2017

SERVICE MANUAL

SCR95H

SCR95HC

LIT-11616-30-15

BL3-28197-10

EAS20002

SCR95H/SCR95HC

SERVICE MANUAL

©2016 by Yamaha Motor Corporation, U.S.A.

First edition, June 2016

All rights reserved.

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in U.S.A.

P/N LIT-11616-30-15

EAS20003

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

• This Service Manual contains information regarding periodic maintenance to the emission control sys-

tem. Please read this material carefully.

• Designs and specifications are subject to change without notice.

EAS30001

IMPORTANT MANUAL INFORMATION

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

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

WARNING

NOTICE

TIP

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.

• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-

tially.

1

7

3

5

4

6

2

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.

EAS10003 TABLE OF CONTENTS

GENERAL INFORMATION

1

SPECIFICATIONS

2

PERIODIC CHECKS AND

ADJUSTMENTS

3

CHASSIS

4

ENGINE

5

FUEL SYSTEM

6

ELECTRICAL SYSTEM

7

TROUBLESHOOTING

8

1

GENERAL INFORMATION

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

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

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

FEATURES......................................................................................................1-2

INSTRUMENT FUNCTIONS.....................................................................1-2

IMPORTANT INFORMATION .........................................................................1-4

PREPARATION FOR REMOVAL AND DISASSEMBLY...........................1-4

REPLACEMENT PARTS...........................................................................1-4

GASKETS, OIL SEALS AND O-RINGS ....................................................1-4

LOCK WASHERS/PLATES AND COTTER PINS.....................................1-4

BEARINGS AND OIL SEALS....................................................................1-5

CIRCLIPS..................................................................................................1-5

RUBBER PARTS.......................................................................................1-5

BASIC SERVICE INFORMATION...................................................................1-6

QUICK FASTENERS.................................................................................1-6

ELECTRICAL SYSTEM.............................................................................1-7

SPECIAL TOOLS ..........................................................................................1-11

IDENTIFICATION

1-1

EAS20007

IDENTIFICATION

EAS30002

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped

into the right side of the steering head pipe.

EAS30003

MODEL LABEL

The model label “1” is affixed to the frame under

the seat. This information will be needed to order

spare parts.

1

1

FEATURES

1-2

EAS20008

FEATURES

EAS30682

INSTRUMENT FUNCTIONS

Multi-function meter unit

WARNING

EWA17650

Be sure to stop the vehicle before making

any setting changes to the multi-function

meter unit. Changing settings while riding

can distract the operator and increase the

risk of an accident.

The multi-function meter unit is equipped with

the following:

• a speedometer

• an odometer

• two tripmeters

• a fuel reserve tripmeter

• a clock

• a self-diagnosis device

TIP

• Be sure to turn the key to “ON” before using the

“SELECT” switch.

• To switch the speedometer and odometer/trip-

meter displays between kilometers and miles,

select the odometer mode, and then push the

“SELECT” switch for 5 seconds.

Speedometer

The speedometer shows the vehicle’s traveling

speed.

Odometer, tripmeters, fuel reserve tripmeter

and clock

The odometer shows the total distance traveled.

The tripmeters show the distance traveled since

they last reset.

The fuel reserve tripmeter shows the distance

traveled since the fuel level warning light came

on.

The clock displays time in 12-hour format.

TIP

• The odometer will lock at 999999.

• The tripmeters will reset and continue counting

after 999.9 is reached.

In normal operation, use the “SELECT” switch to

change the display between the odometer

“ODO”, tripmeters “TRIP 1” and “TRIP 2”, and

the clock in the following order:

ODO → TRIP 1 → TRIP 2 → clock → ODO

If the fuel level warning light comes on, the dis-

play automatically changes to the fuel reserve

tripmeter “TRIP F” and starts counting the dis-

tance traveled from that point. In this case, use

the “SELECT” switch to change the display be-

tween the various tripmeters and the odometer

1. Speedometer

2. Odometer/tripmeter/fuel reserve

tripmeter/clock

2

1

1. “SELECT” switch

1. Odometer/tripmeter/fuel reserve

tripmeter/clock

1

1

FEATURES

1-3

in the following order:

TRIP F → TRIP 1 → TRIP 2 → clock → ODO →

TRIP F

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

LECT” switch, and then push the “SELECT”

switch for one second. If you do not reset the fuel

reserve tripmeter manually, after refueling and

traveling 5 km (3 mi) it will reset automatically

and disappear from the display.

[To set the clock]

1. Use the “SELECT” switch to change the dis-

play to the clock mode.

2. Push the “SELECT” switch for 5 seconds.

The hour digits will start flashing.

3. Use the “SELECT” switch to set the hours.

4. Push the “SELECT” switch for one second

and the minute digits will start flashing.

5. Use the “SELECT” switch to set the minutes.

6. Push the “SELECT” switch for one second to

start the clock.

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 and

the display will indicate an error code.

If the display indicates any error codes, note the

code number, and then check the vehicle.

Refer to “FUEL INJECTION SYSTEM” on page

7-27.

NOTICE

ECA20220

If the display indicates a fault code, the vehi-

cle should be checked as soon as possible

in order to avoid engine damage.

1. Clock

1. Error code display

2. Engine trouble warning light “

”

1

1

2

IMPORTANT INFORMATION

1-4

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 1-11.

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

IMPORTANT INFORMATION

1-5

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.

BASIC SERVICE INFORMATION

1-6

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.