2016

SERVICE MANUAL

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2UD-F8197-E0

EBS20002

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SERVICE MANUAL

©2015 by Yamaha Motor Co., Ltd.

First edition, July 2015

All rights reserved.

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

EBS20003

IMPORTANT

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers

and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-

ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles

should have a basic understanding of mechanics and the techniques to repair these types of vehicles.

Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-

cle unsafe and unfit for use.

This model has been designed and manufactured to perform within certain specifications in regard to

performance and emissions. Proper service with the correct tools is necessary to ensure that the vehi-

cle will operate as designed. If there is any question about a service procedure, it is imperative that you

contact a Yamaha dealer for any service information changes that apply to this model. This policy is

intended to provide the customer with the most satisfaction from his vehicle and to conform to federal

environmental quality objectives.

Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-

nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and

will appear in future editions of this manual where applicable.

TIP

Designs and specifications are subject to change without notice.

EBS30001

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.

This is the safety alert symbol. It is used to alert you to potential personal

injury hazards. Obey all safety messages that follow this symbol to avoid

possible injury or death.

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

sult in death or serious injury.

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

age to the vehicle or other property.

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

WARNING

NOTICE

TIP

EBS20004

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

4

6

2

EBS20005

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.

G

M

BF

B

T R

.

.

LS

M

S

LT

E

New

EBS10003 TABLE OF CONTENTS

GENERAL INFORMATION

1

SPECIFICATIONS

2

PERIODIC CHECKS AND

ADJUSTMENTS

3

CHASSIS

4

ENGINE

5

COOLING SYSTEM

6

FUEL SYSTEM

7

DRIVE TRAIN

8

ELECTRICAL SYSTEM

9

TROUBLESHOOTING

10

1

GENERAL INFORMATION

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

VEHICLE IDENTIFICATION NUMBER.....................................................1-1

MODEL LABEL..........................................................................................1-1

FEATURES......................................................................................................1-3

OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM

(for EPS models) ......................................................................................1-3

INSTRUMENT FUNCTIONS.....................................................................1-5

IMPORTANT INFORMATION .........................................................................1-7

PREPARATION FOR REMOVAL AND DISASSEMBLY...........................1-7

REPLACEMENT PARTS...........................................................................1-7

GASKETS, OIL SEALS AND O-RINGS ....................................................1-7

LOCK WASHERS/PLATES AND COTTER PINS.....................................1-7

BEARINGS AND OIL SEALS....................................................................1-8

CIRCLIPS..................................................................................................1-8

RUBBER PARTS.......................................................................................1-8

BASIC SERVICE INFORMATION...................................................................1-9

QUICK FASTENERS.................................................................................1-9

ELECTRICAL SYSTEM...........................................................................1-10

SPECIAL TOOLS ..........................................................................................1-14

IDENTIFICATION

1-1

EBS20009

IDENTIFICATION

EBS30003

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped

into the frame.

EBS30004

MODEL LABEL

The model label “1” is affixed at the location in

the illustration. This information will be needed to

order spare parts.

1

IDENTIFICATION

1-2

FEATURES

1-3

EBS20010

FEATURES

EBS30007

OUTLINE OF THE EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models)

4

5

7

6

1

2

3

d

c

e

a

b

f

FEATURES

1-4

NOTICE

ECB01790

To prevent accidental damage to the EPS unit, it must not be disassembled.

1. Speed information from speed sensor

2. Engine RPM information from ECU

3. Battery

4. EPS control unit

5. EPS motor

6. Torque sensor

7. EPS unit

a. Operates steering

b. Twists torsion bar

c. Sends the torque sensor signal

d. EPS control unit calculates assist power

e. Electricity output switched by EPS control unit

f.

Activates EPS motor

FEATURES

1-5

EBS30008

INSTRUMENT FUNCTIONS

Multi-function display

The multi-function display is equipped with the

following:

• a speedometer

• an odometer

• two tripmeters (which show the distance trav-

eled since they were last set to zero)

• a clock

• an hour meter (which shows the total time the

engine has been running)

• a fuel meter

• a self-diagnosis device

Odometer and tripmeter modes

Pushing the “SELECT” button switches the dis-

play between the odometer mode “ODO” and

the tripmeter modes “TRIP A” and “TRIP B” in

the following order:

ODO → TRIP A → TRIP B → ODO

To reset a tripmeter, select it by pushing the “SE-

LECT” button, and then push the “RESET” but-

ton for at least three seconds. The tripmeters

can be used to estimate the distance that can be

traveled with a full tank of fuel. This information

will enable you to plan future fuel stops.

TIP

Pushing and holding in the “SELECT” button,

and turning the key to “

” (on) while the button

is pushed, switches the display between “mph”

and “km/h”.

Clock mode

Pushing the “CLOCK” button switches the dis-

play between the clock mode “CLOCK” and the

hour meter mode “HOUR” in the following order:

CLOCK → HOUR → CLOCK

To set the clock

1. Set the display to the clock mode.

2. Push the “SELECT” button and “RESET” but-

ton together for at least three seconds.

3. When the hour digits start flashing, push the

“RESET” button to set the hours.

4. Push the “SELECT” button, and the minute

digits will start flashing.

5. Push the “RESET” button to set the minutes.

6. Push the “SELECT” button and then release

it to start the clock.

Fuel meter

The fuel meter indicates the amount of fuel in the

fuel tank. The display segments of the fuel meter

disappear from “F” (full) towards “E” (empty) as

the fuel level decreases. When the “E” segment

disappears and the fuel level warning indicator

flashes, refuel as soon as possible.

TIP

This fuel meter is equipped with a self-diagnosis

system. If the electrical circuit is not working cor-

rectly, all the display segments and fuel level

warning indicator will start flashing. If this occurs,

check the electrical circuit.

Refer to “SIGNALING SYSTEM” on page 9-19.

1. “SELECT” button

2. “RESET” button

3. “CLOCK” button

4. Speedometer

5. Fuel meter

6. Clock/Hour meter

7. Odometer/Tripmeter A/Tripmeter B

4

5

7

6

1

2

3

1. Fuel level warning indicator

2. Fuel meter

3. “E” segment

1

2

3

FEATURES

1-6

Self-diagnosis device

This model is equipped with a self-diagnosis de-

vice for various electrical circuits.

If a problem is detected in any of those circuits,

the engine trouble warning light will come on or

flash and the multi-function display will indicate

an fault code.

If the multi-function display indicates an fault

code, note the code number, and check the ve-

hicle.

NOTICE

ECB02030

If the display indicates a fault code, the vehi-

cle should be checked as soon as possible

in order to avoid engine damage.

1. Fault code display

2. Engine trouble warning light

1

2