes 1 time.
The first digit of the identification number has been set as 1.
Push and hold the main switch again.
Release the main switch after the smart key system indicator light “ ” flashes 2 times.
The second digit of the identification number has been set as 2.
Repeat the above procedure until all 6 digits of the identification number have been set.
5. The smart key system indicator light “ ” will come on for 10 seconds if the correct 6-digit identifica-
tion number was entered.
TIP
When one of the following situations applies, emergency mode will be terminated and the smart key
system indicator light will flash quickly for 3 seconds. In this case, start over again from step 2.
• When there are no main switch operations for 10 seconds during the identification number input pro-
cess.
• When the smart key system indicator light is allowed to flash nine or more times.
• The identification number is not entered correctly.
6. While the smart key system indicator light is on, push the main switch once more to complete emer-
gency mode access. The smart key indicator light will go off and then come back on for approximate-
ly 4 seconds.
7. While the smart key system indicator light is on, turn the main switch to “ON”. The vehicle can now
be operated normally.
EAS31536
REGISTERING A SMART KEY
The following procedure can be used to register additional smart keys or a new smart key in case the
original smart key is lost.
TIP
• A maximum of 6 smart keys can be registered to the smart key unit.
• Be sure to register the smart keys one at a time. Do not register multiple smart keys at the same time.
B63-F8197-EZ.book Page 114 Monday, January 23, 2017 4:12 PM
SMART KEY SYSTEM (GDR155-A)
8-115
1. Place the smart key “1” that will be registered within 80 cm (31.5 in) “a” of the main switch.
2. Perform steps 1–5 in “SMART KEY SYSTEM EMERGENCY MODE” on page 8-112.
3. While the smart key system indicator light “ ” is on for 10 seconds, push the main switch “1” for 5
seconds until buzzer sounds once.
4. The smart key indicator light (red) “1” on the new smart key comes on for 10 seconds.
TIP
While the smart key indicator light on the smart key is on, the smart key system indicator light “ ” flash-
es according to the number of currently registered smart keys. (For example, if 5 smart keys are regis-
tered, the indicator light flashes 5 times.)
5. While the smart key indicator light is on for 10 seconds, push the button on the smart key to transmit
a signal from the smart key to the smart key unit.
6. If the smart key is registered successfully, the smart key system indicator light “ ” will come on for
3 seconds, and then the smart key system will turn off.
If the smart key was not registered successfully, the smart key system indicator light “ ” will flash for
3 seconds, and then the smart key system will turn off.
TIP
If this registration procedure is performed for a smart key that is already registered, the smart key sys-
tem indicator light “ ” will flash for 7 seconds (on for 0.2 second and off for 0.8 second).
EAS31537
DISABLING A SMART KEY
If a smart key is lost or stolen, the smart key can be disabled.
a
1
1
1
B63-F8197-EZ.book Page 115 Monday, January 23, 2017 4:12 PM
SMART KEY SYSTEM (GDR155-A)
8-116
1. Place all of the smart keys “1” 300 cm (118.1 in) “a” or more away from the vehicle or lock the com-
munication.
2. Perform steps 1–5 in “SMART KEY SYSTEM EMERGENCY MODE” on page 8-112.
3. While the smart key system indicator light “ ” is on for 10 seconds, perform the following procedure.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼▼▼
a. Push the main switch “1” 5 times or more until buzzer sounds 3 times.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲ ▲▲▲▲
4. Check that the smart key system indicator light “ ” goes off (the smart key disable mode is activat-
ed).
5. Turn on (unlocked setting) the smart keys that you want to enable and place them within 80 cm (31.5
in) of the smart key unit.
6. Push the main switch for 5 seconds or more to start the communication between the smart key unit
and the smart keys that are located within 80 cm (31.5 in) of the unit.
TIP
The number of smart keys that currently can be used will be indicated.
Number of flashes = Number of verified smart keys. (1 cycle of on for 0.3 second and off for 0.3 second
= 1 smart key)
7. Push the main switch for 5 seconds or more. The use of only the verified smart keys will be enabled.
The use of all other smart keys will be disabled.
TIP
If the procedure was not completed successfully, repeat the procedure from step 1.
a
1
1
B63-F8197-EZ.book Page 116 Monday, January 23, 2017 4:12 PM
SMART KEY SYSTEM (GDR155-A)
8-117
EASB631013
DISABLING THE POWER-ON ALARM
1. Place the smart key “1” that will be registered within 80 cm (31.5 in) “a” of the main switch.
2. Push the main switch and the smart key system indicator light will come on for approximately
4 sec-
onds
.
3. While the smart key system indicator light is on, turn the main switch to “ON”.
4. Extend and retract the sidestand by hand for 10 times or more within 15 seconds from vehicle power
on.
5. When the buzzer sounds, the setting is complete.
• If the buzzer sounds 2 times: The power-on alarm is turned off.
• If the buzzer sounds 1 times: The power-on alarm is turned on.
EAS31719
REPLACEMENT PARTS LIST
TIP
When replacing the parts, refer to the following sections.
• Refer to “SMART KEY SYSTEM EMERGENCY MODE” on page 8-112.
• Refer to “REGISTERING A SMART KEY” on page 8-114.
a
1
Faulty part
Required item when re-
placing parts
Replacement parts (when an item
is required in order to replace
parts)
Remarks
:
Required.
:
Replace.
:
Smart key identifi-
cation number or
smart key is re-
quired.
:
Do not replace.
:
Not required. * :
This part must be replaced
even if it is not faulty.
Smart key
identifica-
tion num-
ber
Smart key Smart key
Smart key
unit
SGCU
Smart key
Register the smart key identification
number in the emergency mode.
Smart key unit
* *
Replace the smart key, smart key unit,
and SGCU as a set.
SGCU
When the vehicle system is turned on,
the smart key identification number is
automatically registered to the SGCU.
Smart key unit/SGCU
*
Replace the smart key, smart key unit,
and SGCU as a set.
Smart key/Smart key unit
*
Replace the smart key, smart key unit,
and SGCU as a set.
B63-F8197-EZ.book Page 117 Monday, January 23, 2017 4:12 PM
8-118
SMART KEY SYSTEM (GDR155-A)
Smart key/SGCU
Register the smart key identification
number in the emergency mode.
When the vehicle system is turned on,
the smart key identification number is
automatically registered to the SGCU.
Smart key/Smart key
unit/SGCU
Replace the smart key, smart key unit,
and SGCU as a set.
Faulty part
Required item when re-
placing parts
Replacement parts (when an item
is required in order to replace
parts)
Remarks
:
Required.
:
Replace.
:
Smart key identifi-
cation number or
smart key is re-
quired.
:
Do not replace.
:
Not required. * :
This part must be replaced
even if it is not faulty.
Smart key
identifica-
tion num-
ber
Smart key Smart key
Smart key
unit
SGCU
B63-F8197-EZ.book Page 118 Monday, January 23, 2017 4:12 PM
ELECTRICAL COMPONENTS
8-119
EAS20089
ELECTRICAL COMPONENTS
1
2
3
4
5
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27,28,29,30
31
32
6
1. Smart key unit (GDR155-A)
2. Main relay
3. Starter charge relay
4. Fuse box
5. Battery
6. Main switch
7. Front brake light switch
8. Rear brake light switch
9. Auxiliary DC jack
10. Turn signal relay
11. ABS ECU (GDR155-A)
12. Buzzer (GDR155-A)
13. Diode (GDR155-A)
14. Horn
15. Front wheel sensor
16. SGCU (starter generator control unit)
17. Fuel pump
18. Fuel sender
19. Sidestand switch
20. VVA (variable valve actuator) solenoid
21. O
2
sensor
22. Spark plug
23. Coolant temperature sensor
24. Starter generator
25. Crankshaft position sensor
26. Ignition coil
27. Throttle body sensor assembly
28.Intake air pressure sensor
29. Intake air temperature sensor
30. Throttle position sensor
31. ISC (idle speed control) unit
32. Fuel injector
B63-F8197-EZ.book Page 119 Monday, January 23, 2017 4:12 PM
8-120
ELECTRICAL COMPONENTS
EAS30549
CHECKING THE SWITCHES
GDR155
ON
OPEN
OFF
LOCK
L
PUSH
R
HI
LO
PUSH
FREE
ON
OFF
PUSH
FREE
Br
R/Y
R
BB
B
B
Dg
Ch
Br/W
P
B
L
L
Y/R
Y/R
B
L/W
1
2
3
4
5
6
7
8
9
B
L/W
Br
R/Y
R
L/B
Y
Dg
Ch
Br/W
P
B
L/B
Y
1. Main switch
2. Light switch
3. Start switch
4. Front brake light switch
5. Sidestand switch
6. Rear brake light switch
7. Turn signal switch
8. Horn switch
9. Dimmer switch
B63-F8197-EZ.book Page 120 Monday, January 23, 2017 4:12 PM
ELECTRICAL COMPONENTS
8-121
GDR155-A
ON
OPEN
OFF
LOCK
L
PUSH
R
HI
LO
PUSH
FREE
ON
OFF
PUSH
FREE
ON
OFF
Br
R/Y
R
BB
B
B
Dg
Ch
Br/W
P
B
L
L
Y/R
Y/R
B
L/W
B
L/W
Y/W
B/W
Br
R/Y
R
L/B
Y
Dg
Ch
Br/W
P
B
L/B
Y
B
L
B/W
Y/W
B L
2
1
3
4
6
7
8
9
10
11
5
1. Main switch
2. Request switch
3. Light switch
4. Start switch
5. Stop and Start switch
6. Front brake light switch
7. Sidestand switch
8. Rear brake light switch
9. Turn signal switch
10.Horn switch
11. Dimmer switch
B63-F8197-EZ.book Page 121 Monday, January 23, 2017 4:12 PM
8-122
ELECTRICAL COMPONENTS
Check each switch for continuity with the digital circuit tester. If the continuity reading is incorrect, check
the wiring connections and if necessary, replace the switch.
NOTICE
ECA14371
Never insert the tester probes into the coupler terminal slots. Always insert the probes from the
opposite end “a” of the coupler, taking care not to loosen or damage the leads.
TIP
When checking for continuity, switch back and forth between the switch positions a few times.
The switches and their terminal connections are illustrated as in the following example of the main
switch.
The switch positions “a” are shown in the far left column and the switch lead colors “b” are shown in the
top row.
The continuity (i. e., a closed circuit) between switch terminals at a given switch position is indicated by
“ ”. There is continuity between red and brown when the switch is turned to “ON”.
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927
ON
OPEN
OFF
LOCK
Br
R/Y
R
Br
R/Y
R
b
a
B63-F8197-EZ.book Page 122 Monday, January 23, 2017 4:12 PM
ELECTRICAL COMPONENTS
8-123
EAS30550
CHECKING THE BULBS AND BULB
SOCKETS
TIP
Do not check any of the lights that use LEDs.
Check each bulb and bulb socket for damage or
wear, proper connections, and also for continuity
between the terminals.
Damage/wear Repair or replace the bulb,
bulb socket or both.
Improperly connected Properly connect.
No continuity Repair or replace the bulb, bulb
socket or both.
Types of bulbs
The bulbs used on this vehicle are shown in the
illustration.
• Bulbs “a” are used for turn signal and taillights
and can be removed from the socket by push-
ing and turning the bulb counterclockwise.
• Bulbs “b” are used for auxiliary lights and can
be removed from their respective sockets by
carefully pulling them out.
Checking the condition of the bulbs
The following procedure applies to all of the
bulbs.
1. Remove:
•Bulb
NOTICE
ECA22810
Be sure to hold the socket firmly when re-
moving the bulb. Never pull the lead, other-
wise it may be pulled out of the terminal in
the coupler.
2. Check:
• Bulb (for continuity)
(with the digital circuit tester)
No continuity Replace.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Connect the positive tester probe to terminal
“1” and the negative tester probe to terminal
“2”, and check the continuity.
b. Connect the positive tester probe to terminal
“1” and the negative tester probe to terminal
“3”, and check the continuity.
c. If either of the readings indicate no continuity,
replace the bulb.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
Checking the condition of the bulb sockets
The following procedure applies to all of the bulb
sockets.
1. Check:
• Bulb socket (for continuity)
(with the digital circuit tester)
No continuity Replace.
TIP
Check each bulb socket for continuity in the
same manner as described in the bulb section;
however, note the following.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Install a good bulb into the bulb socket.
b. Connect the digital circuit tester probes to the
respective leads of the bulb socket.
c. Check the bulb socket for continuity. If any of
the readings indicate no continuity, replace
the bulb socket.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927
B63-F8197-EZ.book Page 123 Monday, January 23, 2017 4:12 PM
8-124
ELECTRICAL COMPONENTS
EAS30551
CHECKING THE FUSES
The following procedure applies to all of the fus-
es.
NOTICE
ECA20520
To avoid a short circuit, always turn the main
switch to “OFF” when checking or replacing
a fuse.
1. Remove:
• Battery cover
Refer to “GENERAL CHASSIS (1)” on page
4-1.
2. Check:
•Fuse
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Connect the digital circuit tester to the fuse
and check the continuity.
b. If there is no continuity, replace the fuse.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
3. Replace:
•Blown fuse
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Turn the main switch to “OFF”.
b. Install a new fuse of the correct amperage
rating.
c. Set on the switches to verify if the electrical
circuit is operational.
d. If the fuse immediately blows again, check
the electrical circuit.
WARNING
EWA13310
Never use a fuse with an amperage rating
other than that specified. Improvising or us-
ing a fuse with the wrong amperage rating
may cause extensive damage to the electri-
cal system, cause the lighting and ignition
systems to malfunction and could possibly
cause a fire.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
4. Install:
• Battery cover
Refer to “GENERAL CHASSIS (1)” on page
4-1.
EAS31006
REPLACING THE SGCU (starter generator
control unit)
1. Turn the main switch to “OFF”.
2. Replace the SGCU (starter generator control
unit).
3. Clean the throttle body.
Refer to “CLEANING THE ISC (IDLE SPEED
CONTROL) UNIT AND THROTTLE BODY”
on page 7-12.
4. Check:
• Engine idling speed
Start the engine, warm it up, and then mea-
sure the engine idling speed.
EAS30552
CHECKING AND CHARGING THE BATTERY
WARNING
EWA13290
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of poi-
sonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
• Wear protective eye gear when handling or
working near batteries.
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927
Fuses
Amperage
rating
Q’ty
Main 30 A 1
ABS motor (GDR155-A) 10 A 1
Fuel injection system 7.5 A 1
Ignition 7.5 A 1
Signaling system 7.5 A 1
Backup 7.5 A 1
Headlight 7.5 A 1
ABS solenoid (GDR155-A) 7.5 A 1
Auxiliary DC jack 2 A 1
Smart key system
(GDR155-A)
2 A 1
ABS control unit
(GDR155-A)
2 A 1
Spare 30 A 1
Spare 10 A 1
Spare 7.5 A 1
Spare 2 A 1
Engine idling speed
1500–1700 r/min
Fuses
Amperage
rating
Q’ty
B63-F8197-EZ.book Page 124 Monday, January 23, 2017 4:12 PM
ELECTRICAL COMPONENTS
8-125
• Charge batteries in a well-ventilated area.
• Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
• DO NOT SMOKE when charging or han-
dling batteries.
• KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
• Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
• Skin — Wash with water.
• Eyes — Flush with water for 15 minutes and
get immediate medical attention.
INTERNAL
• Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg or
vegetable oil. Get immediate medical atten-
tion.
NOTICE
ECA20530
• This is a VRLA (Valve Regulated Lead Acid)
battery. Never remove the sealing caps be-
cause the balance between cells will not be
maintained and battery performance will
deteriorate.
• Charging time, charging amperage and
charging voltage for a VRLA (Valve Regu-
lated Lead Acid) battery are different from
those of conventional batteries. The VRLA
(Valve Regulated Lead Acid) battery should
be charged according to the appropriate
charging method. If the battery is over-
charged, the electrolyte level will drop con-
siderably. Therefore, take special care
when charging the battery.
TIP
Since VRLA (Valve Regulated Lead Acid) bat-
teries are sealed, it is not possible to check the
charge state of the battery by measuring the
specific gravity of the electrolyte. Therefore, the
charge of the battery has to be checked by mea-
suring the voltage at the battery terminals.
1. Remove:
• Battery cover
Refer to “GENERAL CHASSIS (1)” on page
4-1.
2. Disconnect:
• Battery leads
(from the battery terminals)
NOTICE
ECA13640
First, disconnect the negative battery lead
“1”, and then positive battery lead “2”.
3. Remove:
•Battery
4. Check:
• Battery charge
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Connect a digital circuit tester to the battery
terminals.
TIP
• The charge state of an VRLA (Valve Regulated
Lead Acid) battery can be checked by measur-
ing its open-circuit voltage (i.e., the voltage
when the positive battery terminal is discon-
nected).
• No charging is necessary when the open-cir-
cuit voltage equals or exceeds 12.8 V.
b. Check the charge of the battery, as shown in
the charts and the following example.
• Positive tester probe
positive battery terminal
• Negative tester probe
negative battery terminal
Example
Open-circuit voltage = 12.0 V
Charging time = 6.5 hours
Charge of the battery = 20–30%
2
1
B63-F8197-EZ.book Page 125 Monday, January 23, 2017 4:12 PM
8-126
ELECTRICAL COMPONENTS
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
5. Charge:
• Battery
(refer to the appropriate charging method)
WARNING
EWA13300
Do not quick charge a battery.
NOTICE
ECA13671
• Do not use a high-rate battery charger
since it forces a high-amperage current
into the battery quickly and can cause bat-
tery overheating and battery plate damage.
• If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
• When charging a battery, be sure to remove
it from the vehicle. (If charging has to be
done with the battery mounted on the vehi-
cle, disconnect the negative battery lead
from the battery terminal.)
• To reduce the chance of sparks, do not
plug in the battery charger until the battery
charger leads are connected to the battery.
• Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.
• Make sure the battery charger lead clips are
in full contact with the battery terminal and
that they are not shorted. A corroded bat-
tery charger lead clip may generate heat in
the contact area and a weak clip spring may
cause sparks.
• If the battery becomes hot to the touch at
any time during the charging process, dis-
connect the battery charger and let the bat-
tery cool before reconnecting it. Hot
batteries can explode!
• As shown in the following illustration, the
open-circuit voltage of a VRLA (Valve Reg-
ulated Lead Acid) battery stabilizes about
30 minutes after charging has been com-
pleted. Therefore, wait 30 minutes after
charging is completed before measuring
the open-circuit voltage.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
Charging method using a variable-current
(voltage) charger
a. Measure the open-circuit voltage prior to
charging.
TIP
Voltage should be measured 30 minutes after
the engine is stopped.
b. Connect a charger and ammeter to the bat-
tery and start charging.
A. Open-circuit voltage (V)
B. Charging time (hours)
C. Relationship between the open-circuit voltage
and the charging time at 20 °C (68 °F)
D. These values vary with the temperature, the
condition of the battery plates, and the
electrolyte level.
A. Open-circuit voltage (V)
B. Charging condition of the battery (%)
C. Ambient temperature 20 °C (68 °F)
A. Open-circuit voltage (V)
B. Time (minutes)
C. Charging
D. Ambient temperature 20 °C (68 °F)
E. Check the open-circuit voltage.
B63-F8197-EZ.book Page 126 Monday, January 23, 2017 4:12 PM
ELECTRICAL COMPONENTS
8-127
TIP
Set the charging voltage to 16–17 V. If the set-
ting is lower, charging will be insufficient. If too
high, the battery will be over-charged.
c. Make sure that the current is higher than the
standard charging current written on the bat-
tery.
TIP
If the current is lower than the standard charging
current written on the battery, set the charging
voltage adjust dial at 20–24 V and monitor the
amperage for 3–5 minutes to check the battery.
d. Adjust the voltage so that the current is at the
standard charging level.
e. Set the time according to the charging time
suitable for the open-circuit voltage.
f. If charging requires more than 5 hours, it is
advisable to check the charging current after
a lapse of 5 hours. If there is any change in
the amperage, readjust the voltage to obtain
the standard charging current.
g. Measure the battery open-circuit voltage after
leaving the battery unused for more than 30
minutes.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
Charging method using a constant volt-
age charger
a. Measure the open-circuit voltage prior to
charging.
TIP
Voltage should be measured 30 minutes after
the engine is stopped.
b. Connect a charger and ammeter to the bat-
tery and start charging.
c. Make sure that the current is higher than the
standard charging current written on the bat-
tery.
TIP
If the current is lower than the standard charging
current written on the battery, this type of battery
charger cannot charge the VRLA (Valve Regu-
lated Lead Acid) battery. A variable voltage
charger is recommended.
d. Charge the battery until the battery’s charg-
ing voltage is 15 V.
TIP
Set the charging time at 20 hours (maximum).
e. Measure the battery open-circuit voltage after
leaving the battery unused for more than 30
minutes.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
6. Install:
•Battery
7. Connect:
• Battery leads
(to the battery terminals)
NOTICE
ECA13630
First, connect the positive battery lead “1”,
and then the negative battery lead “2”.
8. Check:
• Battery terminals
Dirt Clean with a wire brush.
Loose connection Connect properly.
9. Lubricate:
• Battery terminals
10.Install:
• Battery cover
Refer to “GENERAL CHASSIS (1)” on page
4-1.
• Standard charging current is reached
Battery is good.
• Standard charging current is not reached
Replace the battery.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
Recommended lubricant
Dielectric grease
1
2
B63-F8197-EZ.book Page 127 Monday, January 23, 2017 4:12 PM
8-128
ELECTRICAL COMPONENTS
EAS30553
CHECKING THE RELAYS
Check each switch for continuity with the digital
circuit tester. If the continuity reading is incor-
rect, replace the relay.
1. Disconnect the relay from the wire harness.
2. Connect the digital circuit tester and battery
(12 V) to the relay terminals as shown.
Check the relay operation.
Out of specification Replace.
Main relay
Starter charge relay
First step:
Second step:
EAS30554
CHECKING THE TURN SIGNAL RELAY
1. Check:
• Turn signal relay input voltage
Out of specification The wiring circuit from
the main switch to the turn signal relay cou-
pler is faulty and replace the wire harness.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Connect the digital circuit tester to the turn
signal relay terminal as shown.
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
Result
Continuity
(between “3” and “4”)
1. Positive tester probe
2. Negative tester probe
3. Negative tester probe
+
R
Br/R
R/W,Br
B/W,B
1
2
3
4
Y
/R
R
Br
1
3
2
Br/R
R
/B
Result
Continuity
(between “1” and “2”)
No continuity
(between “1” and “3”)
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
5. Negative tester probe
Result
No continuity
(between “3” and “4”)
Continuity
(between “3” and “5”)
Turn signal relay input voltage
DC 12V
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927
• Positive tester probe
Brown “1”
• Negative tester probe
Ground
+
Y/R
R
R/B
Br
2
1
3
5
4
Br/R
B63-F8197-EZ.book Page 128 Monday, January 23, 2017 4:12 PM
ELECTRICAL COMPONENTS
8-129
b. Turn the main switch to “ON”.
c. Measure the turn signal relay input voltage.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
2. Check:
• Turn signal relay output voltage
Out of specification Replace.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Connect the digital circuit tester to the turn
signal relay terminal as shown.
b. Turn the main switch to “ON”.
c. Measure the turn signal relay output voltage.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS30555
CHECKING THE DIODE (GDR155-A)
1. Check:
• Diode
Out of specification Replace.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Disconnect the diode from the wire harness.
b. Connect the digital circuit tester to the diode
terminals.
c. Check the diode for continuity.
d. Check the diode for no continuity.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS30556
CHECKING THE IGNITION SPARK GAP
1. Check:
• Ignition spark gap
Out of specification Perform the ignition
system troubleshooting, starting with step 5.
Refer to “TROUBLESHOOTING” on page
8-5.
TIP
If the ignition spark gap is within specification,
the ignition system circuit is operating normally.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Disconnect the spark plug cap from the spark
plug.
b. Connect the ignition checker “1” as shown.
Turn signal relay output voltage
DC 12V
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927
• Positive tester probe
Brown/White “1”
• Negative tester probe
Ground
Br/W
Br
1
Br/W
Br
1
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927
Continuity
Positive tester probe
Brown/White “1”
Negative tester probe
Brown/Black “2”
No continuity
Positive tester probe
Blue/Black “2”
Negative tester probe
Brown/White “1”
Minimum ignition spark gap
6.0 mm (0.24 in)
Br/B
Br/W
2
1
B63-F8197-EZ.book Page 129 Monday, January 23, 2017 4:12 PM
8-130
ELECTRICAL COMPONENTS
c. Turn the main switch to “ON”.
d. Measure the ignition spark gap “a”.
e. Crank the engine by pushing the “ ” of the
start switch and gradually increase the spark
gap until a misfire occurs.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS30557
CHECKING THE SPARK PLUG CAP
1. Check:
• Spark plug cap resistance
Out of specification Replace.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Remove the spark plug cap from the spark
plug lead.
b. Connect the digital circuit tester to the spark
plug cap as shown.
c. Measure the spark plug cap resistance.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS30558
CHECKING THE IGNITION COIL
1. Check:
• Primary coil resistance
Out of specification Replace.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Disconnect the ignition coil connectors from
the ignition coil terminals.
b. Connect the digital circuit tester to the ignition
coil as shown.
c. Measure the primary coil resistance.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
2. Check:
• Secondary coil resistance
Out of specification Replace.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Connect the digital circuit tester to the ignition
coil as shown.
Ignition checker
90890-06754
Oppama pet–4000 spark checker
YM-34487
2. Ignition coil
Resistance
3.75–6.25 k
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927
Primary coil resistance
2.16–2.64
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927
• Positive tester probe
Brown “1”
• Negative tester probe
Orange “2”
Secondary coil resistance
8.64–12.96 k
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927
B63-F8197-EZ.book Page 130 Monday, January 23, 2017 4:12 PM
ELECTRICAL COMPONENTS
8-131
b. Measure the secondary coil resistance.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS30566
CHECKING THE STARTER GENERATOR
1. Disconnect:
• Starter generator coupler
(from the wire harness)
2. Check:
• Starter generator resistance
Out of specification Replace the starter
generator assembly.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Connect the digital circuit tester to the starter
generator coupler as shown.
b. Measure the starter generator resistance.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS30573
CHECKING THE FUEL SENDER
1. Remove:
• Fuel pump
(from the fuel tank)
2. Check:
• Fuel sender resistance
Out of specification Replace the fuel pump
assembly.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Connect the digital circuit tester to the fuel
sender terminals as shown.
b. Move the fuel sender float to minimum “3”
and maximum “4” level position.
• Positive tester probe
Brown “1”
• Negative tester probe
High tension cord “2”
Starter generator resistance
0.048–0.072
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927
• Positive tester probe
Red/Yellow “1”
• Negative tester probe
Red/Blue “2”
• Positive tester probe
Red/Yellow “1”
• Negative tester probe
Red/White “3”
• Positive tester probe
Red/Blue “2”
• Negative tester probe
Red/White “3”
Fuel sender
Sender unit resistance (full)
10.0–14.0
Sender unit resistance (empty)
267.0–273.0
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927
• Positive tester probe
Green “1”
• Negative tester probe
Black “2”
R/Y
R/L
R/W
3
2
1
L/B
R/L
G
B
2
1
B63-F8197-EZ.book Page 131 Monday, January 23, 2017 4:12 PM
8-132
ELECTRICAL COMPONENTS
c. Measure the fuel sender resistance.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS30578
CHECKING THE COOLANT TEMPERATURE
SENSOR
1. Remove:
• Coolant temperature sensor
Refer to “CYLINDER HEAD” on page 5-9.
WARNING
EWA14130
• Handle the coolant temperature sensor
with special care.
• Never subject the coolant temperature sen-
sor to strong shocks. If the coolant temper-
ature sensor is dropped, replace it.
2. Check:
• Coolant temperature sensor resistance
Out of specification Replace.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Connect the digital circuit tester to the coolant
temperature sensor terminals as shown.
b. Immerse the coolant temperature sensor “1”
in a container filled with coolant “2”.
TIP
Make sure that the coolant temperature sensor
terminals do not get wet.
c. Place a thermometer “3” in the coolant.
d. Heat the coolant or let it cool down to the
specified temperatures.
e. Measure the coolant temperature sensor re-
sistance.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
3. Install:
• Coolant temperature sensor
EAS30681
CHECKING THE FUEL INJECTOR
1. Check:
• Fuel injector resistance
Out of specification Replace the fuel injec-
tor.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Disconnect the fuel injector coupler from fuel
injector.
b. Connect the digital circuit tester to the fuel in-
jector terminals as shown.
Coolant temperature sensor re-
sistance
2512–2777 at 20 °C (2512–
2777 at 68 °F)
Coolant temperature sensor re-
sistance
210–221 at 100 °C (210–221
at 212 °F)
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927
4
3
T
R
.
.
Coolant temperature sensor
15 N·m (1.5 kg·m, 11 lb·ft)
Resistance
12.0 at 20 °C (12.0 at 68 °F)
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927
• Positive tester probe
Injector terminal “1”
• Negative tester probe
Injector terminal “2”
3
1
2
B63-F8197-EZ.book Page 132 Monday, January 23, 2017 4:12 PM
ELECTRICAL COMPONENTS
8-133
c. Measure the fuel injector resistance.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS31612
CHECKING THE VVA SOLENOID
1. Check:
• VVA solenoid resistance
Out of specification Replace.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Disconnect the VVA solenoid coupler from
the VVA solenoid.
b. Connect the digital circuit tester to the VVA
solenoid terminal as shown.
c. Measure the VVA solenoid resistance.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS31553
CHECKING THE SMART KEY BATTERY
(GDR155-A)
1. Check:
• Smart key battery voltage
Out of specification Replace the smart key
battery.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Remove the smart key battery from the smart
key.
b. Connect the digital circuit tester to the smart
key battery as shown.
c. Measure the smart key battery voltage.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EAS31555
CHECKING THE BUZZER (GDR155-A)
1. Check:
• Buzzer operation
Buzzer does not sound Replace.
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Disconnect the buzzer coupler from the wire
harness.
b. Connect the battery (12 V) to the buzzer cou-
pler as shown.
Resistance
1.8–2.2 at 20 °C (1.8–2.2 at
68 °F)
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927
• Positive tester probe
Solenoid terminal “1”
• Negative tester probe
Solenoid terminal “2”
21
21
Smart key battery voltage
2.7–3.2 V
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927
• Positive tester probe
positive battery terminal “1”
• Negative tester probe
negative battery terminal “2”
• Positive battery lead
Red “1”
• Negative battery lead
Black “2”
1
2
B63-F8197-EZ.book Page 133 Monday, January 23, 2017 4:12 PM
8-134
ELECTRICAL COMPONENTS
c. Check that the buzzer sounds.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
EASB631012
CHECKING THE MAIN SWITCH SOLENOID
(GDR155-A)
1. Check:
• Main switch solenoid
▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼
a. Disconnect the main switch solenoid coupler
from the wire harness.
b. Connect the digital circuit tester to the main
switch solenoid as shown.
c. Check the main switch solenoid continuity.
d. If there is no continuity, replace the main
switch assembly.
▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927
• Positive tester probe
Red/White “1”
• Negative tester probe
Black “2”
BR
1
2
R/W
B
1
2
B63-F8197-EZ.book Page 134 Monday, January 23, 2017 4:12 PM
9
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 ........................................9-3
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE............9-5
SELF-DIAGNOSTIC FUNCTION TABLE ..................................................9-5
COMMUNICATION ERROR WITH THE YAMAHA
DIAGNOSTIC TOOL ................................................................................ 9-5
DIAGNOSTIC CODE: SENSOR OPERATION TABLE .............................9-6
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE ........................ 9-7
EVENT CODE TABLE.....................................................................................9-9
B63-F8197-EZ.book Page 1 Monday, January 23, 2017 4:12 PM
TROUBLESHOOTING
9-1
EAS20090
TROUBLESHOOTING
EAS30599
GENERAL INFORMATION
TIP
The following guide for troubleshooting does not
cover all the possible causes of trouble. It should
be helpful, however, as a guide to basic trouble-
shooting. Refer to the relative procedure in this
manual for checks, adjustments, and replace-
ment of parts.
EAS31258
STARTING FAILURE/HARD STARTING
Engine
1. Cylinder and cylinder head
• Loose spark plug
• Loose cylinder head or cylinder
• Damaged cylinder head gasket
• Damaged cylinder gasket
• Worn or damaged cylinder
• Incorrect valve clearance
• Improperly sealed valve
• Incorrect valve-to-valve-seat contact
• Incorrect valve timing
• Faulty valve spring
• Seized valve
2. Piston and piston ring(s)
• Improperly installed piston ring
• Damaged, worn or fatigued piston ring
• Seized piston ring
• Seized or damaged piston
3. Air filter
• Improperly installed air filter
• Clogged air filter element
4. Crankcase and crankshaft
• Improperly assembled crankcase
• Seized crankshaft
Fuel system
1. Fuel tank
• Empty fuel tank
• Clogged fuel tank cap breather hole
• Deteriorated or contaminated fuel
• Clogged or damaged fuel hose
2. Fuel pump
• Faulty fuel pump
• Clogged fuel pump filter
3. Throttle body
• Deteriorated or contaminated fuel
• Sucked-in air
Electrical system
1. Battery
• Discharged battery
• Faulty battery
2. Fuse(s)
• Blown, damaged or incorrect fuse
• Improperly installed fuse
3. Spark plug
• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap
4. Ignition coil
• Cracked or broken ignition coil body
• Broken or shorted primary or secondary coils
• Faulty spark plug lead
5. Ignition system
• Faulty SGCU
• Faulty crankshaft position sensor
• Broken starter generator rotor woodruff key
6. Switches and wiring
• Faulty main switch
• Broken or shorted wiring
• Faulty front, rear or both brake light switches
• Faulty start switch
• Faulty sidestand switch
• Improperly grounded circuit
• Loose connections
7. Starting system
• Faulty starter generator
• Faulty starter charge relay
• Faulty main relay
EAS30601
INCORRECT ENGINE IDLING SPEED
Engine
1. Cylinder and cylinder head
• Incorrect valve clearance
• Damaged valve train components
2. Air filter
• Clogged air filter element
Fuel system
1. Throttle body
• Damaged or loose throttle body joint
• Faulty ISC (idle speed control) unit
• Improper throttle grip free play
Electrical system
1. Battery
• Discharged battery
B63-F8197-EZ.book Page 1 Monday, January 23, 2017 4:12 PM
TROUBLESHOOTING
9-2
• Faulty battery
2. Spark plug
• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap
3. Ignition coil
• Broken or shorted primary or secondary coil
• Faulty spark plug lead
4. Ignition system
• Faulty SGCU
• Faulty crankshaft position sensor
EAS30602
POOR MEDIUM-AND-HIGH-SPEED
PERFORMANCE
Refer to “STARTING FAILURE/HARD START-
ING” on page 9-1.
Engine
1. Air filter
• Clogged air filter element
Fuel system
1. Throttle body
• Faulty throttle body
2. Fuel pump
• Faulty fuel pump
EAS30849
FAULTY CLUTCH
Engine operates but vehicle will not move
1. V-belt
• Bent, damaged or worn V-belt
• Slipping V-belt
2. Primary sheave cam and primary sheave
slider(s)
• Damaged or worn primary sheave cam
• Damaged or worn primary sheave slider
3. Clutch spring
• Damaged clutch spring
4. Transmission gear(s)
• Damaged transmission gear
Clutch slips
1. Clutch shoe spring(s)
• Damaged, loose or worn clutch shoe spring
2. Clutch shoe(s)
• Damaged or worn clutch shoe
3. Primary sliding sheave
• Seized primary sliding sheave
Poor starting performance
1. V-belt
• Slipping V-belt
• Oil or grease on the V-belt
2. Primary sliding sheave
• Faulty operation
3. Clutch shoe(s)
• Bent, damaged or worn clutch shoe
Poor speed performance
1. V-belt
• Slipping V-belt
• Oil or grease on the V-belt
2. Primary sheave weight(s)
• Faulty operation
• Worn primary sheave weight
3. Primary fixed sheave
• Worn primary fixed sheave
4. Primary sliding sheave
• Worn primary sliding sheave
5. Secondary fixed sheave
• Worn secondary fixed sheave
6. Secondary sliding sheave
• Worn secondary sliding sheave
EAS30607
OVERHEATING
Engine
1. Clogged coolant passages
2. Cylinder head and piston
• Heavy carbon buildup
3. Engine oil
• Incorrect oil level
• Incorrect oil viscosity
• Inferior oil quality
Cooling system
1. Coolant
• Low coolant level
2. Radiator
• Damaged or leaking radiator
• Faulty radiator cap
• Bent or damaged radiator fin
3. Water pump
• Damaged or faulty water pump
4. Thermostat
• Thermostat stays closed
5. Hose(s) and pipe(s)
• Damaged hose
• Improperly connected hose
• Damaged pipe
• Improperly connected pipe
B63-F8197-EZ.book Page 2 Monday, January 23, 2017 4:12 PM
TROUBLESHOOTING
9-3
Fuel system
1. Throttle body
• Damaged or loose throttle body joint
2. Air filter
• Clogged air filter element
Chassis
1. Brake(s)
• Dragging brake
Electrical system
1. Spark plug
• Incorrect spark plug gap
• Incorrect spark plug heat range
2. Ignition system
• Faulty SGCU
EAS30608
OVERCOOLING
Cooling system
1. Thermostat
• Thermostat stays open
EAS30609
POOR BRAKING PERFORMANCE
1. Disc brake
• Worn brake pad
• Worn brake disc
• Air in hydraulic brake system
• Leaking brake fluid
• Faulty brake caliper kit
• Faulty brake caliper seal
• Loose union bolt
• Damaged brake hose
• Oil or grease on the brake disc
• Oil or grease on the brake pad
• Incorrect brake fluid level
2. Drum brake
• Worn brake shoe
• Worn or rusty brake drum
• Incorrect brake lever free play
• Incorrect brake camshaft lever position
• Incorrect brake shoe position
• Damaged or fatigued brake shoe spring
• Oil or grease on the brake shoe
• Oil or grease on the brake drum
EAS30610
FAULTY FRONT FORK LEGS
Leaking oil
• Bent, damaged or rusty inner tube
• Cracked or damaged outer tube
• Improperly installed oil seal
• Damaged oil seal lip
• Incorrect oil level (high)
• Loose damper rod bolt
• Damaged damper rod bolt copper washer
• Cracked or damaged front fork cap O-ring
Malfunction
• Bent or damaged inner tube
• Bent or damaged outer tube
• Damaged fork spring
• Bent or damaged damper rod
• Incorrect oil viscosity
• Incorrect oil level
EAS30611
UNSTABLE HANDLING
1. Handlebar
• Bent or improperly installed handlebar
2. Steering head components
• Improperly installed lower bracket
(improperly tightened ring nut)
• Damaged ball bearing or bearing race
3. Front fork leg(s)
• Uneven oil levels (both front fork legs)
• Unevenly tensioned fork spring (both front
fork legs)
• Broken fork spring
• Bent or damaged inner tube
• Bent or damaged outer tube
4. Swingarm
• Worn bearing or bushing
• Bent or damaged swingarm
5. Rear shock absorber assembly(-ies)
• Faulty rear shock absorber spring
• Leaking oil
6. Tire(s)
• Uneven tire pressures (front and rear)
• Incorrect tire pressure
• Uneven tire wear
7. Wheel(s)
• Incorrect wheel balance
• Deformed cast wheel
• Damaged wheel bearing
• Bent or loose wheel axle
• Excessive wheel runout
8. Frame
• Bent frame
• Damaged steering head pipe
• Improperly installed bearing race
EAS30612
FAULTY LIGHTING OR SIGNALING SYSTEM
Headlight does not come on
• Wrong headlight LED
B63-F8197-EZ.book Page 3 Monday, January 23, 2017 4:12 PM
TROUBLESHOOTING
9-4
• Too many electrical accessories
• Incorrect connection
• Improperly grounded circuit
• Poor contacts (main switch or light switch)
Tail/brake light does not come on
• Wrong tail/brake light LED
• Too many electrical accessories
• Incorrect connection
Turn signal does not come on
• Faulty turn signal switch
• Faulty turn signal relay
• Faulty diode (GDR155-A)
• Burnt-out turn signal light bulb
• Incorrect connection
• Damaged or faulty wire harness
• Improperly grounded circuit
• Faulty battery
• Blown, damaged or incorrect fuse
Turn signal blinks slowly
• Faulty turn signal relay
• Faulty main switch
• Faulty turn signal switch
• Incorrect turn signal light bulb
Turn signal remains lit
• Faulty turn signal relay
• Burnt-out turn signal light bulb
Turn signal blinks quickly
• Incorrect turn signal light bulb
• Faulty turn signal relay
• Burnt-out turn signal light bulb
Horn does not sound
• Damaged or faulty horn
• Faulty main switch
• Faulty horn switch
• Faulty battery
• Blown, damaged or incorrect fuse
• Faulty wire harness
B63-F8197-EZ.book Page 4 Monday, January 23, 2017 4:12 PM
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
9-5
EAS20116
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
EAS31118
SELF-DIAGNOSTIC FUNCTION TABLE
TIP
For details of the fault code, refer to “TROUBLESHOOTING METHOD” on page 8-45.
EAS31259
COMMUNICATION ERROR WITH THE YAMAHA DIAGNOSTIC TOOL
TIP
For details of the fault code, refer to “TROUBLESHOOTING METHOD” on page 8-45.
Fault code No. Item
12
Crankshaft position sensor: no normal signals are received from the crankshaft position
sensor.
13 Intake air pressure sensor: open or short circuit detected.
14 Intake air pressure sensor: system malfunction (clogged hole or detached).
15 Throttle position sensor: open or short circuit detected.
16 Throttle position sensor: stuck throttle position sensor is detected.
21 Coolant temperature sensor: open or short circuit detected.
22 Intake air temperature sensor: open or short circuit detected.
24
O
2
sensor: no normal signals are received from the O
2
sensor.
37
Component other than ISC (idle speed control) unit is defective (ISC operating sound is
heard).
Defective ISC (idle speed control) unit (ISC operating sound is not heard).
39 Fuel injector: open or short circuit detected.
42 Front wheel sensor: no normal signals are received from the front wheel sensor.
44 EEPROM fault code number: an error is detected while reading or writing on EEPROM.
46 Charging voltage is abnormal.
50
Faulty SGCU memory. (When this malfunction is detected in the SGCU, the fault code
number might not appear on the tool display.)
61 ISC (idle speed control) unit: open or short circuit detected.
84 VVA (variable valve actuator) solenoid: open or short circuit detected.
Fault code No. Item
Er-1 (fault code
display)
SGCU (starter generator control unit) internal malfunction (output signal error): signals
cannot be transmitted between the SGCU and the multi-function meter.
Waiting for con-
nection (Yamaha
diagnostic tool)
SGCU (starter generator control unit) internal malfunction (output signal error): Signals
cannot be transmitted between the SGCU and Yamaha diagnostic tool.
Er-2
SGCU (starter generator control unit) internal malfunction (output signal error): no sig-
nals are received from the SGCU within the specified duration.
Er-3
SGCU (starter generator control unit) internal malfunction (output signal error): data from
the SGCU cannot be received correctly.
Er-4 (fault code
display)
SGCU (starter generator control unit) internal malfunction (input signal error): non-regis-
tered data has been received from the meter.
Er-4 (Yamaha di-
agnostic tool)
SGCU (starter generator control unit) internal malfunction (input signal error): no normal
signals are received from the Yamaha diagnostic tool.
B63-F8197-EZ.book Page 5 Monday, January 23, 2017 4:12 PM
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
9-6
EAS31120
DIAGNOSTIC CODE: SENSOR OPERATION TABLE
Diagnostic
code No.
Item Tool display Procedure
01 Throttle position sensor sig-
nal
• Fully closed position 13–21 Check with throttle valve fully
closed.
• Fully open position 97–107 Check with throttle valve fully
open.
03 Intake air pressure Displays the intake air pres-
sure.
Operate the throttle while
pulling the brake lever and
pushing the start switch “ ”.
(If the display value changes,
the performance is OK.)
05 Intake air temperature When engine is cold: Dis-
plays temperature closer to
air temperature
When engine is hot: Air tem-
perature + approx. 20 °C (68
°F)
Compare the actually mea-
sured air temperature with
the computer display value.
06 Coolant temperature When engine is cold: Dis-
plays temperature closer to
air temperature.
When engine is hot: Displays
current coolant temperature.
Compare the actually mea-
sured coolant temperature
with the computer display
value.
07 Front wheel speed pulse Front wheel speed pulse
0–999
Check that the number in-
creases when the front wheel
is rotated. The number is cu-
mulative and does not reset
each time the wheel is
stopped.
09 Fuel system voltage
(battery voltage)
Approximately 12.0 Compare the actually mea-
sured battery voltage with
the computer display value.
(If the actually measured bat-
tery voltage is low, recharge
the battery.)
20 Sidestand switch Extend and retract the side-
stand.
• Stand retracted ON
• Stand extended OFF
60 EEPROM fault code display —
• No history 00
• No malfunctions detected
(If the self-diagnosis fault
code 44 is indicated, the
SGCU is defective.)
History exists
11(ISC (idle speed control)
learning is being carried out)
B63-F8197-EZ.book Page 6 Monday, January 23, 2017 4:12 PM
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
9-7
EAS31121
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE
61 Malfunction history code dis-
play
—
• No history 00
• History exists Fault codes 12–84
• (If more than one code
number is detected, the
display alternates every
two seconds to show all the
detected code numbers.
When all code numbers are
shown, the display repeats
the same process.)
62 Malfunction history code era-
sure
• No history 00 —
• History exists • Displays the total number
of malfunctions, including
the current malfunction,
that have occurred since
the history was last erased.
(For example, if there have
been three malfunctions,
“03” is displayed.)
To erase the history, click
“Actuator Check” on the Ya-
maha diagnostic tool screen.
67 ISC (idle speed control)
learning condition display
ISC (idle speed control)
learning data erasure
00
ISC (idle speed control)
learning data has been
erased.
01
It is not necessary to erase
the ISC (idle speed control)
learning data.
02
It is necessary to erase the
ISC (idle speed control)
learning data.
To erase the ISC (idle speed
control) learning data, click
“Actuator Check” on the Ya-
maha diagnostic tool screen
3 times in 5 seconds.
70 Control number 0–254 [-] —
90
(GDR155-A)
Stop and Start System
switch
Set to “ON” and “OFF” the
Stop and Start System
switch.
• Set to “ON” ON
• Set to “OFF” OFF
Diagnostic
code No.
Item Actuation Procedure
30 Ignition coil Actuates ignition coil five
times at one-second inter-
vals.
The “ ” and “CHECK” indi-
cator on the Yamaha diag-
nostic tool screen come on
each time the ignition coil is
actuated.
Check that a spark is gener-
ated five times.
• Connect an ignition check-
er.
Diagnostic
code No.
Item Tool display Procedure
B63-F8197-EZ.book Page 7 Monday, January 23, 2017 4:12 PM
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
9-8
36 Fuel injector Actuates fuel injector five
times at one-second inter-
vals.
The “ ” and “CHECK” indi-
cator on the Yamaha diag-
nostic tool screen come on
each time the fuel injector is
actuated.
Disconnect the fuel pump
coupler.
Check that fuel injector is ac-
tuated five times by listening
for the operating sound.
45 VVA (variable valve actuator)
solenoid
Actuates the VVA (variable
valve actuator) solenoid five
times at five-second inter-
vals.
The “ ” and “CHECK” indi-
cator on the Yamaha diag-
nostic tool screen come on
each time the VVA (variable
valve actuator) solenoid is
actuated.
Remove the VVA (variable
valve actuator) solenoid from
the cylinder head, and then
connect the VVA (variable
valve actuator) solenoid cou-
pler.
Refer to “CYLINDER HEAD”
on page 5-9.
Visually check that the VVA
(variable valve actuator) so-
lenoid is actuated five times.
52 Headlight relay Actuates the headlight five
times at five-second inter-
vals.
The “ ” and “CHECK” indi-
cator on the Yamaha diag-
nostic tool screen come on
each time the headlight is
actuated.
Check that the headlight is
on five times.
54 ISC (idle speed control) unit Fully closes the ISC valve,
and then opens the valve.
This operation takes approxi-
mately 3 seconds.
Check that the ISC (idle
speed control) unit operates
by listening for the operating
sound while the ISC unit op-
erates for 3 seconds.
Diagnostic
code No.
Item Actuation Procedure
B63-F8197-EZ.book Page 8 Monday, January 23, 2017 4:12 PM
EVENT CODE TABLE
9-9
EAS20164
EVENT CODE TABLE
No. Item Symptom Possible cause Remarks
192 Intake air pressure sen-
sor
Brief abnormality de-
tected in intake air pres-
sure sensor
Same as for fault code
number 13
Perform the checks and
maintenance jobs for
fault code number 13.
193 Throttle position sensor Brief abnormality de-
tected in throttle posi-
tion sensor
Same as for fault code
number 15
Perform the checks and
maintenance jobs for
fault code number 15.
196 Coolant temperature
sensor
Brief abnormality de-
tected in coolant tem-
perature sensor
Same as for fault code
number 21
Perform the checks and
maintenance jobs for
fault code number 21.
197 Intake air temperature
sensor
Brief abnormality de-
tected in intake air tem-
perature sensor
Same as for fault code
number 22
Perform the checks and
maintenance jobs for
fault code number 22.
218 Crankshaft position
sensor
Brief abnormality de-
tected in crankshaft po-
sition sensor
Same as for fault code
number 12
Perform the checks and
maintenance jobs for
fault code number 12.
240 O
2
sensor
(Correction value re-
mains at upper limit)
Correction value re-
mains at upper limit
during O
2
feedback
• Open or short circuit
in the wire harness
between the sensor
and the SGCU
Gray/Red–Gray/Red
• Low fuel pressure
• Clogged fuel injector
•Sensor malfunction
• Defective SGCU
• Defective fuel injec-
tion system
• If a fault code is indi-
cated, perform the
checks and mainte-
nance jobs for the
fault code first.
* Event code number
240 may be indicated
even if the system is
normal.
241 O
2
sensor
(Correction value re-
mains at lower limit)
Correction value re-
mains at lower limit dur-
ing O
2
feedback
• Open or short circuit
in the wire harness
between the sensor
and the SGCU
Gray/Red–Gray/Red
• Low fuel pressure
• Clogged fuel injector
•Sensor malfunction
• Defective SGCU
• Defective fuel injec-
tion system
• If a fault code is indi-
cated, perform the
checks and mainte-
nance jobs for the
fault code first.
* Event code number
241 may be indicated
even if the system is
normal.
242 ISC (idle speed control)
(Correction value re-
mains at upper limit)
Correction value re-
mains at upper limit
while the engine is
idling
Low engine idling
speed
• Clogged throttle body
• Improperly adjusted
throttle cable
• Defective fuel injec-
tion system
• Dirty or worn spark
plug
• Defective battery
• Defective SGCU
• Execute the diagnos-
tic mode (diagnostic
code number 67) and
check the ISC mainte-
nance requirements.
• If a fault code is indi-
cated, perform the
checks and mainte-
nance jobs for the
fault code first.
* Event code number
242 may be indicated
even if the system is
normal.
B63-F8197-EZ.book Page 9 Monday, January 23, 2017 4:12 PM
EVENT CODE TABLE
9-10
243 ISC (idle speed control)
(Correction value re-
mains at lower limit)
Correction value re-
mains at lower limit
while the engine is
idling
High engine idling
speed
• Improperly adjusted
throttle cable
• Defective fuel injec-
tion system
• Dirty or worn spark
plug
• Defective battery
• Defective SGCU
• If a fault code is indi-
cated, perform the
checks and mainte-
nance jobs for the
fault code first.
* Event code number
243 may be indicated
even if the system is
normal.
244 Difficult/unable to start
engine
Engine starting diffi-
cult/unable condition
detected
• Empty fuel tank
• Defective fuel injec-
tion system
• Dirty or worn spark
plug
• Defective battery
• Defective SGCU
• If a fault code is indi-
cated, perform the
checks and mainte-
nance jobs for the
fault code first.
* Event code number
244 may be indicated
even if the system is
normal.
245 Engine stall Engine stall detected • Empty fuel tank
• Improperly adjusted
throttle cable
• Defective fuel injec-
tion system
• Dirty or worn spark
plug
• Defective battery
• Defective SGCU
• If a fault code is indi-
cated, perform the
checks and mainte-
nance jobs for the
fault code first.
* Event code number
245 may be indicated
even if the system is
normal.
No. Item Symptom Possible cause Remarks
B63-F8197-EZ.book Page 10 Monday, January 23, 2017 4:12 PM
EAS20091
WIRING DIAGRAM
GDR155 2017
1. Battery
2. Main fuse
3. Fuel injection system fuse
4. Backup fuse
5. Ignition fuse
6. Headlight fuse
7. Signaling system fuse
8. Auxiliary DC jack fuse
9. Auxiliary DC jack
10.Main switch
11.Main relay
12. Starter charge relay
13. Handlebar switch (right)
14. Light switch
15. Start switch
16. Side stand switch
17. Starter generator
18. Coolant temperature sensor
19. Throttle body sensor assembly
20. Intake air pressure sensor
21. Intake air temperature sensor
22. Throttle position sensor
23. O
2
sensor
24. Front wheel sensor
25. SGCU (starter generator con-
trol unit)
26. Crankshaft position sensor
27. Ignition coil
28. Spark plug
29. ISC (idle speed control) unit
30. Injector
31. Fuel pump
32. Fuel sender
33. VVA (variable valve actuator)
solenoid
34. Yamaha diagnostic tool cou-
pler
35. Engine ground 2
36. Rear brake light switch
37. Front brake light switch
38. Meter assembly
39. Multi-function meter
40. Coolant temperature warning
light
41. Engine trouble warning light
42. Meter light
43. Turn signal indicator light (left)
44. Turn signal indicator light (right)
45. High beam indicator light
46. Turn signal relay
47. Horn
48. Handlebar switch (left)
49. Dimmer switch
50. Horn switch
51. Turn signal switch
52. License light
53. Tail/brake light assembly
54. Brake light
55. Taillight
56. Rear turn signal light (right)
57. Rear turn signal light (left)
58. Front turn signal light (right)
59. Front turn signal light (left)
60. Headlight
61. Auxiliary light
62. Frame ground
63. Engine ground 1
GDR155-A 2017
1. Battery
2. ABS solenoid fuse
3. ABS motor fuse
4. ABS control unit fuse
5. Main fuse
6. Smart key system fuse
7. Auxiliary DC jack fuse
8. Fuel injection system fuse
9. Backup fuse
10. Ignition fuse
11. Headlight fuse
12. Signaling system fuse
13. Auxiliary DC jack
14. Main switch
15. Request switch
16. Main switch solenoid
17. Smart key unit
18. Buzzer
19. Main relay
20. Starter charge relay
21. Handlebar switch (right)
22. Light switch
23. Start switch
24. Stop and Start System switch
25. Side stand switch
26. Starter generator
27. Coolant temperature sensor
28. Throttle body sensor assembly
29. Intake air pressure sensor
30. Intake air temperature sensor
31. Throttle position sensor
32. O
2
sensor
33. SGCU (starter generator con-
trol unit)
34. Crankshaft position sensor
35.Ignition coil
36. Spark plug
37. ISC (idle speed control) unit
38. Injector
39. Fuel pump
40. Fuel sender
41. VVA (variable valve actuator)
solenoid
42. Yamaha diagnostic tool cou-
pler
43. Engine ground 2
44. Front wheel sensor
45. ABS test coupler
46. ABS ECU
47. Rear brake light switch
48. Front brake light switch
49. Meter assembly
50. Multi-function meter
51. Coolant temperature warning
light
52. ABS warning light
53. Engine trouble warning light
54. Meter light
55. Turn signal indicator light (left)
B63-F8197-EZ.book Page 1 Monday, January 23, 2017 4:12 PM
56. Turn signal indicator light (right)
57. Stop and Start System indica-
tor light
58. Smart key system indicator
light
59. High beam indicator light
60. Turn signal relay
61. Diode
62. Horn
63. Handlebar switch (left)
64. Dimmer switch
65. Horn switch
66. Turn signal switch
67. License light
68. Tail/brake light assembly
69. Brake light
70. Taillight
71. Rear turn signal light (right)
72. Rear turn signal light (left)
73. Front turn signal light (right)
74. Front turn signal light (left)
75. Headlight
76. Auxiliary light
77. Frame ground
78. Engine ground 1
EAS30613
COLOR CODE
BBlack
Br Brown
Ch Chocolate
Dg Dark green
GGreen
Gy Gray
LBlue
O Orange
PPink
RRed
Sb Sky blue
WWhite
YYellow
B/L Black/Blue
B/R Black/Red
B/W Black/White
B/Y Black/Yellow
Br/B Brown/Black
Br/R Brown/Red
Br/W Brown/White
G/R Green/Red
G/W Green/White
G/Y Green/Yellow
Gy/R Gray/Red
L/B Blue/Black
L/R Blue/Red
L/W Blue/White
L/Y Blue/Yellow
O/B Orange/Black
P/W Pink/White
R/B Red/Black
R/L Red/Blue
R/W Red/White
R/Y Red/Yellow
W/B White/Black
W/G White/Green
W/L White/Blue
W/R White/Red
W/Y White/Yellow
Y/B Yellow/Black
Y/L Yellow/Blue
Y/R Yellow/Red
Y/W Yellow/White
B63-F8197-EZ.book Page 2 Monday, January 23, 2017 4:12 PM
B63-F8197-EZ.book Page 3 Monday, January 23, 2017 4:12 PM
B63-F8197-EZ.book Page 1 Monday, January 23, 2017 4:12 PM
B63-F8197-EZ.book Page 2 Monday, January 23, 2017 4:12 PM
GDR155 2017
WIRING DIAGRAM
ON
OPEN
OFF
LOCK
L
PUSH
R
ON
OFF
HI
LO
PUSH
FREE
PUSH
FREE
B
W/R
Br
R
G/W
Br
R/Y
R
R
Br/R
R/W,Br
B/W,B
(B)
Br/R
R
Y/R
Br
R/B
RWG
R/YR/L
R/W
(B)
B/LG/R
(B)
B/L
Y L
P/WBr/W
Gy/R
(B)
B
(B)
(B)
G/Y
W/R
B/Y
O
P
O/B
G
B/W
W/L
Ch
Sb Y
B
/
L
Br/B
R/B
Gy
B/L
W/B
L
W/Y
R
Br/W
B
P/WR/W
L/Y
B/L
G/R
Y/LB/R
Gy/R
L/B
R/L
W
B
Y/BY/R
GWR
G
L/Y
W/R
Br/B
W/L
W/B
(B)
W/R
W/LBr/B
W/Y
B/L
W/B
(B)
(B)
P
G/Y
Sb Gy
Br
(B)
O/B
(Gy)
G
Ch
B/W
R
Y/L Y/L
(B)
R
B/Y
(Gy)
G
B/W
R/L
W
W
B
B/YBr
(B)
BB
Br B
BBr
B
B
(L)
L/Y
B
(L)
Br
Br/W
(R)
L
Y/R
B/Y
L/B
B
L/W
(R)
Br
G
(L)
Dg
Ch
Br/W
(R)
Y
L
(R)
L/B
Y
(L)
Br/W
Ch
Dg
(B)
B
Dg
Ch
(B)
Ch
Dg
B
P
B
P
B
Br
B
L
B
L
Y
B
GY
Y/B
(B)
YBr
B
Br
Y/B
R
Y
BChDg
Y/L
B/W
G
(Gy)
YG
B
Br
R
R
R
B
B
R
Br/R
Br
Br
R
B
Br/R
B/W
Br/R
Br/R
RBr
Br
Br Br
Br
Br
Br
Br
Br
Br
R
R
R
R
R
RR
RR
R
B
B
B
BBBB
B
B
B
BBBB
G/W
G/W
R/Y
Br
R/W
R/B
Y/R
Br/R
Br/R
W/R
W/R
R/W
R/Y
R/W
R/L
P/W
Br/W
Gy/RGy/R
L/B
L/Y
G/R
B/L
G/R
B/L
B/L
L
B
Y
P/W
Br/W
B/L
L
Y
W
R
R
W/R
W/L
W/B
W/Y
Br/B
B/L
G/Y
Gy
Sb
O/B
B/Y B/Y
R
G
B/W
Ch
Y/LY/LY/L
R
B/W
R/B
Y/R
Y/B
Y/B
B/R
B/R
B/W
O
G
O
Br
P
G
W
R/L
W
R/L
B
W
B/Y
B/Y
B/Y
L/BL/B
B/Y
B/Y
B
B
B
B
Br
Br
Br
Br
Br
Br
P
PL
Br/W
Br/W
DgCh
Ch
Ch
Ch Ch
Dg
Ch Dg
YBr Br
B
B
BB
B
LL
B
Ch Dg
Dg
Dg Dg
BY
Y
Y
Y
YG
L/B
Br
Br Br
B/YB/Y
Y
W/R
W/L
W/B
W/Y
Br/B
B/L
L/Y
G/Y
Gy
Sb
O/B
Br
Ch
P
G
B
B
B
B/W
G
W
R
G
L/Y
B
L/B
G
L/W
L
B
Y/R
B/Y
Br
Br
Br Br
B
B
B
B
B
Br
G
L
G
B
B
B
B
B
Br Br
Br
Y/B
B
Y/B
B/W
Y/L
RChDgY
Br G
B
1
2
3
4
5
6
7
8
9
10
11
12
13
14 15
16
17
18
19
20
21
22
23
25
26
27
28
29
30
31
32
33
34
35 35
63
24
3637
38
39
40 41 42 43
44 45
46
47
48
49
50 51
52
53
54 5556575859
6061
62
GDR155-A 2017
WIRING DIAGRAM
ON
OPEN
OFF
LOCK
L
PUSH
R
ON
OFF
HI
LO
PUSH
FREE
PUSH
FREE
ON
OFF
B
W/R
B
B/Y
B
L
R/W
B
(B)
R/W
B
(B)
Br
R
G/W
Br
R/Y
R
(B)
ChB
L/Y
R/BY/L
G/W
Dg
R/W
Br
W/R
B/Y
R
R/B
R
R
Br/R
R/W,Br
B/W,B
B
R
(B)
Br/R
R
Y/R
Br
R/B
RWG
R/YR/L
R/W
(B)
B/LG/R
(B)
B/L
Y L
P/WBr/W
Gy/R
(B)
B
(B)
(B)
G/Y
W/R
B/Y
O
P
O/B
G
B/W
W/L
Ch
Sb Y
B
/
L
Br/B
R/B
Gy
B/L
W/B
L
W/Y
R
Br/W
B
P/WR/W
L/B
B/L
G/R
Y/LB/R
Gy/R
L/Y
W/G
W
B
Y/BY/R
GWR
G
L/Y
W/R
Br/B
W/L
W/B
(B)
W/R
W/LBr/B
W/Y
B/L
W/B
(B)
(B)
P
G/Y
Sb Gy
Br
(B)
O/B
(Gy)
G
Ch
B/W
R
Y/L Y/L
(B)
R
B/Y
(Gy)
G
B/W
LG
W
B
L/RL/B
RB
R
L/RL/BY/L
B/W
R/LB/Y
Br
W/L
LGWB
B/YBr
(B)
BB
Br B
BBr
B
B
(L)
L/Y
B
(L)
Br
Br/W
Br/B
Br/W
(R)
L
Y/R
B/Y
L/B
(B)
B
W/G
B
L/W
(B)
B/W
Y/W
(R)
Br
G
(L)
Dg
Ch
Br/W
(R)
Y
L
(R)
L/B
Y
(L)
Br/B
Ch
Dg
(B)
B
Dg
Ch
(B)
Ch
Dg
B
P
B
P
B
Br
B
L
B
L
Y
B
(B)
YBr
B
Br
W/R
Y/B
R
Y
BCh
W/L
Dg
Y/L
B/W
G
(Gy)
R
Br
BrBr
Br
Br
R
R
RR
BB
B
R
G/W
Br/R
R
Br
Br Br
Br
Br
R
RR
R
R
B
R
B
Br/R
B/W
Br/R
Br/R
RBr
Br
R/B
R
R
R
Br
Br Br
Br
Br
Br
Br
Br
Br
R
R
R
R
R
RR
RR
G/W
R
B
L
B
B
B
B
B
B
BBBB
B
BBBB
BBBBBB
B
G/W
R/W
R/Y
B/Y
Br
R/W
L/Y
W/R
R/W
R/B
Y/R
Br/R
Br/R
R/B
Dg
Ch
B
Y/L
G/W
B/Y
Br
W/R
W/R
R/L
R/W
R/Y
R/W
R/L
P/W
W/G
Br/W
Gy/RGy/R
L/B
L/Y
G/R
B/L
G/R
B/L
B/L
L
W
B
Y
P/W
Br/W
B/L
L
Y
W
R
R
W/R
W/L
W/B
W/Y
Br/B
B/L
G/Y
Gy
Sb
O/B
B/Y B/Y
R
G
B/W
Ch
Y/LY/LY/L
R
B/W
R/B
L/BL/B
L/RL/R
Y/R
Y/B
Y/B
B/R
B/R
B/W
B/W
O
G
O
Br
P
G
G
L
B
W
G
WBr
R
R/L
W/L
B/Y
B/YB/Y
B/Y
B/Y
L/BL/B
W/GW/G
B/Y
B/Y
B
B
B
B
Br
Br
Br
Br
Br
Br
P
PL
Br/W
Br/W
Br/B
Br/B
DgCh
Ch
Ch
Ch Ch
Ch
Dg
Ch Dg
YBr Br
B
B
BB
B
LL
B
Ch Dg
Dg
Dg Dg
Dg
BY
Y
Y
Y
YG
Br/WL/B
Br
Br Br
B/YB/Y
Y
L
B
B/WY/L
R
B
W/R
W/L
W/B
W/Y
Br/B
B/L
L/Y
G/Y
Gy
Sb
O/B
Br
Ch
P
G
B
B
B
B/W
G
W
R
G
Y/L
Y/L
Y/LY/L
L/YL/Y
L/Y
L/Y
B
B
L/B
G
B/WL/W
L
Y/W
B
Y/R
W/GB/Y
Br
Br
Br Br
B
B
B
B
B
Br
G
L
G
B
B
B
B
B
Br Br
Br
Y/B
B
Y/B
W/RB/W
Y/L
RChDgY
Br G
B
W/L
1
2
3
4
5
6
7
8
9
10
11
12
13
14
16
15
17
18
19
20
21
22
23 24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43 43
78 78
44
45
46
4748
49
50
51 52 53 54 55
56 57 58 59
60
61
62
63
64
65 66
67
68
69 7071727374
7576
77
GY
Y/B
YG
B
GDR155 2017
WIRING DIAGRAM
ON
OPEN
OFF
LOCK
L
PUSH
R
ON
OFF
HI
LO
PUSH
FREE
PUSH
FREE
(B)
(B)
(B)
(B) (B)
(B)
(B)
(B)
(B)
(B)
(Gy)
(B)
(Gy)
(B)
(L)
(L)
(R)
(R)
(L)
(R)
(R)
(L)
(B)
(B)
(B)
(Gy)
1
2
3
4
5
6
7
8
9
10
11
12
13
14 15
16
17
18
19
20
21
22
23
25
26
27
28
29
30
31
32
33
34
35 35
63
24
3637
38
39
40 41 42 43
44 45
46
47
48
49
50 51
52
53
54 5556575859
6061
62
GDR155-A 2017
WIRING DIAGRAM
ON
OPEN
OFF
LOCK
L
PUSH
R
ON
OFF
HI
LO
PUSH
FREE
PUSH
FREE
ON
OFF
(B)
(B)
(B)
(B)
(B)
(B)
(B) (B)
(B)
(B)
(B)
(B)
(B)
(Gy)
(B)
(Gy)
(B)
(L)
(L)
(R)
(B)
(B)
(R)
(L)
(R)
(R)
(L)
(B)
(B)
(B)
(Gy)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
16
15
17
18
19
20
21
22
23 24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43 43
78 78
44
45
46
4748
49
50
51 52 53 54 55
56 57 58 59
60
61
62
63
64
65 66
67
68
69 7071727374
7576
77
