YZF-h1M

Service Manual

LIT-11616-33-33
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 YAMAHA
SERVICE MANUAL

BASIC INFORMATION

LIT-11616-MC-BO YOA-28197-10
IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics.
This manual contains only basic instructions that must be observed during servicing. Refer to the ap-
plicable service manual for detailed information on checking, adjustment, and replacement.
TIP
Designs and specifications are subject to change without notice.

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
L\ 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

4 WARNING result in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid

NOTICE damage to the vehicle or other property.

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

BASIC INFORMATION
SERVICE MANUAL
©2017 by Yamaha Motor Corporation, U.S.A.
First edition, January 2017
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-MC-BO
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 Molybdenum disulfide oil

Er
i

6 Filling fluid Gear oil

|)
&>—
Lubricant Brake fluid
YL!

Special tool ae) | Wheel bearing grease

Loe || NR
> (BO) SPQ}

Tightening torque =@isB-§ |ithium-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.

 CONTENTS

IMPORTANT INFORMATION

y |
PREPARATION FOR REMOVAL AND DISASSEMBLY.....................00::5-

aa ==
REPLACEMENT PARTS...
GASKETS, OIL SEALS AND O- RINGS...

MMMY
LOCK WASHERS/PLATES AND COTTER PINS...
BEARINGS AND OIL SEALS ND COTTER PINS wrrrnrnrnnnn nnn
CIRCLIPS..
REASSEMBLY OF PARTS USING LOCKING AGENT (LOCTITE®) saiateasa
RUBBER PARTS...

BASIC SERVICE INFORMATION

QUICK FASTENERS...
ELECTRICAL SYSTEM..
GENERAL TIGHTENING TORQUE SPECIFICATIONS..
ADJUSTING THE WHEEL STATIC AWE
CHECKING THE SWITCHES..
CHECKING THE BULBS AND BULB SOCKETS .
CHECKING AND CHARGING THE SEM cece

TROUBLESHOOTING 16
GENERAL INFORMATION.. wees 16
TROUBLESHOOTING OF ENGINE (fault code not detected)... wee 16
TROUBLESHOOTING OF CLUTCH.. ied
TROUBLESHOOTING OF TRANSMISSION .. we eeeeeeeeeeueeeeeeeueeeeeeees ... 30
TROUBLESHOOTING OF COOLING SYSTEM cocccscsssssssssssesssssssssseseceseee 31
TROUBLESHOOTING OF BRAKE .. sata Oe
TROUBLESHOOTING AT ABS WARNING LIGHT... A OO
TROUBLESHOOTING OF SUSPENSION..
TROUBLESHOOTING OF STEERING/HANDLING . ... 36
TROUBLESHOOTING OF CHARGING SYSTEM Senn 3/7
TROUBLESHOOTING OF LIGHTING SYSTEM oocsecoocccoeecoeeee cece. 3/
TROUBLESHOOTING OF SIGNALING SYSTEM ceccsccccccccccscecesceccssseceeeeee 3/7
 IMPORTANT INFORMATION

IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.

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
2. Use only the proper tools and cleaning equip-
lips with grease.
ment.
Refer to “SPECIAL TOOLS’ in the applicable
service manual.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders, i |
pistons and other parts that have been “mat- 1_—-> ||
ed” through normal wear. Mated parts must i |
always be reused or replaced as an assem-
bly.

1. Oil
2. Lip
3. Spring
4. Grease

LOCK WASHERS/PLATES AND COTTER

PINS
After removal, replace all lock washers/plates
“1” and cotter pins. After the bolt or nut has been
4. During disassembly, clean all of the parts and tightened to specification, bend the lock tabs
place them in trays in the order of disassem- along a flat of the bolt or nut.
bly. This will soeed up assembly and allow for
the correct installation of all parts.
5. Keep all parts away from any source of fire.

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.
 IMPORTANT INFORMATION

BEARINGS AND OIL SEALS REASSEMBLY OF PARTS USING LOCKING

Install bearings “1” and oil seals “2” so that the AGENT (LOCTITE®)
manufacturer marks or numbers are visible. Before reassembling screws, bolts, and nuts, or
When installing oil seals, lubricate the oil seal other parts, using locking agent (LOCTITE®),
lips with a light coat of lithium-soap-based remove all the old locking agent, and then apply
grease. Oil bearings liberally when installing, if new locking agent and reassemble the parts. Al-
appropriate. so, a specified amount of time is required for the
locking agent to cure.
NOTICE
Do not spin the bearing with compressed air RUBBER PARTS
because this will damage the bearing surfac- Check rubber parts for deterioration during in-
es. 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.

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.

s—_> a

EMM Ls
 BASIC SERVICE INFORMATION

BASIC SERVICE INFORMATION

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.

Screw type 1
1. Remove:
¢ Quick fastener
TIP
To remove the quick fastener, loosen the screw
with a screwdriver, then pull the fastener out.

ae

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 “a” in with a screwdriver. Make sure that
the pin is flush with the fastener’s head. 2. Install:
¢ Quick fastener
TIP
To install the quick fastener, insert the fastener
into the part to be secured and tighten the screw.

Xo + en
 BASIC SERVICE INFORMATION

Be i
Screw type 2
1. Remove:
e Quick fastener
TIP
To remove the quick fastener, loosen the screw
with a screwdriver, then pull the fastener out.

ELECTRICAL SYSTEM

Electrical parts handling

NOTICE
Never disconnect a battery lead while the en-
gine is running; otherwise, the electrical
components could be damaged.

2. Install:
* Quick fastener
TIP NOTICE
To install the quick fastener, insert the fastener When disconnecting the battery leads from
into the part to be secured and tighten the screw the battery, be sure to disconnect the nega-
EE oe 19
a. 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.
 BASIC SERVICE INFORMATION

ECA16610
TIP
NOTICE
lf a battery lead is difficult to disconnect due to
Turn the main switch to “OFF” before dis-
rust on the battery terminal, remove the rust us-
connecting or connecting an electrical com-
ing hot water.
ponent.

ECA16760
EC A16620
NOTICE
NOTICE
Be sure to connect the battery leads to the
Handle electrical components with special
correct battery terminals. Reversing the bat-
care, and do not subject them to strong
tery lead connections could damage the
shocks.
electrical components.

ECA16630
ECGAI6TT1
NOTICE
NOTICE
Electrical components are very sensitive to
When connecting the battery leads to the
and can be damaged by static electricity.
battery, be sure to connect the positive bat-
Therefore, never touch the terminals and be
tery lead first, then the negative battery lead.
sure to keep the contacts clean.
lf 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.
 BASIC SERVICE INFORMATION

ECA16E40
TIP
NOTICE
When resetting the ECU by turning the main
For waterproof couplers, never insert the
switch to “OFF”, be sure to wait approximately 5
tester probes directly into the coupler. When
seconds before turning the main switch back to
“ON”. performing any checks using a waterproof
coupler, use the specified test harness or a
suitable commercially available test har-
ness.

Checking the electrical system

TIP
Before checking the electrical system, make
Checking the connections
sure that the battery voltage is at least 12 V.
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
e Lead
¢ Coupler
¢ Connector
ECAT6780

NOTICE
¢ When disconnecting a coupler, release the
coupler lock, hold both sections of the cou-
pler securely, and then disconnect the cou-
ECA14371
pler.
NOTICE ¢ There are many types of coupler locks;
Never insert the tester probes into the cou- therefore, be sure to check the type of cou-
pler terminal slots. Always insert the probes pler lock before disconnecting the coupler.
from the opposite end “a” of the coupler, tak-
ing care not to loosen or damage the leads.
 BASIC SERVICE INFORMATION

¢ Make sure all connections are tight.

ECATB790

NOTICE
When disconnecting a connector, do not pull
the leads. Hold both sections of the connec-
tor securely, and then disconnect the con-
nector.

4. Check:
¢ Continuity
(with the digital circuit tester (CD732))

2. Check:
F- Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
chometer
e Lead
YU-A1927
¢ Coupler
¢ Connector TIP
Moisture — Dry with an air blower.
If there is no continuity, clean the terminals.
Rust/stains — Connect and disconnect sev-
e When checking the wire harness, perform
eral times.
steps (1) to (4).
e As a quick remedy, use a contact revitalizer
available at most part stores.

3. Connect:
e Lead
¢ Coupler
« Connector
TIP
e When connecting a coupler or connector, push
both sections of the coupler or connector to-
gether until they are connected securely.
 BASIC SERVICE INFORMATION

GENERAL TIGHTENING TORQUE

SPECIFICATIONS
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread pitch.
Refer to the applicable service manual for tight-
ening torque specifications of special compo-
nents or assemblies. To avoid warpage, tighten
multi-fastener assemblies in a crisscross pattern
and progressive stages until the specified tight-
ening torque is reached. Unless otherwise spec-
5. Check: ified, tightening torque specifications require
e Resistance clean, dry threads. Components should be at
room temperature.
Digital circuit tester (CD732)
90890-03243

©)
Model 88 Multimeter with ta-
chometer
YU-A1927 oa
TIP A
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 A. Distance between flats
will be shown. B. Outside thread diameter

General tightening
Intake air temperature sensor re-
sistance A (nut) bom torques
5.40-6.60 kQ at 0 °C (32 °F) N-m kgf-m lb-ft
290-390 © at 80 °C (176 °F)
10mm | 6mm 6 0.6 44
12mm} 8mm 15 1.5 11
14mm | 10 mm 30 3 22
17 mm | 12 mm 55 5.5 41
19 mm | 14mm 85 8.5 63
22 mm | 16mm 130 13 95.9
 BASIC SERVICE INFORMATION

ADJUSTING THE WHEEL STATIC BALANCE TIP

TIP Start with the lightest weight.
e After replacing the tire, wheel or both, the
wheel static balance should be adjusted.
e Adjust the wheel static balance with the brake
disc installed.
1. Remove:
¢ Balancing weight(s)
2. Find:
¢ Wheel’s heavy spot
TIP
Place the wheel on a suitable balancing stand.

=: ®) @Nae
b. Turn the wheel 90° so that the heavy spot is
a. Spin the wheel. positioned as shown.
b. When the wheel stops, put an “X,” mark at
the bottom of the wheel.

(@) c. If the heavy spot does not stay in that posi-

tion, install a heavier weight.
c. Turn the wheel 90° so that the “X,” mark is d. Repeat steps (b) and (c) until the wheel is
positioned as shown. balanced.
d. Release the wheel. 4. Check:
e. When the wheel stops, put an “X,” mark at ¢ Wheel static balance
the bottom of the wheel. a. Turn the wheel and make sure it stays at
each position shown.
X

f. Repeat steps (c) through (e) several times

until all the marks come to rest at the same b. Ifthe wheel does not remain stationary at all
spot. of the positions, rebalance it.
g. The spot where all the marks come to rest is
the wheel’s heavy spot “X”.
3. Adjust:
¢ Wheel static balance
a. Install a balancing weight “1” onto the rim
exactly opposite the heavy spot “X”.
 BASIC SERVICE INFORMATION

CHECKING THE SWITCHES

Check each switch for continuity with the digital b
circuit tester. If the continuity reading is incor- R/W|Br/L|Br/R
rect, check the wiring connections and if neces- ON |O+O+0
sary, replace the switch. a OFF
P= O : 2)
NOTICE
Never insert the tester probes into the cou- RW.
pler terminal slots. Always insert the probes
from the opposite end “a” of the coupler, tak-
on | |BriR

ing care not to loosen or damage the leads.

CHECKING THE BULBS AND BULB

#&
SOCKETS
Digital circuit tester (CD732) Check each bulb and bulb socket for damage or
90890-03243 wear, proper connections, and also for continuity
Model 88 Multimeter with ta- between the terminals.
chometer Damage/wear — Repair or replace the bulb,
YU-A1927 bulb socket or both.
Improperly connected — Properly connect.
TIP No continuity > Repair or replace the bulb, bulb
¢ Before checking for continuity, set the digital socket or both.
circuit tester to the “Q” range.
¢ When checking for continuity, switch back and Types of bulbs
forth between the switch positions a few times. The bulbs used on this vehicle are shown in the
following illustration.
* Bulbs “a” and “b” are used for the headlights
and usually use a bulb holder that must be de-
tached before removing the bulb. The majority
of these types of bulbs can be removed from
their respective socket by turning them coun-
terclockwise.
* Bulbs “c” are used for turn signal lights and can
be removed from the socket by pushing and
turning the bulb counterclockwise.
* Bulbs “d” and “e” are used for license plate and
The terminal connections for switches (e.g., auxiliary lights and can be removed from their
main switch, engine stop switch) are indicated in respective sockets by carefully pulling them
an illustration as shown in the following exam- out.
ple.
The switch positions “a” are shown in the far left
column and the switch lead colors “b” are shown
in the top row in the switch illustration.
TIP

“O——. " indicates a continuity of electricity be-

tween switch terminals (i.e., a closed circuit at
the respective switch position).
The example illustration below shows that:
There is continuity between red/white, brown/
blue and brown/red when the switch is set to
“ON”.

There is continuity between red/white and

brown/red when the switch is set to “p<”.

10
 BASIC SERVICE INFORMATION

Digital circuit tester (CD732)

90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927

TIP
Before checking for continuity, set the digital cir-
cuit tester to the “QO” range.

a. Connect the positive tester probe to termi-

nal “1” and the negative tester probe to ter-
minal “2”, and check the continuity.
b. Connect the positive tester probe to termi-
nal “1” and the negative tester probe to ter-
minal “3”, and check the continuity.
c. If either of the readings indicate no continu-
ity, replace the bulb.

Checking the condition of the bulbs

The following procedure applies to all of the 4
bulbs. 4
1. Remove: YY
* Bulb o/ 5

°
Since the headlight bulb gets extremely hot,
keep flammable products and your hands Checking the condition of the bulb sockets
away from the bulb until it has cooled down. The following procedure applies to all of the bulb
~cavaaes sockets.
NOTICE 1. Check:

¢ Be sure to hold the socket firmly when re- * Bulb socket (for continuity)
moving the bulb. Never pull the lead, other- (with the digital circuit tester)
wise it may be pulled out of the terminal in No continuity — Replace.
the coupler.
¢ Avoid touching the glass part ofa headlight Digital circuit tester (CD732)
90890-03243
bulb to keep it free from oil, otherwise the
Model 88 Multimeter with ta-
transparency of the glass, the life of the
bulb, and the luminous flux will be adverse- ee
ly affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened TIP
with alcohol or lacquer thinner. Check each bulb socket for continuity in the
2. Check: Same manner as described in the bulb section;
Bulb (for continuity) however, note the following.
(with the digital circuit tester)
No continuity > Replace. a. Install a good bulb into the bulb socket.
b. Connect the digital circuit tester probes to
the respective leads of the bulb socket.

11
 BASIC SERVICE INFORMATION

c. Check the bulb socket for continuity. If any siderably. Therefore, take special care
of the readings indicate no continuity, re- when charging the battery.
place the bulb socket.
TIP
CHECKING AND CHARGING THE BATTERY since VRLA (Valve Regulated Lead Acid) bat-
EWA13290
teries are sealed, it is not possible to check the
charge state of the battery by measuring the
Batteries generate explosive hydrogen gas specific gravity of the electrolyte. Therefore, the
and contain electrolyte which is made of poi- charge of the battery has to be checked by mea-
sonous and highly caustic sulfuric acid. suring the voltage at the battery terminals.
Therefore, always follow these preventive
measures: 1. Check:
¢ Wear protective eye gear when handling or ¢ Battery charge
working near batteries. a. Connect a digital circuit tester to the battery
¢ Charge batteries in a well-ventilated area. terminals.
¢ Keep batteries away from fire, sparks or
¢ Positive tester probe >
open flames (e.g., welding equipment,
positive battery terminal
lighted cigarettes). * Negative tester probe >
¢ DO NOT SMOKE when charging or han- negative battery terminal
dling batteries.
e KEEP BATTERIES AND ELECTROLYTE
TIP
OUT OF REACH OF CHILDREN.
¢ The charge state of a VRLA (Valve Regulated
¢ Avoid bodily contact with electrolyte as it
can Cause severe burns or permanent eye Lead Acid) battery can be checked by measur-
ing its open-circuit voltage (i.e., the voltage
injury.
FIRST AID IN CASE OF BODILY CONTACT: when the positive battery terminal is discon-
nected).
EXTERNAL
¢ Skin — Wash with water. ¢« No charging is necessary when the open-cir-
cuit voltage equals or exceeds 12.8 V.
¢ Eyes — Flush with water for 15 minutes and
get immediate medical attention. b. Check the charge of the battery, as shown
INTERNAL in the charts and the following example.
¢ Drink large quantities of water or milk fol-
Example
lowed with milk of magnesia, beaten egg or
Open-circuit voltage = 12.0 V
vegetable oil. Get immediate medical atten-
Charging time = 6.5 hours
tion. Charge of the battery = 20-30%
VRLA type battery
A
ECA13661

NOTICE 13.0
¢ This is a VRLA (Valve Regulated Lead Acid)
12.5
battery. Never remove the sealing caps be-
cause the balance between cells will not be 12.0¢---------
I
maintained and battery performance will I
11.54 I
deteriorate. I
I
¢ Charging time, charging amperage and
-
ii

|
charging voltage for a VRLA (Valve Regu- 5 65 10 B
lated Lead Acid) battery are different from D
those of conventional batteries. The VRLA Open-circuit voltage (V)
OWS

(Valve Regulated Lead Acid) battery should Charging time (hours)

be charged according to the appropriate Relationship between the open-circuit volt-
charging method. If the battery is over- age and the charging time at 20 °C (68 °F)
These values vary with the temperature, the
GO

charged, the electrolyte level will drop con-

condition of the battery plates, and the elec-
trolyte level.
 BASIC SERVICE INFORMATION

ulated Lead Acid) battery stabilizes about

30 minutes after charging has been com-
‘3 fo}. pleted. Therefore, wait 30 minutes after
charging is completed before measuring
I i the open-circuit voltage.
1
11 :i I

A.
I !
10}——— 4 I
t I 18 --———-4.
|
l 17
100. 75 SO 302520 0 B 16
15
A. Open-circuit voltage (V) 14

B. Charging condition of the battery (%) 13

12 ~~ ——+- ae
C. Ambient temperature 20 °C (68 °F)
11
10
2. Charge:
¢ Battery
(refer to the appropriate charging method) Open-circuit voltage (V)

MmOOW>
EWA13300 Time (minutes)
Charging
Do not quick charge a battery. Ambient temperature 20 °C (68 °F)
Check the open-circuit voltage.
ECGA13671

NOTICE Charging method using a variable-current

¢ Do not use a high-rate battery charger (voltage) charger
since it forces a high-amperage current a. Measure the open-circuit voltage prior to
into the battery quickly and can cause bat- charging.
tery overheating and battery plate damage. TIP
¢ If it is impossible to regulate the charging
Voltage should be measured 30 minutes after
current on the battery charger, be careful
the engine is stopped.
not to overcharge the battery.
¢ When charging a battery, be sure to remove b. Connect a charger and ammeter to the bat-
it from the vehicle. (If charging has to be tery and start charging.
done with the battery mounted on the vehi- TIP
cle, disconnect the negative battery lead Set the charging voltage to 16—17 V. If the set-
from the battery terminal.) ting is lower, charging will be insufficient. If too
¢ To reduce the chance of sparks, do not high, the battery will be over-charged.
plug in the battery charger until the battery
charger leads are connected to the battery. c. Make sure that the current is higher than
¢ Before removing the battery charger lead the standard charging current written on the
clips from the battery terminals, be sure to battery.
turn off the battery charger. TIP
¢ Make sure the battery charger lead clips are lf the current is lower than the standard charging
in full contact with the battery terminal and current written on the battery, set the charging
that they are not shorted. A corroded bat- voltage adjust dial at 20-24 V and monitor the
tery charger lead clip may generate heat in amperage for 3—5 minutes to check the battery.
the contact area and a weak clip spring may
cause sparks. ¢ Standard charging current is reached
¢ If the battery becomes hot to the touch at Battery is good.
any time during the charging process, dis- ¢ Standard charging current is not reached
connect the battery charger and let the bat- Replace the battery.
tery cool before reconnecting it. Hot
batteries can explode! d. Adjust the voltage so that the current is at
¢ As shown in the following illustration, the the standard charging level.
open-circuit voltage of a VRLA (Valve Reg-

13
 BASIC SERVICE INFORMATION

e. Set the time according to the charging time Open type battery
suitable for the open-circuit voltage. 1. Check:
f. If charging requires more than 5 hours, it is e Electrolyte level
advisable to check the charging current af- The electrolyte level should be between the
ter a lapse of 5 hours. If there is any change minimum level mark “a” and the maximum
in the amperage, readjust the voltage to ob- level mark “b”.
tain the standard charging current. Below the minimum level mark — Add dis-
g. Measure the battery open-circuit voltage af- tilled water to the proper level.
ter leaving the battery unused for more than ECAI3610

30 minutes. NOTICE
Add only distilled water. Tap water contains
12.8 V or more --- Charging is complete.
minerals which are harmful to the battery.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.

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.
2. Check:
b. Connect a charger and ammeter to the bat- ° Specific gravity
tery and start charging. Less than 1.28 — Recharge the battery.

A
c. Make sure that the current is higher than
the standard charging current written on the Specific gravity
battery. 1.28
TIP
lf the current is lower than the standard charging 3. Charge:
current written on the battery, this type of battery e Battery
charger cannot charge the VRLA (Valve Regu- Battery charging amperage and time
lated Lead Acid) battery. A variable voltage Refer to “ELECTRICAL SPECIFICATIONS”
charger is recommended. in the applicable service manual.

d. Charge the battery until the battery’s EWAIS300

charging voltage is 15 V.
TIP Do not quick charge a battery.
Set the charging time at 20 hours (maximum). ECA13620

NOTICE
e. Measure the battery open-circuit voltage af-
ter leaving the battery unused for more than * Loosen the battery sealing caps.
30 minutes. ¢ Make sure the battery breather hose and
battery vent are free of obstructions.
12.8 V or more --- Charging is complete. ¢ To ensure maximum performance, always
12.7 V or less --- Recharging is required.
charge a new battery before using it.
Under 12.0 V --- Replace the battery.
* Do not use a high-rate battery charger.
They force a high-amperage current into
the battery quickly and can cause battery
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.

14
 BASIC SERVICE INFORMATION

¢ 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 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 batter-
ies can explode!

TIP
Replace the battery whenever:
e battery voltage does not rise to specification or
bubbles fail to rise during charging,
¢ sulphation of one or more battery cells occurs
(as indicated by the battery plates turning white
or material accumulating in the bottom of the
battery cell),
° specific gravity readings after a long, slow
charge indicate that one battery cell’s charge is
lower than the rest,
® warpage or buckling of the battery plates or in-
sulators is evident.
4. Check:
¢ Battery breather hose and battery vent
Obstruction —> Clean.
Damage — Replace.

15
 TROUBLESHOOTING

TROUBLESHOOTING
GENERAL INFORMATION
TIP
Troubleshooting information provided here does not cover all the trouble symptoms, possible causes,
and remedial actions. Some items may not apply depending on the model. Use this information as a
guide and quick reference matrix when performing basic troubleshooting. Refer to the applicable Ser-
vice manual for detailed information on checking, adjustment, and replacement.

TROUBLESHOOTING OF ENGINE (fault code not detected)

TIP
lf a fault code is detected, refer to the “ECU SELF-DIAGNOSTIC FUNCTION?” under “FUEL INJEC-
TION SYSTEM’ (ELECTRICAL SYSTEM) in the Service manual.

Engine does not crank.

Symptom Possible cause Actions
Starter motor does not operate | Refer to “TROUBLESHOOTING” under “ELECTRIC STARTING
SYSTEM’ (ELECTRICAL SYSTEM) in the Service manual.
Starter motor operates, but the | Starter clutch malfunction Replace the starter clutch.
engine does not crank. Improper oil grade (starter Change to recommended en-
clutch slipping) gine oil.
Stuck piston or seized crank- | Disassemble and check the en-
shaft gine. Replace defective parts.

Engine will not start or is difficult to start, but it cranks (fuel injection models).
Symptom Possible cause Actions
Spark plug does not produce a | Refer to “TROUBLESHOOTING?” under “IGNITION SYSTEM”
spark (ELECTRICAL SYSTEM) in the Service manual.
Fuel not supplied — Measure the fuel pressure.
Empty fuel tank Fill the fuel tank with fuel.
Clogged fuel tank cap breather | Clean the fuel tank cap.
hole
Clogged or damaged fuel hose | Clean, repair, or replace the
fuel hose.
Fuel leakage Check the fuel passage. Repair
or replace as necessary.
Clogged fuel pump Clean or replace the fuel pump.
Cracks or damage in fuel pump | Replace the fuel pump.
Fuel pump malfunction Refer to “TROUBLESHOOT-
ING” under “FUEL PUMP SYS-
TEM” (ELECTRICAL SYSTEM)
in the Service manual.
Failed or clogged fuel injector | Replace the fuel injector.
ECU failure Replace the ECU.
— Wateror foreign material in fuel, | Change fuel.
degraded fuel

16
 TROUBLESHOOTING

Symptom Possible cause Actions

Compression pressure is low Measure the compression pres-
sure.
Loose spark plug Tighten the spark plug to the
specified torque.
Loose cylinder head or cylinder Tighten bolts or nuts on cylinder
head and cylinder to the speci-
fied torque.
Damaged cylinder head gasket Replace the cylinder head gas-
ket.
Incorrect valve timing Adjust the valve timing.
Incorrect valve clearance Adjust the valve clearance.
Worn valve guide Replace the valve guide.
Bent, damaged, or stuck valve Replace the valve.
Poor contact between valve Reface the valve-to-valve-seat
and valve seat contact.
Fatigued or broken valve spring Replace the valve spring.
Worn, damaged, or stuck piston Replace the piston and piston
ring rings as a Set.
Seized or damaged piston Replace the piston and piston
rings as a Set.
Worn or damaged cylinder bore Replace the cylinder, piston,
and piston rings as a set.

17
 TROUBLESHOOTING

Engine will not start or is difficult to start, but it cranks (carburetor models).
Symptom Possible cause Actions
Spark plug does not produce a Refer to “TROUBLESHOOTING?” under “IGNITION SYSTEM”
spark (ELECTRICAL SYSTEM) in the Service manual.
Fuel not supplied Empty fuel tank Fill the fuel tank with fuel.
Clogged fuel tank cap breather Clean the fuel tank cap.
hole
Clogged or damaged fuel hose Clean, repair, or replace the
fuel hose.
Fuel leakage Check the fuel passage. Repair
or replace as necessary.
Clogged fuel cock strainer Clean or replace the fuel cock
strainer.
Clogged fuel cock Clean or replace the fuel cock.
Cracked, damaged or worn fuel Replace the fuel cock.
cock.
Clogged carburetor fuel pas- Clean the carburetor.
sage
Clogged needle valve or needle Clean the needle valve or nee-
valve seat dle valve seat.
Damaged float Replace the float.
Clogged pilot jet Clean the pilot jet.
Clogged starter jet Clean the starter jet.
Bent or damaged starter plung- Replace the starter plunger.
er
Incorrectly adjusted starter ca- Adjust the starter cable.
ble
Water or foreign material in fuel, Change fuel.
degraded fuel

18
 TROUBLESHOOTING

Symptom Possible cause Actions

Compression pressure is low Measure the compression pres-
sure.
loose spark plug Tighten the spark plugs to the
specified torque.
Loose cylinder head or cylinder Tighten bolts or nuts on cylinder
head and cylinder to the speci-
fied torque.
Damaged cylinder head gasket Replace the cylinder head gas-
ket.
Incorrect valve timing Adjust the valve timing.
Incorrect valve clearance Adjust the valve clearance.
Worn valve guide Replace the valve guide.
Bent, damaged, or stuck valve Replace the valve.
Poor contact between valve Reface the valve-to-valve-seat
and valve seat contact.
Fatigued or broken valve spring Replace the valve spring.
Worn, damaged, or stuck piston Replace the piston and piston
ring rings as a Set.
Seized or damaged piston Replace the piston and piston
rings as a Set.
Worn or damaged cylinder bore Replace the cylinder, piston,
and piston rings as a set.

Incorrect idling speed or mid-to-high speed (fuel injection models)

Symptom Possible cause Actions
Spark plug does not produce a | Incorrect spark plug gap Adjust the spark plug gap.
spark Worn or damaged spark plug _| Replace the spark plug.
Defective spark plug cap Replace the spark plug cap.
Defective ignition coil Replace the ignition coil.
ECU failure Replace the ECU.
Low fuel pressure — Measure the fuel pressure.
Fuel leakage Check the fuel passage. Repair
or replace as necessary.
Clogged fuel pump Clean or replace the fuel pump.
Cracks or damage in fuel pump Replace the fuel pump.
Fuel pump malfunction Refer to “TROUBLESHOOT-
ING” under “FUEL PUMP SYS-
TEM” (ELECTRICAL SYSTEM)
in the Service manual.
Fuel not supplied Failed or clogged fuel injector Replace the fuel injector.
ECU failure Replace the ECU.
Compression pressure is low Refer to “Engine will not start or is difficult to start, but it cranks (fu-
el injection models)”.

19
 TROUBLESHOOTING

Symptom Possible cause Actions

Worn camshaft lobe Replace the camshaft.
Water or foreign material in fuel, | Change fuel.
degraded fuel
Contaminated throttle body or Clean the throttle body.
clogged internal passage
Incorrectly adjusted throttle ca- Adjust the throttle grip free play.
ble
Improperly synchronized throt- Adjust synchronization of throt-
tle bodies tle bodies.
Incorrectly adjusted idling Adjust the idle adjusting screw.
speed (idle adjusting screw)
Contaminated idle speed con- Clean the idle speed control
trol (ISC) valve (ISC) valve.
Damaged idle speed control Replace the idle speed control
(ISC) valve (ISC) valve.
Incorrect idle speed control Reset the learning value of idle
(ISC) valve position speed control (ISC) valve.
Incorrect throttle position sen- Adjust the throttle position sen-
sor angle sor angle.
Incorrect acceleration position Adjust the acceleration position
sensor angle sensor angle.
Faulty ECU Replace the ECU.
Failed air induction system Check the air induction system.
Repair or replace faulty parts.
Clogged vacuum hose Clean the vacuum hose.
Cracks and damage in vacuum Replace the vacuum hose.
hose
Damaged throttle body joint Replace the throttle body joint.
Loose throttle body joint Tighten the throttle body joint
bolts to the specified torque.
Clogged air filter element Clean or replace the air filter el-
ement.
Incorrect oil level (high) Adjust the oil level to the speci-
fied level.

20
 TROUBLESHOOTING

Incorrect idling speed (carburetor models)

Symptom Possible cause Actions
Spark plug does not produce a | Incorrect spark plug gap Adjust the spark plug gap.
spark Worn or damaged spark plug _| Replace the spark plug.
Defective spark plug cap Replace the spark plug cap.
Defective ignition coil Replace the ignition coil.
CDI unit failure Replace the CDI unit.
Fuel not supplied Fuel leakage Check the fuel passage. Repair
or replace as necessary.
Clogged carburetor fuel pas- Clean the carburetor.
sage
Clogged needle valve or needle | Clean the needle valve or nee-
valve seat dle valve seat.
Damaged float Replace the float.
Compression pressure is low | Refer to “Engine will not start or is difficult to start, but it cranks
(carburetor models)”.

21
 TROUBLESHOOTING

Symptom Possible cause Actions

Worn camshaft lobe Replace the camshaft.
Water or foreign material in fuel, | Change fuel.
degraded fuel
Clogged carburetor air passage Clean the carburetor.
Incorrectly adjusted throttle ca- Adjust the throttle grip free play.
ble
Improperly synchronized carbu- Adjust synchronization of car-
retors buretors.
Incorrectly adjusted idling Adjust the throttle stop screw.
speed (throttle stop screw)
Incorrectly adjusted pilot screw Adjust the pilot screw.
Incorrectly adjusted pilot air Adjust the pilot air screw.
screw
Clogged pilot jet Clean the pilot jet.
Loose pilot jet Tighten the pilot jet to the spec-
ified torque.
Damaged or worn needle valve Replace the needle valve seat.
seat
Loose needle valve seat Tighten the needle valve seat to
the specified torque.
Damaged or worn needle valve Replace the needle valve.
Incorrect fuel level Adjust the fuel level to the prop-
er level.
Bent, worn, or damaged starter Replace the starter plunger.
plunger
Incorrectly adjusted starter ca- Adjust the starter cable.
ble
Clogged or damaged carbure- Clean, repair, or replace the
tor breather hose carburetor breather hose.
Incorrect throttle position sen- Adjust the throttle position sen-
sor angle sor angle.
Failed air induction system Check the air induction system.
Repair or replace faulty parts.
Clogged vacuum hose Clean the vacuum hose.
Cracks and damage in vacuum Replace the vacuum hose.
hose
Damaged carburetor joint Replace the carburetor joint.
Loose carburetor joint Tighten the carburetor joint
bolts to the specified torque.
Clogged air filter element Clean or replace the air filter el-
ement.
Incorrect oil level (high) Adjust the oil level to the speci-
fied level.

22
 TROUBLESHOOTING

Incorrect mid-high speed (carburetor models)

Symptom Possible cause Actions
Spark plug does not produce a | Incorrect spark plug gap Adjust the spark plug gap.
spark Worn or damaged spark plug _| Replace the spark plug.
Defective spark plug cap Replace the spark plug cap.
Defective ignition coil Replace the ignition coil.
CDI unit failure Replace the CDI unit.
Fuel not supplied Fuel leakage Check the fuel passage. Repair
or replace as necessary.
Clogged carburetor fuel pas- Clean the carburetor.
sage
Clogged needle valve or needle | Clean the needle valve or nee-
valve seat dle valve seat.
Damaged float Replace the float.
Compression pressure is low | Refer to “Engine will not start or is difficult to start, but it cranks
(carburetor models)”.

23
 TROUBLESHOOTING

Symptom Possible cause Actions

Worn camshaft lobe Replace the camshaft.
Water ore material in fuel, Change fuel.
degraded fue
Clogged carburetor air passage Clean the carburetor.
Incorrectly adjusted throttle cable Adjust the throttle grip free play.
Improperly synchronized carbu- Adjust synchronization of car-
retors buretors.
Incorrectly adjusted pilot screw Adjust the pilot screw.
Incorrectly adjusted pilot air screw Adjust the pilot air screw.
Clogged pilot jet Clean the pilot jet.
Loose pilot jet Tighten the pilot jet to the spec-
ified torque.
Clogged main nozzle Clean the main nozzle.
Loose main nozzle Tighten the main nozzle to the
specified torque.
Clogged main jet Clean the main jet.
Loose main jet Tighten the main jet to the spec-
ified torque.
Bent, damaged, or worn jet needle Replace the jet needle.
Cracks or damage in the piston Replace the piston valve dia-
valve diaphragm phragm.
Problem with piston valve move- Replace the piston valve.
ment (movement is not smooth)
Damaged or worn needle valve seat Replace the needle valve seat.
Loose needle valve seat Tighten the needle valve seat to
the specified torque.
Damaged or worn needle valve Replace the needle valve.
Incorrect fuel level Adjust the fuel level to the prop-
er level.
Bent, worn, or damaged starter Replace the starter plunger.
plunger
Incorrectly adjusted starter cable Adjust the starter cable.
Clogged or damaged carbure- Clean, repair, or replace the
tor breather hose carburetor breather hose.
Incorrect throttle position sen- Adjust the throttle position sen-
sor angle sor angle.
Failed air induction system Check the air induction system.
Repair or replace faulty parts.
Clogged vacuum hose Clean the vacuum hose.
Cracks and damage in vacuum hose Replace the vacuum hose.
Damaged carburetor joint Replace the carburetor joint.
Loose carburetor joint che ae the carburetor joint
bolts to the specified torque.
Clogged air filter element Clean or replace the air filter element.
Incorrect oil level (high) Adjust the oil level to the speci-
fied level.

24
 TROUBLESHOOTING

Excessive noise from engine

Symptom Possible cause Actions
Noise heard from around cylin- | Incorrect valve clearance (too | Adjust the valve clearance.
der head wide)
Fatigued or broken valve spring | Replace the valve spring.
Worn or damaged camshaft Replace the camshaft.
lobe
Worn or damaged valve lifter | Replace the valve lifter and cyl-
inder head as a set.
Worn or damaged rocker arm__| Replace the rocker arm.
Worn or damaged rocker arm_| Replace the rocker arm shaft.
shaft
Worn or damaged camshaft Replace the camshaft.
journal
Worn or damaged cylinder Replace the cylinder head.
head (camshaft journal)
Noise heard from around timing | Worn or damaged timing chain | Replace the timing chain and
chain camshaft sprocket as a Set.
Worn or damaged camshaft Replace the timing chain and
sprocket camshaft sprocket as a set.
Worn or damaged timing chain | Replace the timing chain guide.
guide
Cracked, damaged, or faulty Replace the timing chain ten-
timing chain tensioner sioner.
Noise heard from around piston | Worn or damaged piston ring | Replace the piston and piston
rings as a Set.
Worn or damaged piston Replace the piston and piston
rings as a Set.
Worn piston (piston pin hole) Replace the piston and piston
pin as a set.
Worn or damaged piston pin Replace the piston pin.
Worn or damaged cylinder bore | Replace the cylinder, piston,
and piston rings as a set.
Carbon buildup in piston head | Clean the piston head and com-
and combustion chamber bustion chamber.

25
 TROUBLESHOOTING

Symptom Possible cause Actions

Noise heard from around crank- Worn or damaged crankshaft Replace the crankshaft.
shaft journal or crank pin
Cracked, worn, or damaged Replace the balancer drive
balancer shaft gear and balancer shaft as a
set.
Worn or damaged balancer Replace the balancer drive
drive gear. gear and balancer shaft as a
set.
Worn or damaged big end bear- Replace the big end bearing.
ing
Worn or damaged crankshaft Replace the crankshaft journal
journal bearing bearing.
Worn or damaged balancer Replace the balancer shaft
shaft journal bearing journal bearing.

26
 TROUBLESHOOTING

TROUBLESHOOTING OF CLUTCH

Manual clutch

Symptom Possible cause Actions

Clutch slippage Improperly assembled clutch Reassemble the clutch.
Improperly adjusted clutch ca- Adjust the clutch lever free play.
ble
Improperly assembled clutch Reassemble the clutch master
master cylinder (hydraulic cylinder.
clutch)
Improperly assembled clutch Reassemble the clutch fluid
fluid reservoir (hydraulic clutch) reservolr.
Improperly assembled clutch Reassemble the clutch release
release cylinder (hydraulic cylinder.
clutch)
Damaged clutch release cylin- Replace the clutch release cyl-
der (hydraulic clutch) inder.
Incorrect clutch fluid level (low) Add clutch fluid to the specified
(hydraulic clutch) level.
Damaged clutch hose (hydrau- Replace the clutch hose.
lic clutch)
Loose union bolt (hydraulic Tighten the union bolt to the
clutch) specified torque.
Loose clutch spring Tighten the clutch spring bolts
to the specified torque.
Fatigued or broken clutch Replace the clutch springs as a
spring set.
Warped pressure plate Replace the pressure plate.
Worn friction plate Replace the friction plates as a
set.
Warped or worn clutch plate Replace the clutch plates as a
set.
Incorrect oil level Adjust the engine oil level to the
specified level.
Incorrect oil viscosity (low) Change to recommended en-
gine oil.
Deteriorated oil Change to recommended en-
gine oil.

27
 TROUBLESHOOTING

Symptom Possible cause Actions

Clutch drags Air in hydraulic clutch system Bleed the hydraulic clutch sys-
(hydraulic clutch) tem.
Fluid leakage from hydraulic Check the hydraulic clutch sys-
clutch system (hydraulic clutch) tem and repair or replace faulty
parts as necessary.
Faulty clutch spring Replace the clutch springs as a
set.
Warped pressure plate Replace the pressure plate.
Swollen friction plate Replace the friction plates as a
set.
Warped clutch plate Replace the clutch plates asa
set.
Bent pull rod (outer pull type) Replace the pull rod.
Worn pull rod tooth (outer pull Replace the pull rod and pull le-
type) ver shaft as a set.
Bent push rod (inner push type) Replace the push rod.
Damaged or worn clutch boss Replace the clutch boss.
Seized clutch housing bushing Replace the clutch housing.
Improperly installed pull lever Align the match mark on the pull
lever before installation.
Incorrect oil level Adjust the engine oil level to the
specified level.
Incorrect oil viscosity (high) Change to recommended en-
gine oil.
Deteriorated oil Change to recommended en-
gine oil.
Clutch noise Damaged or worn primary driv- Replace the primary drive gear
en gear or crankshaft, and the clutch
housing as a set.
Loose clutch boss nut Tighten the clutch boss nut to
the specified torque.
Fatigued clutch damper Replace the clutch housing.
Worn clutch housing bearing Replace the clutch housing
bearing.
Worn pressure plate bearing Replace the pressure plate
bearing.

28
 TROUBLESHOOTING

V-belt automatic transmission

Symptom Possible cause Actions

Possible to start engine but im- | Damaged or worn V-belt Replace the V-belt.
possible to drive motorcycle == | Damaged primary sliding Replace the primary sliding
sheave (slider rib) sheave.
Loose primary fixed sheave nut | Tighten the primary fixed
sheave nut to the specified
torque.
Damaged secondary compres- | Replace the secondary com-
sion spring pression spring.
Damaged transmission gear Check the transmission gear.
Replace defective parts.
Clutch slippage Damaged clutch shoe spring Replace the clutch shoe
springs as a Set.
Damaged or worn clutch shoe __| Replace the clutch shoes and
springs as a set.
Damaged or worn clutch hous- | Replace the clutch housing.
ing
Poor starting performance Damaged or worn V-belt Replace the V-belt.
Oil or grease on the V-belt Clean the V-belt, primary
sheave, and secondary
sheave.
Faulty primary sliding sheave | Check the primary sliding
sheave, cam, and slider. Repair
or replace faulty parts as neces-
sary.
Damaged or worn clutch shoe __| Replace the clutch shoes and
springs as a Set.
Damaged or worn clutch hous- | Replace the clutch housing.
ing
Poor speed performance Damaged or worn V-belt Replace the V-belt.
Oil or grease on the V-belt Clean the V-belt, primary
sheave, and secondary
sheave.
Faulty primary sliding sheave __| Check the primary sliding
sheave, cam, and slider. Repair
or replace faulty parts as neces-
sary.
Damaged or worn primary Replace the primary sheave
sheave weight weight as a set.
Worn primary fixed sheave Replace the primary fixed
(pulley side) sheave.
Worn primary sliding sheave Replace the primary sliding
(pulley side) sheave.

29
 TROUBLESHOOTING

Symptom Possible cause Actions

Noise from clutch and transmis- Damaged or worn transmission Check the transmission gear.
sion gear Replace defective parts.
Worn main axle spline Replace the main axle.
Worn drive axle spline Replace the drive axle.
Damaged or worn transmission Replace the transmission bear-
bearing ing.

TROUBLESHOOTING OF TRANSMISSION
Symptom Possible cause Actions
Difficult or impossible to shift Clutch drags Refer to “Clutch drags”.
transmission gear
Improperly adjusted shift rod Adjust the shift rod installation
length.
Bent shift shaft Replace the shift shaft.
Foreign object in a shift drum Remove foreign object from
groove shift drum groove.
Damaged shift drum Replace the shift drum.
Seized shift fork Replace the shift fork and shift
fork guide bar as a Set.
Bent shift fork guide bar Replace the shift fork guide bar.
Foreign object between trans- Remove foreign object from
mission gears transmission gears.
Seized transmission gear Replace the seized gear and
the axle as a set.
Improperly assembled trans- Reassemble the transmission
mission axle assembly.
Jumps out of gear Incorrect shift pedal position Adjust the shift pedal position.
Improperly returned stopper le- Replace the stopper lever
ver spring.
Bent or worn shift fork Replace the shift fork.
Shift drum incorrect axial play | Replace the shift drum.
Worn shift drum groove Replace the shift drum.
Worn transmission gear dog Replace the transmission gear.
Transmission noise Damaged or worn transmission Replace the transmission gear.
gear
Worn main axle spline Replace the main axle.
Worn drive axle spline Replace the drive axle.
Worn bearing Replace the bearing.

30
 TROUBLESHOOTING

TROUBLESHOOTING OF COOLING SYSTEM

Symptom Possible cause Actions
Overheating Carbon buildup in piston head _ | Clean the piston head and com-
and combustion chamber bustion chamber.
Clogged engine cooling water | Check and clean the engine
passages cooling water passages.
Incorrect oil level Adjust the oil level to the speci-
fied level.
Incorrect oil viscosity Change to recommended en-
gine oil.
Inferior oil quality Change to recommended en-
gine oil.
Low coolant level Add recommended coolant to
the specified level.
Damaged or leaking radiator Replace the radiator.
Faulty radiator cap Replace the radiator cap.
Clogged radiator fin Clean the radiator fin.
Bent or damaged radiator fin Repair the radiator fin or re-
place the radiator.
Faulty radiator fan motor Refer to “TROUBLESHOOT-
ING” under “COOLING SYS-
TEM” (ELECTRICAL SYSTEM)
in the Service manual.
Damaged or faulty water pump | Replace the water pump.
Thermostat stays closed Replace the thermostat.
Clogged or damaged oil cooler | Replace the oil cooler.
Damaged hoses or pipes Replace the hose or pipe.
Improperly connected hoses or | Connect the hoses and pipes
pipes properly.
Damaged throttle body joint Replace the throttle body joint.
Loose throttle body joint Tighten the throttle body joint
bolts to the specified torque.
Clogged air filter element Clean or replace the air filter el-
ement.
Brake drags Check the brake system and re-
pair or replace faulty parts as
necessary.
Incorrect spark plug gap Adjust to the specified spark
plug gap.
Incorrect spark plug heat range | Replace the spark plug with the
one of the specified type.
Faulty ECU Replace the ECU.
Over cooling Thermostat stays open Replace the thermostat.

31
 TROUBLESHOOTING

Symptom Possible cause Actions

Noise from water pump Contact between the water Disassemble the water pump
pump housing cover and impel- and replace faulty parts.
ler
Worn water pump housing Replace the water pump hous-
bearing ing bearing.

TROUBLESHOOTING OF BRAKE
Symptom Possible cause Actions
Poor performance of disc brake Worn brake pad Replace the brake pads as a
set.
Worn or deflected brake disc Replace the brake disc.
Air in hydraulic brake system Bleed the hydraulic brake sys-
tem.
Brake fluid leakage Check the hydraulic brake sys-
tem and repair or replace faulty
parts as necessary.
Incorrect brake fluid level (low) Add brake fluid to the specified
level.
Stuck brake caliper piston Replace the caliper piston seal.
Stuck brake caliper and slide Lubricate the caliper slide pin.
pin
Loose union bolt Tighten the union bolt to the
specified torque.
Damaged brake hose and Replace the brake hose and
brake pipe brake pipe.
Oil or grease on the brake disc Clean the brake disc or brake
or brake pad pad.
Insufficient lubrication of brake Lubricate the brake lever or
lever or brake pedal pivot brake pedal pivot.

32
 TROUBLESHOOTING

Symptom Possible cause Actions

Poor performance of drum Worn brake shoe Replace the brake shoes and
brake brake shoe tension springs as a
set.
Corroded or worn brake drum Replace the brake drum.
Incorrect brake pedal position Adjust the brake pedal to the
specified position.
Incorrect brake pedal free play Adjust the brake pedal free play
to specification.
Incorrect brake camshaft lever Install the brake camshaft lever
position to the correct position.
Incorrect brake shoe position Install the brake shoe to the cor-
rect position.
Fatigued or damaged brake Replace the brake shoe tension
shoe tension spring springs as a set.
Damaged brake torque rod Replace the brake torque rod.
Oil or grease on the brake drum Clean the brake drum or brake
or brake shoe shoes.
Insufficient lubrication of brake Lubricate the brake camshaft.
camshaft
Insufficient lubrication of brake Lubricate the brake pedal pivot.
pedal pivot

TROUBLESHOOTING AT ABS WARNING LIGHT

Refer to “TROUBLESHOOTING” under “ABS” (ELECTRICAL SYSTEM) in the Service manual.

33
 TROUBLESHOOTING

TROUBLESHOOTING OF SUSPENSION
Symptom Possible cause Actions
Front fork is hard Bent or damaged inner tube Replace the inner tube.
Bent or damaged outer tube Replace the outer tube.
Damaged or worn outer tube Replace the outer tube bush-
bushing ing.
Bent or damaged damper rod_ | Replace the damper rod.
Bent wheel axle Replace the wheel axle.
Incorrect oil viscosity (high) crange to recommended fork
oil.
Incorrect oil level (high) Adjust to the specified oil level.
Improperly adjusted spring pre- | Adjust the spring preload.
load (hard)
Improperly adjusted rebound _ | Adjust the rebound damping.
damping (hard)
Improperly adjusted compres-_ | Adjust the compression damp-
sion damping (hard) ing.
Front fork is soft Fatigued or broken fork spring | Replace the fork spring.
Incorrect oil viscosity (low) cnange to recommended fork
oil.
Incorrect oil level (low) Adjust to the specified oil level.
Improperly adjusted spring pre- | Adjust the spring preload.
load (soft)
Improperly adjusted rebound _ | Adjust the rebound damping.
damping (soft)
Improperly adjusted compres-_ | Adjust the compression damp-
sion damping (soft) ing.
Leaking oil from front fork Bent, damaged, or corroded in- | Replace the inner tube.
ner tube
Cracked or damaged outer tube | Replace the outer tube.
Improperly installed oil seal Replace the oil seal.
Damaged oil seal lip Replace the oil seal.
Incorrect oil level (high) Adjust to the specified oil level.
Loose damper rod assembly Tighten the damper rod assem-
bolt bly bolt to the specified torque.
Damaged damper rod assem- | Replace the damper rod as-
bly bolt copper washer sembly bolt copper washer.
Cracked or damaged cap bolt | Replace the cap bolt O-ring.
O-ring

34
 TROUBLESHOOTING

Symptom Possible cause Actions

Rear suspension is hard Bent or damaged rear shock Replace the rear shock absorb-
absorber rod er.
Bent swingarm pivot shaft Replace the swingarm pivot
shaft.
Damaged or worn swingarm Replace the swingarm bearing
bearing or bushing or bushing.
Damaged or worn relay arm Replace the relay arm bearing.
bearing
Damaged or worn connecting Replace the connecting arm
arm bearing bearing.
Improperly adjusted rear shock Adjust the spring preload.
absorber spring preload (hard)
Improperly adjusted rear shock Adjust the rebound damping.
absorber rebound damping
(hard)
Improperly adjusted rear shock Adjust the compression damp-
absorber compression damping ing.
(hard)
Rear suspension is soft Oil leaking from rear shock ab- Replace the rear shock absorb-
sorber er.
Gas leaking from rear shock ab- | Replace the rear shock absorb-
sorber er.
Fatigued or damaged rear Replace the rear shock absorb-
shock absorber spring er.
Improperly adjusted rear shock Adjust the spring preload.
absorber spring preload (soft)
Improperly adjusted rear shock Adjust the rebound damping.
absorber rebound damping
(soft)
Improperly adjusted rear shock Adjust the compression damp-
absorber compression damping ing.
(soft)
Oil leaking from rear shock ab- Bent, damaged, or corroded Replace the rear shock absorb-
sorber rear shock absorber rod er.
Damaged oil seal lip Replace the rear shock absorb-
er.

35
 TROUBLESHOOTING

TROUBLESHOOTING OF STEERING/HANDLING
Symptom Possible cause Actions
Handlebar wobble Loose lower ring nut Tighten the lower ring nut to the
specified torque.
Worn bearing or bearing race_ | Replace the bearing and bear-
ing race as a set.
Warped front fork Repair or replace the front fork.
Bent front wheel axle Replace the front wheel axle.
Incorrect tire pressure Adjust to the specified tire pres-
sure.
Worn, deformed, or incorrect tire | Replace the tire.
Heavy steering Lower ring nut is tightened too | Tighten the lower ring nut to the
tight. specified torque.
Bent lower bracket Replace the lower bracket.
Broken bearing or bearing race | Replace the bearing and bear-
ing race as a Set.
Incorrect tire pressure Adjust to the specified tire pres-
sure.
Front wheel vibration Incorrect wheel balance Adjust the wheel balance.
Deformed wheel (cast wheel, | Replace the wheel.
pressed wheel)
Loose spoke (spoke wheel) Tighten the spoke and adjust
the runout.
Damaged or worn wheel bearing | Replace the wheel bearing.
Worn, deformed, or incorrect tire | Replace the tire.
Loose wheel axle or wheel axle | Tighten the wheel axle or wheel
nut axle nut to the specified torque.
Loose wheel axle pinch bolt Tighten the wheel axle pinch
bolt to the specified torque.
Incorrect front fork oil level Adjust to the specified front fork
oil level.
Rear wheel vibration Incorrect wheel balance Adjust the wheel balance.
Deformed wheel (cast wheel, | Replace the wheel.
pressed wheel)
Loose spoke (spoke wheel) Tighten the spoke and adjust
the runout.
Damaged or worn wheel bearing | Replace the wheel bearing.
Worn, deformed, or incorrect tire | Replace the tire.
Loose wheel axle nut Tighten the wheel axle nut to
the specified torque.
Loose swingarm pivot shaft Tighten the swingarm pivot
shaft to the specified torque.
Bent or damaged swingarm Replace the swingarm bearing.
Damaged or worn swingarm Replace the swingarm bearing
bearing or bushing or bushing.

36
 TROUBLESHOOTING

TROUBLESHOOTING OF CHARGING SYSTEM

Symptom Possible cause Actions
Battery is not charged Refer to “TROUBLESHOOTING?” under “CHARGING SYSTEM”
(ELECTRICAL SYSTEM) in the Service manual.

TROUBLESHOOTING OF LIGHTING SYSTEM

Symptom Possible cause Actions
Headlight does not come on Refer to “TROUBLESHOOTING?” under “LIGHTING SYSTEM”
(ELECTRICAL SYSTEM) in the Service manual.
Taillight does not come on Refer to “TROUBLESHOOTING” under “LIGHTING SYSTEM”
(ELECTRICAL SYSTEM) in the Service manual.
License plate light does not Refer to “TROUBLESHOOTING?” under “LIGHTING SYSTEM”
come on (ELECTRICAL SYSTEM) in the Service manual.
Meter light does not come on Refer to “TROUBLESHOOTING?” under “LIGHTING SYSTEM”
(ELECTRICAL SYSTEM) in the Service manual.

TROUBLESHOOTING OF SIGNALING SYSTEM

Symptom Possible cause Actions
Brake light does not come on or Refer to “TROUBLESHOOTING?” under “SIGNALING SYSTEM”
go off (ELECTRICAL SYSTEM) in the Service manual.
Failed front brake light switch or Adjust or replace the front brake
rear brake light switch light switch or rear brake light
switch.
Turn signal light or turn signal Refer to “TROUBLESHOOTING” under “SIGNALING SYSTEM”
indicator light or both fail to (ELECTRICAL SYSTEM) in the Service manual.
blink, blink too early or too late,
or fail to go off
Indicator lights do not come on Refer to “TROUBLESHOOTING?” under “SIGNALING SYSTEM”
properly (ELECTRICAL SYSTEM) in the Service manual.
Horn does not sound Refer to “TROUBLESHOOTING” under “SIGNALING SYSTEM”
(ELECTRICAL SYSTEM) in the Service manual.
Speedometer fails to operate Refer to “TROUBLESHOOTING?” under “SIGNALING SYSTEM”
correctly (ELECTRICAL SYSTEM) in the Service manual.

37
© YAMAHA
 ©VAMAHA _ 2020
SERVICE MANUAL

YZF-R1
YZF-R1M

YZFRIL
YZFRILC
Y¥YZFRIML
YZF1MLC

LIT-11616-33-33 B3L-28197-10
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.
Please refer to “BASIC INFORMATION” (separate volume, YOA-28197-10*) for basic instructions that
must be observed during servicing. Repair and maintenance work attempted by anyone without this
knowledge is likely to render the vehicle 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 their 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
e* If the contents of the manual are revised, the last digit of the manual number will be increased by
one.
¢ 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.

Es«S3a00N

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-
Ly 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

NEG in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid damage to

NOTICE the vehicle or other property.

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

FAS20002

YZFR1L/YZFR1LC/YZFR1ML/YZFR1MLC
SERVICE MANUAL
©2020 by Yamaha Motor Corporation, U.S.A.
First edition, October 2019
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
P/N LIT-11616-33-33
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.
e 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
CLUTCH CLUTCH

(= ae TP

CLUTCH a a Remove the apace and bearing trom the main

Removing the clutch cover « Oil strainer axle, then remove the oll pump drive chain from
= Fietar to “CHL PUMP* on page 5-58. the oil pump driven sprocket. and than remove
As _ « Water pump the clutch howsing and od pump drive chaen trom
— EX Rater
to “WATER PUMP* on page 6-12, the main axe,
3 - at « Friction plates
* Chitch plates
™
Be sure to mark the frictionplates and clutch
plates of note the position of aach part so that
ihey are inatalledin their original positions.
2. Straighten the clutch boes nut rb “a”,

CHECKING
THE FRICTION PLATES 2
The tollawing procedure applies fo all of ihe fric-
fon
1, Check:
* Friction plate
Damapawear
— Replace the iiction plates

3, Locean: er 2, denne:
« Gluten boss nit * Frotion
plate thickness
T™! ul of specthontion
— Aepluce the tricten
While heleling the clutch cae 2" with fhe uriheee: plaice
ae A eel,
fal Gluten holder "3", loceen the hutch bea nut, Tie
5 iidund the Inolion plik a four placea,

Fricthon thickness -——-f

§— Onder Jehan move oy iematn ] gi 823.08 ren (0.118-0.421in)
Front nde ormiing amummbig(Boliem coming Rieter to “GENERAL CHASSIS (Sr om page | 2.00 mm (0.170 in)

Dita
[agate col Redes bo “CHAHOING THE EMCEE O8L” on
page O26

Ce Rete: ip “(CHANGING THE COGILANT™ on

Page oe
| WAvibeed peut TgS) Bore ete Paci 1 Deseret
' —
Latch cae 1 Lior
| @\@

af | | ~~
9
a

6 | Canon covnr quetiane

® Clutch housing “2" CHEC PLATES
CLUTCHNG
THE KI
= — ih aia ee
* C4 pump drive chain
. ~

5-45

GO88877
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

GOH

/)—
Serviceable with engine mounted Gear oil

N'Y Filling fluid Molybdenum disulfide oil

©
e>—
~emey | = Lubricant Brake fluid

Special tool =——€5by Wheel bearing grease

Tightening torque =€. 4 Lithium-soap-based grease

Wear limit, clearance Molybdenum disulfide grease

Engine speed Silicone grease

Electrical data Apply locking agent (LOCTITE®).

Engine oil EAN) Replace the part with a new one.

~ TABLE OF CONTENTS
GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND

ADJUSTMENTS

CHASSIS

ENGINE

COOLING SYSTEM

FUEL SYSTEM

ELECTRICAL SYSTEM

SELF DIAGNOSTIC
 GENERAL INFORMATION

IDENTIFICATION ...........--.-sscseecsssesssssesssseesseeseeeessseeenseseeneeseneeesueeesneeeseteesneeeee
VEHICLE IDENTIFICATION NUMBER .........--se:ssesssssessssessseeeeestesesseseeneeee

mk,

mh
i
MODEL PABE [Link] tet deeeennsaeesteeaceasieeta rede

BASIC SERVICE INFORMATION ......00.. 0... e tear eettteeeeeteaeeeees 1720

PALS eh UE ic ios das artsca tice veereeeert eoeisdnet eda ads cavediwventuatsnveeced WU

SPECIAL TOOLS [Link]. cece e cece cents eee ee caa need sesaeaeeeesessuaeeeeeeesaeaee DOD
 IDENTIFICATION

EAS2o007

IDENTIFICATION
EASSaon02

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped
into the right side of the steering head pipe.

EASSO003

MODEL LABEL
The model label “1” is affixed to the frame under
the passenger seat. This information will be
needed to order spare parts.

1-1
 FEATURES

EAS20008
TIP
FEATURES
This model uses a thin-film-transistor liquid-crys-
EAS3a1 706 tal display (TFT LCD) for good contrast and
GLOSSARY readability in various lighting conditions. Howev-
ABS - Anti-lock Brake System er, due to the nature of this technology, it is nor-
ABS ECU - Anti-lock Brake System Electronic mal for a small number of pixels to be inactive.
Control Unit
BC - Brake Control
CCU - Communication Control Unit STREET MODE
EBM - Engine Brake Management 1 234 5
ECU - Engine Control Unit
ERS - Electronic Racing Suspension «1000 —"s 70 77 iz i a 147 13

GPS - Global Positioning System aa ee‘ulp.

IMU - Inertial Measurement Unit
LCS - Launch Control System
LIF - Lift Control System
PWR - Power delivery mode
QS - Quick Shift 11
QSS - Quick Shift System
SC - Stability Control YRC items LCS/QS/LIF/BC

=
SCS - Slide Control System Speedometer
wh GPS indicator (CCU-equipped models)
SCU - Suspension Control Unit
TCS - Traction Control System Logging indicator (CCU-equipped models)
omwr

YRC - Yamaha Ride Control Clock

Revolution peak hold indicator
EASsa1 Tor
Front brake pressure indicator
DISPLAY
ON

Acceleration indicator
The display has two different main screen dis-
9. Transmission gear display
play modes, STREET MODE and TRACK
10. ERS indicator (YZF-R1M)
MODE. Most of the functions are viewable in ei-
11. YRC items MODE/PWR/TCS/SCS/EBM
ther mode, but the layout differs slightly. The fol-
12. Information display
lowing items can be found on the display.
13. Tachometer
e Speedometer
e Tachometer
e Information display
TRACK MODE
e Transmission gear display
e Front brake pressure indicator
1 2 34 5
| le
e Acceleration indicator SA rerccehreerest
13. 14 ~~ 15
¢« YRC setting display MODE/PWR/TCS/SCS/ a ——
EBM
11 8 Al
LATEST

¢ YRC setting display LCS/QS/LIF/BC ry 12.34.12

e ERS indicator (YZF-R1M)
¢ GPS indicator (CCU-equipped models)
0 [eraeN
ERMpwri tcs3125250 ae;
scs2 eB 1\|7 7 ||
¢ Logging indicator (CCU - equipped models) | |
e Clock 9 8
e Revolution peak hold indicator YRC items LCS/QS/LIF/BC
=

e Lap timer Lap timer

wh

e Various warning icons GPS indicator (CCU-equipped models)

e Error mode warning “Err” Logging indicator (CCU-equipped models)
ns

Clock
Transmission gear display
SBNo

Information display
ERS indicator (YZF-R1M)
 FEATURES

9. YRC items MODE/PWR/TCS/SCS/EBM TIP

10. Speedometer ¢ ODO will lock at 999999 and cannot be reset.
11. Tachometer ¢ TRIP-1 and TRIP-2 will reset to O and begin
EWAI8210
counting again after 9999.9 has been reached.
¢ When the fuel tank reserve level has been
Stop the vehicle before making any setting reached, F-TRIP appears automatically and
changes. Changing settings while riding can begins recording distance traveled from that
distract the operator and increase the risk of point.
an accident. ¢ After refueling and traveling some distance, F-
TRIP will automatically disappear.
Speedometer ¢ Refer to “Unit” on page 1-13 to change the
The speedometer shows the vehicle’s traveling fuel consumption units.
speed. ¢ The air temperature displayed may vary from
the actual ambient temperature.
TIP
¢ In TRACK MODE, information display items
The display can be switched between kilometers FASTEST (fastest lap time) and AVERAGE
and miles. (Refer to “Unit” on page 1-13.) (average lap time) are also available.

Tachometer
TRIP-1, TRIP-2, F-TRIP, FUEL CON, and FUEL
The tachometer shows the engine speed, as
AVE items can be individually reset.
measured by the rotational velocity of the crank-
shaft, in revolutions per minute (r/min). [To reset information display items]
TIP 1. Use the wheel switch to scroll through the dis-
ein TRACK MODE, the tachometer starts at play items until the item you want to reset ap-
8000 r/min. pears.
ein STREET MODE, the tachometer can be col- . Short push the wheel switch and the item will
or-adjusted and has a revolution peak hold in- flash for five seconds. (For STREET MODE,
dicator which can be turned on or off. if both items are resettable items, the top item
ECA19660 will flash first. Scroll down to select the bot-
NOTICE tom item.)
Do not operate the engine in the tachometer . While the item is flashing, press and hold the
red zone. wheel switch for one second.

Transmission gear display

Information display This shows which gear the transmission is in.
This section of the main screen is used to show This model has 6 gears and a neutral position.
additional riding related information such as air The neutral position is indicated by the neutral
and coolant temperature readings, tripmeters, indicator light “N” and by the transmission gear
and fuel consumption statistics. The information display “N”.
display items can be set into four groups via the
MENU screen. Front brake pressure indicator
The information display items are: This shows how much braking power is being
[Link]: air temperature applied to the front brakes.
[Link]: coolant temperature
TRIP-1: tripmeter 1 Acceleration indicator
TRIP-2: tripmeter 2 This shows the vehicle’s forward acceleration
F-TRIP: fuel tripmeter and deceleration forces.
ODO: odometer
FUEL CON: the amount of fuel consumed Revolution peak hold indicator
FUEL AVG: average fuel consumption This small bar momentarily appears within the
CRNT FUEL: current fuel consumption tachometer to mark the most recent peak engine
speed.
 FEATURES

YRC items MODE/PWR/TCS/SCS/EBM e When a YRC item is highlighted but cannot be

The current MODE (YRC mode) and its related adjusted, the YRC item box will return to black.
PWR, TCS, SCS, and EBM settings are shown
here.
The individual settings for YRC items PWR,
TCS, SCS, LCS, QSS, LIF, EBM, and BC can Tos AV LF EC)
be organized into four groups and set inde- «1000 nmin

pendently for each group. These groups of set-

tings are the YRC modes MODE-A, MODE-B,
MODE-C, and MODE-D. Use the mode switch p: 12 6T2
to change YRC modes or make YRC item set-
ting changes from the main screen. MODE-A fl im es ee t= ee

TIP To turn off the traction control system select TCS

The YRC modes come preset from the factory with the center button, then push and hold the up
for different riding conditions. button until TCS OFF is displayed. To turn TCS
When using the factory presets, the suggested back on, select TCS OFF and then press the
YRC modes are as follows. down button (TCS will return to its previous set-
MODE-A: suitable for track riding ting).
MODE-B: softer track-riding setting TIP
MODE-C: suitable for road use
Turning off the traction control system will turn
MODE-D: street use or rainy weather
off the SCS, LCS, and LIF systems for all YRC
modes.
[To change YRC modes or make setting
changes]
YRC items LCS/QS/LIF/BC
1. Push the mode switch center button to scroll
The on/off status of YRC items LCS, QSS, LIF,
left to right and highlight the item you want to
and BC is shown here. When any of these sys-
adjust.
tems are registered (not set to OFF) for the cur-
rently selected YRC mode, its respective icon
will appear.
When LCS is registered for the currently select-
ed YRC mode, its icon will be grey. To activate
the launch control system, press and hold the
center button until the LCS icon stops flashing
and turns white.
TIP
LCS, QSS, LIF, and BC system setting levels
Mode switch “MODE” can only be adjusted from the MENU screen.
oh =

Up button
Center button ERS indicator (YZF-R1M)
Down button
This icon shows the current ERS mode. (Refer
2. Use the mode switch up button or down but- to ““YRC Setting” on page 1-7 and “ERS
ton to change the selected item value (verti- (YZF-R1M)” on page 1-10 to change the reg-
cal scrolling is not possible). istered ERS mode or adjust ERS setting lev-
TIP els.) If the ERS mode disappears from the
ERS indicator (the icon turns blank), stop the
¢ When the malfunction indicator light is on, YRC
vehicle and wait a few seconds until the mode
settings cannot be adjusted.
reappears.
¢e When a YRC function is actively engaged that
item cannot be adjusted. For example, when TIP
decelerating EBM cannot be adjusted. ¢ The suspension will remain fixed at its most re-
cent settings until self-reset has completed.
 FEATURES

¢ If the ERS indicator does not return to normal. [To use the lap timer]
(Refer to “ELECTRONICALLY ADJUSTABLE 1. Short push the wheel switch. The information
SUSPENSION SYSTEM (for YZF-R1M)” on display item will flash for five seconds.
page 9-29.) 2. While the information display item is flashing,
rotate the wheel switch upward. The lap timer
will flash for five seconds.
GPS indicator (CCU-equipped models)
. While the lap timer is flashing, long push the
This icon comes on when a GPS unit is synched
with your vehicle. wheel switch to activate the lap timer or stop
the lap timer.
Logging indicator (CCU-equipped models) 4. When the lap timer has been activated, press
This icon comes on when vehicle data is being the Pass/LAP switch to start the lap timer.
recorded via the logging function. TIP
¢ The engine must be running to use the lap tim-
Clock er.
The clock uses a 12-hour time system. * Set the information display to FASTEST or AV-
ERAGE for additional lap time information.
Lap timer ¢ Accessing the MENU screen will automatically
This stopwatch function measures and records stop the lap timer.
up to forty laps. On the main screen, the lap tim- ¢ Whenever the lap timer is stopped, the current
er shows the current lap time and lap number lap will not be recorded.
(indicated by the LAP mark). Use the Pass/LAP ¢ The lap time record can be viewed and reset
switch to mark lap times. When a lap is complet- from the MENU screen.
ed, the lap timer will show the latest lap time
(marked by the LATEST indicator) for five sec-
Warning icons
onds.
1
Tejas a VILIFIC2
13 1a aff
a n n e
«1000 nmin

— ee
|| | || |
&... 12:34.12 «1000 r/min 17

em eaemns oe
[min )PwA1 Tcs3 sc 2 EBM1 / T-2

3
1. SCU trouble warning “|”
Lap time
2. Auxiliary system warning “=”
Poh=

Latest lap time indicator “LATEST”

3. Coolant temperature warning “5”
Information display item
Lap number
4. Oil pressure warning “=.”
5. Error mode warning “Err”

When an error is detected, the following error-re-

lated warning icons will then be viewable.

SCU trouble warning (YZF-R1M)

This icon appears if a problem is detected in the
front or rear suspension.

Auxiliary system warning

This icon appears if a problem is detected in a
non-engine-related system.
 FEATURES

Coolant temperature warning EAS31708

MENU SCREEN
This icon appears if the coolant temperature
reaches 117 °C (242 °F) or higher. Stop the ve-
ie rrat Sl 10:00
hicle and turn off the engine. Allow the engine to
cool.
ECA10022
YRC Setting
NOTICE
Do not continue to operate the engine if it is Logging
overheating.

Oil pressure warning

This icon appears when the engine oil pressure The MENU screen contains the following setting
is low. When the main switch is first turned to modules. Select a module to make related set-
ON, engine oil pressure has yet to build, so this ting changes. Although some settings can be
icon will come on and stay on until the engine changed or reset via the main screen, the MENU
has been started. screen offers access to all display and control
TIP settings.
lf a malfunction is detected, the oil pressure Module Description
warning icon will flash repeatedly.
Switch the main screen dis-
ECAZ2790 Display Mode __| play between street and track
NOTICE modes.
If the warning light comes on when the en- Adjust YRC settings (all
gine is running, stop the engine immediately YRC Setting models) and ERS settings
and check oil level. If the oil level is below the (YZF-R1M).
minimum level, add sufficient oil of the rec- Lap Time View and reset lap times.
ommended type to raise it up to the correct Turn vehicle information log-
level. If the oil pressure warning light re- Logging ging function on/off (CCU-
mains on even if the oil level is correct, im- equipped models).
mediately turn the engine off and check the View and reset three mainte-
Maintenance ;
vehicle. nance item intervals.

. Set fuel consumption and dis-

Unit
Error mode warning tance units.

When an internal error occurs (e.g., communica- Wallpaper Set background colors.
tion with a system controller has been cut off), Turn the shift indicator on/off
the error mode warning will appear as follows. Shift Indicator | and adjust tachometer set-
“Err’ and “=” indicates an ECU error. tings.
“Err’ and “ v1” indicates an SCU error. , Set the multi-function display
“Err’ only indicates an ABS ECU error. Display Setting window items.
TIP Brightness Adjust screen brightness.
Depending on the nature of the error, the display Clock Adjust the clock.
may not function properly and YRC settings may All Reset Return all settings to factory
be impossible to change. Additionally, ABS may default settings.
not function properly. Use extra care when brak-
ing and check the vehicle immediately. MENU access and operation
The following wheel switch operations are com-
mon operations for accessing, selecting, and
moving within the MENU screen and its mod-
ules.
Long push - press and hold the wheel switch for
one second to access the MENU screen or exit
MENU entirely.
 FEATURES

Select - rotate the wheel switch up or down to 3. Long push the wheel switch to exit the MENU
highlight the desired module or setting item and screen or use the wheel switch to select an-
then short push the wheel switch (briefly press other module.
the wheel switch inward) to confirm the selec-
tion. “YRC Setting”
Triangle mark - certain setting screens have an This module allows you to customize the four
upward pointing triangle mark item. Select the YRC modes MODE-A, MODE-B, MODE-C, and
triangle mark to save setting changes made and MODE-D by adjusting the setting levels (or on/
exit that screen. off status as applicable) of YRC items PWR,
TIP TCS, SCS, LCS, QSS, LIF, EBM, and BC. For
¢ Should vehicle motion be detected, the screen YZF-R1M, you can select the ERS mode to be
will automatically exit MENU and change to the associated with each YRC mode, and also ad-
main screen. just the setting levels of the ERS modes.
¢ To ensure that the desired setting changes are TIP
saved, be sure to exit via the triangle mark. ¢ TCS has 9 setting levels and ERS has 6
Simply performing a long push and exiting the modes.
MENU screen entirely may not save setting « Whenever there are more selections (setting
changes. levels or modes) available than can be shown
on the screen at one time, a scroll bar will ap-
pear to notify you that additional selections are
“Display Mode”
available by scrolling.
There are two main screen display modes,
STREET MODE and TRACK MODE.
PWR
[To set the main screen display mode] Select PWR-1 for the most aggressive throttle
1. From the MENU screen, select “Display response, PWR-2 and PWR-3 for smoother
Mode”. throttle grip/engine response, and use PWR-4
for rainy days or whenever less engine power is
0 Le a tH desirable.

YRC Setting

eyelets
Maintenance

2. Select “STREET MODE?” or “TRACK MODE”

(or select the triangle mark to exit).
1. PWR 1
OP Display Mode pL eal
2. PWR2
3. PWR3
4. PWR4
TRACK MODE 5. Throttle valve opening
6. Throttle grip operation

TCS
This model uses a variable traction control sys-
tem. For each setting level, the further the vehi-
cle is leaned over, the greater the amount of
traction control (system intervention) is applied.
There are 9 setting levels available. Setting level
 FEATURES

1 applies the least amount of overall system in- tion from the selected YRC mode (the LCS icon
tervention, while setting level 9 applies the great- will not appear and the launch control function
est amount of overall traction control. cannot be activated).
TIP When LCS has been set to level 1 or 2 for the se-
¢ TCS can only be turned on or off via the main lected YRC mode, the LCS indicator on the main
screen using the mode switch. screen will appear in a grey color to indicate that
¢ When TCS has been turned off, TCS, SCS, LCS is available. When the launch control sys-
LCS, and LIF will be set to OFF and cannot be tem has been activated (made ready for use via
adjusted. When TCS is turned on again, these the mode switch), the LCS indicator will turn
related-traction control functions will return to white.
their previous setting levels. TIP
LCS works in conjunction with the LIF system.
LCS cannot be used if LIF is turned off.
14
QSS
The quick shift system is divided into QS ¢ (up-
TCS shift) and QS w (downshift) sections. QS ~
and QS w are not linked and can be inde-
pendently turned on or off.
QS ~ can be set to 1, 2, or OFF. Setting level 1
is designed for maximum acceleration, while
setting level 2 is designed to give smooth shifts
1. System intervention
at halfway or less throttle openings. OFF turns
2. Lean angle
the respective upshift or downshift function off,
and the clutch lever must then be used when
scs
shifting in that direction.
SCS can be set to OFF, 1, 2, and 3. OFF turns
TIP
the slide control system off, setting level 1 pro-
vides the least amount of system intervention, * Set QS « to1 for track or sporty riding.
and setting level 3 provides the greatest amount ¢ Set QS ~ to 2 for touring or around town-rid-
of system intervention. ing.

LIF
1A LIF can be set to 1, 2, 3, or OFF. Setting level 3
Ro oo

most strongly reduces wheel lift, and setting lev-

el 1 provides the least amount of system inter-
scs vention. OFF turns LIF off and LCS will be
disabled for the selected YRC mode.

14
BO

1. System intervention
=—

2. Sideward slide
LIF
LCS
LCS can be set to 1, 2, or OFF. Setting level 1
keeps engine speed from rising above 9000 r/
min even when the throttle grip is fully turned.
Setting level 2 keeps engine speed from rising 1. System intervention
above 8000 r/min. OFF disables the LCS func- 2. Wheel lift
 FEATURES

EBM 2. The “YRC Setting” screen is displayed, and

The engine brake management system reduces the YRC mode box “YRC” is highlighted.
engine torque when decelerating. The fuel injec- Short push the wheel switch to enter the box
tion, ignition timing, and electronic throttle valve and then select the YRC mode A, B, C or D
are electronically adjusted by the ECU. There that you want to adjust.
are 3 settings to suit the track, riding conditions,
or your personal preference. Pear

| | tag a

4 oe
Glare SS Geil
1 2 3 45

Triangle mark
2
YRC mode box

oN
EBM1 YRC item
EBM2 ERS mode (YZF-R1M)

OF
EBM3 To ERS menu (YZF-R1M)
Engine brake force
3. Select the YRC item PWR, TCS, SCS,
Engine r/min
LCS, QS4, QSy, LIF, EBM, BC, or ERS
(YZF-R1M) that you want to adjust.
select BC1 when only standard ABS is desired. Pha
ey Teel
ee
Select BC2 to have the brake control system
regulate brake pressure while comering to sup-
press lateral wheel slip.
TIP i
For skilled riders and when riding at the track,
due to varying conditions BC2 brake system en- 2 A
gagement may come on sooner than expected
relative to your desired cornering speed or in-
tended cornering line. YRC item
-& Oh>

Current level setting

[To customize a YRC mode or adjust a YRC Factory preset level
item] YRC mode
1. From the MENU screen, select “YRC Set-
TIP
ting”.
e When a YRC item is selected, the current set-
ror MENU ey ting level is indicated by a blue-framed square
and the factory preset level is indicated in a
grey box.
* Factory preset levels vary depending on the
selected YRC mode.
els
ls Tiare
4. To customize other YRC modes or adjust in-
TaeUte
dividual YRC items, repeat from step 2.
When finished, select the triangle mark on
the far left to return to the MENU screen, or
for YZF-R1M select the “p ” mark to fine tune
 FEATURES

the ERS mode settings.

t al de| Teast
ERS (YZF-R1M) To
T-2
Per eae airs, pL eprili

Lit: Aa
eet Lt

—
SUPPORT

/-
BRAKE CORNER | ACCEL atl
ee ee SUPPORT FIRM
ERS mode

© fh >
Braking support level

OF
- Front overall damping level
ERS mode Rear overall damping level
NOahOoON=

Braking support level Factory preset level

Cornering support level 6. Current level
Acceleration support level
For the road mode R-1, the following settings
Front overall damping level
can be adjusted:
Rear overall damping level
BRAKE SUPPORT: reduces nosedive (front-
Factory preset level
end pitch from braking)
8. Current level
FRONT FIRM: hardens “H’ or softens “S” overall
The ERS consists of three semi-active automat- damping of the front suspension
ic modes (T-1, T-2, R-1) and three manual set- REAR FIRM: hardens “H” or softens “S” overall
ting modes (M-1, M-2, M-3). When an automatic damping of the rear suspension
mode is selected, the SCU will adjust the com- TIP
pression and rebound damping forces based on ¢ T-1 is preset for track use with racing slick tires.
running conditions. For all modes and models, * T-2 is preset for track use with street tires.
spring preload is physically adjusted by hand. ¢ R-1 is preset for road use with street tires.
For track modes T-1 and T-2, the following set-
tings can be adjusted:
eee RL
BRAKE SUPPORT: reduces nosedive (front- re YRC Setting

end pitch from braking) —_— M-1 | 818 22|) 22) t

M-2 || - - y
CORNER SUPPORT: increases damping to ab-
M-3 || h_ ee ee
sorb chassis fluctuations for smooth cornering. = =| 5
Reduce this setting for increased rear wheel __ | | - BS) -=
grip. = —. =| =
ACCEL SUPPORT: reduces rear-end squat
(rear-end pitch due to acceleration)
FRONT FIRM: hardens “H” or softens “S” overall
damping of the front suspension ERS mode
=

REAR FIRM: hardens “H” or softens “S” overall Front compression damping force
oh

damping of the rear suspension Front rebound damping force

Rear compression damping force
oop

Rear rebound damping force

Factory preset level
7. Current level setting
For the manual setting modes M-1, M-2, and M-
3, the following settings can be adjusted:
Fr COM: front compression damping
Fr REB: front rebound damping
Rr COM: rear compression damping
Rr REB: rear rebound damping

1-10
 FEATURES

TIP 3. Select the suspension item that you want to

e M-1 is preset for track use with racing slick adjust, and then rotate the wheel switch to
tires. adjust the setting level.
e M-2 is preset for track use with street tires. TIP
¢ M-3 is preset for street use with street tires. All ERS modes regardless of type are indepen-
dent. Offset level setting changes made in one
mode are not transferred to another mode.
[To adjust the ERS mode settings]
4. To adjust other ERS modes of the same type,
(Pee pile itil]
repeat from step 1. To switch types or when
finished, select the “«q” mark to return to the
main “YRC Setting” menu.

“Lap Time”
Wa vs
This module allows you to view and delete the
era aan lap time record. The fastest lap and the average
lap time stored in the lap time record are dis-
1
played at the top of the screen. Use the wheel
1. To ERS menu switch to scroll and see all lap times. The top
2. Manual modes three fastest laps will be highlighted in silver. Up
3. Automatic modes to 40 laps can be stored in memory. If more than
40 laps are recorded, the oldest laps (starting
TIP from lap 1) will be overwritten.
The ERS setting menu is divided into automatic
and manual setting modes, and the two types ae Salt tL
are accessed separately. Before moving to the
ERS setting menu, make sure the current ERS
YRC Setting
mode corresponds to the same type (automatic
or manual) that you want to adjust.
Logging
1. Select the “p” mark located to the right of
ERS.
2. The display will change to the relevant sus-
pension setting screen and the ERS mode
selection box “SETTING” is highlighted. This module has two options. “Display” allows
you to view the lap time record. “Reset” allows
Short push the wheel switch to enter the box
and select the ERS mode that you want to you to delete the lap time record data.
adjust.
0 led ea 10:00

Pee Adie) ea
Leeeneeenereenneee AEE eeeeeeeneeenenl
8 18) 22), 22 4

P_ =!||>_ =
: S| = 7
_| = =) =
| 8| 22
ee
1 2 3 [To view the lap time record data]
To YRC Setting menu
ERS mode selection box “SETTING”
=o

Factory preset level

Current level setting

1-11
 FEATURES

1. Select “Display”. “Logging” (for CCU-equipped models)

Vehicle and riding information can be recorded
na Te) LIBS (logged) and this data can be accessed with a
smart device. (Refer to “CONNECTING TO THE
Laemseemeamemenenne
lift Aiicmseeememeneeel CCU (for YZF-R1M)” on page 4-8.)

[To start and stop logging]

1. From the MENU screen, select “Logging”.
semen
— een
| Owe
a ee
Nae MENU
| ee 10:00
10:00 |

Se
Ads |e

Pra Lap Time sD) ee

ati t |

1 FASTEST/LAP12 Q2:34.56
2 AVERAGE 02:53.00 ——

02:54.56
02:55.20
ek 02:56.04 TIP
we 02:56.80 lf a CCU is not installed, then the “Logging” mod-
ule cannot be selected.
1. Fastest lap
2. Select “START” to start logging.
2. Average lap time
TIP
3. Lap time record
The arrow of the logging indicator is displayed in
[To reset the lap time record data] green.
1. Select “Reset”.
1
OPe ee -
Ora Male Tel tare See Lt)!

Eye) Fy)

1. Logging indicator
2. Select “YES” to delete all lap time data. (Se-
lect “NO” to exit and return to the previous 3. To stop the “Logging” function, select “STOP”
screen without resetting the lap record.) or turn the vehicle off.

re Te) Hii

Reset ?

1-12
 FEATURES

TIP When using kilometers, the fuel consumption

The logging function will also start automatically units can be changed between km/L or L/
when you start off. 100km. When using miles, MPG will be avail-
able.

“Maintenance” [To set the distance or fuel consumption

This module allows you to record distance trav- units]
eled between engine oil changes (use the OIL 1. From the MENU screen, select “Unit”.
item), and for two other items of your choice (use
INTERVAL 1 and INTERVAL 2). a ee |= | ee De

[To reset a maintenance item] ==

1. From the MENU screen, select “Mainte- ase itlal:

nance”. Teel

ee

Ornat ae 10:00 ee

YRC Setting
2. Select the distance or consumption unit item
you want to adjust.
| Maintenance |

Unt oPrer

lem or mile
Unit

km
Unt

2. Select the item you want to reset.

kr.
Oa ETO lates ie

OIL | 123456 km

IERVAL? RESET TIP

When “km” is selected, “km/L” or “L/100km” can
be set as the fuel consumption units. To set the
fuel consumption units, proceed as follows. If
“mile” is selected, skip step 3.
3. Long push the wheel switch to reset the item.
3. Select the units you want to use.
errat Maintenance aH iTi

ei)/5
a 123456 km
INTERVAL 2 123456 km

TIP
Maintenance item names cannot be changed. 4. Select the triangle symbol to exit.

“Unit”
“Wallpaper”
This module allows you to individually set the
This module allows you to switch the display be- STREET MODE and TRACK MODE display
tween kilometers and miles. background colors to black or white for both day

1-13
 FEATURES

and night settings. A photo sensor equipped in 3. Select the background color (select “BLACK”
the instrument panel detects lighting conditions for a black background or “WHITE” for a
and will automatically change the display be- white background).
tween its day and night settings. The photo sen-
sor also controls a subtle automatic brightness Oe EV tle ili
adjustment function within both day and night
STREET MODE (day)
modes to suit ambient light conditions.

coWHITE.
_—_

4. Select the triangle symbol to exit.

5. To set another background color, repeat from
step 2 or select the triangle symbol to exit this
module.
1. Photo sensor
“Shift indicator’
[To set the wallpaper] The shift indicator module contains the following
1. From the MENU screen, select “Wallpaper”. modules.
Module Description
Paar MENU tH Le Set the shift indicator pattern
to “ON”, “Flash”, or “OFF” and
eerste al] Shift IND Setting
adjust at what r/min the indi-
cator will come on and go off.
Shift IND Bright- Adjust the brightness of the
ness shift indicator.
Shift Indicator
Set the tachometer color dis-
Display Setting play to “ON” or “OFF” and ad-
Tach IND Setting just at what r/min the
2. Select the mode you want to adjust (select tachometer will be green and
orange.
DAY for daytime display settings or NIGHT
for nighttime display settings). Peak Rev IND | Set the tachometer peak rev
Setting indicator to “ON” or “OFF”.

en Welle RT!
a TTT TL
STREET MODE (night)

Tea ence)
aS ee Sell ig)

Indicator
Shift

1-14
 FEATURES

[To make setting changes] Rotate the wheel switch to adjust the r/min at
1. Select “Shift IND Setting”. which the shift timing indicator light will come
on. “IND Start” operational range is 8000—
(Ofer Tae eg Ht 14800 r/min.

Pam Sa eels steel

Shift IND Brightness
x1000r/min 4m 17 72 #73 14 «15
Tach IND Setting
9— a a
ee Pallas]
a eters
Shift IND Setting
ON

Ri

15000 r/min

2. Select “IND Mode”.

] lied Me ls Select “IND Stop” then rotate the wheel

* 1000 rimin 13 «714 switch to adjust the r/min at which the shift
timing indicator will go off. “IND Stop” opera-
Shift IND Setting
tional range is 8500-15000 r/min.
IND Mode | ON

EEE [10000 smn TIP

inStop CES The blue area on the tachometer indicates the

currently set operational range of the shift indica-
tor light.

3. Select “ON” to have the indicator light steadi-

ly, “OFF” to turn the indicator off, or “Flash” to “Shift IND Brightness”
have the shift indicator flash when the indica- The shift timing indicator light has six brightness
tor start threshold has been reached. levels.

0 ed Tim gel
te leg
«1000 rimin 13 14

— Shift IND Setting [_____ShiftIND Brightness

CEE | 10000 rimin

IND Stop Een a— Sen

4. Select “IND Start’. select “Shift IND Brightness”, then use the
wheel switch to adjust the setting. Short push
Tn
the wheel switch to confirm the setting and exit.
Oe Santee
«1000 r/min 77. t2 13 74 #75

Pea dortts at
Shift IND Setting

ON Shift IND Brightness

10000 r/min

15000 r/min

1-15
 FEATURES

“Tach IND Setting” 4. Select “Tach IND 1st” to set the green zone
This module allows you to turn the tachometer starting r/min.
color display on or off. When turned off, the ta-
chometer will display all r/min levels below the oF Fras Team ole liebe pti HeT

gia
red zone in black or white (depending on wallpa- ¥1000 rimin
70
7 t2 73 14ar75)
per settings). When turned on, the mid and mid-
to-high r/min zones can be set to come on in
green and then orange colors.
ee IND Mode
Tach IND Setting
ON

ab
Tach IND 1 8000 r/min
1. Select “Tach IND Setting’.
Be Beas 11000 r/min

Shift IND Setting

5. Set the starting r/min by rotating and then
Shift IND Brightness
short pushing the wheel switch. All r/min
above this value up to the “Tach IND 2nd”
ee Mata PRT lailals setting value (or the 14000 r/min red zone),
will be displayed in green.

ae HM ele Lele shit

2. Select “IND Mode”. 1000 r/min fo 11 72 73 74———
«6715

ft]
«1000 r/min
ed TM elie
Loe ” IND Mode
Tach IND Setting
ON
Sete es LEO

8 Tach IND Setting Belen Bedale | 11000 rmin

IND Mode | ON

8000 rm
11000 sini TIP
sansa
sees — Green bar start setting range: 8000-10000 r/
min.
3. Select ON to turn the tachometer color dis-
play mode on (or select OFF to turn this func- 6. Select “Tach IND 2nd”.
tion off).
Pre Satelit TAN

en Satelite Tiny
*1000 r/min 70 1112 13 14 15
15

x1000rmin = 4q 77 12 #7173 #714 «715 ee

A Tach IND Setting
8
9 agaTach IND Setting IND Mode ON

ON
tt
Been PE 8000 rimin

2000 om 11000 r/min

11000 min
. Set the orange color starting r/min by rotating
and then short pushing the wheel switch. All
r/min above this figure until the 14000 r/min
red zone, will be displayed in orange.
TIP
Orange bar start setting range: 8000—14000 r/
min.

1-16
 FEATURES

on ee
een SI iaueleclets ny!
Lesgos A VILIFIG2
10
«1000 r/min 772 713 14
— «#715 #1000 r/min
6 _ 7_ 8 9 7077 1213 14 15
5 a 4 (ees TT TT Ti
Tach IND Setting i?
IND Mode ON

Tach IND 1st 8000 rimin __jTRIP-1 123.4 mille

1

rane... 123456 mite

This) Pwra1 tcs3 scs2 EBM1 “T-2

8. Select the triangle symbol to exit. 1. Information display item (STREET MODE)

“Peak Rev IND Setting”

This module allows you to turn the revolution
feos
a VILIFIG2 Deen
peak hold indicator on or off. «1000 r/min 10 7 2? 773 14 15

1. Select “Peak Rev IND Setting’. 9 a a ee ee

rae Tim tel ieee 10:00 # Pra12:34.i2

123456 _——
Shift IND Setting

iM Palasee
Tr) Pwrad tcs3 scs2 EBM1 -’ T-2

Tach IND Setting

1. Information display item (TRACK MODE)

[To set the display groups]

1. Select “Display Setting’.
2. Select “IND Mode” and then select ON (to
turn on the indicator) or OFF (to turn off the in- A Prat Sly 10:00
dicator). ele
l liars

shift Indicator

Peak Rev IND Setting

Piel
fer eel
LIND Mode ON
Shift Indicator

nee
2. “DISPLAY-1”, “DISPLAY-2”, “DISPLAY-3”
and “DISPLAY-4” are displayed.

3. Select the triangle symbol to exit. ae eect UnTY

“Display Setting”
DISPLAY-2
This module allows you to set how the informa-
DISPLAY-3
tion display items (like TRIP-1, ODO, C. TEMP,
etc.) are grouped on the main screen. There are DISPLAY-4

four display groups.

1-17
 FEATURES

3. For example, let’s select “DISPLAY-1”. 7. Select the triangle symbol to exit. To set the
4. Select “STREET MODE 1-1”. other display groups, repeat from step 3.

arret WEST | seri) “Brightness”

This module allows you to adjust the general
DISPLAY-1
brightness level of the display screen.
STREETMODE 1-1. ATEMP
Gist | CTEM [To set the brightness]
[Link] 1. Select “Brightness”.
(a —
a Tae Tn

5. Select the desired information display item

with the wheel switch. Wallpaper

Shift Indicator
Display Setting
Display Setting
DISPLAY-1

2. Select the desired brightness level by rotating

the wheel switch, and then short push the
Leanna
seeps wheel switch to fix the setting.

Pra Peet sini Tt)

TIP
The information display items which can be se-
lected are:
[Link]: air temperature
[Link]: coolant temperature
TRIP-1: tripmeter 1
TRIP-2: tripmeter 2
ODO: odometer
FUEL CON: the amount of fuel consumed “Clock”
FUEL AVG: average fuel consumption This module allows you to set the clock.
CRNT FUEL: current fuel consumption
[To set the clock]
6. Select “STREET MODE 1-2” or “TRACK
1. From the MENU screen, select “Clock”.
MODE” to set the remaining DISPLAY-1
group items.

fee EVM tite 10:00

Wallpaper
DISPLAY-1

|STREET MODE 1-2 |

are
[Link]
ORE Ro acta

cTEMP eats
al yt

1-18
 FEATURES

2. When “Clock” is selected, the hours figure will 6. Short push the wheel switch again to exit and
be highlighted. go back to the MENU screen.

Les [are 4 pee

tT “All Reset”
This module resets everything, except the

ba: 34
odometer and clock, to its factory preset or de-
fault setting.
Select YES to reset all items. After selecting
YES, all items will be reset and the screen will
automatically return to the MENU screen.

3. Set the hour by rotating and then short push

the wheel switch.

Clock 10:00

102
4. The minutes figure will become highlighted.

Pa Les [are 4 ue TY

10:EYZ3
5. Set the minutes figure by rotating and then
short push the wheel switch.

one Les [are 4 pet

10 EY]

1-19
 BASIC SERVICE INFORMATION

EAS20010

BASIC SERVICE INFORMATION

EASsa0014

ELECTRICAL SYSTEM

Electrical parts handling

EGA?2611

NOTICE
¢ Do not perform angle adjustment of the IMU
and battery box by pinching the washer
and related parts.
¢ When installing the IMU, apply a thin coat of
silicone grease onto the washer where con-
tacting the IMU grommet.
¢ When installing the IMU, use only a genuine
bolt and washer, and tighten the bolt to the
specified torque.
¢ Pay attention not to expose the IMU to
strong shocks, such as striking or drop-
ping it.
¢ Do not place any foreign objects in and
around the battery box.
¢ Do not obstruct breather opening “a” of the
IMU.
¢ Do not clean the breather opening and do
not blow it with compressed air.
¢ When replacing the collar or grommet, re-
place all four collars and grommets.

Pt

1-20
 SPECIAL TOOLS

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-”.
e For others, use part numbers starting with “90890-”.

. Reference
Tool name/Tool No. lIlustration pages

Yamaha diagnostic tool USB (US) 3-4, 4-80, 4-81,

90890-03269 9-2, 9-23, 9-24
YDT «
YAMAHA DIAGNOSTIC TOOLS

Yamaha diagnostic tool (A/l) 3-4, 4-80, 4-81,

90890-03264 9-2, 9-23, 9-24

Thickness gauge 3-6, 3-7, 3-7, 3-7,

90890-03268 4-42, 4-51, 5-34,
Feeler gauge set 5-65
YU-26900-9
( CA |

Vacuum gauge ——— 3-10

90890-03094 a lea }
Vacuummate eh Ny
; i i
YU-44456

YU-44456

Carburetor angle driver 2 3-10

90890-03173

Steering nut wrench 3-20, 4-110

90890-01403
Exhaust flange nut wrench
YU-A9472

1-21
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration pages

Oil filter wrench 3-29

90890-01426
Oil filter wrench
YU-38411

Oil pressure gauge joint 18 mm 3-30

90890-04176
YU-04176

Oil pressure gauge set 3-30

90890-03120

Vacuum/pressure pump gauge set 4-30

90890-06945
Pressure/vacuum tester
YB-35956-B

Wheel bearing ring nut tool 4-46, 4-48

90890-01574 Z
YM-01574

Fork spring compressor 4-92, 4-97

90890-01441
Fork spring compressor
YM-01441

Rod holder 4-92, 4-97

90890-01434
Damper rod holder double ended
YM-01434

Damper rod holder (@30) 4-93, 4-95

90890-01506
Damper rod holder
YM-01506

Fork seal driver 4-95, 4-95, 4-96,

90890-01442 4-105, 4-105
Adjustable fork seal driver (36-46 mm)
YM-01442

1-22
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration pages

LE 2 4-96, 4-97
ene
aoe90- y 37 90890-01437
908 014
Universal damping rod bleeding tool set -
YM-A8703

YM-A8703
| l)

Rod puller attachment (M10) 4-96, 4-97

90890-01436 area
Universal damping rod bleeding tool set a Li

cern
eh

YM-A8703

YM-A8703
| l)

Front fork cap bolt wrench 42mm 4-102, 4-103,

90890-01575 " 4-107
YM-01575

Ring nut wrench 4-110

90890-01268
Spanner wrench
YU-01268

Ring nut wrench 4-122, 4-124

90890-01507
Ring nut wrench
YM-01507

Damper rod holder (#22) 4-122, 4-124

90890-01365

Drive chain cut & rivet tool 4-126, 4-128

re
90890-01550
Drive chain cut & rivet tool
YM-01550

1-23
 SPECIAL TOOLS

Tool name/Tool No. lllustration

Reference
pages
Compression gauge 90890-03081
5-9
90890-03081
Engine compression tester
YU-33223

YU-33223

Pivot shaft wrench 5-16, 5-16

90890-01485
Frame mount insert wrench
YM-01485

Valve spring compressor 5-27, 5-30, 5-38,

90890-04019 5-43
Valve spring compressor
YM-04019

Valve spring compressor attachment (026) 5-38, 5-43

90890-01243
Valve spring compressor attachment (#26)
YM-01253-1

Valve guide remover (04.5) 5-40

90890-04116
Valve guide remover (4.5 mm)
YM-04116

Valve guide remover (@5) 5-40

90890-04097
Valve guide remover (5.0 mm)
YM-04097

Valve guide installer (64.5) 5-40

90890-04117
Valve guide installer (4.5 mm)
YM-04117

Valve guide installer (95) 5-40

90890-04098
Valve guide installer (5.0 mm)
YM-04098

1-24
 SPECIAL TOOLS

Tool name/Tool No. lllustration

Reference
pages
Valve guide reamer (04.5) 5-40
90890-04118
Valve guide reamer (4.5 mm)
YM-04118

Valve guide reamer (#5) 5-40

90890-04099
Valve guide reamer (5.0 mm)
YM-04099

15mm pin type rotor holding tool 5-46, 5-47

90890-04171
YM-04171

Crankshaft protector 5-46

90890-01382
Crankshaft protector
YM-01382

Flywheel puller 5-46

90890-01404
Flywheel puller
YM-01404

M35xP1.5
Yamaha bond No. 1215 5-47, 5-74
90890-85505
Three bond No. 1215®

Sheave holder 5-49, 5-49

90890-01701
Primary clutch holder
YS-01880-A

Digital circuit tester (CD732)

90890-03243
Model 88 Multimeter with tachometer
YU-A1927

1-25
 SPECIAL TOOLS

: Reference
Tool name/Tool No. lllustration pages

Universal clutch holder 5-64, 5-67

90890-04086 90890-04086 MBXPLDS_ <7
Universal clutch holder 30S
YM-91042 aa
/156
(yt
YM-91042

Piston pin clip rotation tool 5-79

90890-04175
YM-04175

Piston pin puller set 90890-01304 mY &w 5-80

90890-01304 A
Piston pin puller
YU-01304

Connecting rod big end bearing installer 5-83, 5-86

90890-04193 07 08.1 i

~ Go O ©
Connecting rod big end bearing installer = | |

Piston pin clip insertion tool 5-88

90890-04173
YM-04173

Piston pin clip installer tool 5-88

90890-04174
YM-04174

1-26
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration pages

Radiator cap tester 6-5, 6-6

90890-01325
Mityvac cooling system tester kit
YU-24460-A

Radiator cap tester adapter 6-5, 6-6

90890-01352
Pressure tester adapter
YU-33984

Mechanical seal installer (933) ys 6-16

90890-04132
Water pump seal installer (@33)
YM-33221-A

Middle driven shaft bearing driver 028 6-16

90890-04058 a a
Middle drive bearing installer 40 & 50 mm
YM-04058

Pressure gauge 7-18, 7-18

90890-03153
Pressure gauge
YU-03153

Fuel injector pressure adapter 7-18

90890-03210 |
Fuel injector pressure adapter
YU-03210

Fuel pressure adapter 7-18

90890-03176
Fuel pressure adapter
YM-03176
 SPECIAL TOOLS

Tool name/Tool No. Illustration

Reference
pages
Ignition checker 8-45
90890-06754
Oppama pet—4000 spark checker
YM-34487

Test harness— speed sensor (3P) 8-50

90890-03208
Test harness— speed sensor (SP)
YU-03208

TIP
Yamaha diagnostic tool (A/l) 90890-03264
This special tool includes the YDT sub harness (6P) (90890-03266).

==
=
=
=
=

TIP
YDT sub harness (6P) 90890-03266
lf you already have Yamaha diagnostic tool (A/I) (90890-03262), YDT sub harness (6P) (90890-03266)
is separately required.

1-28
 SPECIAL TOOLS

1-29
 SPECIFICATIONS

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ENGINE SPECIFICATIONS ........0.:ccscscesscssssessorscssscecsorscnansecsersenaanessessenaasensenes

CHASSIS SPECIFICATIONS
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ELECTRICAL SPECIFICATIONS 0000.0... eee eee eee cease eeeeee cease eens 2-10

TIGHTENING TORQUES.. 2°12

ENGINE TIGHTENING TORQUES ..cssssssssssssssesssssessssssessenestsvnseseee 2-12
CHASSIS TIGHTENING TORQUES ......ssssssscssssssssssssssesusssssseeseseseeenee 2-14
2-17
 GENERAL SPECIFICATIONS

EAS20013

GENERAL SPECIFICATIONS

Model
Model B3L2 (YZFR1L_except for California)
B3L3 (YZFR1LC_for California)
B4S2 (YZFR1ML_except for California)
B4S3 (YZFR1MLC_for California)

Dimensions
Overall length 2055 mm (80.9 in)
Overall width 690 mm (27.2 in)
Overall height 1165 mm (45.9 in)
Wheelbase 1405 mm (55.3 in)
Ground clearance 130 mm (5.12 in)
Minimum turning radius 3.4 m (11.16 ft)

Weight
Curb weight 203 kg (448 Ib) (YZF-R1)
204 kg (450 Ib) (YZF-R1M)

Loading
Maximum load 185 kg (408 Ib) (YZF-R1)
184 kg (406 Ib) (YZF-R1M)
Riding capacity 2 person

2-1
 ENGINE SPECIFICATIONS

EAS20014

ENGINE SPECIFICATIONS

Engine
Combustion cycle 4-stroke
Cooling system Liquid cooled
Valve train DOHC
Displacement 998 cms
Cylinder arrangement Inline
Number of cylinders 4-cylinder
Bore x stroke 79.0 x 50.9 mm (3.11 x 2.00 in)
Compression ratio 13.0: 1
Compression pressure 1261-1624 kPa/210 r/min (12.6—16.2 kgf/cm?/
210 r/min, 179.4—231.0 psi/210 r/min)
starting system Electric starter

Fuel
Recommended fuel Premium unleaded gasoline (E10 acceptable)
Fuel tank capacity 17 L (4.5 US gal, 3.7 [Link])
Fuel reserve amount 3.0 L (0.79 US gal, 0.66 [Link])

Engine oil
Recommended brand YAMALUBE
Type Full synthetic
SAE viscosity grades 10W-40, 15W-50
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Lubrication system Wet sump
Engine oil quantity
Oil change 3.90 L (4.12 US qt, 3.43 [Link])
With oil filter removal 4.10 L (4.33 US qt, 3.61 [Link])
Quantity (disassembled) 4.90 L (5.18 US qt, 4.31 [Link])

Oil filter
Oil filter type Cartridge

Oil pump
Oil pressure 200.0 kPa/5000 r/min (2.00 kgf/cm?/5000 r/min,
29.0 psi/5000 r/min)

Cooling system
Coolant quantity
Radiator (including all routes) 2.25 L (2.38 US qt, 1.98 [Link])
Coolant reservoir (up to the maximum level
mark) 0.25 L (0.26 US at, 0.22 [Link])
Radiator cap valve opening pressure 107.9-137.3 kPa (1.08—1.37 kgf/cm2, 15.6-19.9
psi)
Cooling system leak test pressure 137.3 kPa (1.37 kgf/cm2, 19.9 psi)
Thermostat
Valve opening temperature 69.0—73.0 °C (156.20—163.40 °F)
Valve full open temperature 85.0 °C (185.00 °F)
Valve lift (full open) 8.0 mm (0.31 in)
 ENGINE SPECIFICATIONS

Spark plug(s)
Manufacturer/model NGK/LMARQE-J
Spark plug gap 0.6-0.7 mm (0.024-0.028 in)
Cylinder head
Warpage limit 0.10 mm (0.0039 in)
Camshaft
Camshaft cap inside diameter 25.500-25.521 mm (1.0039—-1.0048 in)
Camshaft journal diameter 25.459-25.472 mm (1.0023-1.0028 in)
Camshaft-journal-to-camshaft-cap clearance 0.028-0.062 mm (0.001 1-0.0024 in)
Limit 0.080 mm (0.0032 in)
Camshaft lobe dimensions
Lobe height (Intake) 35.291-35.391 mm (1.3894—1.3933 in)
Limit 35.191 mm (1.3855 in)
Lobe height (Exhaust) 34.745-34.845 mm (1.3679—-1.3718 in)
Limit 34.645 mm (1.3640 in)
Camshaft runout limit 0.050 mm (0.0020 in)
Rocker arm/rocker arm shaft
Rocker arm inside diameter 7.987-8.002 mm (0.3144-0.3150 in)
Limit 8.017 mm (0.3156 in)
Rocker arm shaft outside diameter 7.967-7.979 mm (0.3137-0.3141 in)
Limit 7.936 mm (0.3124 in)
Valve, valve seat, valve guide
Valve clearance (cold)
Intake 0.09—0.17 mm (0.0035—0.0067 in)
Exhaust 0.18—0.23 mm (0.0071—0.0091 in)
Valve dimensions
Valve seat contact width (intake) 0.90—1.10 mm (0.0354—0.0433 in)
Limit 1.6 mm (0.06 in)
Valve seat contact width (exhaust) 1.10-—1.30 mm (0.0433—0.0512 in)
Limit 1.8 mm (0.07 in)
Valve stem diameter (intake) 4.975—4.990 mm (0.1959—0.1965 in)
Limit 4.960 mm (0.1953 in)
Valve stem diameter (exhaust) 4.460-4.475 mm (0.1756—0.1762 in)
Limit 4.425 mm (0.1742 in)
Valve guide inside diameter (intake) 5.000—5.012 mm (0.1969-—0.1973 in)
Valve guide inside diameter (exhaust) 4.500—4.512 mm (0.1772—0.1776 in)
Valve-stem-to-valve-quide 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 (0.00339 in)
Valve stem runout 0.010 mm (0.0004 in)
Valve spring
Inner spring
Free length (intake) 34.52 mm (1.36 in)
Limit 32.79 mm (1.29 in)
Free length (exhaust) 36.94 mm (1.45 in)
 ENGINE SPECIFICATIONS

Limit 35.09 mm (1.38 in)

Outer spring
Free length (intake) 35.72 mm (1.41 in)
Limit 33.93 mm (1.34 in)
Free length (exhaust) 36.85 mm (1.45 in)
Limit 35.01 mm (1.38 in)

Cylinder
Bore 79.000—79.010 mm (3.1102-—3.1106 in)
Wear limit 79.060 mm (3.1126 in)

Piston
Diameter 78.961—78.994 mm (3.1087—3.1100 in)
Measuring point (from piston skirt bottom) 8.0 mm (0.31 in)
Piston-to-cylinder clearance 0.006—0.049 mm (0.0002-0.0019 in)
Piston pin bore inside diameter 17.002—17.013 mm (0.6694—0.6698 in)
Limit 17.043 mm (0.6710 in)
Piston pin outside diameter 16.991—17.000 mm (0.6689-—0.6693 in)
Limit 16.971 mm (0.6681 in)
Piston-pin-to-piston-pin-bore clearance 0.002—0.022 mm (0.0001—0.0009 in)

Piston ring
Top ring
End gap limit 0.50 mm (0.0197 in)
Ring side clearance 0.030-0.065 mm (0.0012-0.0026 in)
Side clearance limit 0.115 mm (0.0045 in)
2nd ring
End gap limit 1.15 mm (0.0453 in)
Ring side clearance 0.020-0.055 mm (0.0008-0.0022 in)
Side clearance limit 0.115 mm (0.0045 in)
Connecting rod
Oil clearance 0.033—0.057 mm (0.0013-—0.0022 in)
Bearing color code
Code 1 Blue
Code 2 Black
Code 3 Brown
Code 4 Green
Code 5 Yellow
Code 6 Pink

Crankshaft
Runout limit 0.030 mm (0.0012 in)
Journal oil clearance 0.025—0.043 mm (0.0010—0.0017 in)
Bearing color code
Code 0 White
Code 1 Blue
Code 2 Black
Code 3 Brown
Code 4 Green
Code 5 Yellow
Code 6 Pink
 ENGINE SPECIFICATIONS

Balancer
Balancer shaft runout limit 0.030 mm (0.0012 in)
Bearing color code
Code 0 White
Code 1 Blue
Code 2 Black
Code 3 Brown
Code 4 Green
Code 5 Yellow
Code 6 Pink
Balancer shaft journal to balancer shaft bearing
clearance 0.028—0.046 mm (0.0011—0.0018 in)

Clutch
Clutch type Wet, multiple-disc
Clutch lever free play 10.0—15.0 mm (0.39-—0.59 in)
Assembly width 48.3—49.3 mm (1.90—1.94 in)
Friction plate 1 thickness 2.72—2.88 mm (0.107—0.113 in)
Wear limit 2.62 mm (0.103 in)
Plate quantity 3 pcs
Friction plate 2 thickness 2.72—2.88 mm (0.107-0.113 in)
Wear limit 2.62 mm (0.103 in)
Plate quantity 7 pcs
Clutch plate 1 thickness 2.46—2.74 mm (0.097—0.108 in)
Plate quantity 1 pcs
Warpage limit 0.10 mm (0.004 in)
Clutch plate 2 thickness 2.18—2.42 mm (0.086—0.095 in)
Plate quantity 7 pcs
Warpage limit 0.10 mm (0.004 in)
Plate quantity 1 pcs
Warpage limit 0.10 mm (0.004 in)
Clutch spring free length 47.36 mm (1.86 in)
Limit 44.99 mm (1.77 in)

Drivetrain
Primary reduction ratio 1.634 (67/41)
Transmission type Constant mesh 6-speed
Gear ratio
1st 2.600 (39/15)
2nd 2.176 (37/17)
3rd 1.842 (35/19)
4th 1.579 (30/19)
5th 1.381 (29/21)
6th 1.250 (30/24)
Main axle runout limit 0.08 mm (0.0032 in)
Drive axle runout limit 0.08 mm (0.0032 in)
Secondary reduction ratio 2.563 (41/16)
Final drive Chain

Shifting mechanism
Installed shift rod length 258.5—260.5 mm (10.18—10.26 in)
 ENGINE SPECIFICATIONS

Air filter
Air filter element Oil-coated paper element

Fuel pump
Pump type Electrical
Maximum consumption amperage 5.2 A

Fuel injector
Resistance 12.0 Q

Throttle body
ID mark B3L2 10 (except for California)
B3L3 20 (for California)

Idling condition
Engine idling speed 1200-1400 r/min
Al system Inactive
O, feedback control Inactive
Coolant temperature 90-110 °C (194—230 °F)
Intake vacuum 25.5 kPa (191 mmHg, 7.5 inHg)
Difference in vacuum pressure between the
cylinders 0 kPa—1.3 kPa (O mmHg—10 mmbg, 0 inHg—0.4
inHg)
CO% 1.0—4.0 %
Fuel line pressure (at idle) 300-390 kPa (3.0—3.9 kgf/cm?, 43.5—56.6 psi)

Air induction system

Solenoid resistance 18-22 ©
 CHASSIS SPECIFICATIONS

EAS20015

CHASSIS SPECIFICATIONS

Chassis
Frame type Diamond
Caster angle 24.0 °
Trail 102 mm (4.0 in)

Front wheel
Wheel type Cast wheel
Rim size 17M/C X MT3.50
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 1.0 mm (0.04 in)
Wheel axle bending limit 0.25 mm (0.01 in)

Rear wheel
Wheel type Cast wheel
Rim size 17M/C X MT6.00
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 1.0 mm (0.04 in)
Wheel axle bending limit 0.25 mm (0.01 in)

Front tire
Type Tubeless
size 120/70ZR17M/C (58W)
Manufacturer/model BRIDGESTONE/BATTLAX RACING STREET
RS11F

Rear tire
Type Tubeless
size 190/55ZR17M/C (75W) (YZF-R1)
200/55ZR17M/C (78W)
(YZF-R1M)
Manufacturer/model BRIDGESTONE/BATTLAX RACING STREET
RS11R

Tire air pressure (measured on cold tires)

Front 250 kPa (2.50 kgf/cm, 36 psi)
Rear 290 kPa (2.90 kgf/cm?, 42 psi)

Front brake
Type Hydraulic dual disc brake
Disc outside diameter x thickness 320.0 x 5.0 mm (12.60 x 0.20 in)
Brake disc thickness limit 4.5 mm (0.18 in)
Brake disc runout limit (as measured on wheel) 0.10 mm (0.0039 in)
Brake pad lining thickness limit 0.5 mm (0.02 in)
Master cylinder inside diameter 15.87 mm (0.62 in)
Caliper cylinder inside diameter (Left) 30.23 mm, 27.00 mm (1.19 in, 1.06 in)
Caliper cylinder inside diameter (Right) 30.23 mm, 27.00 mm (1.19 in, 1.06 in)
Specified brake fluid DOT 4

Rear brake
Type Hydraulic single disc brake
 CHASSIS SPECIFICATIONS

Disc outside diameter x thickness 220.0 x 5.0 mm (8.66 x 0.20 in)

Brake disc thickness limit 4.5 mm (0.18 in)
Brake disc runout limit (as measured on wheel) 0.15 mm (0.0059 in)
Brake pad lining thickness limit 1.0 mm (0.04 in)
Master cylinder inside diameter 12.7 mm (0.50 in)
Caliper cylinder inside diameter 30.23 mm (1.19 in)
Specified brake fluid DOT 4

Front suspension
Type Telescopic fork
Spring Coil spring
Shock absorber Hydraulic damper (YZF-R1)
Gas-hydraulic damper (YZF-R1M)
Wheel travel 120 mm (4.7 in)
Fork spring free length 219.5 mm (8.64 in) (YZF-R1)
260.0 mm (10.24 in) (YZF-R1M)
Limit 215.1 mm (8.47 in) (YZF-R1)
254.8 mm (10.03 in) (YZF-R1M)
Recommended oil Yamaha Suspension Oil 01 (YZF-R1)
Ohlins R&T 43 (YZF-R1M)
Inner tube bending limit 0.2 mm (0.01 in)
Quantity (left) 470.0 cm? (15.89 US oz, 16.58 [Link])
(YZF-R1)
263.0 cm? (8.89 US oz, 9.26 [Link]) (YZF-R1M)
Quantity (right) 470.0 cm? (15.89 US oz, 16.58 [Link])
(YZF-R1)
263.0 cm (8.89 US oz, 9.26 [Link]) (YZF-R1M)
Level (left) 84 mm (3.3 in) (YZF-R1)
180 mm (7.1 in) (YZF-R1M)
Level (right) 84 mm (3.3 in) (YZF-R1)
180 mm (7.1 in) (YZF-R1M)
Spring preload
Adjusting system Mechanical adjustable type
Unit for adjustment Turn
Adjustment value (Soft) 0
Adjustment value (STD) 6 (YZF-R1)
3 (YZF-R1M)
Adjustment value (Hard) 15
Rebound damping
Adjusting system Mechanical adjustable type (YZF-R1)
Electronically adjustable type (YZF-R1M)
Unit for adjustment Click (YZF-R1)
Adjustment value from the start position (Soft) 14 (YZF-R1)
Adjustment value from the start position (STD) 7 (YZF-R1)
Adjustment value from the start position (Hard) 1 (YZF-R1)
Compression damping
Adjusting system Mechanical adjustable type (YZF-R1)
Electronically adjustable type (YZF-R1M)
Unit for compression damping adjustment Click (YZF-R1)
Adjustment value from the start position (Soft) 23 (YZF-R1)
Adjustment value from the start position (STD) 17 (YZF-R1)
Adjustment value from the start position (Hard) 1 (YZF-R1)

2-8
 CHASSIS SPECIFICATIONS

Rear suspension
Type Swingarm (link suspension)
Spring Coil spring
Shock absorber Gas-hydraulic damper
Wheel travel 120 mm (4.7 in)
Spring preload
Adjusting system Mechanical adjustable type
Adjustment value (Soft) 77.5 mm (3.05 in) (YZF-R1)
0.0 mm (0.00 in) (YZF-R1M)
Adjustment value (STD) 78.5 mm (3.09 in) (YZF-R1)
4.0 mm (0.16 in) (YZF-R1M)
Adjustment value (Hard) 85.5 mm (3.37 in) (YZF-R1)
9.0 mm (0.35 in) (YZF-R1M)
Rebound damping
Adjusting system Mechanical adjustable type (YZF-R1)
Electronically adjustable type (YZF-R1M)
Unit for adjustment Click (YZF-R1)
Adjustment value from the start position (Soft) 23 (YZF-R1)
Adjustment value from the start position (STD) 12 (YZF-R1)
Adjustment value from the start position (Hard) 1 (YZF-R1)
Compression damping
Adjusting system Mechanical adjustable type (YZF-R1)
Electronically adjustable type (YZF-R1M)
Fast compression damping
Unit for adjustment Turn (YZF-R1)
Adjustment value from the start position (Soft) 5.5 (YZF-R1)
Adjustment value from the start position (STD) 3 (YZF-R1)
Adjustment value from the start position (Hard) 0 (YZF-R1)
Slow compression damping
Unit for adjustment Click (YZF-R1)
Adjustment value from the start position (Soft) 18 (YZF-R1)
Adjustment value from the start position (STD) 12 (YZF-R1)
Adjustment value from the start position (Hard) 1 (YZF-R1)

Drive chain
size 525
Chain type Sealed type
Number of links 113
Drive chain slack (When performing
maintenance/Maintenance stand) 25.0-35.0 mm (0.98—1.38 in)
Drive chain slack (When replacing with a new
one/Maintenance stand) 20.0—30.0 mm (0.79—1.18 in)
Drive chain slack limit (Maintenance stand) 35.0 mm (1.38 in)
15-link length limit 239.3 mm (9.42 in)
 ELECTRICAL SPECIFICATIONS

EAS20016

ELECTRICAL SPECIFICATIONS

Voltage
System voltage 12V

Ignition system
Ignition system TCl
Ignition timing (B.T.D.C.) 3.0—7.0 °s/1300 r/min

Engine control unit

Model TBDF3K

Ignition coil
Primary coil resistance 0.85-1.15 Q
secondary coil resistance 8.50-11.50 kQ

Charging system
Charging system AC magneto
Standard output 14.0 V, 26.3 A at 5000 r/min
Stator coil resistance 0.112-0.168 Q

Rectifier/regulator
Regulator type Three-phase
Regulated voltage (DC) 14.3-14.7 V

Battery
Model YTZ7S(F)
Voltage, capacity 12 V, 6.0 Ah (10 HR)

Bulb wattage
Headlight LED
Brake/tail light LED
Front turn signal/position light LED
Rear turn signal light LED
Auxiliary light LED
License plate light LED
Meter lighting LED

Indicator light
Neutral indicator light LED
Stability control indicator light LED
Oil pressure and coolant temperature warning
light LED
High beam indicator light LED
Turn signal indicator light LED
Fuel level warning light LED
Malfunction indicator light LED
ABS warning light LED
Auxiliary system warning light LED
Shift indicator light LED

2-10
 ELECTRICAL SPECIFICATIONS

Starter motor
Brush overall length limit 5.5 mm (0.22 in)
Brush spring force 4.80-—7.20 N (489-734 of, 17.28-—25.92 oz)
Mica undercut (depth) 2.40 mm (0.09 in)

Solenoid
Steering damper solenoid resistance 49.82—56.18 ©
Intake solenoid resistance 42.0—48.0 Q

Fuel injection sensor

Crankshaft position sensor resistance 189-231 QO
Cylinder identification sensor output voltage (ON) 4.8V
Cylinder identification sensor output voltage
(OFF) 0.8 V
Intake air temperature sensor resistance 5400-6600 © at 0 °C (5400-6600 © at 32 °F)
Intake air temperature sensor resistance 289-391 © at 80 °C (289-391 © at 176 °F)
Coolant temperature sensor resistance 2513-2777 © at 20 °C (2513-2777 Q at 68 °F)
Coolant temperature sensor resistance 210-221 Q at 100 °C (210-221 Q at 212 °F)

Fuse(s)
Main fuse 50.0A
Headlight fuse 7.54
signaling system fuse 7.5A
Ignition fuse 15.0A
Radiator fan motor fuse 15.0A
Sub radiator fan motor fuse 10.0A
Hazard fuse 7.54
ABS ECU fuse 7.5A
SCU fuse 7.5 A (YZF-R1M)
Fuel injection system fuse 15.0A
ABS motor fuse 30.0 A
ABS solenoid fuse 15.0A
Auxiliary fuse 2.0A
Backup fuse 7.5A
Electronic throttle valve fuse 7.54

2-11
 TIGHTENING TORQUES

EAS20017

TIGHTENING TORQUES
EASSa0016

ENGINE TIGHTENING TORQUES

Item mead’ | arty Tightening torque Remarks

Exhaust pipe nut Wits: 8 20 N-m (2.0 kgf-m, 15 Ib-ft)
Muffler protector bolt M6 1 10 N-m (1.0 kgf-m, 7.4 Ib-ft)
EXUP valve pulley cover bolt M6 3 10 N-m (1.0 kgf-m, 7.4 Ib-ft)
Spark plug M10 4 13 N-m (1.3 kgf-m, 9.6 Ib-ft)
Spark plug (new) M10 4 18 N-m (1.8 kgf-m, 13 Ib-ft)
Cylinder head cover bolt M6 6 10 N-m (1.0 kgf-m, 7.4 Ib-ft)
Generator rotor bolt M10 1 85 N-m (8.5 kgf-m, 63 Ib-ft) — ie)
Generator cover bolt M6 8 See TIP.

Clutch boss nut M20 | 1 125 N-m (12.5 kgf-m, 92 lb-ft) Stake.
— ie)

Clutch spring bolt M6 3 10 N-m (1.0 kgf-m, 7.4 Ib-ft)

Clutch cover bolt M6 10 See TIP.
Oil filter cartridge M20 1 17 N-m (1.7 kgf-m, 13 lb-ft)
Oil filter cartridge union bolt M20 1 70 N-m (7.0 kgf-m, 52 Ib-ft) — iC)
Water pump drain bolt M6 1 10 N-m (1.0 kgf-m, 7.4 Ib-ft)
Engine oil drain bolt M14 1 23 N-m (2.3 kgf-m, 17 lb-ft)

TIP
Generator cover bolt
1. Tighten the bolts to 6 N-m (0.6 kgf-m, 4.4 lb-ft) with a torque wrench following the tightening order.
2. Perform the following procedure to all the bolts one by one in the tightening sequence as shown in
the illustration.
a. Loosen the bolt.
b. Tighten the bolt to 3.0 N-m (0.30 kgf-m, 2.2 lb-ft) with a torque wrench.
c. Tighten the bolt further to reach the specified angle 90°.

2-12
 TIGHTENING TORQUES

TIP
Clutch cover bolt
1. Tighten the bolts to 6 N-m (0.6 kgf-m, 4.4 lb-ft) with a torque wrench following the tightening order.
2. Perform the following procedure to all the bolts one by one in the tightening sequence as shown in
the illustration.
a. Loosen the bolt.
b. Tighten the bolt to 3.0 N-m (0.30 kgf-m, 2.2 lb-ft) with a torque wrench.
c. Tighten the bolt further to reach the specified angle 180°.

2-13
 TIGHTENING TORQUES

EAS30017

CHASSIS TIGHTENING TORQUES

Item mead’ | arty Tightening torque Remarks

Front wheel axle nut M24 1 115 N-m (11.5 kgf-m, 85 lb-ft)
Front wheel axle pinch bolt its: 4 21 N-m (2.1 kgf-m, 15 Ib-ft) See TIP.
Rear wheel sprocket nut M10 5 100 N-m (10 kgf-m, 74 lb-ft)
Rear wheel axle nut M24 1 190 N-m (19 kgf-m, 140 Ib-ft)
Rear brake caliper bolt (front) M12 1 27 N-m (2.7 kgf-m, 20 Ib-ft) = >4

Rear brake caliper bolt (rear) Mg 1 12 N-m (1.2 kgf-m, 8.9 Ib-ft) —

Brake caliper bleed screw Més 3 5 N-m (0.5 kgf-m, 3.7 lb-ft)
Front brake caliper bolt M10 4 35 N-m (3.5 kgf-m, 26 lb-ft)
Handlebar bolt M6 2 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Handlebar pinch bolt Ms 2 32 N-m (3.2 kgf-m, 24 lb-ft)
Clutch cable locknut M8 1 7 N-m (0.7 kgf-m, 5.2 Ib-ft)
Lower bracket pinch bolt M8 4 23 N-m (2.3 kgf-m, 17 lb-ft) See TIP.
Upper bracket pinch bolt Wits: 2 26 N-m (2.6 kgf-m, 19 Ib-ft)
Lower ring nut M30 1 See TIP.

Drive sprocket nut M22 | 1 140 N-m (14 kgf-m, 103 lb-ft) =
— ie)
Rear frame bolt M10 4 37 N-m (3.7 kgf-m, 27 Ib-ft)

TIP
Lower ring nut
1. Tighten the ring nut to 52 N-m (5.2 kgf-m, 38 Ib-ft) with a torque wrench, then loosen the lower ring
nut completely.
2. Tighten the lower ring nut to 14 N-m (1.4 kgf-m, 10 Ib-ft).
TIP
Front wheel axle pinch bolt
1. Tighten the pinch bolt “2”, pinch bolt “1”, and pinch bolt “2” to 21 N-m (2.1 kgf-m, 15 Ib-ft) in this order.
2. Check that the right end of the front axle is flush with the front fork. If necessary, manually push the
front axle or lightly tap it with a soft hammer until its end is flush with the front fork. However, if the
surface of the front axle end Is not parallel to the surface of the front fork, align a point on the outer

VN
edge of the axle with the fork, making sure that the axle does not protrude past the fork.
3. Tighten the pinch bolt “4”, pinch bolt “3”, and pinch bolt “4” to 21 N-m (2.1 kgf-m, 15 Ib-ft) in this order.

~ \ fee
f \ / 7 \

2-14
 TIGHTENING TORQUES

TIP
Lower bracket pinch bolt
Tighten each bolt to 23 N-m (2.3 kgf-m, 17 lb-ft) in the order pinch bolt “1” > pinch bolt “2” > pinch bolt
“1” — pinch bolt “2”.

2-15
 TIGHTENING TORQUES

2-16
 CABLE ROUTING

EAS20021

CABLE ROUTING
Handlebar (front view)

2-17
 CABLE ROUTING

Handlebar switch lead (right)

=
ron Clutch cable
Handlebar switch lead (left)
Clutch switch connector
Main switch lead
coONOa

Horn lead
Radiator bracket (left)
Intake solenoid vacuum hose
Horn
. Steering damper solenoid lead
. Front brake hose
. Front fork stepping motor sub-wire harness
Route the handlebar switch lead (right) to the rear
of the front brake hose. Be sure not to pinch the
handlebar switch lead (right) between the front fork
and the front brake hose.
Make sure that the horn lead and clutch switch
lead do not cross.
Make sure that the leads do not cross within the
range shown in the illustration.
Fasten the horn lead to the lower bracket with a
plastic locking tie. Position the plastic locking tie
between the outer tube and the steering lock
portion of the lower bracket. Face the buckle of the
plastic locking tie forward with the end pointing
upward, and then cut off the excess end of the tie
to 5 mm (0.2 in) or less.
To front wheel sensor
mm

Route the clutch cable to the rear of the handlebar

switch lead (right).
Route the handlebar switch lead (right) to the front
of the main switch lead.
Route the horn lead to the front of the lower
bracket.
For YZF-RiM
Connect the front fork stepping motor coupler
(right), which is identified by the tape on the lead,
to the right front fork leg.
Route the front fork stepping motor sub-wire
harness to the rear of the clutch cable and
handlebar switch lead (left).
Insert the projection on the front fork stepping
motor sub-wire harness holder into the hole in the
cable guide from the bottom of the guide. Route
the front fork stepping motor sub-wire harness
under the clutch cable.
. Connect the front fork stepping motor coupler (left/
right), and then slide the waterproof cover uniil it
contacts the front fork cap bolt (left/right).
. Fasten the front fork stepping motor sub-wire
harness at the lower edge of the black tape to the
straight section of the brake fluid reservoir hose
with the holder. Face the catch of the holder
downward.

2-18
 CABLE ROUTING

Frame (front right side view)

2-19
 CABLE ROUTING

Clutch cable
Front brake hose (front brake master cylinder to
hydraulic unit)
Steering damper solenoid lead
w

Front fork stepping motor sub-wire harness (for

>

YZF-R1M)
Coolant reservoir breather hose
OM

Side cover (right)

Damper
POON

Radiator stay
Radiator bracket
Fasten the clutch cable and front fork stepping
motor sub-wire harness (for YZF-R1M) at the
positioning tape (white) on the cable and lead to
the radiator stay with a plastic locking tie.
Route the front fork stepping motor sub-wire
harness to the inside of the clutch cable. (For
YZF-RiM)
Route the front fork stepping motor sub-wire
harness between the ribs on the SCU stay. (For
YZF-R1M)
Install the front fork stepping motor sub-wire
harness holder completely onto the tab on the
headlight stay. (For YZF-R1M)
Route the front fork stepping motor sub-wire
harness to the outside of the coolant reservoir. (For
YZF-R1M)
Cross the coolant reservoir breather hose and
clutch cable so that the hose is routed to the
outside of the cable.
Route the coolant reservoir breather hose along
the clutch cable.
Fasten the coolant reservoir breather hose at the
paint mark to the clutch cable with the holder.
Route the coolant reservoir breather hose above
the clutch cable.
Route the front fork stepping motor sub-wire
harness between the right side cover and the
radiator. Make sure that the front fork stepping
motor sub-lead does not protrude past the right
side cover. (For YZF-R1M)
Route the coolant reservoir breather hose between
the damper and the radiator filler neck.
Point the end of the plastic locking tie outward. Do
not cut off the excess end of the plastic locking tie.
Route the coolant reservoir breather hose to the
outside of the clutch cable.
. Fasten the coolant reservoir breather hose at the
paint mark to the clutch cable with the holder.
Make sure that the end of the holder contacts the
radiator bracket as shown in the illustration.

2-20
 CABLE ROUTING

Frame (rear right side view)

| YAGIARIA |

2-21
 CABLE ROUTING

Muffler protector bracket (right)

bw = O, sensor lead
Rear wheel sensor lead
PNOAhG

Rear brake light switch lead

EXUP cable
Frame
Clutch cover
Route the Os sensor lead over the muffler
protector bracket (right).
Route the rear wheel sensor lead to the outside of
00

the EXUP cables and to the inside of the brake

hose.
Route the rear brake light switch lead to the
outside of the rear wheel sensor lead.
Push in the O. sensor lead from the outside until it
is aligned with the mating surface of the clutch
cover.

2-22
 CABLE ROUTING

Electrical components tray (left side view)

7
r

2-23
 CABLE ROUTING

Intake funnel servo motor lead D. Fasten the right handlebar switch leads, left
Main switch coupler handlebar switch leads and radiator fan motor
Handlebar switch coupler (right) (non-waterproof leads with a plastic locking tie. The leads may be
4-pole) fastened in any order. Do not fasten the rectifier/
regulator lead with the plastic locking tie. Face the
Handlebar switch coupler (left) (non-waterproof 2-
buckle of the plastic locking tie upward, and then
pole)
cut off the excess end of the tie to 5 mm (0.2 in) or
Handlebar switch coupler (right) (non-waterproof less.
6-pole)
Insert the projection on the coupler completely into
Handlebar switch coupler (left) (waterproof 10- the hole in the electrical components tray.
pole)
Install the coupler completely onto the tab on the

vT1
Handlebar switch coupler (right) (waterproof 4- electrical components tray.
pole)
. Fasten the coupler with the holder on the electrical

oO
Handlebar switch coupler (right) (waterproof 6- components tray.
pole)
The radiator fan motor leads may cross.

-=r
Headlight contro! unit coupler
Fasten the horn lead at the white tape with a
10. Headlight control unit plastic locking tie.
11. Radiator fan motor lead coupler (right) (black) 15—25 mm (0.59-0.98 in)
Radiator fan motor lead coupler (left) (white)

S=rxes
12.
90—100 mm (3.54—3.94 in)
13. Rectifier/regulator lead
Inward
14. Horn lead
. Cut off the excess end of the plastic locking tie to 5
15. Main switch lead mm (0.20 in) or less.
16. Handlebar switch lead (left) 60°
17. Handlebar switch lead (right) Position the buckle of the plastic locking tie within
18. Secondary injector #1 the range shown in the illustration.
19. Secondary injector #2 Forward
UO
20. Secondary injector #3 30°
21. Secondary injector #4 Position the horn lead within the range shown in
22. Fuel hose 2 (secondary injector fuel rail side) the illustration.
23. Fuel hose 3 (fuel hose 2 to throttle body) Fasten the secondary injector lead with the holders
on the air filter case. Make sure that the white tape
24. Rear shock absorber assembly stepping motor
on the lead is positioned between the holders.
lead (for YZF-R1M)
Fasten the secondary injector lead to the fuel rail
20. Coolant temperature sensor lead
with a plastic locking tie. Position the plastic locking
26. Crankcase breather hose tie at the narrow portion of the fuel rail.
ef. Fuel hose 1 (fuel tank to fuel hose 2) Route the coolant temperature sensor lead under
26. Secondary injector lead the fuel hose.
29. Fuel rail Route the secondary injector lead to the rear of the
30. Handlebar switch lead (right) (non-waterproof 4- cross bar.
pole) Fasten the secondary injector lead to the fuel rail
31. Handlebar switch lead (left) (non-waterproof 2- with a plastic locking tie. Point the end of the plastic
pole) locking tie rearward. Do not cut off the excess end
32. Handlebar switch lead (right) (non-waterproof 6- of the plastic locking tie.
pole) Make sure that the leads do not protrude to the
33. Handlebar switch lead (left) (waterproof 10-pole) outside of the guide on the electrical components
tray.
34. Handlebar switch lead (right) (waterproof 4-pole)
Route the main switch leads under the wire
The leads may be fastened in any order.
<=

harness. Fasten the right handlebar switch leads and left

Fasten the main switch leads at the white tape to handlebar switch lead with a plastic locking tie.
the wire harness with a plastic locking tie. Position Face the buckle of the plastic locking tie forward,
the plastic locking tie between the wire harness and then cut off the excess end of the tie to 5 mm
holder and the wire harness protector. Face the (0.2 in) or less.
buckle of the plastic locking tie downward, and
then cut off the excess end of the tie to 5mm (0.2
in) or less.
Connect the intake funnel servo motor coupler on
top of the frame, and then place it between the air
filter case and the frame.

2-24
 CABLE ROUTING

Frame (left side view)

2-25
 CABLE ROUTING

Secondary injector lead . Fasten the sidestand switch lead, O5 sensor lead
=
kwh Throttle position sensor (left), and oil pressure switch lead with the holder.
Wire harness The catch of the holder may be facing in any
Fuel tank breather hose (except for California) direction.
Fuel tank drain hose . Make sure that the grommet does not protrude
from the sidestand switch cover. Face the slit in the
AaNoOa

Engine ground lead

grommet inward. Make sure that the projection on
Starter motor lead the sidestand switch cover is hooked onto the
Gear position sensor lead groove in the grommet. Align the grommet with the
Shift sensor paint mark on the fuel tank drain hose.
. Sidestand switch lead Place the coupler cover behind the coupler cover
. O» sensor lead (left) (stator coil side) and push it inside the projection
on the chain case cover.
. Oil pressure switch lead
. Position the coupler cover (stator coil coupler,
. ECU (engine contro! unit) coupler crankshaft position sensor coupler) to the inside of
. Frame the thermostat assembly as shown in the
. Grommet illustration.
. Oil pressure switch connector . Route the shift sensor lead outside the fuel tank
. Sidestand switch coupler (black) drain hose and fuel tank breather hose (except for
California).
. Oo sensor coupler
. Fasten the stator coil lead and the shift sensor lead
. Shift sensor coupler (white) to the thermostat assembly at the positioning tape
. Crankshaft position sensor coupler on the shift sensor lead with a plastic locking tie.
. Stator coil coupler Position the plastic locking tie to the inside of the
. Thermostat assembly protruding portion on the thermostat assembly.
Point the end of the plastic locking tie rearward and
. Shift sensor lead
upward. Do not cut off the excess end of the plastic
. Thermostat assembly locking tie.
. Stator coil lead Route the shift sensor lead between the protruding
To secondary injector
D>

portions on the thermostat assembly.

Route the starter motor lead under the engine
ground lead.
Route the gear position sensor lead to the inside of
0

the starter motor lead.

Route the fuel tank drain hose and fuel tank
9

breather hose (except for California) over the boss

for the shift shaft of the crankcase.
Route the fuel tank drain hose through the guide of
the cover and position it in front of the fuel tank
breather hose. Align the paint mark on the fuel tank
drain hose to the guide area of the cover. (except
for California)
Maich the length of the fuel tank breather hose
coming out of the quide to the length of the fuel
tank drain hose. (except for California)
. Position the cable holder below the oil level check
window.
Insert the plastic locking tie into the frame hole.
The position of the plastic locking tie may change
after installation; however, make sure that it does
not come off.
Fasten the wire harness with the plastic locking tie.
Face the buckle of the plastic locking tie upward,
and then cut off the excess end of the tie to 5 mm
(0.2 in) or less.
Fasten the sidestand switch lead, O5 sensor lead
(left), and oil pressure switch lead with the holder.
Position the holder between the coupler cover and
the drive sprocket cover. The catch of the holder
may be facing in any direction.
The leads may be routed in any order.
Except for California.
-

. For California.

2-26
 CABLE ROUTING

Frame (top view)

A Dco Os
= aH fosaeg D =

: Deere te ve
sh
oe :

2-27
 CABLE ROUTING

Auxiliary light lead

=
kwh Steering damper solenoid coupler
Intake solenoid lead (sub-wire harness)
Steering damper solenoid lead
Front turn signal/position light lead (right)
AaNoOa

Meter assembly
Meter assembly coupler
Intake solenoid vacuum hose
Front turn signal/position light lead (left)
. Wire harness
. Headlight assembly
. Headlight cover
. Fuse box 2
. Front cowling
Route the auxiliary light lead under the wire
harness.
Place the steering damper solenoid lead and
intake solenoid lead (sub-wire harness) in the gap
between the front cowling and front cowling
assembly stay.
Route the front turn signal/position light lead (right)
under the steering damper solenoid lead and
intake solenoid lead (sub-wire harness).
To front turn signal/position light (right)
m ©

Install the holder on the steering damper solenoid

lead to the curved section of the slit used for
connecting the lead in the headlight assembly.
Install the meter assembly coupler and coupler
cover securely to the meter assembly. Make sure
that the edges of the coupler cover are not rolled
up.
. Fasten the intake solenoid vacuum hose with the
holders on the wire harness (2 locations).
Insert the projection on the wire harness holder
into the hole in the side cover bracket from the
inside.
To front turn signal/position light (left)
Fasten the intake solenoid vacuum hose, front turn
signal/position light lead (left), and auxiliary light
lead with the holder. Position the holder to the
outside of and above the head light control unit
holder. The catch of the holder may be facing in
any direction.
Face the holder on the steering damper solenoid
lead downward, and then install the holder
completely onto the rib of the headlight assembly.
Connect the front turn signal/position light coupler
(right), and then fasten the front turn signal/position
light leads (right) with the holder as shown in the
illustration. The leads may be routed in any order.
. To intake solenoid
z=

Install fuse box 2 onto the rib of the front side

cowling inner panel (left).
Insert the projection on the wire harness holder
into the hole in the front cowling from the inside.
Position the plastic locking tie to the outside of the
intake solenoid vacuum hose and front turn signal/
position light lead (left).

2-28
 CABLE ROUTING

Frame (top view) (for YZF-R1M)

2-29
 CABLE ROUTING

Steering damper solenoid coupler (Ohlins:

OPTION)
Steering damper solenoid coupler
Intake solenoid lead
Front turn signal/position light lead (right)
Sub-wire harness (front fork stepping motor)
Sub-wire harness (SCU, steering damper
solenoid, sub-wire harness)
Meter assembly coupler
Intake solenoid vacuum hose
Auxiliary light lead
10. Front turn signal/position light lead (left)
11. Wire harness
12. SCU (Suspension Control Unit)
13. Steering damper solenoid lead
The steering damper solenoid coupler (Ohlins:
OPTION) may be positioned in any place.
Route the front turn signal/position light lead (right)
under the intake solenoid lead, steering damper
solenoid lead, and sub-wire harness (front fork
stepping motor).
Connect the sub-wire harness (front fork stepping
motor) to the sub-wire harness (SCU, steering
damper solenoid, sub-wire harness).
To front turn signal/position light (left)
m ©

Connect the sub-wire harness (SCU, steering

damper solenoid, sub-wire harness) to the wire
harness.
After connecting the SCU coupler, install the
rubber cover completely until it contacts the SCU
(Suspension Control Unit). Make sure that the
edges of the coupler cover are not rolled up.
To front turn signal/position light (right)
=o)

Route the sub-wire harness (SCU, steering

damper solenoid, sub-wire harness) over the
intake solenoid vacuum hose.
To intake solenoid

2-30
 CABLE ROUTING

Frame (top view)

2-31
 CABLE ROUTING

Horn lead . Route the intake solenoid vacuum hose over the
= Main switch lead guide and to the outside of the projection on the
guide.
kwh
Handlebar switch lead (left)
Handlebar switch lead (right) . Fasten the main switch lead and wire harness to
the guide with a plastic locking tie. Face the buckle
Cylinder identification sensor coupler
of the plastic locking tie downward, and then cut off
AaNoOa

Ignition coil #4 coupler the excess end of the tie to 5 mm (0.2 in) or less.
Front wheel sensor lead Fasten the leads (right handlebar switch lead [blue
Atmospheric pressure sensor coupler tape], left handlebar switch lead [gray tape] and
Intake air pressure sensor coupler main switch lead [white tape] at the positioning
. Ignition coil #3 coupler tape on each lead to the guide with a plastic
locking tie. Face the buckle of the plastic locking tie
. Intake air temperature sensor coupler
rearward, and then cut off the excess end of the tie
. Ignition coil #2 coupler to 5 mm (0.2 in) or less.
. Intake funnel servo motor coupler
. Air induction system solenoid coupler
. Ignition coil #1 coupler
. Wire harness
. Intake solenoid vacuum hose
. Radiator bracket
. Radiator fan motor lead
. Front brake hose
. Atmospheric pressure sensor hose
. Intake air temperature sensor lead
. Guide
Fasten the horn lead at the white tape with the
holder on the lower bracket cover as shown in the
illustration.
Identified by the mark “A” on the lead
OD

Route the ignition coil #2 lead over the air

induction system solenoid lead.
Insert the projection on the wire harness holder
Oo

into the hole in the frame.

To front wheel sensor
mm

Fasten the edge of the shrink-tubing portion of the

front wheel sensor lead to the brake pipe witha
plastic locking tie.
Fasten the front wheel sensor lead at the
positioning tape with the holder as shown in the
illustration.
. Fasten the front wheel sensor lead at the bend in
the brake pipe with a plastic locking tie as shown in
the illustration. Point the end of the plastic locking
tie rearward. Do not cut off the excess end of the
plastic locking tie.
Make sure that the end of the atmospheric
pressure sensor hose contacts the air filter case
duct. Point the ends of the hose clamp to the
rearward. Position the hose clamp 0—4 mm (0—0.2
in) from the end of the hose.
Make sure that the atmospheric pressure sensor
hose is coming out of the inside of the air filter case
duct.
Fold the intake air temperature sensor lead so that
it does not get on the lock part of the coupler as
shown in the illustration.
Wrap the insulating tape around the intake air
temperature sensor lead, wrapping it more than
once, then three wraps or more around the lead
and the coupler together.
. The folded portion of the intake air temperature
sensor lead does not have to be wrapped with
insulating tape.

2-32
 CABLE ROUTING

Frame (top view)

Shi

pa
alt fl
Or AFal

ra
a

2-33
 CABLE ROUTING

Primary injector #1
akon = Primary injector #2
Primary injector #3
Primary injector #4
Coolant temperature sensor coupler (sub-wire
harness)
O, sensor lead
®

Neutral switch coupler

2&8 ™

Fuel pump lead

Engine ground lead
. Starter motor lead
=~;

. Rear shock absorber assembly stepping motor

lead (for YZF-R1M)
. Frame
. Cooling system air bleed hose
. Canister purge hose (for California)
. Throttle servo motor coupler
. Round terminal
. Combination terminal
. Coolant temperature sensor lead (sub-wire
harness)
To O», sensor
To fuel pump
Route the starter motor lead under the wire
harness.
Insert the projection on the wire harness holder
into the hole in the frame.
For YZF-R1M
mm

Route the rear shock absorber assembly stepping

motor lead (for YZF-R1M) to the outside of the fuel
hose.
. Connect the rear shock absorber assembly
stepping motor leads (for YZF-R1M) according to
those with identification tape (yellow) and those
without identification tape, and then cover the
couplers with the coupler cover.
. Fasten the rear shock absorber assembly stepping
motor leads (for YZF-R1M) to the lower portion of
the brake hose with a plastic locking tie. Position
the plastic locking tie between the front of the
frame and rear end of the coupler cover. Be sure to
fasten the plastic locking tie around the protective
sleeves of the leads, not the leads themselves.
Face the buckle of the plastic locking tie inward
with the end pointing downward. Do not cut off the
excess end of the plastic locking tie.
To rear shock absorber assembly
Fasten the wire harness to the cross bar witha
plastic locking tie at the concave portion of the air
filter case. Point the end of the plastic locking tie
downward. Do not cut off the excess end of the
plastic locking tie.
Fasten the coolant temperature sensor lead and
wire harness to the cross bar with a plastic locking
tie at the concave portion of the air filter case. Point
the end of the plastic locking tie downward. Do not
cut off the excess end of the plastic locking tie.
Route the coolant temperature sensor lead to the
engine side of the canister purge hose (for
California) and the cooling system air bleed hose.
Fasten the engine ground leads with the bolt so
that the crimped section of the terminal is facing
upward.

2-34
 CABLE ROUTING

Rear fender (top view)

2-35
 CABLE ROUTING

Rear wheel sensor coupler Route the rear shock absorber assembly stepping
= Rear brake light switch coupler motor lead to the outside of the EXUP cables, to
the inside of the rear brake light switch lead, and to
kwh
Hydraulic unit
the inside of the brake hose. (For YZF-R1M)
Battery
Route the EXUP cables to the front of the rear
Joint coupler
shock absorber assembly gas cylinder.
AaNoOa

Yamaha diagnostic tool coupler

Route the Yamaha diagnostic tool coupler lead
Tail/brake light lead under the joint coupler.
Rear turn signal light coupler Route the negative battery lead under the joint
EXUP servo motor coupler.
. Starter relay Route the negative battery lead between the ribs.
. Wire harness Route the Yamaha diagnostic tool coupler lead
. Hydraulic unit tray outside of the negative battery lead.
. Rear wheel sensor lead Fasten the tail/brake light lead, license plate light
. Rear brake light switch lead lead with the holder. The leads may be routed in
any order.
. EXUP cable 2
Route the positive battery lead over the EXUP
. EXUP cable 1
servo motor lead and starter relay lead.
. Brake hose
Route the starter motor lead under the main fuse
. Rear shock absorber assembly stepping motor lead.
lead (for YZF-R1M)
Route the starter motor lead into the space in the
. Rear shock absorber assembly gas cylinder battery box.
. Yamaha diagnostic tool coupler lead Insert the projection on the holder into the hole in
. Negative battery lead the battery box.
. Battery box Route the starter motor lead under the wire
. License plate light lead harness and negative battery lead.
. Rear turn signal light lead (left) Route the fuse box lead between the outer rib of
. Rear turn signal light lead (right) the hydraulic unit tray and the rib for installing the
fuse box.
. Positive battery lead
Route the negative battery lead under the other
. Starter relay lead
leads.
. EXUP servo motor lead
Route the Yamaha diagnostic tool coupler lead,
. Main fuse lead joint coupler lead, IMU lead, and CCU lead to the
. Starter motor lead inside of the rib on the hydraulic unit tray. The
. Fuse box leads may be routed in any order.
. Fuse box lead Route the starter motor lead under the negative
. Joint coupler lead battery lead.
. IMU lead
. CCU lead (To sub-wire harness for YZF-R1M)
The rear turn signal light leads, license plate light
lead, and tail/brake light lead may be routed in any
order.
Insert the projection on the rear wheel sensor
coupler into the hole in the hydraulic unit tray.
Position the rear brake light switch coupler toward
the hydraulic unit.
Fasten the rear wheel sensor lead and rear brake
light switch lead to the hydraulic unit tray with a
plastic locking tie. Point the end of the plastic
locking tie upward, and then cut off the excess end
of the tie to 5 mm (0.2 in) or less.
Route the rear brake light switch lead to the
outside of the EXUP cables, and between the
brake hoses.
Fasten the rear wheel sensor lead and rear brake
light switch lead to the brake hose with a plastic
locking tie. Point the end of the plastic locking tie
downward.
Route the rear wheel sensor lead to the outside of
the EXUP cables, and between the brake hoses.
. Route the rear shock absorber assembly stepping
motor lead to the inside of the brake hose and to
the inside of rear brake light switch lead. (For
YZF-R1M)

2-36
 CABLE ROUTING

Rear fender (left side view)

2-37
 CABLE ROUTING

Rear fender
— Oy OOmhBWOh
rPe+-0 Mudguard assembly
License plate light lead
License plate light coupler
Rear turn signal light coupler (left)
Rear turn signal light coupler (right)
EXUP cable 2
EXUP cable 1
Rear turn signal light lead (left)
. Rear turn signal light lead (right)
. Hydraulic unit tray
me

. Route the license plate light lead under the rear

turn signal light couplers.
Rear turn signal light (left): Connect the black
00

sections of the coupler. Rear turn signal light

(right): Connect the white sections of the coupler.
The rear turn signal light coupler (left) and rear turn
signal light coupler (right) may be positioned in any
order.
Insert the projection on each rear turn signal light
lead holder into the hole in the tail/brake light
bracket. The rear turn signal light lead holders may
be placed in any order.
Make sure that the license plate light lead is not
positioned on top of the nut on the mudguard
assembly.
Fasten the license plate light lead and rear turn
signal light leads with the holder. Position the
holder to the rear of the ends of the protective
sleeves of the rear turn signal light leads, making
sure that the protective sleeves are not rolled up.
Fasten the license plate light lead with the holders
on the mudguard assembly.
. Route the EXUP cables through the guide on the
hydraulic unit tray.

2-38
 CABLE ROUTING

Rear brake hose (right side view)

i a “4 i
1
5 - I spe
5 als f
ry er
Aer] pet
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TY
Hf
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ae zh. 13)

2-39
 CABLE ROUTING

Hydraulic unit
akon = Rear frame
Brake fluid reservoir
Frame
Brake hose (rear brake master cylinder to
hydraulic unit)
Rear wheel sensor lead
&

Rear brake master cylinder

om

Swingarm assembly
Rear wheel sensor lead cover
©

10. Rear wheel sensor protector

. Rear wheel sensor
12. Rear brake caliper
13. Brake hose (hydraulic unit to rear brake caliper)
14. Brake fluid reservoir hose
15. Hydraulic unit brake pipe (hydraulic unit to rear
brake caliper)
16. Hydraulic unit brake pipe (rear brake master
cylinder to hydraulic unit)
17. Rear brake hose bracket
18. Rear fender
Make sure that the rear wheel sensor lead does
not protrude from the rear wheel sensor lead cover.
Route the rear wheel sensor lead between the
swingarm assembly and the rear wheel sensor
lead cover.
59.3°
moo

57.3°
Install the holder 0-10 mm (0—0.39 in) from the slit
in the brake hose protector.
Position the holder as shown in the illustration.
G@)

. Route the rear wheel sensor lead to the rear of the

brake hose (hydraulic unit to rear brake caliper).
. Position the holder 0-10 mm (0—0.39 in) from the
top edge of the brake hose protector.
Fasten the rear wheel sensor lead under the white
tape on the lead with the holder.
Install the larger diameter side of the holder on the
metal fitting section of the brake hose (rear brake
master cylinder to hydraulic unit).
Fasten the grommet on the rear wheel sensor lead
with the holder.
Fasten the grommet on the rear wheel sensor lead
with the holder on the rear wheel sensor lead
cover.
. Fasten the grommet on the rear wheel sensor lead
with the holder on the rear wheel sensor protector.
. Fasten the rear wheel sensor lead with the holder
on the rear wheel sensor protector.
Route the brake hose (hydraulic unit to rear brake
caliper) between the rear brake hose holder and
the swingarm assembly.
Fasten the brake hose (hydraulic unit to rear brake
caliper) with the holder. Face the catch of the
holder upward.

2-40
 CABLE ROUTING

Front brake hose (left side view)

fe ™y f sy

2-41
 CABLE ROUTING

Brake hose (front brake master cylinder to

—. hydraulic unit)
Brake hose (hydraulic unit to front brake calipers)
wh
DrPoeaNnanp

Front wheel sensor lead

Front brake caliper
Front wheel sensor
Front fork leg
Collar
Front brake masier cylinder
Front wheel sensor protector
Point the open ends of the holder forward.
Fasten the front wheel sensor lead to the brake
hose (hydraulic unit to front brake calipers) with the
holder. Position the holder above the flange on the
brake hose (hydraulic unit to front brake calipers).
Route the front wheel sensor lead to the inside of
the brake hose (hydraulic unit to front brake
calipers).
Route the front wheel sensor lead along the left
hose of the brake hose (hydraulic unit to front
brake calipers) without any slack.
Route the front wheel sensor lead to the inside of
the brake hose (hydraulic unit to front brake
calipers).
Fasten the front wheel sensor lead at the white
tape with the holder.
Install the holder on the shrink-tubing portion of the
brake hose (hydraulic unit to front brake calipers).
. Install the collar so that the edge of the collar is
positioned 1—2 mm (0.04—0.08 in) from the end of
the projection.
. 90°
Install the collar so that its slit is positioned within
the range shown in the illustration.
For YZF-R1M
c_

Route the front wheel sensor lead through the

guide on the front wheel sensor protector.
Fasten the brake hose (front brake master cylinder
to hydraulic unit) at the shrink-tubing portion of the
hose to the outer tube with a plastic locking tie.
Position the plastic locking tie below the flange on
the brake hose (front brake master cylinder to
hydraulic unit).
Rearward
==

Position the buckle of the plastic locking tie 10 mm

(0.39 in) or more from the brake hose (front brake
master cylinder to hydraulic unit).
Forward
00

Cut off the excess end of the plastic locking tie to 5

mm (0.2 in) or less. The end of the plastic locking
tie may be pointing in any direction.

2-42
 CABLE ROUTING

Front brake hose (left side view)

2-43
 CABLE ROUTING

Brake hose bracket

Pon= Frame
Brake hose (hydraulic unit to front brake calipers)
Brake hose (front brake master cylinder to
hydraulic unit)
Install the brake hose (front brake master cylinder
>

to hydraulic unit) so that it is on the inside relative

to the brake hose (hydraulic unit to front brake
calipers). There is an identifying white paint mark
on the upper surface of the pipe of the brake hose
(front brake master cylinder to hydraulic unit).

2-44
 CABLE ROUTING

Hydraulic unit assembly (top and left side view)

2-45
 CABLE ROUTING

1. Brake hose (front brake master cylinder to brake

hose joint)
Brake hose (front brake calipers to brake hose
joint)
Brake hose (front brake caliper side brake hose
joint to hydraulic unit)
Brake hose (front brake master cylinder side brake
>

hose joint to hydraulic unit)

Brake hose (rear brake master cylinder to
un

hydraulic unit)
Brake hose (hydraulic unit to rear brake caliper)
QDPrtsSeOONn®D

Hydraulic unit
Rear frame
Hydraulic tray
. Rear brake hose bracket
. Brake hose joint
. 23mm (0.91 in)
54.8°
. 17.2 mm (0.68 in)
Install the hydraulic unit brake pipe (front brake
master cylinder to hydraulic unit) and hydraulic unit
brake pipe (hydraulic unit to front brake calipers) so
that they are parallel to each other.

2-46
 CABLE ROUTING

Fuel tank (top and left side view)

ORY Z Tyee -
? 7 Padi dh SeA
XX ARXRR RAY
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a 7

RR RRR
RRR

2-47
 CABLE ROUTING

Fuel tank
OPparoh= Fuel pump
Fuel tank breather hose
Fuel tank drain hose
Fuel hose 1 (fuel tank to fuel hose 2)
Point the end of the hose clamp outward.
Install the fuel tank drain hose with its white paint
mark facing outward.

2-48
 CABLE ROUTING

Canister (for California)

=FS,
==

a
oh
|

ee
J
=a

=e |
-

2-49
 CABLE ROUTING

Fuel hose 1 (fuel tank to fuel hose 2)

h —
FW mle
Canister
Canister holder
wm

O, sensor coupler
Be

Neutral switch coupler

ODO

Fuel pump lead

OOxA

Fuel tank breather hose (fuel tank to canister)

Fuel tank drain hose
Starter motor lead
. Canister purge hose (hose joint to canister)
A

. Canister bracket
a
Pe

. Route the neutral switch lead and Os sensor lead

to the front of and under the fuel tank breather
hose (fuel tank to canister).
Point the ends of the hose clamp in the direction
0

shown in the illustration.

Install the fuel tank breather hose (fuel tank to
m©

canister) with its yellow paint mark facing upward.

Install the canister with its stamped mark facing
OnmOF

upward.
To throttle bodies
To fuel tank
Install the fuel tank breather hose (fuel tank to
canister) with its white paint mark facing outward.
Install the canister purge hose (hose joint to
-

canister) onto the canister so that the end of the

hose is pointing in the direction of the arrow shown.

2-50
 CABLE ROUTING

Air filter case and throttle bodies (top and left side view)

2-51
 CABLE ROUTING

Air filter case

=
ron secondary injector
Fuel hose (fuel rail to fuel rail)
Crankcase breather hose
Fuel hose 2 (secondary injector fuel rail side)
coONOa

Canister purge hose (for California)

Throttle body position sensor
Intake solenoid vacuum hose
Cooling system air bleed hose
. Fuel hose 3 (fuel hose 2 to throttle body)
. Service hose
. Fuel hose 1 (fuel tank to fuel hose 2)
To one-way valve (intake solenoid)
Route the service hose to the under the cooling
system air bleed hose.
Point the ends of the hose clamp to the right.
Position the hose clamp 0O—5 mm (0—0.2 in) from
the end of the hose.

2-52
 CABLE ROUTING

Air cut-off valve (right side view)

2-53
 CABLE ROUTING

Air filter case

Air cut-off valve
Air induction system hose (air filter case to air cut-off
wo

valve)
Cylinder head cover
Air induction system hose (air cut-off valve to reed
on

valve cover)
Cylinder identification sensor
Cylinder identification sensor lead
PN

. Point the end of the clamp to the right. Install the air
induction system hose (air filter case to air cut-off
valve) with its white paint mark facing outward. Make
sure that the clamp is not installed on the flange of the
hose fitting of the air filter case.
When installing the air induction system hose (air
filter case to air cut-off valve), may apply water to the
air induction system hose.
Point the end of the clamp to the left.
W

Point the end of the clamp upward.

OO

Insert the air induction system hose (air cut-off valve

to reed valve cover) until it contacts the reed valve
cover. Make sure that the clamp is not installed on the
flange of the hose fitting of the reed valve cover.
Point the end of the clamp to the right.

2-54
 CABLE ROUTING

Air duct (left and right side view)

2-55
 CABLE ROUTING

Air intake duct valve

oaPonh= Air intake duct
Surge tank
Surge tank hose
One-way valve
Intake solenoid vacuum hose (one-way valve to
intake solenoid)
Intake solenoid vacuum hose (intake solenoid to
air intake duct valve)
Intake solenoid
> ©

Install the surge tank hose onto the surge tank,

making sure that the end of the hose contacts the
tank.
Install the intake solenoid vacuum hoses onto the
intake solenoid, making sure that the end of each
hose contacts the solenoid.
Install the intake solenoid vacuum hose (intake
solenoid to air intake duct valve) up to the bend in
the hose fitting of the air intake duct valve.
Install the surge tank hose with its white paint mark
facing upward.
Position the hose holder 13 mm (0.51 in) or less
from the end of the one-way valve.
Install the surge tank hose onto the one-way valve,
making sure that the end of the hose contacts the
valve.
Install the intake solenoid vacuum hose (one-way
valve to intake solenoid) onto the one-way valve,
making sure that the end of the hose contacts the
valve.
Install the plastic locking tie completely onto the rib
on the air intake duct.
Cut off the excess end of the plastic locking tie to 5
mm (0.2 in) or less.

2-56
 CABLE ROUTING

Radiator (left side view)

2-57
 CABLE ROUTING

Cooling system air bleed hose

=
Poh Thermostat assembly
Hose clamp
Radiator inlet hose
Cylinder
POONGa

Crankcase
Generator cover
Water pump outlet pipe
Radiator outlet hose
Align the white paint mark on the radiator inlet
hose, projection on the radiator pipe, and crimped
section of the hose clamp. Install the radiator inlet
hose up to the center of the projection on the
radiator pipe. After installing the hose clamp, the
end of the radiator inlet hose should cover the
projection on the radiator pipe.
Oval shaped projection on the hose clamp (2
locations)
Align the yellow paint mark on the radiator inlet
hose, projection on the thermostat assembly, and
oval shaped projections on the hose clamp. Install
the radiator inlet hose until it contacts the
projection on the thermostat assembly.
Hose clamp installation details
QOmnmo

2 mm (0.08 in) or more

Installed length: 20 mm (0.79 in)
Make sure not to install the hose clamp on the
raised portion of the hose fitting of the thermostat
assembly.
When installing the thermostat assembly, make
sure that the projection on the thermostat
assembly fits into the slot in the generator cover.
3mm (0.12 in) or more
Installed length
Make sure that the hose clamp is not installed in a
slanted position as shown in the illustration.
Make sure to hook the end of the hose clamp
securely onto the projection on the hose clamp.
(Do not install the hose clamp as shown in the
illustration.)
Install the hose clamp so that both edges are
parallel to each other.
Make sure that the projection on the center of the
hose clamp fits into the cutout in the clamp.
Face the crimped section of the hose clamp to the
left.

2-58
 CABLE ROUTING

Radiator (right side view)

2-59
 CABLE ROUTING

Air induction system hose U. 3 mm (0.12 in) or more

=
Poh Cooling system air bleed hose V. Make sure not to install the hose clamp on the
Radiator raised portion of the hose fitting of the water pump
Radiator outlet hose inlet pipe.
Hose clamp cover W. Make sure that the hose clamp is not installed ina
slanted position as shown in the illustration.
POONGa

Hose clamp
X. Make sure to hook the end of the hose clamp
Water pump inlet pipe
securely onto the projection on the hose clamp.
Water pump outlet pipe (Do not install the hose clamp as shown in the
Thermostat assembly illustration.)
Route the cooling system air bleed hose under the Install the hose clamp so that both edges are
fuel rail. parallel to each other.
Route the cooling system air bleed hose to the
0

outside of the air induction system hose.

Point the ends of the hose clamp to the right. Make
sure not to install the hose clamp on the raised
portion of the hose fitting.
Install the radiator outlet hose onto the radiator
pipe until the end of the hose contacts the
projection on the pipe. Align the white paint mark
on the radiator outlet hose with the projection on
the radiator pipe. Align the white paint mark on the
radiator outlet hose with the outer ribs on the hose
fittings.
Align the yellow paint mark on the radiator outlet
hose, the black paint mark on the water pump inlet
pipe, and the crimped section of the hose clamp.
Insert the radiator outlet hose up to the center of
the white paint mark on the water pump inlet pipe.
Align the white paint mark on the cooling system
air bleed hose with the projection on the
thermostat housing. Install the cooling system air
bleed hose onto the thermostat housing until the
end of the hose contacts the projection on the pipe.
Point the ends of the hose clamp away from the
projection on the thermostat housing and toward
the bolt. Make sure not to install the hose clamp on
the raised portion of the hose fitting.
Hose clamp installation details
ALOT

2 mm (0.08 in) or more

Installed length: 20 mm (0.79 in)
Make sure not to install the hose clamp on the
raised portion of the hose fitting.
Install the hose clamp cover so that the end of the
cover is pointed to the right.
. Position the yellow paint mark on the radiator
outlet hose within the range shown in the
llustration. Install the screw clamp with the screw
head facing to the right.
. Face the fastener of the screw clamp to the right
within the 45° range shown in the illustration.
Detail of the hose fitting portion: Keep a hose
clamp interference of O—1 mm (0—0.04 in) with
respect to the basic diameter of the hose as
shown. The hose clamp interference refers to the
basic external hose diameter and excludes any
bulging at the end of the hose.
Make sure not to install the hose clamp on the
-U

raised portion of the hose fitting.

3mm (0.12 in) or more
4opoO

Installed length
O—1 mm (0—0.04 in)
Make sure that the projection on the center of the
hose clamp fits into the cutout in the clamp.

2-60
 CABLE ROUTING

Muffler (top and left side view)

2-61
 CABLE ROUTING

Exhaust chamber
rPOoamhuh= EXUP valve pulley cover
Muffler
EXUP servo motor
EXUP cable 2
EXUP cable 1
Route EXUP cable 1 and EXUP cable 2 through
the guide. Route EXUP cable 1 above EXUP cable
2. Align the white paint mark on each cable with
the guide.

2-62
 CABLE ROUTING

CCU (top and right side view) (for YZF-R1M)

2-63
 CABLE ROUTING

CCU (Communication Control Unit)

Noaprhonh= GPS unit lead
GPS unit coupler
Wire harness coupler cap
Wire harness coupler (to sub-wire harness)
Yamaha diagnostic tool coupler
CCU (Communication Control Unit) lead (Sub-wire
harness)
Passenger seat cover
O

GPS unit
©

. Rear cover
>=

. Fasten the CCU and CCU bracket with the plastic

locking tie.
Fasten the CCU and CCU bracket with the band.
Ow

Connect the CCU coupler (sub-wire harness) to

the CCU.
Fasten the sub-wire harness to the rear frame with
the clamp. Align the corrugated end of the sub-wire
harness with end of the clamp.
Route the GPS unit lead between the passenger
seat cover and the rear cover.
Route the GPS unit lead as shown in the
illustration.
Route the GPS unit lead to the inside of the vehicle
through the hole in the passenger seat cover.
Fasten the GPS unit lead with the clamp on the
passenger seat cover.

2-64
 CABLE ROUTING

2-65
 PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE... ooo... ccc eec ccc cnsee cee eseceseeeessuneesseesseesnee GU

INTRODUCTION.. 3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM.. ba teseeeeeseeeeeeee OT
GENERAL MAINTENANCE AND LUBRICATION CHART. seseseere Onl
CHECKING THE VEHICLE USING THE YAMAHA DIAGNOSTIC
TOOL... Be ncphandindasivwvaniwts aides seed vandie SoA
CHECKING THE FUEL LINE (Primary injector)... jebeuatwesaipenwasatvagucessesisa or
CHECKING THE FUEL LINE (Secondary injector) ... ebeeeaesseaeeseessesseeee OMA
CHECKING THE SPARK PLUGS coccssscssccsscssssssssiccssssssssisssvesesessessssssseeseees 35
ADJUSTING THE VALVE CLEARANCE ....... cece eee eee eeeeseeeeeeees OO
CHECKING THE ENGINE IDLING SPEED .......00.00. eee ceeeeeeeeeeee OF
SYNCHRONIZING THE THROTTLE BODIES............ cece eee OP"
CHECKING THE THROTTLE BODY JOINTS “soesssssstttssteseessisssiseessssese 3 11
CHECKING THE CRANKCASE BREATHER HOSE ...........0......... G971
CHECKING THE EXHAUST SYSTEM... be eeseeeseeessseeeeeesesseeseeee OUT
CHECKING THE CANISTER (for California oniy).. seaceasneccaneeteceeesessanee7d I
CHECKING THE AIR INDUCTION SYSTEM... scocssssssisteassesesssssseeeee B42
REPLACING THE AIR FILTER ELEMENT “scssssssstisisessssssssssssesssssesesssssee 42
ADJUSTING THE CLUTCH LEVER FREE PLAY ..................... cee O12
CHECKING THE BRAKE OPERATION .......... cece ceecee cee eeeeeeeeeeeeeee OTTO
CHECKING THE BRAKE FLUID LEVEL................. oe eecceeeeeeeeeeeeeeeee OIG
ADJUSTING THE FRONT DISC BRAKE............c eee eeeee eee O14
CHECKING THE FRONT BRAKE PADG ....................ccccceeceseeeeeeeeseeeeeeee OIA
ADJUSTING THE REAR DISC BRAKE ............ cece eteeeeeeeeeeee OIA
CHECKING THE REAR BRAKE PADS ............. 0... ccccc cece ceeeee esses eeeeeeeeee OTTD
CHECKING THE FRONT BRAKE HOSES ............c cece ceee eee eeeeee eee OTD
CHECKING THE REAR BRAKE HOSE... j ccuautuwdavsaveessdeeueqd= bo)
BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS) er 6
CHECKING THE WHEELS.. sah egnah opdhowyswna ews ey naspwussineseKsweashoreseesan eo
CHECKING THE TIRES... siausddiceyevieuaayanstassseeessadsieaseieeeaisanc
CHECKING THE WHEEL BEARINGS... ba eeseeeeacessesesseeeeeeecssessesenees O71
CHECKING THE SWINGARM OPERATION... pruvadhtasansdesavsanvess seuvesnddsiseaasae =O
LUBRICATING THE SWINGARM PIVOT ....................c:cccsceeeeeeeeeeeeeeeeees OT 18
DRIVE CHAIN SLACK... bebe eeeceeesecaeeeeessuuesseseessssseeessseeeesseeees On 1G
LUBRICATING THE DRIVE CHAIN... (eiavivedsiviidnsdaue be
CHECKING AND ADJUSTING THE STEERING HEAD eedeessaeeeeeseeeeeseeee OIG
LUBRICATING THE STEERING HEAD..............0....ccc cc ceecccceeeeeeeeeeeeeee eens OP2O
CHECKING THE STEERING DAMPER....................... cc cesceeceeeeceesseeeeeees O20
CHECKING THE CHASSIS FASTENERS ............ ce ceeeee cess eeeeeees OULU
LUBRICATING THE BRAKE LEVER ....0....ccc0cccscciscrccscsscnsereccassesscterresennee Oe
LUBRICATING THE CLUTCH LEVER... cece eee teeee ee eeeee OO
LUBRICATING THE PEDAL ....0... 00... cece cecc ccc eeeceeeeeceeseeeecesesseesseceessseees O72
CHECKING THE SIDESTAND............ 0... ccc cee ceensseeseceeeneeeceensneesaaeeeceees OUT
LUBRICATING THE SIDESTAND............. 00. ccccceeeceeceeeeceeeeeeeeeeeeeeeeeee O72
CHECKING THE SIDESTAND SWITCH... cee ceeee cesses ee eeeee OPT
CHECKING THE FRONT FORK.. is Sig Whvatudias tesstenace OTe |
ADJUSTING THE FRONT FORK LEGS (for YZF-Ri).. be edeeesaeeeceseeeeeenees O72
ADJUSTING THE PRELOAD OF THE FRONT FORK LEGS
(for YZF-R1M) .. 3-23
ADJUSTING THE DAMPING FORCE OF THE FRONT FORK LEGS |
AND REAR SHOCK ABSORBER ASSEMBLY (for YZF-R1M)............. . 3-23
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 3-25
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
(for YZF-R1)... 3°25
ADJUSTING THE PRELOAD OF THE REAR SHOCK ABSORBER
ASSEMBLY (for YZF-R1M)... weve O27
CHECKING THE CONNECTING ARM AND RELAY ARM.. tesseeeee 720
CHECKING THE ENGINE OIL LEVEL... wees 3728
CHANGING THE ENGINE OIL .. vanes O29
MEASURING THE ENGINE OIL PRESSURE..
CHECKING THE COOLANT LEVEL. cscssssssssssessssssssesssesssssssessesssssssssssseee 3-31
CHECKING THE COOLING SYSTEM....0000. oe cece eee e cece eeeeeeeeeeee .3-32
CHANGING THE COOLANT... sannee STO
ADJUSTING THE EXUP CABLES.. vanes O74
CHECKING THE FRONT BRAKE LIGHT SWITCH... pebeawitanesdcuasceseusdoe
ADJUSTING THE REAR BRAKE LIGHT SWITCH ..........000ee 3-35
CHECKING AND LUBRICATING THE CABLES ..........0... eee eee .3-35
CHECKING THE THROTTLE GRIP... soeeee OTD
CHECKING AND CHARGING THE BATTERY... wee OOD
CHECKING THE FUSES... panes OSD
ADJUSTING THE HEADLIGHT BEAMS... ... 3°36
 PERIODIC MAINTENANCE

EAS2o022

PERIODIC MAINTENANCE
EASao00e2

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.
EASSa0614

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

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

INITIAL ODOMETER READINGS

. - | 8000 mi | 12000 mi | 16000 mi | 20000 mi

No. ITEM ROUTINE (1000 im) (7000 Km) | (13000 | (19000 | (25000 | (31000
ar or km) km) km) km)
1 month | 6 months ad ae _ sé
12 months | 18 months | 24 months |30 months

* Check fuel hoses for cracks or | |

1 Fuel line damage. v v ‘ Vv ‘
* Replace if necessary.
* Check condition. my my my
2 Spark plugs * Adjust gap and clean.
* Replace. v V
3 Valve clearance
* Check and adjust valve clear-
ance when engine is cold. Every 26600 mi (42000 km)

* Check breather hose for

4 it nit shat cracks or damage. V v v v V
y * Replace if necessary.
5|*| Fuel injection * Adjust synchronization. V v v V V V
* Check for leakage.
« Tighten if necessary.
6|*| Exhaust system |, Replace gasket(s) it neces- ‘ v ‘ v ‘
sary.
Evaporative emis-
3 sion control sys- . emg system for J J

oh yor California | , Replace if necessary.

* Check the air cut-off valve,

‘ Air induction sys- oe valve, and hose for dam- J J
tem * Replace any damaged parts if
necessary.

EASSO615

GENERAL MAINTENANCE AND LUBRICATION CHART

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

INITIAL ODOMETER READINGS

. - | 8000 mi | 12000 mi | 16000 mi | 20000 mi

No. ITEM ROUTINE 600
ee
mi _ | (7000
4000 km)
mi | (13000
km)
| (19000
km)
| (25000
km)
| (31000
km)
or or or or
1 month | 6 months | 45 months |18 months |24 months |30 months
, , : * Perform dynamic inspection
1|* peoueeee at using Yamaha diagnostic tool. v V Vv v v V
*« Check the error codes.
2|"| Airfilterelement | * Replace. Every 24000 mi (37000 km)
te * Check operation.
3 Gluten * Adjust or replace cable. V " V V V 7
« Check operation, fluid level,
: and for fluid leakage.
. Front brake * Replace brake pads if neces- V V V V V V
sary.
« Check operation, fluid level,
r and for fluid leakage.
Hear brake * Replace brake pads if neces- V V v V V V
sary.
*« Check for cracks or damage.
* Check for correct routing and V v V V V
6|*| Brake hoses clamping.
* Replace. Every 4 years
7| "| Brake fluid * Change. Every 2 years
* Check runout and for dam-
8|*| Wheels age. V Vv v v V
* Replace if necessary.
« Check tread depth and for
damage.
9|*| Tires * Replace if necessary. V Vv v Vv V
« Check air pressure.
* Correct if necessary.
* Check bearings for smooth
10| * | Wheel bearings operation. V v v v V
* Replace if necessary.
* Check operation and for ex- y ny y my \
, | Swingarm pivot cessive play.
"| "| bearings * Moderately repack with lithi-
um-soap-based grease.
.
Every 32000 mi (50000 km)

« Check chain slack, alignment

and condition. «diy i
12 Drive chain * Adjust and lubricate chain Every 500 mi (800 Se ein al eee, nding in the
with a special O-ring chain lu- g
bricant thoroughly.
« Check bearing assemblies for
: ; looseness. V V v V V \
13| “| Steering bearings Mod ) cwith lh
* um-soap-based
Moderately repackgrease.
with lithi- Every 16000 mi , (25000 km)

14|*| Steering damper | ° wae and for oll V v V V y

* Check all chassis fitting and
15| *| Chassis fasteners | __ fasteners. V VJ V V V
* Correct if necessary.

16 ae lever pivot |, Apply silicone grease lightly. V Vv v v y

Brake pedal pivot | * Apply lithium-soap-based
17) | shaft grease lightly. N V V V \
Clutch lever pivot | * Apply lithium-soap-based
16 shaft grease lightly. V V V V \
Shift pedal pivot | * Apply molybdenum disulfide
19) | shaft grease lightly. V V V V \
* Check operation.
20| | Sidestand pivot * Apply lithium-soap-based V Vv v v y
grease lightly.
 PERIODIC MAINTENANCE

INITIAL ODOMETER READINGS

No. ITEM ROUTINE 600 mi | 2000 mi

(1000 km) | (7000 km)
(13000
km
"19000"
km
"(25000
k
“(31000
k !
af or OE on oe ty
1 month | 6 months | 45 months |18 months |24 months |30 months
«| @Sidestand switch
21| *| . * Check operation and replace
if necessary. v 1| Vv v Vv y

* Check operation and for oil

22| * | Front fork leakage. 1 v ‘ v V
* Replace if necessary.
* Check operation and for oil |
23) * eee sorber leakage. ‘ v v v y
y * Replace if necessary.
» | Rear suspension | * Check operation.
24 link pivots * Correct i necessary. V V
.
25| | Engine oil' * Change (warm engine before
draining). v ‘ Vv v v y

26 » | cartridge
Engine oil filter
* Replace. v Vv v
* Check hoses for cracks or | J J J \
damage. N
27|*| Cooling system | « Replace if necessary.
* Change coolant. V
28| * | EXUP system
y anos
play andCREpulley
rsIOn:position.
Come Nee v Every ry 12000 mi (19000 km)
29] * » || Front
prake and rear
switches * Check operation. v \ v ‘ v \
* Apply Yamaha cable lubricant |
30) *| Control cables or other suitable cable lubri- v V v V v 1
cant thoroughly.
* Check operation. | ! |
31| *| Throttle grip * Lubricate throttle grip housing \ v ‘ v \
tube guides.
. | Lights, signals * Check operation.
82) "| and switches « Adjust headlight beam. V > V V V v

TIP
e Air filter
¢ This model’s air filter uses a disposable oil-coated paper element. This element cannot be cleaned
with compressed air, doing so will only damage tt.
¢ The air filter element needs to be replaced more frequently when riding in unusually wet or dusty
areas.
e Hydraulic brake service
¢ Regularly check the front and rear brake fluid levels. Replenish if necessary.
¢ Every two years replace the rear brake master cylinder, the internal components of the front brake
master cylinder, and the brake calipers, and change the brake fluid.
¢ Replace the brake hoses every four years or sooner if cracked, damaged, or if any section of the
stainless steel brake hose has turned black.
 PERIODIC MAINTENANCE

EASa2024 EAS30619

CHECKING THE VEHICLE USING THE CHECKING THE FUEL LINE (Primary
YAMAHA DIAGNOSTIC TOOL injector)
Use the Yamaha diagnostic tool and check the The following procedure applies to all of the fuel,
vehicle according to the following procedure. drain and breather hoses.
1. Remove: 1. Remove:
e Rider seat e Rider seat
¢ Battery cover Refer to “GENERAL CHASSIS (1)” on page
Refer to “GENERAL CHASSIS (1)” on page 4-1.
4-1. e Fuel tank
2. Remove the protective cap, and then connect Refer to “FUEL TANK” on page 7-1.
the Yamaha diagnostic tool to the coupler. 2. Check:
¢ Fuel hose “1”
: Yamaha diagnostic tool USB (US) e Fuel tank drain hose “2”
ge 90890-03269 ¢ Fuel tank breather hose “3”
Yamaha diagnostic tool (A/l)
Cracks/damage —> Replace.
90890-03264
Loose connection — Connect properly.
ECA14940

TIP NOTICE
e Yamaha diagnostic tool (A/l) (90890-03264) in- Make sure the fuel tank breather hose is rout-
cludes YDT sub harness (6P) (90890-03266). ed correctly.
e If you already have Yamaha diagnostic tool (A/
|) (90890-03262), YDT sub harness (6P) TIP
(90890-03266) is separately required. Before removing the fuel hoses, place a few
rags in the area under where it will be removed.
Refer to “YDT” on page 9-2.
3. Check:
* DTC
TIP
Use the “Diagnosis of malfunction” function of
the Yamaha diagnostic tool to check the DTC.
For information about using the Yamaha diag-
nostic tool, refer to the operation manual that is
included with the tool.
DTC number is displayed — Check and re-
pair the probable cause of the malfunction.
3. Install:
Refer to “SELF-DIAGNOSTIC FUNCTION
e Fuel tank
AND DIAGNOSTIC CODE TABLE” on page
Refer to “FUEL TANK” on page 7-1.
9-32.
4 . Perform: e Rider seat
Refer to “GENERAL CHASSIS (1)” on page
¢« Dynamic inspection
4-1.
TIP
Use the “Dynamic inspection” function of the EAS31633

CHECKING THE FUEL LINE (Secondary

Yamaha diagnostic tool version 3.0 and after to
injector)
perform the dynamic inspection. For information
1. Remove:
about using the Yamaha diagnostic tool, refer to
e Rider seat
the operation manual that is included with the
Refer to “GENERAL CHASSIS (1)” on page
tool.
4-1.
5. Install: ¢ Fuel tank cover
¢ Rider seat e Fuel tank
¢ Battery cover Refer to “FUEL TANK” on page 7-1.
Refer to “GENERAL CHASSIS (1)” on page
4-1.
 PERIODIC MAINTENANCE

a
2. Check:
¢ Fuel hose “1” Manufacturer/model
Cracks/damage —> Replace. NGK/LMARQE-J
Loose connection — Connect properly.
4. Check:
TIP ¢ Electrode “1”
Before removing the fuel hose, place a few rags Damage/wear — Replace the spark plug.
in the area under where it will be removed. ¢ Insulator “2”
Abnormal color + Replace the spark plug.
Normal color is medium-to-light tan.
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.

Spark plug gap

3. Install: 0.6—0.7 mm (0.024—0.028 in)
¢ Fuel tank
Refer to “FUEL TANK” on page 7-1.
¢ Rider seat
Refer to “GENERAL CHASSIS (1)” on page
4-1.
EASSa0620

CHECKING THE SPARK PLUGS

The following procedure applies to all of the
spark plugs.
1. Remove: GO088880
¢ Rider seat
7. Install:
Refer to “GENERAL CHASSIS (1)” on page
e Spark plugs
4-1.
e Ignition coils
¢ Fuel tank
Refer to “FUEL TANK” on page 7-1. Spark plug
¢ Air filter case 13 N-m (1.3 kgf-m, 9.6 Ib-ft)
Refer to “AIR FILTER CASE” on page 7-5. Spark plug (new)
e Air cut-off valve 18 N-m (1.8 kgf-m, 13 Ib-ft)
Refer to “AIR INDUCTION SYSTEM” on
page 7-20. TIP
2. Remove: * Before installing the spark plug, clean the
¢ Ignition coils spark plug and gasket surface.
¢ Spark plugs ¢ If the spark plug is a new one, tighten it to 18
ECA13320
N-m (1.8 kgf-m, 13 lb-ft).
NOTICE
Before removing the spark plugs, blow away 8. Install:
any dirt accumulated in the spark plug wells e Air cut-off valve
with compressed air to prevent it from falling Refer to “AIR INDUCTION SYSTEM?” on
into the cylinders. page 7-20.
e Air filter case
3. Check:
Refer to “AIR FILTER CASE” on page 7-5.
¢ Spark plug type
e Fuel tank
Incorrect — Change.
Refer to “FUEL TANK” on page 7-1.
 PERIODIC MAINTENANCE

e Rider seat 4. Measure:

Refer to “GENERAL CHASSIS (1)” on page e Valve clearance

-
4-1. Out of specification — Adjust.
EASs0622
Valve clearance (cold)
ADJUSTING THE VALVE CLEARANCE Intake
The following procedure applies to all of the 0.09-0.17 mm (0.0035—0.0067 in)
valves. Exhaust
TIP 0.18—0.23 mm (0.0071—0.0091 in)
e Valve clearance adjustment should be made
on acold engine, at room temperature. a. Turn the crankshaft counterclockwise.
e When the valve clearance is to be measured or b. When piston #1 is at TDC on the compres-
adjusted, the piston must be at top dead center sion stroke, align the TDC mark “a” on the
(TDC) on the compression stroke. generator rotor with the generator rotor
cover slot “b”.
1. Remove:
¢ Rider seat
Refer to “GENERAL CHASSIS (1)” on page
4-1.
¢ Front panel cover
Refer to “GENERAL CHASSIS (3)” on page
4-9.
* Front side cowling
Refer to “GENERAL CHASSIS (5)” on page
4-16.
¢ Side cover
* Front side cowling inner panel TIP
Refer to “GENERAL CHASSIS (6)” on page TDC on the compression stroke can be found
4-23. when the camshaft lobes are turned away from
* Side cover bracket each other.
Refer to “GENERAL CHASSIS (8)” on page
c. Measure the valve clearance #1 witha
4-32.
thickness gauge.
¢ Electrical components tray
TIP
Refer to “GENERAL CHASSIS (9)” on page
4-34. Measure the valve clearance between the cam
* Fuel tank lobe and rocker arm “c’”.
Refer to “FUEL TANK” on page 7-1.
¢ Air filter case
Refer to “AIR FILTER CASE” on page 7-5.
e Air cut-off valve
J Thickness gauge
90890-03268
Feeler gauge set
Refer to “AIR INDUCTION SYSTEM” on YU-26900-9
page 7-20.
¢ Radiator
Refer to “RADIATOR” on page 6-3.
2. Remove:
* Ignition coils
¢ Spark plugs
¢ Cylinder head cover
¢ Cylinder head cover gasket
Refer to “CAMSHAFTS’” on page 5-18.
3. Remove:
¢ Timing mark accessing bolt
e Crankshaft end cover
Refer to “GENERATOR?” on page 5-44.
 PERIODIC MAINTENANCE

TIP
e lf the valve clearance is incorrect, record the
measured reading.
¢ Measure the valve clearance in the following
sequence.

Valve clearance measuring sequence

Cylinder #1 — #3 — #2 — #4

‘f i. Measure the valve clearance #2 witha

thickness gauge.

POY
Thickness gauge
90890-03268
Feeler gauge set
YU-26900-9
QS j.. Turn the crankshaft counterclockwise.
GO8BES3
k. When piston #4 is at TDC on the compres-
A. Front sion stroke, align the TDC mark “f’ on the
generator rotor with the generator rotor
d. Turn the crankshaft counterclockwise.
e. When piston #3 is at TDC on the compres- cover slot “b”.
sion stroke, align the TDC mark “d” on the
generator rotor with the generator rotor
cover slot “b”.

|. Measure the valve clearance #4 witha

thickness gauge.

Thickness gauge
f. Measure the valve clearance #3 witha 90890-03268
thickness gauge. Feeler gauge set
YU-26900-9
KL Thickness gauge
f 90890-03268 5. Remove:
Feeler gauge set
¢ Camshaft
YU-26900-9
TIP
g. Turn the crankshaft counterclockwise. ¢ Refer to “CAMSHAFTS” on page 5-18.
h. When piston #2 is at TDC on the compres- ¢ When removing the timing chain and cam-
sion stroke, align the TDC mark “e” on the shafts, fasten the timing chain with a wire to re-
generator rotor with the generator rotor trieve it if it falls into the crankcase.
cover slot “b”.
6. Adjust:
e Valve clearance
a. Pull the rocker arm “1” up, and then re-
move the valve pad “2”.
 PERIODIC MAINTENANCE

d. Calculate the sum of the values obtained

in steps (b) and (c) to determine the re-
quired valve pad thickness and the valve
pad number.
Example:
1.60 mm (0.063 in) + 0.03 mm (0.001 in) =
1.63 mm (0.064 in)
The valve pad number is A63.
e. Round off the valve pad number according
to the following table, and then select the
TIP suitable valve pad.
e Cover the timing chain opening with a rag to Last digit Rounded value
prevent the valve pad from falling into the 0,1,2 0
crankcase. 3, 4, 5,6 5
¢ Make a note of the position of each valve pad
7,8,9 10
so that they can be installed in the correct
place.
TIP
b. Calculate the difference between the Refer to the following table for the available
specified valve clearance and the mea- valve pads.
sured valve clearance.
Example: Valve pad range No. A60—-A99, BOO—B40
Specified valve clearance = 0.09-0.17 Valve pad thickness
1.60—2.40 mm
(0.0630-0.0944 in)
mm (0.004—0.007 in)
Measured valve clearance = 0.20 mm 1/7 thicknesses in 0.05
(0.008 in) Available valve pads mm (0.002 in) incre-
0.20 mm (0.008 in) - 0.17 mm (0.007 in) = ments

0.03 mm (0.001 in)

Example:
c. Check the thickness of the current valve
Valve pad number = A63
pad. Rounded value = A65
TIP New valve pad number = A65
e The letter and number “a” marked on the valve f. Install the new valve pad “3” and then,
pad indicate the valve pad thickness. push the rocker arm “1” down.
e The letter A marked on the valve pad indicates TIP
1 mm (0.04 in), while B indicates 2 mm (0.08
¢ Lubricate the valve pad with molybdenum di-
in).
sulfide oil.
e The number marked on the valve pad indicates ¢ Install the valve pad in the correct place.
hundredths of millimeters.
Example:
lf the valve pad is marked “A60”, the pad
thickness is 1.60 mm (0.063 in).
lf the valve pad is marked “B30”, the pad
thickness is 2.30 mm (0.091 in).

g. Install the exhaust and intake camshafts,

timing chain and camshaft caps.

G088886
 PERIODIC MAINTENANCE

%
Refer to “CHECKING AND CLEANING THE
Camshaft cap bolt THROTTLE BODIES” on page 7-15.
8 N-m (0.8 kgf-m, 5.9 Ib-ft) a. Connect the Yamaha diagnostic tool.
Camshaft cap bolt (new) Use the diagnostic code number “67”.
10 N-m (1.0 kgf-m, 7.4 Ib-ft)
Refer to “SELF-DIAGNOSTIC FUNC-
TION AND DIAGNOSTIC CODE TABLE”
TIP
on page 9-32.
e Refer to “CAMSHAFTS’” on page 5-18. Check the ISC (Idle Speed Control) lean-
e Lubricate the camshaft lobes and camshaft ing value.
journals.
e First, install the exhaust camshaft. EASSOTS?

¢ Align the camshaft sprocket marks with the cyl- SYNCHRONIZING THE THROTTLE BODIES
inder head surface. TIP
If the camshaft cap bolt is a new one, it is not Before synchronizing the throttle bodies, check
necessary to apply engine oil onto the mating the following items:
surface and threads of the bolt. * Valve clearance
e If the camshaft cap bolt is a new one, tighten it ¢ Spark plugs
to 10 N-m (1.0 kgof-m, 7.4 lb-ft). e Air filter element
e Turn the crankshaft counterclockwise several ¢ Throttle body joints
full turns to seat the parts. ¢ Fuel hose
¢« Exhaust system
h. Measure the valve clearance again.
¢ Breather hoses
i. Ifthe valve clearance is still out of specifi-
cation, repeat all of the valve clearance
adjustment steps until the specified clear- Checking the throttle body synchronization
ance is obtained. 1. Stand the vehicle on a level surface.
7. Install: TIP
¢ All removed parts Place the vehicle on a maintenance stand.
TIP
2. Remove:
For installation, reverse the removal procedure. e Rider seat
Refer to “GENERAL CHASSIS (1)” on page
EASSaI017
4-1.
CHECKING THE ENGINE IDLING SPEED
e Fuel tank
TIP
Refer to “FUEL TANK” on page 7-1.
Prior to checking the engine idling speed, the e Air filter case
throttle body synchronization should be adjusted Refer to “AIR FILTER CASE” on page 7-5.
properly, the air filter element should be clean, 3. Remove:
and the engine should have adequate compres- e Caps “1”
sion. e Service hose cap “2”
1. Start the engine and let it warm up for several
minutes.
2. Check:
¢ Engine idling speed
Out of specification — Go to next step.

oy
3. Check:
Engine idling speed
1200—1400 r/min
|

¢ ISC (Idle Speed Control) learning value 4. Install:

“00” or “O01” — Check the intake system. e Vacuum gauge “1”
“02” — Clean the throttle bodies.
 PERIODIC MAINTENANCE

ECA21300

Vacuum gauge NOTICE

90890-03094 Do not turn the bypass air screw (white paint
Vacuummate mark) of the throttle body that is the stan-
YU-44456 dard. Otherwise, the engine may run roughly
at idle and the throttle bodies may not oper-
ate properly.
TIP
¢ Turn the bypass air screw using the carburetor
angle driver.
eget
air —
Teva e After each step, rev the engine two or three
a aN times, each time for less than a second, and
Ne: check the synchronization again.
¢ If a bypass air screw was removed, turn the
screw in fully and be sure to synchronize the
el

5. Install: throttle bodies.

e Air filter case * If the throttle body synchronization can not be
Refer to “AIR FILTER CASE” on page 7-5. adjusted using the bypass air screw, clean or
¢ Fuel tank replace the throttle bodies.
Refer to “FUEL TANK” on page 7-1. ¢ The difference in vacuum pressure between
6. Check: the throttle bodies should not exceed 1.33 kPa
¢ Throttle body synchronization (10 mmHg).
a. Start the engine, warm it up for several
minutes, and then let it run at the specified
4<s5| Carburetor angle driver 2
engine idling speed.

a
90890-03173
Engine idling speed
1200-1400 r/min

b. Check the vacuum pressure.

a Difference in vacuum pressure

between the cylinders
0 kPa—1.3 kPa (0 mmHg—10
mmHg, 0 inHg—0.4 inHg)
iy i, fay 7
ihe eo
lf out of specification — Adjust the throttle —=s
— ee

body synchronization. 2. Stop the engine and remove the measuring

equipment.
Adjusting the throttle body synchronization 3. Install:
1. Adjust: e Caps
¢ Throttle body synchronization e Service hose cap
a. Start the engine, warm it up for several 4. Install:
minutes, and then let it run at the specified
e Air filter case

ey
engine idling speed.
Refer to “AIR FILTER CASE” on page 7-5.
Engine idling speed e Fuel tank
1200-1400 r/min Refer to “FUEL TANK” on page 7-1.
e Rider seat
b. Using the throttle body that has the bypass Refer to “GENERAL CHASSIS (1)” on page
air screw “1” with a white paint mark as the 4-1.
standard, adjust the other throttle bodies
by turning its bypass air screw in or out.

3-10
 PERIODIC MAINTENANCE

EAS31316
e Exhaust chamber “2”
CHECKING THE THROTTLE BODY JOINTS
e Muffler “S”
1. Remove:
Cracks/damage —> Replace.
¢ Throttle bodies
¢ Gasket “4”
Refer to “THROTTLE BODIES” on page
Exhaust gas leaks —> Replace.
7-11.
2. Check:
2. Check:
Tightening torque
¢ Throttle body joints
e Exhaust pipe nut “5”
Cracks/damage —> Replace.
e Exhaust pipe joint bolt “6”
Refer to “THROTTLE BODIES” on page
e Exhaust chamber bolt “7”
7-11.
e Muffler bolt “8”
3. Install:
¢ Muffler joint bolt “9”
¢ Throttle bodies
Refer to “THROTTLE BODIES” on page \ Exhaust pipe nut
7-11.
EAS30800
oy 20 N-m (2.0 kgf-m, 15
Exhaust pipe joint bolt
Ib-ft)

CHECKING THE CRANKCASE BREATHER 20 N-m (2.0 kgf-m, 15 Ib-ft)

HOSE Exhaust chamber bolt
20 N-m (2.0 kgf-m, 15 Ib-ft)
1. Remove:
Muffler bolt
¢ Rider seat
20 N-m (2.0 kgf-m, 15 Ib-ft)
Refer to “GENERAL CHASSIS (1)” on page Muffler joint bolt
4-1. 10 N-m (1.0 kgf-m, 7.4 lb-ft)
¢ Fuel tank
Refer to “FUEL TANK” on page 7-1.
2. Check:
¢ Crankcase breather hose “1”
Cracks/damage — Replace.
Loose connection —> Connect properly.
ECA13450

NOTICE
Make sure the crankcase breather hose is
routed correctly.

3. Install:
e Fuel tank FAS S0626

CHECKING THE CANISTER (for California

Refer to “FUEL TANK” on page 7-1.
only)
e Rider seat
1. Remove:
Refer to “GENERAL CHASSIS (1)” on page
e Rider seat
4-1.
Refer to “GENERAL CHASSIS (1)” on page
4-1.
CHECKING THE EXHAUST SYSTEM e Fuel tank
1. Check: Refer to “FUEL TANK” on page 7-1.
¢ Exhaust pipe “1”

3-11
 PERIODIC MAINTENANCE

2. Check: 4. Install:
¢ Canister “1” e Air filter element
¢ Canister purge hose e Upper air filter case
¢ Fuel tank breather hose EC AZOT 10

Cracks/damage —> Replace. NOTICE

Loose connection — Connect properly. Never operate the engine without the air filter
TIP element installed. Unfiltered air will cause
rapid wear of engine parts and may damage
Make sure that the canister breather “a” is not
the engine. Operating the engine without the
blocked, and if necessary, clean it.
air filter element will also affect throttle body
synchronization, leading to poor engine per-
formance and possible overheating.
TIP
¢ Align projections “a” of the air filter element to
the slots “b” of the air filter case and install.
¢ When installing the air filter element into the air
filter case, make sure that the sealing surfaces
are aligned to prevent any air leaks.

3. Install:
¢ Fuel tank
Refer to “FUEL TANK” on page 7-1.
e Rider seat
Refer to “GENERAL CHASSIS (1)” on page
4-1.
EASSOB27

CHECKING THE AIR INDUCTION SYSTEM

Refer to “AIR INDUCTION SYSTEM” on page
7-20.
5. Install:
EASS0628 e Fuel tank
REPLACING THE AIR FILTER ELEMENT Refer to “FUEL TANK” on page 7-1.
1. Remove: e Rider seat
e Rider seat Refer to “GENERAL CHASSIS (1)” on page
Refer to “GENERAL CHASSIS (1)” on page 4-1.
4-1.
* Fuel tank
ADJUSTING THE CLUTCH LEVER FREE
Refer to “FUEL TANK” on page 7-1. PLAY
2. Remove:
1. Check:
e Upper air filter case e Clutch lever free play “a”
* Air filter element
Out of specification — Adjust.
Refer to “AIR FILTER CASE” on page 7-5.
3. Check: Clutch lever free play
* Air filter element 10.0—15.0 mm (0.39-0.59 in)
* Air filter seal
Damage — Replace.
TIP
¢ Replace the air filter element every 40000 km
(24000 mi) of operation.
e The air filter needs more frequent service if you
are riding in unusually wet or dusty areas.

3-12
 PERIODIC MAINTENANCE

e. Install the front side cowling (right).

Refer to “GENERAL CHASSIS (5)” on
page 4-16.
EASS0801

CHECKING THE BRAKE OPERATION

1. Check:
¢ Brake operation
Brake not working properly — Check the
G088887
brake system.
Refer to “FRONT BRAKE” on page 4-52 and
2. Adjust: “REAR BRAKE?” on page 4-63.
¢ Clutch lever free play
TIP
Handlebar side Drive on the dry road, operate the front and rear
a. Turn the adjusting bolt “1” until the speci- brakes separately and check to see if the brakes
fied clutch lever free play is obtained. are operating properly.

EAS #0632

CHECKING THE BRAKE FLUID LEVEL

1. Stand the vehicle on a level surface.
TIP
* Place the vehicle on a maintenance stand.
¢ Make sure the vehicle is upright.
2. Check:
G088888
e Brake fluid level
Below the minimum level mark — Add the
TIP specified brake fluid to the proper level.
lf the specified clutch lever free play cannot be
obtained on the handlebar side of the cable, use Front brake
the adjusting nut on the engine side. Specified brake fluid
DOT 4
Rear brake
Engine side Specified brake fluid
a. Remove the front side cowling (right). DOT 4
Refer to “GENERAL CHASSIS (5)” on
EW A13090
page 4-16.
b. Loosen the locknut “1”.
c. Turn the adjusting nut “2” until the speci- ¢ Use only the designated brake fluid. Other
fied clutch lever free play is obtained. brake fluids may cause the rubber seals to
d. Tighten the locknut “1”. deteriorate, causing leakage and poor
brake performance.
\ Clutch cable locknut * Refill with the same type of brake fluid that
& 7 N-m (0.7 kgf-m, 5.2 Ib-ft) 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.

3-13
 PERIODIC MAINTENANCE

ECA13540
erably reduce brake performance resulting
NOTICE in loss of control and possibly cause an ac-
Brake fluid may damage painted surfaces cident. Therefore, check and if necessary,
and plastic parts. Therefore, always clean up bleed the brake system.
any spilt brake fluid immediately. ECA13490

TIP NOTICE
In order to ensure a correct reading of the brake After adjusting the brake lever position,
fluid level, make sure the top of the brake fluid make sure there is no brake drag.
reservoir is horizontal.
EFAS 30633

CHECKING THE FRONT BRAKE PADS

EASS0630

ADJUSTING THE FRONT DISC BRAKE The following procedure applies to all of the
1. Adjust: brake pads.
¢ Brake lever position 1. Operate the brake.
(distance “a” from the throttle grip to the brake 2. Check:
lever) e Front brake pad
Wear indicators “a” almost touch the brake
disc — Replace the brake pads as a set.
Refer to “FRONT BRAKE” on page 4-52.

-
Ay Ke ‘
i) a x‘4
hae
‘
hil ae‘A, ay iei?) 1)
i % ns% wen 4
ALKyy I Kh LAY
i

G088889
hsbt
ie

. Push the brake lever forward.

. Turn the adjusting dial “1” until the brake
lever is in the desired position.
. Align the appropriate setting on the adjust- FAS S0631

ADJUSTING THE REAR DISC BRAKE

ing dial with the mark “a” on the brake le-
1. Adjust:
ver.
¢ Brake pedal position
a. Loosen the locknut “1”.
b. Turn the adjusting bolt “2” until the speci-
fied brake pedal position is obtained.
EWA18830

After adjusting the brake pedal position,

check that the end of the adjusting bolt “a” is
visible through the hole “b”.
G088890 c. Tighten the locknut “1” to specification.
EWA17050

Rear brake master cylinder lock-

e After adjusting the brake lever position, nut
16 N-m (1.6 kgf-m, 12 Ib-ft)
make sure the pin on the brake lever holder
is firmly inserted in the hole in the adjusting EWA17030

dial.
¢ A soft or spongy feeling in the brake lever A soft or spongy feeling in the brake pedal
can indicate the presence of air in the brake can indicate the presence of air in the brake
system. Before the vehicle is operated, the system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will consid-

3-14
 PERIODIC MAINTENANCE

air must be removed by bleeding the brake 2. Check:

system. Air in the brake system will consid- ¢ Brake hose surface
erably reduce braking performance. Partly blackened surface on the brake hose
EOA13510 — Replace.
NOTICE 3. Check:
After adjusting the brake pedal position, * Brake hose holder *2"
make sure there is no brake drag. Loose — Tighten the holder bolt.
~ \Y
pS i 1

1 ys
a aS 2

ass 4. Hold the vehicle upright and apply the brake

2. Adjust: several times.
¢ Rear brake light switch 5. Check:
Refer to “ADJUSTING THE REAR BRAKE ¢ Brake hose
LIGHT SWITCH” on page 3-35. Brake fluid leakage — Replace the damaged
hose.
CHECKING THE REAR BRAKE PADS Refer to “FRONT BRAKE” on page 4-52.
The following procedure applies to all of the FAS30636
brake pads. CHECKING THE REAR BRAKE HOSE
1. Operate the brake. 1. Check:
2. Check: e Brake hose “1”
e Rear brake pad Cracks/damage/wear —> Replace.
Wear indicator grooves “a” almost disap- 2. Check:
peared — Replace the brake pads as a set. ¢ Brake hose holder “2”
Refer to “REAR BRAKE” on page 4-63. Loose connection > Tighten the holder bolt.

a a

rl

3. Hold the vehicle upright and apply the rear

CHECKING THE FRONT BRAKE HOSES : oa times.
The following procedure applies to all of the ellen
e Brake hose
a and brake hose holders. Brake fluid leakage —> Replace the damaged
hose. : :
¢ Brake hose “1”
Cracks/damage/wear — Replace. Refer to "REAR BRAKE" on page 4-63.

3-15
 PERIODIC MAINTENANCE

EAS30893

BLEEDING THE HYDRAULIC BRAKE

SYSTEM (ABS)
EwA14000

Always bleed the brake system when the

brake related parts are removed.
ECA22640

NOTICE
¢ Bleed the brake system in the following or-
der.
¢ Ist step: Front brake master cylinder
e 2nd step: Front brake calipers
¢ 3rd step: Rear brake caliper
EWAI6530

Bleed the ABS whenever:

¢ the system is disassembled.
e a brake hose is loosened, disconnected or
replaced. \
¢ the brake fluid level is very low.
A. Front brake master cylinder
¢ brake operation is faulty.
B. Front brake caliper (left/right)
TIP C. Rear brake caliper
¢ Be careful not to spill any brake fluid or allow
d. Place the other end of the hose into a con-
the brake fluid reservoir to overflow.
tainer.
e When bleeding the ABS, make sure that there
e. Slowly apply the brake several times.
is always enough brake fluid before applying
f. Fully squeeze the brake lever or fully de-
the brake. Ignoring this precaution could allow
press the brake pedal and hold it in posi-
air to enter the ABS, considerably lengthening
tion.
the bleeding procedure.
g. Loosen the bleed screw.
¢ If bleeding is difficult, it may be necessary
to let
TIP
the brake fluid settle for a few hours.
¢ Repeat the bleeding procedure when the tiny Loosening the bleed screw will release the pres-
bubbles in the hose have disappeared. sure and cause the brake lever to contact the
throttle grip or the brake pedal to fully extend.
1. Bleed:
° ABS h. Tighten the bleed screw and then release
a. Fill the brake fluid reservoir to the proper the brake lever or brake pedal.
level with the specified brake fluid. Repeat steps (e) to (h) until all of the air
b. Install the diaphragm (brake fluid reser- bubbles have disappeared from the brake
voir). fluid in the plastic hose.
c. Connect a clear plastic hose “1” tightly to Check the operation of the hydraulic unit.
the bleed screw “2”. Refer to “HYDRAULIC UNIT OPERA-
TION TEST” on page 4-79.
A ECA1TO61

NOTICE
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 fluid reservoir
to the proper level with the specified brake
fluid.

3-16
 PERIODIC MAINTENANCE

|. Tighten the bleed screw to specification.

Tire air pressure (measured on
Front brake master cylinder cold tires)
) bleed screw Front
5 N-m (0.5 kgf-m, 3.7 Ib-ft) 250 kPa (2.50 kgf/cm2, 36 psi)
Brake caliper bleed screw Rear
5 N-m (0.5 kgf-m, 3.7 Ib-ft) 290 kPa (2.90 kgf/cm?, 42 psi)
Maximum load
m. Fill the brake fluid reservoir to the proper 185 kg (408 Ib) (YZF-R1)
level with the specified brake fluid. 184 kg (406 Ib) (YZF-R1M)
Refer to “CHECKING THE BRAKE FLUID * Total weight of rider, passenger, cargo
LEVEL” on page 3-13. a nd accessories
EWA13110

2. Check:
After bleeding the hydraulic brake system, e Tire surfaces
check the brake operation. Damage/wear — Replace the tire.
EWAI3190

E4S31428

CHECKING THE WHEELS It is dangerous to ride with a worn-out tire.

The following procedure applies to both of the When the tire tread reaches the wear limit, re-
wheels. place the tire immediately.
1. Check:
e Wheel Wear limit (front)
Damage/out-of-round — Replace. 1.0 mm (0.04 in)
Wear limit (rear)
EWA13260

1.0 mm (0.04 in)

Never attempt to make any repairs to the
wheel. EW A14090

TIP After extensive tests, the tires listed below

After a tire or wheel has been changed or re- have been approved by Yamaha Motor Co.,
placed, always balance the wheel. Lid. for this model. The front and rear tires
should always be by the same manufacturer
EAS31429
and of the same design. No guarantee con-
CHECKING THE TIRES cerning handling characteristics can be giv-
The following procedure applies to both of the en if a tire combination other than one
tires. approved by Yamaha is used on this vehicle.
1. Check:
¢ Tire pressure
Front tire
Out of specification — Regulate.
EWA1S181
Size
120/70ZR17M/C (58W)
Manufacturer/model
¢ The tire pressure should only be checked BRIDGESTONE/BATTLAX RAC-
and regulated when the tire temperature ING STREET RS11F
equals the ambient air temperature.
¢ The tire pressure and the suspension must
be adjusted according to the total weight Rear tire
(including cargo, rider, passenger and ac- Size
cessories) and the anticipated riding 190/55ZR17M/C (75W) (YZF-R1)
speed. 200/55ZR17M/C (78W)
(YZF-R1M)
¢ Operation of an overloaded vehicle could
Manufacturer/model
cause tire damage, an accident or an injury. BRIDGESTONE/BATTLAX RAC-
NEVER OVERLOAD THE VEHICLE. ING STREET RS11R

3-17
 PERIODIC MAINTENANCE

EWA13210
Refer to “INSTALLING THE SWINGARM’” on
page 4-123.
New tires have a relatively low grip on the
road surface until they have been slightly
FASS31923

DRIVE CHAIN SLACK

worn. Therefore, approximately 100 km
should be traveled at normal speed before Checking the drive chain slack
any high-speed riding is done. EWAI3120

TIP
Securely support the vehicle so that there is
For tires with a direction of rotation mark “1”:
no danger of it falling over.
¢ Install the tire with the mark pointing in the di-
rection of wheel rotation.
EFC A13550

NOTICE
e Align the mark “2” with the valve installation
point. A drive chain that is too tight will overload
the engine and other vital parts, and one that
is too loose can skip and damage the swing-
arm or cause an accident. Therefore, keep
the drive chain slack within the specified lim-
its.
1. Shift the transmission into the neutral posi-
tion.
2. Check:
¢ Drive chain slack “a”
G088891 Out of specification — Adjust.

Drive chain slack (When perform-

EASS00-41

CHECKING THE WHEEL BEARINGS

ing maintenance/Maintenance
The following procedure applies to all of the
stand)
wheel bearings. 25.0—35.0 mm (0.98—1.38 in)
1. Check: Drive chain slack (When replac-
¢ Wheel bearings ing with a new one/Maintenance
Refer to “CHECKING THE FRONT WHEEL” stand)
on page 4-38 and “CHECKING THE REAR 20.0—30.0 mm (0.79—1.18 in)
WHEEL” on page 4-47. Drive chain slack limit (Mainte-
nance stand)
EAS3SOn02
35.0 mm (1.38 in)
CHECKING THE SWINGARM OPERATION
1. Check:
¢ Swingarm operation
Swingarm not working properly — Check the
swingarm.
Refer to “SWINGARM” on page 4-120.
2. Check:
* Swingarm excessive play
Refer to “SWINGARM” on page 4-120.
EASSOB43

LUBRICATING THE SWINGARM PIVOT

1. Lubricate: EC ASOBTO

° Oil seals NOTICE

e Collars Improper drive chain slack will overload the

=
engine as well as other vital parts of the mo-
Recommended lubricant
Lithium-soap-based grease torcycle and can lead to chain slippage or
breakage. If the drive chain slack is more
than the specified limit, the chain can dam-

3-18
 PERIODIC MAINTENANCE

age the frame, swingarm, and other parts. To This vehicle has a drive chain with small rubber
prevent this from occurring, keep the drive O-rings between each side plate. Steam clean-
chain slack within the specified limits. ing, high-pressure washing, certain solvents,
and the use of a coarse brush can damage
Adjusting the drive chain slack these O-rings. Therefore, use only kerosene to
EWA13120 clean the drive chain. Wipe the drive chain dry
and thoroughly lubricate it with chain lubricant
Securely support the vehicle so that there is that is suitable for O-ring chains. Do not use any
no danger of it falling over. other lubricants on the drive chain since they
may contain solvents that could damage the O-
1. Loosen:
rings.
e Wheel axle nut
Refer to “REAR WHEEL” on page 4-43. Recommended lubricant
Ey
2. Adjust: Chain lubricant suitable for O-
e Drive chain slack ring chains
a. Loosen both locknuts “1”.
b. Turn both adjusting bolts “2” until the spec- EFAS 30645

ified drive chain slack is obtained. CHECKING AND ADJUSTING THE

STEERING HEAD
1. Stand the vehicle on a level surface.
EWAI3120

Securely support the vehicle so that there is

no danger of it falling over.
TIP
Place the vehicle on a maintenance stand so
that the front wheel is elevated.
2. Check:
TIP e Steering head
¢ To maintain the proper wheel alignment, adjust Grasp the bottom of the front fork legs and
both sides evenly. gently rock the front fork.
¢ There should be no clearance between the ad- Blinding/looseness — Adjust the steering
justing block and adjusting bolt. head.
3. Remove:
c. Tighten the wheel axle nut to specification.
¢ Upper bracket
Rear wheel axle nut 4. Adjust:
190 N-m (19 kgf-m, 140 Ib-ft) e Steering head
a. Remove the lock washer “1”, the upper
d. Tighten the locknuts to specification. ring nut “2”, and the rubber washer “3”.

Chain puller adjusting bolt lock-

nut
16 N-m (1.6 kgf-m, 12 lb-ft)
EAS30803

LUBRICATING THE DRIVE CHAIN

The drive chain consists of many interacting
parts. If the drive chain is not maintained proper-
ly, it will wear out quickly. Therefore, the drive GO088s92
chain should be serviced, especially when the
vehicle is used in dusty areas. b. Loosen the lower ring nut “4” and then
tighten it to specification with a steering
nut wrench “5”.

3-19
 PERIODIC MAINTENANCE

TIP TIP
* Set the torque wrench at a right angle to the Make sure the lock washer tabs “a” sit correctly
steering nut wrench. in the ring nut slots “b”.
¢ Move the steering to the left and right a couple
of times to check that it moves smoothly.

5. Install:
G088893
¢ Upper bracket
Refer to “HANDLEBARS’” on page 4-83.
KL. Steering nut wrench
gp 90890-01403 EAS 30646

Exhaust flange nut wrench LUBRICATING THE STEERING HEAD

YU-A9472 1. Lubricate:
¢ Upper bearing
e Lower bearing
X Lower ring nut (initial tightening ¢ Bearing race

=
%& torque)
52 N-m (5.2 kgf-m, 38 Ib-ft) Recommended lubricant
Lithium-soap-based grease
c. Loosen the lower ring nut completely, then
tighten it to specification. FASS1644
EWA13140 CHECKING THE STEERING DAMPER
Refer to “CHECKING THE STEERING DAMP-
Do not overtighten the lower ring nut. ER” on page 4-111.
EAS31186
Lower ring nut (final tightening CHECKING THE CHASSIS FASTENERS
torque) Make sure that all nuts, bolts, and screws are
14 N-m (1.4 kgf-m, 10 Ib-ft) properly tightened.
Refer to “CHASSIS TIGHTENING TORQUES”
d. Check the steering head for looseness or
on page 2-14.
binding by turning the front fork all the way
in both directions. If any binding is felt, re- FAS S0804

move the lower bracket and check the up- LUBRICATING THE BRAKE LEVER
per and lower bearings. Lubricate the pivoting point and metal-to-metal
Refer to “STEERING HEAD” on page moving parts of the lever.
4-108.
Recommended lubricant
. Install the rubber washer “3”.
Silicone grease
Install the upper ring nut “2”.
—h

. Finger tighten the upper ring nut, then EAS S0805

align the slots of both ring nuts. If neces- LUBRICATING THE CLUTCH LEVER
sary, hold the lower ring nut and tighten Lubricate the pivoting point and metal-to-metal
the upper ring nut until their slots are moving parts of the lever.
aligned.
h. Install the lock washer “1”. Recommended lubricant
Lithium-soap-based grease

3-20
 PERIODIC MAINTENANCE

EASS0649 EAS 30806

LUBRICATING THE PEDAL ADJUSTING THE FRONT FORK LEGS (for

Lubricate the pivoting point and metal-to-metal YZF-R1)
moving parts of the pedal. The following procedure applies to both of the

=
front fork legs.
Recommended lubricant EWAIS120

Molybdenum disulfide grease

Securely support the vehicle so that there is
EAS30650
no danger of it falling over.
CHECKING THE SIDESTAND
1. Check:
* Sidestand operation Spring preload
EWAITO4O
Check that the sidestand moves smoothly.
Rough movement — Repair or replace.
Always adjust both front fork legs evenly.
EASa0651
Uneven adjustment can result in poor han-
LUBRICATING THE SIDESTAND dling and loss of stability.
Lubricate the pivoting point, metal-to-metal mov-
ECA13590
ing parts and spring contact point of the side-
NOTICE
stand.
Never go beyond the maximum or minimum
Recommended lubricant adjustment positions.
Lithium-soap-based grease 1. Adjust:
¢ Spring preload
EASSa0652

CHECKING THE SIDESTAND SWITCH a. Turn the adjusting nut “1” in direction “a” or
“hy”.

Refer to “ELECTRICAL COMPONENTS?” on

page 8-38.
Direction “a”
EAS30653 Spring preload is increased (suspen-
CHECKING THE FRONT FORK sion is harder).
1. Stand the vehicle on a level surface. Direction “b”
EWAIS3120
Spring preload is decreased (suspen-
sion is softer).
Securely support the vehicle so that there is
no danger of it falling over.
Spring preload
2. Check: Minimum (soft)
¢ Inner tube 0 turn(s) in direction a”
Damage/scratches — Replace. Standard
* Front fork leg
6 turn(s) in direction “a”
Oil leaks between inner tube and outer tube
Maximum (hard)
— Replace the oil seal.
15 turn(s) in direction “a”
Refer to “FRONT FORK (for YZF-R1)” on
page 4-89 or refer to “FRONT FORK (for * With the adjusting nut fully turned in di-
YZF-R1M)” on page 4-100. rection “b”
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.
a

Refer to “FRONT FORK (for YZF-R1)” on

page 4-89 or refer to “FRONT FORK (for
YZF-R1M)” on page 4-100.

3-21
 PERIODIC MAINTENANCE

Rebound damping Compression damping

ECA13590 ECA13590

NOTICE NOTICE
Never go beyond the maximum or minimum Never go beyond the maximum or minimum
adjustment positions. adjustment positions.
1. Adjust: 1. Adjust:
* Rebound damping ¢« Compression damping
a. Turn the adjusting bolt “1” in direction “a” a. Turn the adjusting bolt “1” in direction “a”
or “b”.
or “hy”

Direction “a” Direction “a”

Rebound damping is increased (sus- Compression damping is increased
pension is harder). (suspension is harder).
Direction “b” Direction “b”
Rebound damping is decreased (sus- Compression damping is decreased
pension is softer). (suspension is softer).

Rebound damping Compression damping

Minimum (soft) Minimum (soft)
14 click(s) in direction “b’”* 23 click(s) in direction “b”*
Standard Standard
7 click(s) in direction “b’* 17 click(s) in direction “b”*
Maximum (hard) Maximum (hard)
1 click(s) in direction “b’* 1 click(s) in direction “b”*
* With the adjusting bolt fully turned in di- * With the adjusting bolt fully turned in di-
rection “a” rection “a”

TIP TIP
e Although the total number of clicks of a damp- ¢ Although the total number of clicks of a damp-
ing force adjusting mechanism may not exactly ing force adjusting mechanism may not exactly
match the above specifications due to small match the above specifications due to small
differences in production, the actual number of differences in production, the actual number of
clicks always represents the entire adjusting clicks always represents the entire adjusting
range. To obtain a precise adjustment, check range. To obtain a precise adjustment, check
the number of clicks and modify the minimum the number of clicks and modify the minimum
and standard specifications as necessary. and standard specifications as necessary.
e When turning the damping force adjusting bolt ¢ When turning the damping force adjusting bolt
in direction “a”, the 0 click position and the 1 in direction “a”, the 0 click position and the 1
click position may be the same. click position may be the same.

3-22
 PERIODIC MAINTENANCE

EAS31635

ADJUSTING THE PRELOAD OF THE FRONT Spring preload

FORK LEGS (for YZF-R1M) Minimum (soft)
The following procedure applies to both of the 0 turn(s) in direction
ti 3”

front fork legs. Standard

EWAIS120
3 turn(s) in direction “a”
Maximum (hard)
Securely support the vehicle so that there is tc
no danger of it falling over. 15 turn(s) in direction
* With the adjusting nut fully turned in di-
rection “b”
Spring preload
Ew Ai7040

Always adjust both front fork legs evenly.

Uneven adjustment can result in poor han-
dling and loss of stability.
ECA13590

NOTICE
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
* Spring preload e. Connect the coupler on each fork.
a. Turn the main switch to “OFF”. f. Slide the rubber cover to the original posi-
b. Slide the rubber cover “1” back at each tion.
coupler.
Cc. Disconnect the coupler “2” on each front
FASS0941

ADJUSTING THE DAMPING FORCE OF THE

fork. FRONT FORK LEGS AND REAR SHOCK
ABSORBER ASSEMBLY (for YZF-R1M)

t lia pia lal aL)

‘——— T-1
T-2 ++ fe
bile
8
R-1 4 an 7
—

0 bo BRAKE | CORNER | ACCEL REAR

d. Turn the adjusting bolt “S” in direction “a”

or “b”. ERS mode
=

Braking support level

Direction “a”
oh

Cornering support level

Spring preload is increased (suspen- Acceleration support level
sion is harder).
Soak

Front overall damping level

Direction “b”
Rear overall damping level
Spring preload is decreased (suspen-
sion is softer). Factory preset level
8. Current level

The ERS consists of three semi-active automat-

ic modes (T-1, T-2 and R-1) and three manual
setting modes (M-1, M-2 and M-3). When an au-
tomatic mode is selected, the SCU will adjust the
compression and rebound damping forces

3-23
 PERIODIC MAINTENANCE

based on running conditions. For all modes and

models, spring preload is physically adjusted by he pia el ee CET)

hand. — M-1 | 8 18 22 2
For track modes T-1 and T-2, the following set- wee fee de |"
tings can be adjusted:
BRAKE SUPPORT: reduces nosedive (front-
_ =) Se _
=~ = =
end pitch from braking)
CORNER SUPPORT: increases damping to ab- ve in °
sorb chassis fluctuations for smooth cornering.
Reduce this setting for increased rear wheel
grip. 1. ERS mode
ACCEL SUPPORT: reduces rear-end squat 2. Front compression damping force
(rear-end pitch due to acceleration) 3. Front rebound damping force
FRONT FIRM: hardens “H” or softens “S” overall 4. Rear compression damping force
damping of the front suspension 5. Rear rebound damping force
REAR FIRM: hardens “H” or softens “S” overall 6. Factory preset level
damping of the rear suspension 7. Current level setting

Pra Tet sti ILY

For the manual setting modes M-1, M-2, and M-
T-1
3, the following settings can be adjusted:
T-2
Fr COM: front compression damping
6 Fr REB: front rebound damping
1, <a
_ Rr COM: rear compression damping
Rr REB: rear rebound damping
Oe
2
sis TIP
¢ M-1 is preset for track use with racing slick
tires.
ERS mode ¢ M-2 is preset for track use with street tires.
akon =

Braking support level ¢ M-3 is preset for street use with street tires.
Front overall damping level 1. Adjust:
Rear overall damping level ¢« Damping force
Factory preset level a. Turn the main switch to “ON”.
6. Current level b. Long push the wheel switch to enter the
For the road mode R-1, the following settings MENU screen.
can be adjusted:
BRAKE SUPPORT: reduces nosedive (front- O mex MENU Lt

end pitch from braking)

FRONT FIRM: hardens “H” or softens “S” overall YRC Setting
damping of the front suspension
REAR FIRM: hardens “H” or softens “S” overall
Logging
damping of the rear suspension
TIP
¢ T-1 is preset for track use with racing slick tires.
e T-2 is preset for track use with street tires.
c. Select “YRC Setting”.
¢ R-1 is preset for road use with street tires.

3-24
 PERIODIC MAINTENANCE

f. Select the suspension item that you want

aT or | |= | to adjust, and then rotate the wheel switch
to adjust the setting level.
TIP
a All ERS modes regardless of type are indepen-
ee ee
dent. Offset level setting changes made in one
mode are not transferred to another mode.
Sanat aaa

g. To adjust other ERS modes of the same

type, repeat from step (d). To switch types
d. Select the “p” mark located to the right of or when finished, select the “<q” mark to
ERS. return to the main “YRC Setting” menu.
TIP EAS 30808

The ERS setting menu is divided into automatic CHECKING THE REAR SHOCK ABSORBER
and manual setting modes, and the two types ASSEMBLY
are accessed separately. Before moving to the Refer to “CHECKING THE REAR SHOCK AB-
ERS setting menu, make sure the current ERS SORBER ASSEMBLY” on page 4-117.
mode corresponds to the same type (automatic FAS 30655

or manual) that you'd like to adjust. ADJUSTING THE REAR SHOCK ABSORBER
ASSEMBLY (for YZF-R1)
EWAI3120
it MPH Teel ee at

Securely support the vehicle so that there is

no danger of it falling over.

Spring preload
es ECA13590

NOTICE
Never go beyond the maximum or minimum
adjustment positions.
1. To ERS menu
2. Manual modes 1. Adjust:
3. Automatic modes ¢ Spring preload
a. Loosen the locknut “1”.
e. The display will change to the relevant
b. Adjust the spring preload with the special
suspension setting screen and the ERS
wrench included in the owner's tool kit.
mode selection box “SETTING?” is high-
c. Turn the adjusting ring “2” in direction “a”
lighted. Short push the wheel switch to en-
or “b”.
ter the box and select the ERS mode that
you want to adjust. Direction “a”
Spring preload is increased (suspen-
AP [= 10:00
re sion is harder).
8 18 22 224 4 Direction “b”
Spring preload is decreased (Ssuspen-
-
=| =
— ——
a sion is softer).
=> ne
» Ali ==

To YRC Setting menu

oh =

ERS mode selection box “SETTING”

Factory preset level
Current level setting

3-25
 PERIODIC MAINTENANCE

Direction “a”
Rebound damping is increased (sus-
pension is harder).
Direction “b”
Rebound damping is decreased (sus-
pension is softer).

Rebound damping
Minimum (soft)
TIP 23 click(s) in direction “b”
Standard
The spring preload setting is determined by
measuring distance “c”. The longer distance “c” 12 click(s) in direction “b”
Maximum (hard)
is, the higher the spring preload; the shorter dis-
tance “c” is, the lower the spring preload. 1 click(s) in direction “b”
* With the adjusting screw fully turned in
direction “a”

TIP
¢ Although the total number of clicks of a damp-
ing force adjusting mechanism may not exactly
match the above specifications due to small
differences in production, the actual number of
clicks always represents the entire adjusting
range. To obtain a precise adjustment, check
the number of clicks and modify the minimum
and standard specifications as necessary.
Spring preload ¢ When turning the damping force adjusting
Minimum
screw in direction “a”, the O click position and
77.5 mm (3.05 in)
the 1 click position may be the same.
Standard
78.5 mm (3.09 in)
Maximum
85.5 mm (3.37 in)

d. Tighten the locknut to the specified torque.

4 Spring preload adjusting ring

locknut (for YZF-R1)
28 N-m (2.8 kgf-m, 21 Ib-ft)

Rebound damping
ECA13590

NOTICE Compression damping (for fast compres-

Never go beyond the maximum or minimum sion damping)
ECA13590
adjustment positions. NOTICE
1. Adjust: Never go beyond the maximum or minimum
¢ Rebound damping adjustment positions.
a. Turn the adjusting screw “1” in direction
fe" or “hy” 1. Adjust:
¢« Compression damping (for fast compression
damping)
a. Turn the adjusting bolt “1” in direction “a”
or “b”.

3-26
 PERIODIC MAINTENANCE

Direction “a” Direction “a”

Compression damping is increased Compression damping is increased
(suspension is harder). (suspension is harder).
Direction “b” Direction “b”
Compression damping is decreased Compression damping is decreased
(suspension is softer). (suspension is softer).

a Fast compression damping

Minimum (soft)
5.5 turn(s) in direction “b””
Standard
Slow compression damping
Minimum (soft)
18 click(s) in direction “b”
Standard
3 turn(s) in direction “b” 12 click(s) in direction “b”
Maximum (hard) Maximum (hard)
0 turn(s) in direction “b” 1 click(s) in direction “b”
* With the adjusting bolt fully turned in di- * With the adjusting screw fully turned in
rection “a” direction “a”

TIP TIP
Although the total number of turns of a damping ¢ Although the total number of clicks of a damp-
force adjusting mechanism may not exactly ing force adjusting mechanism may not exactly
match the above specifications due to small dif- match the above specifications due to small
ferences in production, the actual number of differences in production, the actual number of
turns always represents the entire adjusting clicks always represents the entire adjusting
range. To obtain a precise adjustment, check range. To obtain a precise adjustment, check
the number of turns and modify the minimum the number of clicks and modify the minimum
and standard specifications as necessary. and standard specifications as necessary.
¢ When turning the damping force adjusting
screw in direction “a”, the O click position and
the 1 click position may be the same.

Compression damping (for slow compres-

sion damping)
ECA13590

NOTICE EFAS S0942

Never go beyond the maximum or minimum

ADJUSTING THE PRELOAD OF THE
adjustment positions.
REAR SHOCK ABSORBER ASSEMBLY
(for YZF-R1M)
1. Adjust: EWAIS120

* Compression damping (for slow compression

damping) Securely support the vehicle so that there is
a. Turn the adjusting screw “1” in direction no danger of it falling over.
“a” or “b”.

3-27
 PERIODIC MAINTENANCE

Spring preload
ECA13590 Spring preload
NOTICE Minimum
Never go beyond the maximum or minimum 0 mm (0.00 in)
adjustment positions. Standard
4 mm (0.16 in)
1. Adjust: Maximum
* Spring preload 9 mm (0.35 in)
a. Loosen the locknut “1”.
b. Adjust the spring preload with the special d. Tighten the locknut to the specified torque.
wrench included in the owner's tool kit.
c. Turn the adjusting ring “2” in direction “a” Spring preload adjusting ring
ON locknut (for YZF-R1M)
or “b”.
25 N-m (2.5 kgf-m, 18 lb-ft)
Direction “a”
EAS 30809
Spring preload is increased (suspen- CHECKING THE CONNECTING ARM AND
sion is harder).
RELAY ARM
Direction “b”
Spring preload is decreased (Ssuspen- Refer to “CHECKING THE CONNECTING ARM
sion is softer). AND RELAY ARM” on page 4-117.
EAS 30656

CHECKING THE ENGINE OIL LEVEL

1. Stand the vehicle on a level surface.
TIP
* Place the vehicle on a maintenance stand.
¢ Make sure the vehicle is upright.
2. Start the engine, warm it up for several min-
utes, and then tum it off.
3. Check:
e Engine oil level
The engine oil level should be between the
TIP minimum level mark “a” and maximum level
The spring preload setting is determined by mark “b”.
measuring distance “c”. The longer distance “c” Below the minimum level mark —> Add the
is, the higher the spring preload; the shorter dis- recommended engine oil to the proper level.
tance “c” is, the lower the spring preload.

3-28
 PERIODIC MAINTENANCE

VD Recommended brand
YAMALUBE
Type
Full synthetic
SAE viscosity grades
10W-40, 15W-50
Recommended engine oil grade
API service SG type or higher,
JASO standard MA
ECA13361

NOTICE 4. Drain:
¢ Engine oil also lubricates the clutch and the e Engine oil
wrong oil types or additives could cause (completely from the crankcase)
clutch slippage. Therefore, do not add any 5. If the oil filter cartridge is also to be replaced,
chemical additives or use engine oils witha perform the following procedure.
grade of “CD” or higher and do not use oils a. Remove the front side cowling (left).
labeled “ENERGY CONSERVING II’. Refer to “GENERAL CHASSIS (5)” on
¢ Do not allow foreign materials to enter the page 4-16.
crankcase. b. Remove the oil filter cartridge “1” with an
oil filter wrench “2”.
TIP
Before checking the engine oil level, wait a few Oil filter wrench
minutes until the oil has settled. 90890-01426
Oil filter wrench
4. Start the engine, warm it up for several min- YU-38411
utes, and then turn it off.
5. Check the engine oil level again.
TIP
Before checking the engine oil level, wait a few
minutes until the oil has settled.

EASSO657

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. c. Lubricate the O-ring of the new oil filter
3. Remove: cartridge with a thin coat of lithium-soap-
* Engine oil filler cap “1” based grease.
¢ Engine oil drain bolt “2” ECAS5890

* Gasket “3” NOTICE

Make sure the O-ring is positioned correctly
in the groove of the oil filter cartridge.
d. Tighten the new oil filter cartridge to spec-
ification with an oil filter wrench.

\ Oil filter cartridge

| %, | 17 N-m (1.7 kgf-m, 13 Ib-ft)

e. Install the front side cowling (left).

Refer to “GENERAL CHASSIS (5)” on
page 4-16.

3-29
 PERIODIC MAINTENANCE

6. Install: ¢ Oil pressure switch joint (with the oil pressure

¢ Engine oil drain bolt switch) “2”
(along with the gasket [XW#)
EWA12990

4 WARNING
Engine oil drain bolt The engine, muffler and engine oil are ex-
23 N-m (2.3 kgf-m, 17 Ib-ft) tremely hot.

7. Fill:
¢ Crankcase
(with the specified amount of the recom-
mended engine oil)

NY Engine oil quantity

Oil change
3.90 L (4.12 US qt, 3.43 [Link])
With oil filter removal
4.10 L (4.33 US qt, 3.61 [Link])
Quantity (disassembled) 4. Install:

i
4.90 L (5.18 US qt, 4.31 [Link]) e Oil pressure gauge joint 18 mm “1”
e Oil pressure switch joint bolt “2”
8. Install:
¢ Engine oil filler cap Oil pressure gauge joint 18 mm
(along with the O-ring [XEW9) 90890-04176
9. Start the engine, warm it up for several min- YU-04176
utes, and then turn it off.
[Link]:
¢« Engine
N Oil pressure switch joint bolt
(for engine oil leaks) % 10 N-m (1.0 kgf-m, 7.4 lb-ft)

[Link]:
¢ Engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL” on page 3-28.
EAS30810

MEASURING THE ENGINE OIL PRESSURE

1. Check:
¢ Engine oil level
Below the minimum level mark “a” > Add the
recommended engine oil to the proper level.
5. Install:
e Oil pressure gauge “1”
e Adapter C “2”

Va Oil pressure gauge set

90890-03120

2. Remove:
¢ Front side cowling (left)
3. Remove:
¢ Oil pressure switch joint bolt “1”

3-30
 PERIODIC MAINTENANCE

6. Start the engine, warm it up for several min- EAS S081 1

CHECKING THE COOLANT LEVEL

utes.
ECAIZ410
1. Stand the vehicle on a level surface.
NOTICE TIP
When the engine is cold, the engine oil will * Place the vehicle on a maintenance stand.
have a higher viscosity, causing the engine ¢ Make sure the vehicle is upright.
oil pressure to increase. Therefore, be sure
2. Check:
to measure the engine oil pressure after
¢ Coolant level
warming up the engine. The coolant level should be between the
7. Measure: maximum level mark “a” and minimum level
¢ Engine oil pressure mark “b”.
(at the following conditions) Below the minimum level mark — Add the

a
recommended coolant to the proper level.
Oil pressure
200.0 kPa/5000 r/min (2.00 kgf/
cm2/5000 r/min, 29.0 psi/5000 r/
min) THEI
FERFEPrtrtt

Engine oil pressure Possible causes

« Faulty oil pump b

BEEK

* Clogged oil filter

_—_—

Below specification * Leaking oil passage

* Broken or damaged
oil seal
ECAZ1261
* Faulty oil filter
Above specification * Oil viscosity too high NOTICE
¢ Adding water instead of coolant dilutes the
8. Remove: antifreeze concentration of the coolant. If
¢ Oil pressure gauge water is used instead of coolant; check,
¢ Adapter C and if necessary, correct the antifreeze
* Oil pressure switch joint bolt concentration of the coolant.
¢ Oil pressure switch joint (with the O-ring) ¢ Use only distilled water. However, if dis-
9. Install: tilled water is not available, soft water may
© O-ring “1” [ET be used.
* Oil pressure switch joint (with the oil pressure 3. Start the engine, warm it up for several min-
switch) “2” utes, and then tum it off.
¢ Oil pressure switch joint bolt “S” 4. Check:
¢ Coolant level
Oil pressure switch joint bolt
10 N-m (1.0 kgf-m, 7.4 Ib-ft) TIP
Before checking the coolant level, wait a few
minutes until it settles.

3-31
 PERIODIC MAINTENANCE

EAS30812
sidual pressure to escape. When the hissing
CHECKING THE COOLING SYSTEM
sound has stopped, press down on the radi-
1. Check:
ator cap and turn it counterclockwise to re-
¢ Radiator “1”
move.
¢ Radiator inlet hose “2”
¢ Radiator outlet hose “3”
¢ Water pump inlet pipe “4” — —

¢ Water pump outlet pipe “5” ol oy

* Oil cooler “6”
¢ Oil cooler outlet hose “7” TE Ns
¢ Oil cooler inlet hose “8”
a TOK
Cracks/damage — Replace.
Ke A\
iN
Refer to “RADIATOR?” on page 6-3, “OIL
COOLER?’ on page 6-7, “THERMOSTAT” on
page 6-9 and “WATER PUMP” on page 6-13.
2. Remove:
¢ Water pump drain bolt “1”
e Copper washer “2”

3. Drain:
e Coolant
(from the engine and radiator)
4. Install:
e Water pump drain bolt
¢ Copper washer KEW
EASa0813
Water pump drain bolt
CHANGING THE COOLANT
10 N-m (1.0 kgf-m, 7.4 Ib-ft)
1. Remove:
* Front side cowling (right) 5. Remove:
¢ Front muffler protector (right) e Coolant reservoir cap “1”
Refer to “GENERAL CHASSIS (5)” on page ~ _
4-16.
¢ Radiator cap “1”

Ta
Shr
1

me
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- ¢ Coolant reservoir bolt “1”
clockwise toward the detent to allow any re- e Coolant reservoir “2”

3-32
 PERIODIC MAINTENANCE

ECAZ1I291

NOTICE
¢ Adding water instead of coolant dilutes the
antifreeze concentration of the coolant. If
water is used instead of coolant; check,
and if necessary, correct the antifreeze
concentration of the coolant.
¢ Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.
¢ If coolant comes into contact with painted
7. Drain:
surfaces, immediately wash them with wa-
¢ Coolant
ter.
(from the coolant reservoir)
* Do not mix different types of antifreeze.
8. Install:
¢ Coolant reservoir [Link]:

My
¢ Coolant reservoir bolt e Coolant reservoir
(with the recommended coolant to the maxi-
Ny Coolant reservoir bolt | mum level mark “a”)
7 N-m (0.7 kgf-m, 5.2 Ib-ft)

FEREP rerettt rrttit}>

9. Fill:

|
at]
* Cooling system
(with the specified amount of the recom-
mended coolant)

VD Recommended antifreeze
ig2
EE
—
High-quality ethylene glycol anti-
freeze containing corrosion
inhibitors for aluminum engines
Mixing ratio [Link]:
1:1 (antifreeze : water) ¢ Coolant reservoir cap
Coolant quantity
[Link] the water pump air bleed bolt “1” to
Radiator (including all routes)
allow any trapped air to escape from the wa-
2.25 L (2.38 US qt, 1.98 [Link])
Coolant reservoir (up to the maxi- ter pump.
mum level mark)
0.25 L (0.26 US qt, 0.22 [Link]) 2 oS eI:
Handling notes for coolant
Coolant is potentially harmful and should be
handled with special care.
EW A13040

¢ If coolant splashes in your eyes, thorough-

ly wash them with water and consult a doc-
tor.
[Link] coolant begins to flow out, tighten the
¢ If coolant splashes on your clothes, quickly
water pump air bleed bolt to the specified
wash it away with water and then with soap
torque.
and water.
¢ If coolant is swallowed, induce vomiting \y Water pump air bleed bolt
and get immediate medical attention. 10 N-m (1.0 kgf-m, 7.4 Ib-ft)

3-33
 PERIODIC MAINTENANCE

[Link] the specified coolant into the radiator

until it is full.
[Link]:
¢ Radiator cap
[Link] the engine, warm it up for several min-
utes, and then turn it off.
[Link]:
¢ Coolant level
Refer to “CHECKING THE COOLANT LEV-
EL” on page 3-31.
TIP 3. Adjust:
Before checking the coolant level, wait a few e EXUP cable free play
minutes until the coolant has settled. a. Turn the main switch to “ON”.
[Link]: b. Loosen the locknut “1”.
¢ Front muffler protector (right) c. Turn the adjusting nut “2” until the projec-
* Front side cowling (right) tion “a” on the EXUP valve pulley slightly
Refer to “GENERAL CHASSIS (5)” on page contacts the stopper “b” and make sure
4-16. the EXUP cable (black metal) “S” is not
slack.
EAS31389
d. Tighten the locknut “1” to specification.
ADJUSTING THE EXUP CABLES
1. Remove: N EXUP cable locknut
e EXUP valve pane cover “1”
% 6 N-m (0.6 kgf-m, 4.4 Ib-ft)

aes
(Rie

>
1
TS
2. Check:
* EXUP system operation e. Loosen the locknut “4”.
a. Activate the diagnostic mode and select f. Turn the adjusting nut “5” until the tension
the diagnostic code number “53”. of the EXUP cable (white metal) “6” is the
Refer to “FUEL INJECTION SYSTEM” on same as that of the EXUP cable (black
page 9-11. metal) “3”.
b. Set the start/engine stop switch to “-”. g. Tighten the locknut “4” to specification.
c. Check that the EXUP valve operates prop-
erly. X EXUP cable locknut

TIP % 6 N-m (0.6 kgf-m, 4.4 Ib-ft)

Check that the projection “a” on the EXUP valve

pulley contacts the stopper “b” (fully open posi-
tion). If the projection does not contact the stop-
per, adjust the EXUP cable free play.

3-34
 PERIODIC MAINTENANCE

EAS 30660

CHECKING AND LUBRICATING THE

CABLES
The following procedure applies to all of the in-
ner and outer cables.
EWAIS270

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.
4. Install:
1. Check:
e EXUP valve pulley cover e Outer cable
Damage — Replace.
2. Check:
e Cable operation
EAS3a2661 Rough movement -> Lubricate.
CHECKING THE FRONT BRAKE LIGHT
SWITCH =a Recommended lubricant
Refer to “ELECTRICAL COMPONENTS” on Engine oil or a suitable cable lu-
bricant
page 8-38.
EASS0659 TIP
ADJUSTING THE REAR BRAKE LIGHT
Hold the cable end upright and pour a few drops
SWITCH
of lubricant into the cable sheath or use a suit-
TIP able lubricating device.
The rear brake light switch is operated by the
movement of the brake pedal. EAS30815

Adjustment is correct when the brake light CHECKING THE THROTTLE GRIP
comes on by depressing the brake pedal 5.5— 1. Check:
12.0 mm (0.22-—0.47 in) or more. ¢ Throttle grip movement
Rough movement —> Lubricate or replace the
1. Check:
defective part(s).
¢ Rear brake light operation timing
Incorrect > Adjust. — Recommended lubricant
2. Adjust: | | Suitable cable lubricant
¢ Rear brake light operation timing
a. Hold the main body “1” of the rear brake TIP
light switch so that it does not rotate and With the engine stopped, turn the throttle grip
turn the adjusting nut “2” until the rear slowly and release it. Make sure that the throttle
brake light comes on at the proper time. grip turns smoothly and returns properly when
released.
Repeat this check with the handlebar turned all
the way to the left and right.

EAS S0816

CHECKING AND CHARGING THE BATTERY

Refer to “CHECKING AND CHARGING THE
BATTERY” on page 8-42.
EAS S0662

CHECKING THE FUSES

Refer to “CHECKING THE FUSES” on page
8-41.

3-35
 PERIODIC MAINTENANCE

EAS30664

ADJUSTING THE HEADLIGHT BEAMS

1. Adjust:
¢ Headlight beam (vertically)
TIP
To adjust the headlight beam (vertically), insert
a crosshead screwdriver into the holes “a” in the
headlight cover and turn the adjusting screw.

2. Adjust:
* Headlight beam (horizontally)
TIP
To adjust the headlight beam (horizontally), in-
sert a crosshead screwdriver into the holes “a” in
the headlight cover and turn the adjusting screw.

3-36
 PERIODIC MAINTENANCE

3-37
 CHASSIS

GENERAL CHASSIS (1).. 4-1

REMOVING THE TAIL COVER.. sent 4-5
REMOVING THE REAR SIDE COVER... waeeee 400
INSTALLING THE IMU.. 4-5
INSTALLING THE REAR SIDE COVER..
INSTALLING THE TAIL 8 SIDE COVER rnnnnmnnnnnnerr 4-6

GENERAL CHASSIS (2)... 4-7

REMOVING THE TAIL COVER .. bee eeeeeeeecaeeeeseeeeeeeseeeeeeeeeeeeeeeeeees 4-8
INSTALLING THE CCU (for YZF- -R1M) seuss vaisab used snakusandasunseavedennse sservoushcs
CONNECTING TO THE CCU (for YZF-R1M) ....0.. eee eeeeeeeeeeees 4-8
INSTALLING THE TAIL COVER Wu... cece eeceeceeee eee eee cae ee eee saeaaaeeeeseasauee 4-8

GENERAL CHASSIS (3)... vaneeee 4Y

REMOVING THE FRONT PANEL (LEFT) ...
REMOVING THE FRONT PANEL COVER (LEFT). dade ot sce ceedeutssevedtucsuees 4-10
REMOVING THE FRONT PANEL (RIGHT )..........0.0..cceeeceeeeeeeeeeeeeeeeaees 4-10
REMOVING THE FRONT PANEL COVER (RIGHT) ..............000 ae 4-11
INSTALLING THE FRONT PANEL COVER (LEFT)..............ccccceeeeeeees 4-11
INSTALLING THE FRONT PANEL (LEFT)... 4-11
INSTALLING THE FRONT PANEL COVER (RIG HT) . vee 4-12
INSTALLING THE FRONT PANEL (RIGHT)... 4-12

GENERAL CHASSIS (4)... wenn 4°13

REMOVING THE FRONT UPPER COWLING...
INSTALLING THE FRONT UPPER COWLING .. pas Suey ws eof ginaen at essen'en ss yeyesen 4-14

GENERAL CHASSIS (5)... wees 4°16

REMOVING THE FRONT MU FFLER PROTECTOR (LEFT)... veer 4°18
REMOVING THE FRONT MUFFLER PROTECTOR (RIGHT)... wees 4°18
REMOVING THE FRONT SIDE COWLING (LEFT) (for YZF-R1) ...eeeeeees 4-18
REMOVING THE FRONT SIDE COWLING (RIGHT) (for YZF-R1)........ 4-19
REMOVING THE FRONT SIDE COWLING (LEFT) (for YZF-R1M) ....... 4-19
REMOVING THE FRONT SIDE COWLING (RIGHT) (for YZF-R1M)..... 4-19
INSTALLING THE FRONT SIDE COWLING (RIGHT) (for YZF-R1)....... 4-20
INSTALLING THE FRONT SIDE COWLING (LEFT) (for YZF-R1)......... 4-20
INSTALLING THE FRONT SIDE COWLING (RIGHT) (for YZF-R1M).... 4-20
INSTALLING THE FRONT SIDE COWLING (LEFT) (for YZF-R1M)...... 4-21
INSTALLING THE FRONT MUFFLER PROTECTOR (LEFT) ................ 4-21
INSTALLING THE FRONT MUFFLER PROTECTOR (RIGHT).............. 4-21

GENERAL CHASSIS (6)... veers 4-23

REMOVING THE SIDE COVER (LEFT) ... ween 4-26
REMOVING THE SIDE COVER (RIGHT)... veeees 4-26
INSTALLING THE SIDE COVER (LEFT)... es veers 4-26
INSTALLING THE SIDE COVER BRACKET (RIGHT... veeees 4-26
INSTALLING THE SIDE COVER (RIGHT)... 4-27
GENERAL CHASSIS (7)... . venee 4-28
CHECKING THE AIR INTAKE DUCT VALVE.. wees 4°30
CHECKING THE VACUUM LINE... veers 4-30
ASSEMBLING THE AIR INTAKE DUCT ASSEMBLY... eteeeeeteeseeeeeee 4°30
INSTALLING THE AIR INTAKE DUCT VALVE evecescceceseccesccssssssssssssssseen 4-31

GENERAL CHASSIS (8)... be verre 4-32

REMOVING THE ECU (engine control unit) ... vere 4-33
INSTALLING THE ECU (engine control unit)... 4-33

GENERAL CHASSIS (9) ............ccccceeccssseeeceensenseeceseseeseeeeeeseeeseeeseeennensesseseneas 4-34

FRONT WHEEL... wee 4-35

REMOVING THE FRONT WHEEL...
DISASSEMBLING THE FRONT WHEEL. cccccccccssssssssssssssvesecsseseeseeeseseee 4-38
CHECKING THE FRONT WHEEL.. wn 4-38
ASSEMBLING THE FRONT WHEEL... ....4-39
MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR
ROTOR... 1.11. 4-40
ADJUSTING THE FRONT WHEEL STATIC BALANCE .. se seeeeeesaeees 4-40
INSTALLING THE FRONT WHEEL (DISC BRAKE)...........0...0 4-40

REAR WHEEL.. wees 4-43

REMOVING THE REAR WH EEL. wieees 4-46
DISASSEMBLING THE REAR WHEEL .. veeees 4-46
CHECKING THE REAR WHEEL... veers 4-47
CHECKING THE REAR WHEEL DRIVE. HUB. veers 4-47
CHECKING AND REPLACING THE REAR WHEEL SPROCKET .. 4-47
CHECKING THE REAR WHEEL SPROCKET BRACKET .essssssssscssecseee 4-47
ASSEMBLING THE REAR WHEEL .. veeeee 4-48
MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR |
ROTOR... veveee 4-49
ADJUSTING THE REAR WHEEL STATIC. BALANCE... iiddueterieces Oe
INSTALLING THE REAR WHEEL (DISC BRAKE) ................eeeeeeee 4-49

FRONT BRAKE.. wee 4-52

INTRODUCTION .. weve D7
CHECKING THE FRONT BRAKE DISCS.
REPLACING THE FRONT BRAKE PADS...sider guttanesdusalstaateadetestsaesinect
saved 4-57
REMOVING THE FRONT BRAKE CALIPERS ............000 eee 4-59
DISASSEMBLING THE FRONT BRAKE CALIPERS. ............... cece 4-59
CHECKING THE FRONT BRAKE CALIPERS........000 occa 4-59
ASSEMBLING THE FRONT BRAKE CALIPERS... weve 4-59
INSTALLING THE FRONT BRAKE CALIPERS.. ......4-60
REMOVING THE FRONT BRAKE MASTER CYLINDER. eseseeeeees 4-61
CHECKING THE FRONT BRAKE MASTER CYLINDER. oscssssssssssssssseee 4-61
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER...........0.0..... 4-61
INSTALLING THE FRONT BRAKE MASTER CYLINDER..............000.... 4-61
 INTRODUCTION .. bee eeeeecesaeaeeneeceseeaetseeeesseseeeeeees 4°68
CHECKING THE REAR BRAKE DISC... piegashausastdsanadeieadegentciaessises OG
REPLACING THE REAR BRAKE PADS. ccccsssssssssssssssssssessesssssesesseeesseesee 4-68
REMOVING THE REAR BRAKE CALIPER ...00.. occ eee e settee eee 4°69
DISASSEMBLING THE REAR BRAKE CALIPER ......0... ee 4-69
CHECKING THE REAR BRAKE CALIPER................[Link] eee eee eee ee A470
ASSEMBLING THE REAR BRAKE CALIPER ...............cccceeeeeeeeeeeeeee
ee 4270
INSTALLING THE REAR BRAKE CALIPER... ve etsteeeeeeeeeseeeeeee
4°70
REMOVING THE REAR BRAKE MASTER CYLINDER .. Stenitentaeeraavenskeit
CHECKING THE REAR BRAKE MASTER CYLINDER svecccsssssssssssssssses 4-72
THE REAR BRAKE MASTER CYLINDER.. seseaeeeeeeeeseaeeee4002
INSTALLING THE REAR BRAKE MASTER CYLINDER... siveddeueveraztencse tere

ABS (Anti-lock Brake System)... ese caeeecuaccueeceeeescaseesescssecenncesseceseesssseess

4004
ABS COMPONENTS CHART .. dices duiwedivaviveteinecaar ee
REMOVING THE HYDRAULIC UNIT ASSEMBLY ... beeeeeeeeeeeeeneee el
CHECKING THE HYDRAULIC UNIT ASSEMBLY occccccccccccssssssssssceeeseeeee 4-78
CHECKING THE BRAKE PIPES... jideshadeguasageanecscenss 4-0 OG
INSTALLING THE HYDRAULIC UNIT ASSEMBLY... pesteseteeeeeeeee 4°78
HYDRAULIC UNIT OPERATION TEST voccccccscsssssssssssesessssssssssssevsseseseseeee 479
CHECKING THE ABS WARNING LIGHT ............... ee ceecce cesses ee eeeeeeeee 4°82

HANDLEBARS.. sid Sa wised waned Fatt SUS sb deehie a du saevasewsens es descend AOE
REMOVING THE HANDLEBARS ... eoeadeaespe,ecpeetegetaweceventgssateciety. so ee
CHECKING THE HANDLEBARS uv vsssssssscccessescseccssssssssssssssssssssssseeersereeee 4-86
INSTALLING THE HANDLEBARS ......00. oo. cece ceee cece cee ceneeeeeeeeeeeeeee ss 4°86

FRONT FORK (for YZF-R1)... beeen eeeeeeeesaseeeeeeeees4°89

REMOVING THE FRONT FORK LEGS (for YZF- -Ri).. Sedieedevarvesces ee
DISASSEMBLING THE FRONT FORK LEGS (for YZF-Ri).. sesneeeeeeeeseees 4°92
CHECKING THE FRONT FORK LEGS (for YZF-R1) ........00. ee 494
ASSEMBLING THE FRONT FORK LEGS (for YZF-R1)......................4°94
INSTALLING THE FRONT FORK LEGS (for YZF-R1) .........0.... 4-98

FRONT FORK (for YZF-R1M)... er setusdeddageietiestideatsiestsewee=FU

HANDLING THE FRONT FORK (for YZF-R1 M)... bee eaeeeeeeeeseeseeeeeees 42102
DISPOSING OF FRONT FORK LEG (for YZF-R1 M).. jdestanuveviwerdduaveenee Vee
REMOVING THE FRONT FORK LEGS (for YZF-R1 M) ccccccsccsccscccsssesee 4-102
DISASSEMBLING THE FRONT FORK LEGS (for YZF-R1M).............. 4-103
CHECKING THE FRONT FORK LEGS (for YZF-R1M) .......000000 4-104
ASSEMBLING THE FRONT FORK LEGS (for YZF-R1M)..........00000.. 4-104
INSTALLING THE FRONT FORK LEGS ....000 00 cece eee 4-106

STEERING HEAD... wo1s4°108

REMOVING THE LOWER BRACKET...
CHECKING THE STEERING HEAD vccccssssssssssessssessesessessssesssssssssesssesse 4-110
INSTALLING THE STEERING HEAD......000. 00... e cece ee eeee eee e eee eeeeteees 4-111
GHEGCRKING THE STEERING DAMPER vveiiccccteeiicecescccciciswcccseceteveriwsness 4-111
REAR SHOCK ABSORBER
THE REA R ASSEMBLY
SH OC K Re ..anER. sees eeeeueeseeeeeeuaeeeeeeeeeueees 4-112
eG
HANDLI NG
....4°116
DISPOSING OF A REAR SHOCK ABSORBER .. wieee4-116
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY... seveeeeee 40116
DISASSEMBLING THE REAR SHOCK ABSORBER ASSEMBLV....... 4-117
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................. 4-117
CHECKING THE CONNECTING ARM AND RELAY ARM................... 4-117
ASSEMBLING THE REAR SHOCK ABSORBER ASSEMBLY .............. 4-118
INSTALLING THE RELAY ARM... 114-118
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY .. 4-119

SWINGARM... weeeee4-120
REMOVING THE SWINGARM.. 4-122
CHECKING THE SWINGARM nmr 4-122
INSTALLING THE SWINGARM ooo -cccccccccccccscccccccecccseccccsececcsecceseccceseecce 4-123

CHAIN DRIVE... w+ 4-125

REMOVING THE DRIVE CHAIN... wee 4-126
CHECKING THE DRIVE CHAIN.. w4-126
CHECKING THE DRIVE SPROCKET... 4-127
CHECKING THE REAR WHEEL SPROCKET oocccccsssssssssssesssesssseeeceeee 4-127
CHECKING THE REAR WHEEL DRIVE HUB......... eects 4-127
INSTALLING THE DRIVE CHAIN ..000 0. e eee ee cee ee eee eeeeeeeneeeees 4-127
ADJUSTING THE SHIFT PEDAL. ...........c..c0cccecceecseeeseeeeeeeeseseeeeeeeeeseeeees 4-129
 GENERAL CHASSIS (1)
EAS20026

GENERAL CHASSIS (1)

Removing the seats and battery

Order Job/Parts to remove Q’ty Remarks

1 Rider seat
Passenger seat
co; &] Go| Po

ee

Battery cover
ee

Negative battery lead Disconnect.

ee

Positive battery lead Disconnect.

om)

Battery
ee

IMU coupler
CoO; “|

ee

IMU (Inertial Measurement Unit)

a
 GENERAL CHASSIS (1)

Removing the rear side covers and rear fender (for YZF-R1)

Order Job/Parts to remove Remarks

Refer to “GENERAL CHASSIS (1)” on page

Rider seat/Passenger seat/Battery cover
4-1.
Tail cover
bP] —

Seat lock bracket

Rear side inner cover (left)
o/]

Rear side outer cover (left)

om) &/]

mee

Rear side inner cover (right)

Rear side outer cover (right)
|
co; S|

Tail/brake light bracket

Tail/brake light coupler Disconnect.
Rear turn signal light coupler
O;}

Disconnect.
License plate light coupler Disconnect.
=k
©

Special washer
ak.
ol,

Mudguard assembly
ok
ho

Rear fender
ok
Go

Tail/brake light
—
A

4-2
 GENERAL CHASSIS (1)

Removing the rear side covers and rear fender (for YZF-R1M)

Order Job/Parts to remove Remarks

Refer to “GENERAL CHASSIS (1)” on page

Rider seat/Passenger seat/Battery cover
4-1.
Tail cover
bP] —

Seat lock bracket

Rear side cover (left)
o/]

Rear side cover (right)

om) &/]

ee

Tail/brake light bracket

Tail/brake light coupler Disconnect.
|
co; S|

Rear turn signal light coupler Disconnect.

License plate light coupler Disconnect.

Special washer
O;}

Mudguard assembly
=k
©

Rear fender
ak.
ol,

Se

Tail/brake light
—_h
ho

4-3
 GENERAL CHASSIS (1)

Disassembling the mudguard assembly

Order Job/Parts to remove Remarks

Mudguard assembly cover

—.

Clamp
G! Po

Stay
Rear turn signal light
om) om) &/]

Cover

License plate light

oO; S|)

Rear reflector
Rear reflector
Oo;

Reflector bracket

4-4
 GENERAL CHASSIS (1)
EA533139

REMOVING THE TAIL COVER

1. Remove:
© Tail cover “1”

EFAS31636

INSTALLING THE IMU

ECA22611

NOTICE
a. Remove the quick fasteners. ¢ Do not perform angle adjustment of the IMU
b. Unhook the projections “a” on the tail cov- and battery box by pinching the washer
er “1” from the holes “b” in the rear fender, and related parts.
and then remove the tail cover. ¢ When installing the IMU, apply a thin coat of
silicone grease onto the washer where con-
tacting the IMU grommet.
¢ When installing the IMU, use onlya genuine
bolt and washer, and tighten the bolt to the
specified torque.
¢ Pay attention not to expose the IMU to
strong shocks, such as striking or drop-
ping it.
*¢ Do not place any foreign objects in and
around the battery box.
EAS31908
¢ Do not obstruct breather opening “a” of the
REMOVING THE REAR SIDE COVER IMU.
The following procedure applies to both of the * Do not clean the breather opening and do
rear side covers. not blow it with compressed air.
1. Remove: ¢ When replacing the collar or grommet, re-
e Rear side inner covers and rear side outer place all four collars and grommets.
covers (YZF-R1) “1”
¢ Rear side covers (YZF-R1M) “1”

1
A —

Pott

1. Install:
a. Remove the bolts and quick fastener. e IMU (Inertial Measurement Unit) “1”
b. Unhook the projection “a” on the rear side a. Connect the IMU coupler “2” to the IMU.
inner covers (YZF-R1)/rear side covers b. Install the IMU “1”, washers and IMU bolts,
(YZF-R1M) from the hole “b” in the rear and then tighten the bolts to specification.
fender, and then remove the rear side in- TIP
ner covers (YZF-R1)/rear side covers
Apply a thin coat of silicone grease onto the
(YZF-R1M).
washers where contacting the grommets.

4-5
 GENERAL CHASSIS (1)

— Recommended lubricant INSTALLING THE TAIL COVER

Silicone grease 1. Install:
— e Tail cover “1”

\y IMU bolt
| 2.0 N-m (0.20 kgf-m, 1.5 Ib-ft)

a. Fit the projections “a” on the tail cover “1”

into the holes “b” in the rear fender, and
then install the quick fasteners.

EAS 31909

INSTALLING THE REAR SIDE COVER

The following procedure applies to both of the
rear side covers.
1. Install:
e Rear side cover “1”

a. Fit the projection “a” on the rear side in-

ner covers (YZF-R1)/rear side covers
(YZF-R1M) into the hole “b” in the rear
fender, and then tighten the rear side
cover bolts.

\y Rear side cover bolt

oN 9 N-m (0.9 kgf-m, 6.6 Ib-ft)

4-6
 GENERAL CHASSIS (2)

GENERAL CHASSIS (2)

EAS20155

Removing the CCU (for YZF-R1M)

Order Job/Parts to remove Remarks

Rider seat/Passenger seat/Battery cover Refer to “GENERAL CHASSIS (1)” on page

4-1,
Passenger seat cover
ks
—

GPS unit coupler

P|

Disconnect.
|e
cw)

Cushion
|
om) &;

GPS unit
|

Tail cover
ft

CCU coupler (sub-wire harness)

OO; oO; ~s) &)

Disconnect.
|

Band
fl

CCU (Communication Conirol Unit)

|

CCU bracket 1
fl

CCU bracket 2
=k
©

fc

Wire harness coupler Disconnect.

—_—
ol,

lt

Yamaha diagnostic tool coupler

=k
ho

Sub-wire harness
—k
Go

vm
 GENERAL CHASSIS (2)
EAS33363

REMOVING THE TAIL COVER

Refer to “GENERAL CHASSIS (1)” on page 4-1.
EASa3a71

INSTALLING THE CCU (for YZF-R1M)

TIP
When the passenger seat cover is attached, the
total number of occupants is reduced to one per-
son. Depending on your area’s regulations, it
may be necessary to change the vehicle’s regis-
tration to reflect this. Contact your local authori- c. Turn the main switch to “ON” and ap-
ties. proach the vehicle with a wireless capable
smartphone or tablet.
EASS1676 d. Connect to the wireless network “Yamaha
CONNECTING TO THE CCU (for YZF-R1M) Motor Network” by inputting the CCU seri-
The CCU (Communication Control Unit) con- al number as the password.
nects to the vehicle’s CAN (Controller Area Net- TIP
work) and has a GPS receiver to enable the Since all CCU-equipped models put out a simi-
recording of vehicle and riding data. (Refer to larly named wireless network, have only one ve-
“MENU SCREEN” on page 1-6.) Logging data hicle turned on at a time to avoid confusion.
and YRC setting data can be accessed when a
smartphone or tablet is connected to the CCU e. Install the passenger seat cover assembly
wireless network. to the original position, and then install the
TIP bolts.
From the Google®© or Apple© application store,
download the “Y-TRAC’ application to make use
yy Passenger seat cover bolt (for
YZF-R1M)
of the logging data and the “YRC Setting” appli- 7 N-m (0.7 kgf-m, 5.2 Ib-ft)
cation to remotely adjust the YRC settings.
FAS 33364
1. Connect: INSTALLING THE TAIL COVER
¢ CCU wireless network Refer to “GENERAL CHASSIS (1)” on page 4-1.
a. Remove the bolts “1” and then remove the
passenger seat cover assembly “2” as
shown.

b. Note down the CCU serial number “a”.

4-8
 GENERAL CHASSIS (3)
EA520156

GENERAL CHASSIS (3)

Removing the front panel covers

Order Job/Parts to remove Q’ty Remarks

1 Front panel (left)
|

Front panel cover (left)

Gc] Po

Front panel (right) For YZF-R1

|

Front panel (right) For YZF-R1M

&|

|
1)

Front panel cover (right)

me
mo)

Storage compartment
mf

4-9
 GENERAL CHASSIS (3)
EAS31 352
c. Unhook the projections “e” on the front
REMOVING THE FRONT PANEL (LEFT)
panel cover (left) from the holes “f’ on the
1. Remove:
front cowling.
¢ Front panel (left) “1”
d. Unhook the projections “g” on the front
panel cover (left) from the holes “h” on the
front upper cowling.

a4
1

a. Remove the quick fastener and bolt.

b. Slide the front panel (left) upward. Unhook
the projections “a” on the front panel (left)
“1” from the holes “b” in the front panel REMOVING THE FRONT PANEL (RIGHT)
cover (left). 1. Remove:
. Slide the front panel (left) forward. Unnook e Front panel (right) “1”
the projections “c” on the front panel (left)
“1” from the holes “d” in the front panel
cover (left).

a. Remove the quick fastener and bolt.

b. Slide the front panel (right) upward. Un-
hook the projections “a” on the front panel
EASS3347
(right) “1” from the holes “b” in the front
REMOVING THE FRONT PANEL COVER panel cover (right).
(LEFT) Slide the front panel (right) forward. Un-
1. Remove:
hook the projections “c” on the front panel
¢ Front panel cover (left) “1”
(right) “1” from the holes “d” in the front
panel cover (right).

a. Unhook the projection “a” on the front pan-

el cover (left) from the grommet “b” on the
side cover bracket.
b. Unhook the projections “c” on the front
panel cover (left) from the holes “d” on the
side cover bracket.

4-10
 GENERAL CHASSIS (3)
a. Fit the projections “a” on the front panel
REMOVING THE FRONT PANEL COVER
cover (left) into the holes “b” on the front
(RIGHT)
upper cowling.
1. Remove: b
. Insert the projections “c” on the front panel
¢ Front panel cover (right) “1”
cover (left) into the grommets “d” on the
side cover bracket.
c. Fit the projections “e” on the front panel
cover (left) into the holes “f’ on the front
cowiling.
d. Fit the projections “g” on the front panel
cover (left) into the grommets “h” on the
side cover bracket.
ae

a. Unhook the projection “a” on the front pan-

el cover (right) from the grommet “b” on
the side cover bracket.
b. Unhook the projections “c” on the front
panel cover (right) from the holes “d” on
the side cover (right).
c. Unhook the projections “e” on the front
panel cover (right) from the holes “f’ on the

d.
front cowling.
Unhook the projections “g” on the front
INSTALLING
1. Install:
THE FRONT PANEL (LEFT)
panel cover (right) from the holes “h’ on * Front panel (left) “1”
the front upper cowling.

a. Fit the projections “a” on the front panel

EASaa249 (left) “1” into the holes “b” in the front panel
ripe THE FRONT PANEL COVER cover (left). Slide the front panel (left) rear-
. ward.
1. Install: b. Fit the projections “c” on the front panel
¢ Front panel cover (left) “1 (left) “1” into the holes “b” in the front panel
cover (left). Slide the front panel (left)
downward.
c. Install the bolt and quick fastener.

y Front panel bolt (left)

> 3.8 N-m (0.38 kgf-m, 2.8 Ib-ft)

4-11
 GENERAL CHASSIS (3)

EAS33960 a. Fit the projections “a” on the front panel

INSTALLING THE FRONT PANEL COVER (right) “1” into the holes “b” in the front pan-
(RIGHT) el cover (right). Slide the front panel (right)
1. Install: rearward.
¢ Front panel cover (right) “1” b. Fit the projections “c” on the front panel
(right) “1” into the holes “d” in the front pan-
el cover (right). Slide the front panel (right)
downward.
c. Install the bolt and quick fastener.

Yy Front panel bolt (right)

> 3.8 N-m (0.38 kgf-m, 2.8 lb-ft)

a. Fit the projections “a” on the front panel

cover (right) into the holes “b” on the front
upper cowling.
b. Insert the projections “c” on the front panel
cover (right) into the grommets “d” on the
side cover (right).
c. Fit the projections “e” on the front panel
cover (right) into the holes “f’ on the front
cowling.
d. Fit the projections “g” on the front panel
cover (right) into the grommets “h” on the
side cover (right).

EASSSa52

INSTALLING THE FRONT PANEL (RIGHT)

1. Install:
¢ Front panel (right) “1”

4-12
 GENERAL CHASSIS (4)
EAS20157

GENERAL CHASSIS (4)

Removing the Rearview mirrors and windshield

Order Job/Parts to remove Q’ty Remarks

Front panel cover pre to “GENERAL CHASSIS (3)” on page

1 Front turn signal/position light coupler 2 Disconnect.

2 Rearview mirror 2
3 Front upper cowling 1
q Windshield 1

4-13
 GENERAL CHASSIS (4)
EAS31 362
d. Remove the front upper cowling bolts “7”.
REMOVING THE FRONT UPPER COWLING
1. Remove:
¢ Front upper cowling “1”

e. Remove the front upper cowling “1”.

f. Unhook the projections “a” on the front up-
per cowling from the holes “b” on the front
a. Remove the holder “2” from the front turn
cowling assembly. Unhook the projection
signal/position light lead (left) and auxiliary
“c’ on the front upper cowling from the
light lead. Disconnect the front turn signal/
grommets “d” in the front cowling assem-
position light coupler (left) “3”.
bly. Unhook the projections “e” on the front
upper cowling from the holes “f’ on the
front cowling assembly. Slide the front up-
per cowling upward and then, unhook the
holes “g” in the front upper cowling from
the projections “h” on the front cowling as-
sembly.
a

b. Disconnect the front turn signal/position

light coupler (right) “4”. Remove the front
turn signal/position light lead from the
holder “5”.

EAS31363

INSTALLING THE FRONT UPPER COWLING

1. Install:
e Front upper cowling “1”

c. Remove the rearview mirror nuts, and

then remove the rearview mirrors “6”.

a. Install the front upper cowling “1”.

b. Fit the holes “a” in the front upper cowling
into the projections “b” on the front cowling
assembly and then, slide the front upper
cowling downward. Fit the projection “c”

4-14
 GENERAL CHASSIS (4)
on the front upper cowling into the grom-
mets “d” in the front cowling assembly. Fit
the projections “e” on the front upper cowl-
ing into the holes “f’ on the front cowling
assembly. Fit the projections “g” on the
front upper cowling into the holes “h” on
the front cowling assembly.

c. Install the front upper cowling bolts “2”,

and then tighten the bolts to specification.

Front upper cowling bolt

4.0 N-m (0.40 kgf-m, 3.0 lb-ft)

d. Install the rearview mirrors “3” and rear-

view mirror nuts, and then tighten the nuts
to specification.

\y Rearview mirror nut

y 7 N-m (0.7 kgf-m, 5.2 |b-ft)

e. Connect the front turn signal/position light

couplers “4”.
Fasten the front turn signal/position light
leads to the holders “5”.

4-15
 GENERAL CHASSIS (5)
EAS201 58

GENERAL CHASSIS (5)

Removing the front side cowlings (for YZF-R1)

Order Job/Parts to remove Remarks

2
Zz

Front muffler protector (left)

oc} Po} —

|)

Front side cowling (left)

|

Front muffler protector (right)

|e

Front side cowling (right)

|

Bottom cowling
oO; ~) @) oy]

fm

Front side cowling bracket (front left)

Front side cowling bracket (rear left)
|
lf

Front side cowling bracket (front right)

Front side cowling bracket (rear right)
0;

em

4-16
 GENERAL CHASSIS (5)

Removing the front side cowlings (for YZF-R1M)

Order Job/Parts to remove Q'ty Remarks

Front muffler protector (left)

ek
om) &; ow} ho] —

Front side cowling (left)

oO; sm)

Front muffler protector (right)

emff |

Front side cowling (right)

mt |

Front side cowling bracket (front left)

Front side cowling bracket (rear left)
Front side cowling bracket (front right)
Front side cowling bracket (rear right)

4-17
 GENERAL CHASSIS (5)

REMOVING THE FRONT MUFFLER

PROTECTOR (LEFT)
1. Remove:
¢ Front muffler protector (left) “1”

EAS31696

REMOVING THE FRONT SIDE COWLING

(LEFT) (for YZF-R1)
1. Remove:
e Front side cowling (left) “1”
a. Remove the front muffler protector bolts
(left).
b. Pull the front muffler protector (left) “1”
downward.
c. Unhook the projections “a” on the front
muffler protector (left) “1” from the holes
“b” of the front cowling (left).

Remove the quick fastener screws.

of

Pull the front side cowling (left) “1” for-

ward, and then unhook the projection “a”
on the front side cowling (left) “1” from the
hole “b” of the front cowling.
c. Unhook the projections “c” on the front
side cowling (left) “1” from the slits “d” on
ian the front cowling.
Tmareen RAE meerLer d. Unhook the projections “e” on the front
1R ( side cowling (left) “1” from the holes “f’ on
o¢ cetsa en the bottom cowling.
Front muffler protector (right) “1”
Unhook the projections “g” on the front
©

side cowling (left) “1” from the holes “h’ on

the bottom cowling.

a. Remove the front muffler protector bolts

(right).
b. Pull the front muffler protector (right) “1”
downward.
c. Unhook the projections “a” on the front
muffler protector (right) “1” from the holes
“b” of the front cowling (right).

4-18
 GENERAL CHASSIS (5)
a. Remove the front side cowling bolts, quick
REMOVING THE FRONT SIDE COWLING
fastener screws and quick fasteners.
(RIGHT) (for YZF-R1)
b. Pull the front side cowling (left) “1” for-
1. Remove:
ward, and then unhook the projection “a”
* Front side cowling (right) “1”
on the front side cowling (left) “1” from the
hole “b” of the front cowling.
Unhook the projection “c” on the front side
cowling (left) “1” from the slit “d” on the
front cowling.

Remove the quick fastener screws.

oP

Pull the front side cowling (right) “1” for-

ward, and then unhook the projection “a”
on the front side cowling (right) “1” from
the hole “b” of the front cowling.
EAS33351
Unhook the projections “c” on the front REMOVING THE FRONT SIDE COWLING
side cowling (right) “1” from the slits “d” on (RIGHT) (for YZF-R1M)
the front cowling. 1. Remove:
Remove the projections “e” on the front ¢ Front side cowling (right) “1”
side cowling (right) “1” from the holes “f’
on the bottom cowling.
Remove the projections “g” on the front
side cowling (right) “1” from the holes “h”
on the bottom cowling.

a. Remove the front side cowling bolts and

quick fastener screws.
b. Pull the front side cowling (right) “1” for-
ward, and then unhook the projection “a”
on the front side cowling (right) “1” from
the hole “b” of the front cowling.
REMOVING THE FRONT SIDE COWLING
Unhook the projection “c’” on the front side
(LEFT) (for YZF-R1M)
cowling (right) “1” from the hole “d” on the
1. Remove:
front cowling.
¢ Front side cowling (left) “1”

4-19
 GENERAL CHASSIS (5)
EAS33341
Fit the projection “a” on the front side cowl-
INSTALLING THE FRONT SIDE COWLING
ing (left) “1” into the hole “b” on the front
(RIGHT) (for YZF-R1)
cowiling.
1. Install:
Fit the projection “c” on the front side cowl-
* Front side cowling (right) “1”
ing (left) “1” into the slits “d” on the front
cowling.
Fit the projections “e” on the front side
cowling (left) “1” into the holes “f’ on the
bottom cowiling.
. Fit the projections “g” on the front side
cowling (left) “1” into the holes “h” on the
bottom cowling.

Fit the projection “a” on the front side cowl-

ing (right) “1” into the hole “b” on the front
cowling and slide the front side cowling
(right) “1” backward.
Fit the projection “c” on the front side cowl-
ing (right) “1” into the slits “d” on the front
cowling.
Fit the projections “e” on the front side
e. Install the quick fastener screws.
cowiling (right) “1” into the holes “f’ on the
bottom cowling. EAS33353

Fit the projections “g” on the front side INSTALLING THE FRONT SIDE COWLING
cowling (right) “1” into the holes “h’ on the (RIGHT) (for YZF-R1M)
bottom cowling. 1. Install:
e Front side cowling (right) “1”

e. Install the quick fastener screws.

a. Fit the projection “a” on the front side cowl-
EASS1697
ing (right) “1” into the hole “b” on the front
INSTALLING THE FRONT SIDE COWLING
cowiling.
(LEFT) (for YZF-R1)
b. Fit the projection “c” on the front side cowl-
1. Install:
ing (right) “1” into the hole “d” on the front
¢ Front side cowling (left) “1”
cowiling.

4-20
 GENERAL CHASSIS (5)
EASS3367

INSTALLING THE FRONT MUFFLER

PROTECTOR (LEFT)
1. Install:
¢ Front muffler protector (left) “1”

c. Install the front side cowling bolts, quick

fastener screws and quick fasteners.

a. Fit the projections “a” on the front muffler

protector (left) “1” into the holes “b” of the
INSTALLING THE FRONT SIDE COWLING front cowling (left).

(LEFT) (for YZF-R1M) b. Tighten the front muffler protector bolt.

1. Install:
¢ Front side cowling (left) “1”

a. Fit the projection “a” on the front side cowl-

ing (left) “1” into the hole “b” on the front

b. Fit the projection “c” on the front side cowl- EECTAH IE, MUFFLER
ing (left) “1” into the hole “d” on the front 4 Inetall ( T)
cowling. . Insta:
e Front muffler protector (right) “1”

c. Install the front side cowling bolts, quick Co

fastener screws and quick fasteners. a. Fit the projections “a” on the front muffler
protector (right) “1” into the holes “b” of the
\y Front side cowling bolt front cowling (right).
eS 9 N-m (0.9 kgf-m, 6.6 Ib-ft) b. Tighten the front muffler protector bolt.

4-21
 GENERAL CHASSIS (5)

Front muffler protector bolt

7 N-m (0.7 kgf-m, 5.2 Ib-ft)

4-22
 GENERAL CHASSIS (6)
EAS20159

GENERAL CHASSIS (6)

Removing the side covers and front cowling assembly

Order Job/Parts to remove Q'ty Remarks

Front panel cover cao to “GENERAL CHASSIS (3)” on page

Windshield Fit to “GENERAL CHASSIS (4)” on page

Front side cowling yd to “GENERAL CHASSIS (5)” on page

Side cover (left)

Gc!) ho} —

Side cover (right)

|

Fuse box
|

Front side cowling inner panel (right)

Oo; &|

Front side cowling inner panel (left)

Steering damper solenoid coupler Disconnect.
~!) @)>

ep

Intake solenoid coupler Disconnect.

mek

4-23
 GENERAL CHASSIS (6)

Removing the side covers and front cowling assembly

Order Job/Parts to remove Q’ty Remarks

8 Auxiliary light coupler 1 Disconnect.

9 Headlight control unit coupler 1 Disconnect.
10 Meter assembly coupler 1 Disconnect.

11 Sub-wire harness coupler 1 a ee

12 Front fork stepping motor coupler 1 Bel Lae

13 Intake solenoid vacuum hose 1 Disconnect.

14 Surge tank hose 1 Disconnect.
15 Front cowling assembly 1
16 Side cover bracket (right) 1
17 Damper 1

4-24
 GENERAL CHASSIS (6)

Disassembling the front cowling assembly

* When installing the auxiliary light onto the front cowling, tighten this screw last.

Order Job/Parts to remove Q’ty Remarks

1 Meter assembly 1
2 Headlight control unit coupler 1 Disconnect.
3 Headlight 1

4 SCU coupler 1 Beal ae

5 SCU cover 1 For YZF-R1iM

6 SCU (Suspension Control Unit) 1 For YZF-R1M
7 SCU bracket 1 For YZF-R1M
8 Auxiliary light (left) 1
9 Auxiliary light (right) 1
10 Front cowling assembly stay 1
11 Front cowling 1

4-25
 GENERAL CHASSIS (6)

REMOVING THE SIDE COVER (LEFT)

1. Remove:
e Side cover (left) “1”

EAS33356

INSTALLING THE SIDE COVER (LEFT)

1. Install:
e Side cover (left) “1”
a. Remove the side cover bolt (right) and
quick fastener.
b. Pull the side cover (left) “1” rearward and
unhook the projections “a” on the side cov-
er (left) “1” from the holes “b” of the side
cover bracket.

a. Fit the projections “a” on the side cover

(left) into the holes “b” of the side cover
bracket “1” and slide the side cover (left)
forward.

REMOVING THE SIDE COVER (RIGHT)

1. Remove:
¢ Side cover (right) “1”

b. Install the side cover bolt (left) and quick

fastener.

\y Side cover bolt (left)

Q 7 N-m (0.7 kgf-m, 5.2 Ib-ft)

a. Remove the side cover (left) bolts. FAS33380

b. Pull the side cover (right) “1” downward INSTALLING THE SIDE COVER BRACKET
and remove the hole “a” of the side cover (RIGHT)
(right) “1” from the projection “b” on the 1. Install: |
side cover bracket (right). ¢ Side cover bracket (right) “1”
e Damper

\y Side cover bracket bolt (right)

& 7 N-m (0.7 kgf-m, 5.2 lb-ft)

4-26
 GENERAL CHASSIS (6)
TIP
e Insert the projection “a” on the side cover
bracket (right) “1” in the hole of the frame.
¢ Hook the projection “b” on the side cover
bracket (right) “1” to the frame.
e Push the projection “b” on the side cover brack-
et (right) “1” to align the hole “c” on the side
cover bracket (right) “1” with the hole on the
frame.

INSTALLING THE SIDE COVER (RIGHT) b. Install the side cover bolt (right).

1. Install: a \y Side cover bolt (right)

¢ Side cover (right) “1 | 7 Nem (0.7 kgf-m, 5.2 lb-ft)

a. Fit the hole “a” in the side cover (right) “1”

onto the projection “b” on the side cover
bracket and slide the side cover (right) up-
ward.
TIP
e Position the front cowling assembly “2” on the
side cover (right) “1”.
e Make sure that there is projection “c” on the
side cover (right) “1” in the hole “d” in the front
cowling assembly “2”.

4-27
 GENERAL CHASSIS (7)
EAS20193

GENERAL CHASSIS (7)

Removing the air intake duct

Order Job/Parts to remove Q’ty Remarks

Front panel cover pre to “GENERAL CHASSIS (3)” on page

Windshield ae to “GENERAL CHASSIS (4)” on page

Front side cowling ae. to “GENERAL CHASSIS (5)” on page

Side cover/Front cowling assembly Ae to "GENERAL CHASSIS (6)" on page

1 Intake solenoid vacuum hose 1

2 Surge tank hose 1
3 One-way valve 1
4 Intake solenoid vacuum hose (one-way valve to {
intake solenoid)
5 Intake solenoid vacuum hose (intake solenoid to {
air intake duct valve)

4-28
 GENERAL CHASSIS (7)

Removing the air intake duct

Order Job/Parts to remove Q’ty Remarks

6 Intake solenoid lead (sub-wire harness) 1
7 Intake solenoid bracket 1
8 Intake solenoid 1
9 Air duct 1
10 Surge tank 1
11 Diaphragm 1
12 Air intake duct assembly 1
13 Air intake duct 1
14 Air intake duct guard 1
15 Air intake duct valve 1

4-29
 GENERAL CHASSIS (7)
EASS1645

CHECKING THE AIR INTAKE DUCT VALVE

——t
1. Check:
¢ Air intake duct valve operation
a. Connect the vacuum/pressure pump
gauge set “1” to the air intake duct valve
“or

Vacuum/pressure pump gauge

set
90890-06945
Pressure/vacuum tester 4. Check:
YB-35956-B e Intake solenoid
Damage — Replace.
b. Check that the air intake duct valve oper- 5. Check:
ates when vacuum pressure is applied to e Intake solenoid
the valve using the vacuum/pressure Refer to “SELF-DIAGNOSTIC FUNCTION
pump gauge set. AND DIAGNOSTIC CODE TABLE” on page
Faulty — Replace the air intake duct 9-32.
valve. 6. Check:
e Surge tank
Cracks/damage —> Replace.
EAS33358

ASSEMBLING THE AIR INTAKE DUCT

ASSEMBLY
1. Install:
e Air intake duct (left)
e Air intake duct (right) “1”
e Air intake duct valve “2”
e Air intake duct guard
EASS1B46 e Rubber damper “3”
CHECKING THE VACUUM LINE
1. Check:
¢ Hoses
Loose connections — Connect properly.
Cracks/damage —> Replace. TIP
2. Check: * Install the air intake duct valve within the range
¢ Surge tank of stopper portion “a” and projection “b” inside
Cracks/damage —> Replace. the air intake duct.
3. Check: * Install the rubber damper “3” in the direction of
* One-way valve the illustration so that it makes contact with
Cracks/damage/faulty — Replace. stepped portion “c’” of the air intake duct.
TIP ¢ After installing the air intake duct, make sure
Check that air flows smoothly only in the direc- that there is no gap between the air intake duct
tion of the arrow shown in the illustration. (left) and the air intake duct (right).

4-30
 GENERAL CHASSIS (7)

EASSa1647

INSTALLING THE AIR INTAKE DUCT VALVE

1. Install:
¢ Air intake duct valve
a. Hook the end of the shaft “a” onto the plate
“1” as shown.

b. Align the tabs “b” on the air intake duct

valve “2” with the cutouts “c” in the air in-
take duct “3”, and then turn the air intake
duct valve 90° clockwise.

4-31
 GENERAL CHASSIS (8)
EAS20194

GENERAL CHASSIS (8)

Removing the ECU and side cover bracket

Order Job/Parts to remove Q’ty Remarks

Front panel cover (left) pre to “GENERAL CHASSIS (3)” on page

Front side cowling (left) me to “GENERAL CHASSIS (5)” on page

Side cover (left) ioe to “GENERAL CHASSIS (6)” on page

1 ECU cover 1
2 ECU coupler 3 Disconnect.
3 ECU (Engine Control Unit) 1
4 Wire harness holder 1
5 Side cover bracket 1
6 Side cover bracket damper 1

4-32
 GENERAL CHASSIS (8)
EAS31641

REMOVING THE ECU (engine control unit)

1. Disconnect:
¢ ECU coupler “1”
TIP
While pushing the portion “a” of the ECU cou-
pler, move the lock lever “b” in the direction of
the arrow shown to disconnect the coupler.

EASS1 642

INSTALLING THE ECU (engine control unit)

1. Connect:
e ECU coupler “1”
TIP
Connect the ECU coupler, and then push the
lock lever “a” of the coupler in the direction of the
arrow shown.

4-33
 GENERAL CHASSIS (9)
EAS201 95

GENERAL CHASSIS (9)

Removing the electrical components tray

Order Job/Parts to remove Q’ty Remarks

Front panel cover (left) can to “GENERAL CHASSIS (3)” on page

Side cover (left)/Front side cowling inner panel Refer to “GENERAL CHASSIS (6)” on page
(left) 4-23.
1 Radiator fan motor coupler 2 Disconnect.
2 Handlebar switch coupler (right) 4 Disconnect.
3 Handlebar switch coupler (left) 2 Disconnect.
4 Rectifier/regulator coupler 1 Disconnect.
5 Electrical components tray 1
6 Rectifier/regulator 1

4-34
 FRONT WHEEL

EAS20028

FRONT WHEEL
Removing the front wheel and brake discs (for YZF-R1)

Order Job/Parts to remove Q'ty

Reflector bracket
—.

PO] PO! PO

Reflector
Gc! Po

Front brake hose holder

&/}

Front wheel sensor

|
|) B] PO]

Front brake caliper

oy]

Wheel axle pinch bolt Loosen.

&!)
co; S|)

Front wheel axle nut

Se]

Front wheel axle

RO] PO) RO; —)

Front wheel
;

Collar
—_h
oS

Front brake disc

oll,
ol,

Plate
ok
ho

4-35
 FRONT WHEEL

Removing the front wheel and brake discs (for YZF-R1M)

Order Job/Parts to remove Q'ty Remarks

Reflector bracket
PO
cw] ho]

Reflector
OPO

Front brake hose holder

mH] BO

Front wheel sensor protector

om) om) &/]

HS]

Front wheel sensor

PO]

Front brake caliper

OO; oO; S|)

Wheel axle pinch bolt Loosen.

|
|]

Front wheel axle nut

aS)

Front wheel axle

Front wheel
ok

RO) PO] ROP oe

©

Collar
4+
ok,

Front brake disc

—_h
no

Plate
=k
Go

4-36
 FRONT WHEEL

Disassembling the front wheel

Order Job/Parts to remove Q’ty Remarks

1 Front wheel sensor rotor 1

2 Oil seal 2
3 Wheel ring 1
4 Wheel bearing 2
5 Spacer 1

4-37
 FRONT WHEEL

EA530145
¢ Wheel bearings
REMOVING THE FRONT WHEEL
ECA20981
a. Clean the surface of the front wheel hub.
NOTICE b. Remove the oil seals “1” with a flat-head
screwdriver.
« Keep any type of magnets (including mag-
netic pick-up tools, magnetic screwdrivers, TIP
etc.) away from the front wheel sensor or To prevent damaging the wheel, place a rag “2”
front wheel sensor rotor; otherwise, the between the screwdriver and the wheel surface.
sensor or rotor may be damaged, resulting
in improper performance of the ABS sys- 2> a
tem.
¢ Do not drop the front wheel sensor rotor or
subject it to shocks.
¢ If any solvent gets on the front wheel sen- 7 ee OS
sor rotor, wipe it off immediately.
:
2a
1. Stand the vehicle on a level surface. I

EWAI13120

GO088896

Securely support the vehicle so that there is c. Remove the wheel bearings with a gener-
no danger of it falling over. al bearing puller.
2. Remove: EFAS S0147

¢ Front brake caliper (left) CHECKING THE FRONT WHEEL

¢ Front brake caliper (right) 1. Check:
¢ Front wheel sensor e Wheel axle
ECA21440
Roll the wheel axle on a flat surface.
NOTICE Bends —> Replace.
¢ Do not apply the brake lever when remov- EW A1S460

ing the brake calipers.

¢ Be sure not to contact the sensor electrode Do not attempt to straighten a bent wheel ax-
to any metal part when removing the front le.
wheel sensor from the sensor housing.
2. Check:
3. Elevate: e Tire
* Front wheel e Front wheel
TIP Damage/wear — Replace.
Place the vehicle on a maintenance stand so Refer to “CHECKING THE TIRES” on page
that the front wheel is elevated. 3-17 and “CHECKING THE WHEELS?” on
page 3-17.
4. Loosen: 3. Measure:
¢ Wheel axle pinch bolt e Radial wheel runout “1”
5. Remove: e Lateral wheel runout “2”
e Front wheel axle Over the specified limits - Replace.
e Front wheel
Radial wheel runout limit
E4S530146
1.0 mm (0.04 in)
DISASSEMBLING THE FRONT WHEEL
ECA21340
Lateral wheel runout limit
NOTICE 1.0 mm (0.04 in)
¢ 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.
1. Remove:
« Oil seals

4-38
 FRONT WHEEL

TIP
2 Place a suitable washer “1” between the socket
“2 and the bearing so that both the inner race
“3” and outer race “4” are pressed at the same

=
time, and then press the bearing until the inner
race makes contact with the spacer “5”.

G088897
v
2
4. Check:
¢ Wheel bearings
pL
4 4 —1

ft tel
Front wheel turns roughly or is loose —> Re-
place the wheel bearings.
* Oil seals
Damage/wear — Replace. -—§
GO088899
E4530151
d. Install the new oil seals.
ASSEMBLING THE FRONT WHEEL
ECA21340
2. Install:
NOTICE e Front wheel sensor rotor
¢ Do not drop the wheel sensor rotor or sub- Wheel sensor rotor bolt
ject it to shocks. 8 N-m (0.8 kgf-m, 5.9 Ib-ft)
¢ If any solvent gets on the wheel sensor ro- LOCTITE®
tor, wipe it off immediately.
ECA? 200
1. Install: NOTICE
* Wheel bearings KET Replace the wheel sensor rotor bolts with
* Oil seals DENT new ones.
a. Install the new wheel bearing (right side).
ECA18110 TIP
NOTICE Install the wheel sensor rotor with the stamped
Do not contact the wheel bearing inner race mark “1” facing outward.
“1” or balls “2”. Contact should be made
only with the outer race “3”.
1

TIP
Use a socket “4” that matches the diameter of
the wheel bearing outer race. fo
a/O

GO8s900

3. Measure:
¢ Wheel sensor rotor runout
Out of specification — Correct the wheel sen-
sor rotor runout or replace the wheel sensor
rotor.
G088898
Refer to “MAINTENANCE OF THE FRONT
b. Install the spacer. WHEEL SENSOR AND SENSOR ROTOR”
c. Install the new wheel bearing (left side). on page 4-40.

a Wheel sensor rotor runout limit

0.25 mm (0.01 in)

4-39
 FRONT WHEEL

EA530155
a. Hold the dial gauge ata right angle against
MAINTENANCE OF THE FRONT WHEEL
the wheel sensor rotor surface.
SENSOR AND SENSOR ROTOR
EGA?1070
b. Measure the wheel sensor rotor runout.
NOTICE
¢e Handle the ABS components with care rt

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. a2
« Keep any type of magnets (including mag- GO088902
netic pick-up tools, magnetic screwdrivers,
etc.) away from the front wheel sensor or c. If the runout is still above specification, re-
place the wheel sensor rotor.
front wheel sensor rotor.
¢ Do not drop or shock the wheel sensor or EASS0152

the wheel sensor rotor. ADJUSTING THE FRONT WHEEL STATIC

BALANCE
1. Check:
TIP
¢ Front wheel sensor “1”
Cracks/bends/distortion — Replace. ¢ After replacing the tire, wheel or both, the front
lron powder/dust — Clean. wheel static balance should be adjusted.
¢ Adjust the front wheel static balance with the
brake disc installed.
¢ Be sure to use stick-on type balancing weights.
1. Remove:
e Balancing weight(s)
2. Find:
¢ Front wheel’s heavy spot
3. Adjust:
e Front wheel static balance
4. Check:
2. Check: e Front wheel static balance
¢ Front wheel sensor rotor EFAS S0154
Cracks/damage/scratches — Replace the INSTALLING THE FRONT WHEEL (DISC
front wheel sensor rotor. BRAKE)
lron powder/dust/solvent — Clean. 1. Install:
TIP e Plate
¢ The wheel sensor rotor is installed on the inner ¢ Front brake discs
side of the wheel hub.
XY Front brake disc bolt
ay
e When cleaning the wheel sensor rotor, be
17 N-m (1.7 kgf-m, 13 Ib-ft)
careful not to damage the surface of the sensor
LOCTITE®
rotor.
ECA19150
3. Measure:
NOTICE
¢ Wheel sensor rotor runout
Out of specification — Clean the installation Replace the brake disc bolts with new ones.
surface of the wheel sensor rotor and correct TIP
the wheel sensor rotor runout, or replace the
Tighten the brake disc bolts in stages and ina
wheel sensor rotor.
crisscross pattern.

I Wheel sensor rotor runout limit

0.25 mm (0.01 in)
2. Apply:
e Sealant

4-40
 FRONT WHEEL

ECA14140
TIP
NOTICE
ac Auld teil 2155® onto the comer Before tightening the wheel axle nut, push
down hard on the handlebar(s) several times
and check if the front fork rebounds smooth-
ly.
7. Tighten:
e Front wheel axle pinch bolt
a. Tighten the pinch bolt “2”, pinch bolt “1”,
and pinch bolt “2” to the specified torque in
\ ; this order.

=. \y Front wheel axle pinch bolt

2 &, 21 N-m (2.1 kgf-m, 15 Ib-ft)

b. Check that the right end “a” of the front

axle is flush with the front fork “b”. If nec-
essary, manually push the front axle or
lightly tap it with a soft hammer until its end
is flush with the front fork. However, if the
surface of the front axle end is not parallel
to the surface of the front fork, align a point
on the outer edge of the axle with the fork,
making sure that the axle does not pro-
trude past the fork.
3. Check: 1) HI
¢ Front brake discs 0] / a b
Refer to “CHECKING THE FRONT BRAKE 3 © vk
DISCS” on page 4-57. O} ) Ge
(op
4. Lubricate: ”
* Oil seal lips ( or (@
Recommended lubricant
Y XX |
-aB+ ng O \\ . () \ _
Lithium-soap-based grease | & 06 © \ :
\
5. Install:
* Collar c. Tighten the pinch bolt “4”, pinch bolt “S”,
* Front wheel and pinch bolt “4” to the specified torque in
e Front wheel axle this order.

Eroubyiniee! ete Tut \y Front wheel axle pinch bolt

TIP S| 21. Nem (2.1 kgf-m, 15 Ib-ft)
Apply lithium soap-based grease onto the mat-
ing surface of the front wheel axle nut.
’ {
6. Tighten: O f \ 4
e Front wheel axle nut 2 |

Front wheel axle nut I |

ON 115 N-m (11.5 kgf-m, 85 Ib-ft) 5

4-41
 FRONT WHEEL

8. Install:
¢ Front wheel sensor Séls| Thickness gauge
¢ Front wheel sensor protector (for YZF-R1M) i 90890-03268
Feeler gauge set
N Front wheel sensor bolt YU-26900-9
%& 7 N-m (0.7 kgf-m, 5.2 Ib-ft)
Front wheel sensor protector bolt
(for YZF-R1M)
7 N-m (0.7 kgf-m, 5.2 Ib-ft)
ECA21020

NOTICE
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. [Link]:
TIP
e Front brake calipers
¢ Front brake hose holder
e When installing the front wheel sensor, check
the front wheel sensor lead for twists. Front brake caliper bolt
¢ To route the front wheel sensor lead, refer to 35 N-m (3.5 kgf-m, 26 Ib-ft)
“CABLE ROUTING” on page 2-17. Front brake hose holder bolt
6 N-m (0.6 kgf-m, 4.4 Ib-ft)
9. Measure:
¢ Distance “a” EWA13500

(between the front wheel sensor rotor “1” and

front wheel sensor “2”) Make sure the brake hose is routed properly.
Out of specification — Check the wheel bear-
ing for looseness, and the front wheel sensor
and sensor rotor installation conditions
(warpage caused by overtorque, wrong in-
stallation direction, rotor decentering, LOC-
TITE® on the mounting surface of the rotor,
deformation caused by an impact during ser-
vice and caught foreign materials). If there is
any defective part, repair or replace the de-
fective part.

a Distance “a” (between the front

wheel sensor rotor and front
wheel sensor)
0.9-—1.7 mm (0.035—0.067 in) (for
YZF-R1)
1.1-1.9 mm (0.043-0.075 in) (for
YZF-R1M)

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.

4-42
REAR WHEEL

co
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at
o
Oo
oo
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Cc
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s —- - (NN Pr ee Pre eK le le le

4-43
go
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=or| |.2
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fe isl5|5 = 5 | ¥%

Sisisis| leiz| |3li3) |f

a (2%/G = |& ow

e\sls|
Oo} | a =|6
isis| lgsisis|é
ai8/g 7
Removing the rear wheel

Siojcel/e|Plcl_j/£/2\/2/</8
O/S/S/2/H/F/O/F
|S /5/5
REAR WHEEL

SiG /G(/GlA/G/8iGlS/5)/a
\¥s
Pidloal lo lolol/Lliololia\|ao/z
ric elsit ie le ioc lt |e io jo

fe
® ol-
v —- IN |M lt | /O[nR |oO loa |S IT
©
EAS20029
 REAR WHEEL

Removing the brake disc and rear wheel sprocket

Order Job/Parts to remove Q'ty Remarks

Rear wheel sensor rotor

—.

ek] kek

Rear brake disc

G! Po

ee)

Brake disc carrier

Rear wheel sprocket bracket
om) om) &/]

Rear wheel sprocket

Collar
oO; S|)

Collar
Oil seal
meee
Oo;

Bearing
Rear wheel drive hub 1
—h
©

Rear wheel drive hub damper

4+
ok,

me |

Rear wheel drive hub 2

—_h
no

CD)

Gasket
—k
we

me]

Rear wheel
ok
&

4-44
 REAR WHEEL

Disassembling the rear wheel

Order Job/Parts to remove Q’ty Remarks

1 Collar 1
2 Oil seal 1
3 Wheel bearing 1
4 Spacer 1
5 Oil seal 1
6 Wheel bearing ring nut 1
7 Wheel bearing 1

4-45
 REAR WHEEL

EAS530910 ECA21040

REMOVING THE REAR WHEEL NOTICE

ECA21030

NOTICE ¢ Do not depress the brake pedal when re-

moving the brake caliper.
« Keep any type of magnets (including mag-
¢ Be sure not to contact the sensor electrode
netic pick-up tools, magnetic screwdrivers,
to any metal part when removing the rear
etc.) away from the rear wheel sensor or
wheel sensor from the rear brake caliper
rear wheel sensor rotor; otherwise, the sen-
bracket.
sor or rotor may be damaged, resulting in
improper performance of the ABS system. 3. Loosen:
¢ Do not drop the rear wheel sensor rotor or ¢ Locknuts
subject it to shocks. ¢ Adjusting bolts
¢ If any solvent gets on the rear wheel sensor 4. Remove:
rotor, wipe it off immediately. ¢« Rear wheel axle nut
e Washer
1. Stand the vehicle on a level surface.
EWAI3120
e Rear wheel axle
e Rear wheel
¢ Brake caliper bracket
Securely support the vehicle so that there is ECA21400
no danger of it falling over. NOTICE
TIP Be sure to remove the rear wheel sensor be-
Place the vehicle on a maintenance stand so fore removing the brake caliper bracket, oth-
that the rear wheel is elevated. erwise the sensor could be damaged.
TIP
Push the rear wheel forward and remove the
drive chain from the rear wheel sprocket.

FAS30158

DISASSEMBLING THE REAR WHEEL

EC A21340

NOTICE
¢ 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.
1. Remove:
¢ Wheel bearing ring nut “1”
TIP
Use the wheel bearing ring nut tool “2” to remove
the wheel bearing ring nut by turning it clockwise
fa

Wheel bearing ring nut tool

A. Recommended tool 90890-01574
Tool No.: 2CR-271A0-00 YM-01574
Tool name: STAND HOOK M1 Type

2. Remove:
¢ Rear brake caliper
¢« Rear wheel sensor protector
¢« Rear wheel sensor

4-46
 REAR WHEEL

¢ Rear wheel drive hub dampers

Damage/wear — Replace.
FASS0161

CHECKING AND REPLACING THE REAR

WHEEL SPROCKET
1. Check:
¢ Rear wheel sprocket
More than 1/4 tooth “a” wear —> Replace the
drive sprocket, the rear wheel sprocket and
the drive chain as a set.
Bent teeth — Replace the drive sprocket, the
rear wheel sprocket and the drive chain as a
set.

Ly (ac

a3 \ = |

Kar | Pe)
2. Remove:
¢ Oil seal GOos8s904

¢ Wheel bearings b. Correct

Refer to “DISASSEMBLING THE FRONT 1. Drive chain roller
WHEEL” on page 4-38. 2. Rear wheel sprocket
EA4530159
2. Replace:
CHECKING THE REAR WHEEL
¢ Rear wheel sprocket
1. Check:
a. Remove the rear wheel sprocket nuts,
e Wheel axle
rear wheel sprocket bracket and the rear
¢ Wheel bearings
wheel sprocket.
e Oil seals
b. Clean the rear wheel drive hub with a
Refer to “CHECKING THE FRONT WHEEL”
clean cloth, especially the surfaces that
on page 4-38.
contact the sprocket.
2. Check:
c. Install the new rear wheel sprocket and
e Tire
rear wheel sprocket bracket.
e Rear wheel
Damage/wear — Replace. Rear wheel sprocket nut
Refer to “CHECKING THE TIRES” on page > 100 N-m (10 kgf-m, 74 Ib-ft)
3-17 and “CHECKING THE WHEELS?” on
page 3-17. TIP
3. Measure: Tighten the rear wheel sprocket nuts in stages
e Radial wheel runout and in a crisscross pattern.
e Lateral wheel runout
Refer to “CHECKING THE FRONT WHEEL” EAS33361
on page 4-38. CHECKING THE REAR WHEEL SPROCKET
EA4S30760
BRACKET
CHECKING THE REAR WHEEL DRIVE HUB 1. Check:
1. Check: ¢ Rear wheel sprocket bracket
¢ Rear wheel drive hub Cracks/damage — Replace.
Cracks/damage —> Replace.

4-47
 REAR WHEEL

EA530163

ASSEMBLING THE REAR WHEEL Wheel bearing ring nut tool

ECA21340
90890-01574
NOTICE
YM-01574
¢ Do not drop the wheel sensor rotor or sub-
ject it to shocks.
¢ If any solvent gets on the wheel sensor ro- Wheel bearing ring nut
tor, wipe it off immediately. 80 N-m (8.0 kgf-m, 59 Ib-ft)
LOCTITE®
1. Install:
¢ Wheel bearings DEW
* Oil seal DEW
Refer to “ASSEMBLING THE FRONT
WHEEL” on page 4-39.
2. Install:
¢ Wheel bearing ring nut
TIP
Apply locking agent (LOCTITE®) onto the two
symmetric places on the circumference of the
threads of the wheel bearing ring nut.

4. Apply:
¢ Sealant
TIP
Apply Three Bond No. 1215B® between the
wheel bearing ring nut and the wheel surface.

a. Width: two grooves of the threaded portion

b. Length: more than 40 mm (1.57 in)

3. Tighten:
¢ Wheel bearing ring nut “1”
TIP
Use the wheel bearing ring nut tool “2” to tighten
the wheel bearing ring nut by turning it counter-
clockwise “a”.

4-48
 REAR WHEEL

¢ Be sure to use stick-on type balancing weights.

1. Adjust:
e Rear wheel static balance
Refer to “ADJUSTING THE FRONT WHEEL
STATIC BALANCE” on page 4-40.
EAS30165

INSTALLING THE REAR WHEEL (DISC

BRAKE)
1. Install:
e Rear brake disc
EASSa01 67 e Rear wheel sensor rotor
MAINTENANCE OF THE REAR WHEEL
SENSOR AND SENSOR ROTOR YX Rear brake disc bolt
ECA21060

NOTICE % 30 N-m (3.0 kgf-m, 22 lb-ft)

LOCTITE®
¢ Handle the ABS components with care Rear wheel sensor bolt
since they have been accurately adjusted. 8 N-m (0.8 kgf-m, 5.9 Ib-ft)
Keep them away from dirt and do not sub- LOCTITE®
ject them to shocks. EC AZIO14

e The rear wheel sensor cannot be disassem- NOTICE

bled. Do not attempt to disassemble it. If
* Do not drop the wheel sensor rotor or sub-
faulty, replace with a new one.
ject it to shocks.
¢« Keep any type of magnets (including mag-
¢ If any solvent gets on the wheel sensor ro-
netic pick-up tools, magnetic screwdrivers,
tor, wipe it off immediately.
etc.) away from the rear wheel sensor or
* Replace the brake disc bolts and wheel
rear wheel sensor rotor.
sensor rotor bolts with new ones.
¢ Do not drop or shock the wheel sensor or
the wheel sensor rotor. TIP
1. Check: ¢ Tighten the brake disc bolts in stages and ina
e Rear wheel sensor crisscross pattern.
Refer to “MAINTENANCE OF THE FRONT * Install the wheel sensor rotor with the stamped
WHEEL SENSOR AND SENSOR ROTOR?” mark “a” facing outward.
on page 4-40.
2. Check:
e Rear wheel sensor rotor
Refer to “MAINTENANCE OF THE FRONT
WHEEL SENSOR AND SENSOR ROTOR?”
on page 4-40.
3. Measure:
e Wheel sensor rotor runout
Refer to “MAINTENANCE OF THE FRONT
WHEEL SENSOR AND SENSOR ROTOR?”
on page 4-40. 2. Check:
EAS301 64
¢ Rear brake disc
ADJUSTING THE REAR WHEEL STATIC Refer to “CHECKING THE REAR BRAKE
BALANCE DISC” on page 4-68.
TIP 3. Lubricate:
¢ Oil seal lips

=
e After replacing the tire, wheel or both, the rear
wheel static balance should be adjusted. Recommended lubricant
e Adjust the rear wheel static balance with the Lithium-soap-based grease
brake disc and rear wheel drive hub installed.

4-49
 REAR WHEEL

4. I|nstall:
¢ Collars Drive chain slack (When perform-
¢ Brake caliper bracket ing maintenance/Maintenance
e Rear wheel stand)
25.0—35.0 mm (0.98—1.38 in)
¢ Adjusting blocks
Drive chain slack (When replac-
e Rear wheel axle
ing with a new one/Maintenance
e Washer stand)
e Rear wheel axle nut 20.0-—30.0 mm (0.79—1.18 in)
TIP Drive chain slack limit (Mainte-
¢ Do not install the brake caliper. nance stand)
¢ Align the slot “a” in the swingarm with the pro- 35.0 mm (1.38 in)
jection “b” of the brake caliper bracket.
6. Tighten:
¢ Install the adjusting block (left) so that projec-
e Rear wheel axle nut
tion “c” faces to the front of the vehicle.
¢ Rear brake caliper bolts
¢ Install the adjusting block (right) so that cham-
fered “d” portions become the top and bottom. Rear wheel axle nut
ON 190 N-m (19 kgf-m, 140 Ib-ft)
Rear brake caliper bolt (front)
27 N-m (2.7 kgf-m, 20 Ib-ft)
Rear brake caliper bolt (rear)
12 N-m (1.2 kgf-m, 8.9 Ib-ft)
LOCTITE®
EW ATS 500

Make sure the brake hose is routed properly.

TIP
When tightening the wheel axle nut, there
should be no clearance “a” between the adjust-
ing block “1” and adjusting bolt “2”.

A. Left side
B. Right side

5. Adjust:
e Drive chain slack A. Left side
Refer to “Adjusting the drive chain slack” on B. Right side
page 3-19.
7. Install:
¢ Rear wheel sensor
¢ Rear wheel sensor protector

Rear wheel sensor bolt

7 N-m (0.7 kgf-m, 5.2 lb-ft)
Rear wheel sensor protector bolt
7 N-m (0.7 kgf-m, 5.2 Ib-ft)

4-50
 REAR WHEEL

ECA21080

NOTICE 1
fa 7 a
a
Make sure there are no foreign materials in 2 oc Sr
the rear wheel sensor rotor and rear wheel

To
sensor. Foreign materials cause damage to | x iV Wes |
the rear wheel sensor rotor and rear wheel a oy | MY |
sensor. WI i US
TIP
1
When installing the rear wheel sensor, check the ~© I ZIB~ Dt
rear wheel sensor lead for twists.

8. Measure:
¢ Distance “a”
(between the rear wheel sensor rotor “1” and
rear wheel sensor “2”)
Out of specification — Check the wheel bear-
ing for looseness, and the rear wheel sensor
and sensor rotor installation conditions
(warpage caused by overtorque, wrong in-
stallation direction, rotor decentering, LOC-
TITE® on the mounting surface of the rotor,
deformation caused by an impact during ser-
vice and caught foreign materials). If there is
any defective part, repair or replace the de-
fective part.

Distance “a” (between the rear

wheel sensor rotor and rear
wheel sensor)
1.3-2.1 mm (0.051—0.083 in)

TIP
Measure the distance between the rear wheel
sensor rotor and rear wheel sensor in several
places in one rotation of the rear wheel. Do not
turn the rear wheel while the thickness gauge is
installed. This may damage the rear wheel sen-
sor rotor and the rear wheel sensor.

Thickness gauge
90890-03268
Feeler gauge set
YU-26900-9

4-51
 FRONT BRAKE

EAS20030

FRONT BRAKE
Removing the front brake pads

Order Job/Parts to remove Remarks

The following procedure applies to both of

the front brake calipers.
Brake pad clip
hp! —

ee

Brake pad pin

ee
cw]

Brake pad spring

eeee

Brake pad
om) &;

Reflector
om)

Front brake hose holder

~S)

Front brake caliper

co);

Bleed screw
oO;

Bleed screw Right brake caliper side.

4-52
 FRONT BRAKE

Removing the front brake master cylinder

Order Job/Parts to remove Q'ty Remarks

Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-16.
Brake fluid reservoir cap stopper
hm] —

ee

Brake fluid reservoir cap

Brake fluid reservoir diaphragm holder
cw!)

Brake fluid reservoir diaphragm

om] &;

ee ee

Brake fluid reservoir

mm)

Brake fluid reservoir hose

co; ~s|

Brake lever

Front brake light switch lead connector Disconnect.

0;

Brake hose union bolt

Brake hose gasket
ok
oO

Brake hose
—_—
—

Front brake master cylinder holder

=k
Nh

Front brake master cylinder

=k
Go

Front brake light switch

—_k
&

4-53
 FRONT BRAKE

Disassembling the front brake master cylinder

Order Job/Parts to remove Q’ty Remarks

1 Brake master cylinder kit 1
2 Bleed screw 1
3 Cap 1
4 Brake master cylinder body 1

4-54
 FRONT BRAKE

Removing the front brake calipers

Order Job/Parts to remove Q’ty Remarks

The following procedure applies to both of
the front brake calipers.
Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-16.
1 Reflector 1
2 Front brake hose holder 1
3 Brake hose union bolt 1
4 Brake hose gasket 2
5 Brake hose 1
6 Front brake caliper 1

4-55
 FRONT BRAKE

Disassembling the front brake calipers

Order Job/Parts to remove Remarks

The following procedure applies to both of

the front brake calipers.
Brake pad clip
bP] —

Brake pad pin

—!

Brake pad spring

o/]

|
ho)

Brake pad
om) &/]

Brake caliper piston

B&B) &!)

Brake caliper piston dust seal

|
co; S|

Brake caliper piston seal

|) &)

Bleed screw
—)

Right brake caliper side.

O;}

Bleed screw

4-56
 FRONT BRAKE

EA530168

INTRODUCTION
EWATAIO1

Disc brake components rarely require disas-

sembly. Therefore, always follow these pre-
ventive measures:
¢e Never disassemble brake components un-
less absolutely necessary.
¢ If any connection on the hydraulic brake G098641
system is disconnected, the entire brake
3. Measure:
system must be disassembled, drained,
e Brake disc thickness
cleaned, properly filled, and bled after reas-
Measure the brake disc thickness at a few dif-
sembly.
ferent locations.
¢ Never use solvents on internal brake com-
Out of specification — Replace.

a
ponents.
¢ Use only clean or new brake fluid for clean- Brake disc thickness limit
ing brake components. 4.5 mm (0.18 in)
¢ Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean 4. Adjust:
up any spilt brake fluid immediately. ¢ Brake disc runout
¢ Avoid brake fluid coming into contact with a. Remove the brake disc.
the eyes as it can cause serious injury. b. Rotate the brake disc by one bolt hole.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
¢ Flush with water for 15 minutes and get im-
x c. Install the brake disc.

Front brake disc bolt

mediate medical attention. %& 17 N-m (1.7 kgf-m, 13 Ib-ft)
LOCTITE®
EAS301 69

CHECKING THE FRONT BRAKE DISCS

ECA19150

NOTICE
The following procedure applies to both brake
discs. Replace the brake disc bolts with new ones.
1. Check: TIP
¢ Front brake disc
Tighten the brake disc bolts in stages and ina
Damage/galling — Replace.
crisscross pattern.
2. Measure:
¢ Brake disc runout d. Measure the brake disc runout.
Out of specification — Correct the brake disc e. If out of specification, repeat the adjust-
runout or replace the brake disc. ment steps until the brake disc runout is

a
within specification.
Brake disc runout limit (as mea- lf the brake disc runout cannot be brought
sured on wheel) within specification, replace the brake
0.10 mm (0.0039 in) disc.
. Place the vehicle on a maintenance stand EAS30170

so that the front wheel is elevated. REPLACING THE FRONT BRAKE PADS
. Remove the brake caliper. The following procedure applies to both brake
Hold the dial gauge at a right angle against calipers.
©

the brake disc surface. TIP

. Measure the runout 1.5 mm (0.06 in) be- When replacing the brake pads, it is not neces-
low the edge of the brake disc. sary to disconnect the brake hose or disassem-
ble the brake caliper.
1. Remove:
e Brake pad clips “1”

4-57
 FRONT BRAKE

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

2. Remove:

\ c. Tighten the bleed screw.

YY Brake caliper bleed screw

% 5 N-m (0.5 kgf-m, 3.7 lb-ft)
d. Install the brake pads and brake pad
spring.
TIP
The arrow mark “a” on the brake pad spring
3. Measure: must point in the direction of disc rotation.
¢ Brake pad wear limit “a”
Out of specification —+ Replace the brake
pads as a set.

Brake pad lining thickness limit

0.5 mm (0.02 in)

a
6. Install:
: e Brake pad pin
St a e Brake pad clips
¢ Front brake caliper

Front brake caliper bolt

4. Remove: 35 N-m (3.5 kgf-m, 26 Ib-ft)
¢ Brake caliper
5. Install: 7. Check:
¢ Brake pads e Brake fluid level
¢ Brake pad spring Below the minimum level mark —> Add the
TIP specified brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
Always install new brake pads and new brake LEVEL” on page 3-13.
pad spring as a set.

4-58
 FRONT BRAKE

8. Check: c. Remove the brake caliper piston dust

¢ Brake lever operation seals and brake caliper piston seals.
Soft or spongy feeling > Bleed the brake sys- d. Repeat the previous steps to force out the
tem. right side pistons from the brake caliper.
Refer to “BLEEDING THE HYDRAULIC
FASS0173
BRAKE SYSTEM (ABS)” on page 3-16. CHECKING THE FRONT BRAKE CALIPERS
EaSsa0171 The following procedure applies to both of the
REMOVING THE FRONT BRAKE CALIPERS brake calipers.
The following procedure applies to both of the Recommended brake component
brake calipers. replacement schedule
TIP
Brake pads lf necessary
Before removing the brake caliper, drain the
Piston seals Every two years
brake fluid from the entire brake system.
Piston dust seals Every two years
1. Remove:
Brake hoses Every four years
e Brake hose union bolts
¢ Brake hose gaskets Every two years and
Brake fluid whenever the brake Is
e Brake hoses
disassembled
TIP
Put the end of the brake hose into a container 1. Check:
and pump out the brake fluid carefully. ¢ Brake caliper pistons
Rust/scratches/wear — Replace the brake
EAS301 72
caliper pistons.
DISASSEMBLING THE FRONT BRAKE e Brake caliper cylinders
CALIPERS sScratches/wear — Replace the brake caliper
The following procedure applies to both of the assembly.
brake calipers. e Brake caliper body
1. Remove: Cracks/damage — Replace the brake caliper
¢ Brake caliper pistons assembly.
¢ Brake caliper piston dust seals ¢ Brake fluid delivery passages
¢ Brake caliper piston seals (brake caliper body)
a. Secure the right side brake caliper pistons Obstruction > Blow out with compressed air.
with a piece of wood “a”. EWA13611

b. Blow compressed air into the brake hose

joint opening “b” to force out the left side Whenever a brake caliper is disassembled,
pistons from the brake caliper. replace the brake caliper piston dust seals
EW AT 7060 and brake caliper piston seals.

¢ Never try to pry out the brake caliper pis- FASSO174

tons. ASSEMBLING THE FRONT BRAKE

¢ Do not loosen the bolts “4”. CALIPERS
EWAT6560

¢ 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.

4-59
 FRONT BRAKE

NY?
¢ Brake pad spring
Specified brake fluid ¢ Brake pad pin
DOT 4 e Brake pad clips
¢ Front brake caliper
EAS30175

INSTALLING THE FRONT BRAKE CALIPERS Front brake caliper bolt

The following procedure applies to both of the > 35 N-m (3.5 kgf-m, 26 Ib-ft)
brake calipers.
1. Install: Refer to “REPLACING THE FRONT BRAKE
¢ Front brake caliper “1” PADS” on page 4-57.
(temporarily) 4. Fill:
¢ Brake hose gaskets JXEWG ¢ Brake master cylinder reservoir
e Brake hoses “2” (with the specified amount of the specified
e Brake hose union bolts “3” brake fluid)

sy
EWA1S531
Front brake hose union bolt
32 N-m (3.2 kgf-m, 24 Ib-ft)

EW A13090
Specified brake fluid
DOT 4

Proper brake hose routing is essential to in- ¢ Use only the designated brake fluid. Other
sure safe vehicle operation. brake fluids may cause the rubber seals to
ECAM4170 deteriorate, causing leakage and poor
NOTICE brake performance.
When installing the brake hose onto the * Refill with the same type of brake fluid that
brake caliper “1”, make sure the brake pipe is already in the system. Mixing brake fluids
“a” touches the projection “b” on the brake may result in a harmful chemical reaction,
caliper. 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.
EC A1S540

NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
5. Bleed:
e Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-16.
6. Check:
e Brake fluid level
Below the minimum level mark — Add the
specified brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-13.
7. Check:
e Brake lever operation
2. Remove: Soft or spongy feeling — Bleed the brake sys-
¢ Front brake caliper tem.
3. Install: Refer to “BLEEDING THE HYDRAULIC
¢ Brake pads BRAKE SYSTEM (ABS)” on page 3-16.

4-60
 FRONT BRAKE

NY
EAS30179

REMOVING THE FRONT BRAKE MASTER Specified brake fluid

CYLINDER DOT 4
TIP
Before removing the front brake master cylinder, FASS0182

INSTALLING THE FRONT BRAKE MASTER

drain the brake fluid from the entire brake sys-
CYLINDER
tem.
1. Install:
1. Disconnect: ¢ Front brake master cylinder
¢ Brake light switch connectors e Front brake master cylinder holder
(from the front brake light switch)
2. Remove: Front brake master cylinder hold-
¢ Brake hose union bolt er bolt
¢ Brake hose gaskets 16 N-m (1.6 kgf-m, 12 lb-ft)
¢ Brake hose
TIP
TIP
* Install the front brake master cylinder holder
To collect any remaining brake fluid, place a
with the “UP” mark “a” facing up.
container under the master cylinder and the end
¢ Align the end of the front brake master cylinder
of the brake hose.
with the punch mark “b” on the handlebar.
* First, tighten the upper bolt, then the lower bolt.
EASa0T25

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.
2. Install:
3. Check:
¢ Brake fluid reservoir ¢ Brake hose gaskets JE
¢ Brake fluid reservoir diaphragm holder e Brake hose
Cracks/damage —> Replace. e Brake hose union bolt

Dy
¢ Brake fluid reservoir diaphragm
Front brake hose union bolt
Damage/wear — Replace.
32 N-m (3.2 kgf-m, 24 Ib-ft)
4. Check:
¢ Brake hoses EWAIS531

Cracks/damage/wear —> Replace.

E4S30181 Proper brake hose routing is essential to in-
ASSEMBLING THE FRONT BRAKE MASTER sure safe vehicle operation.
CYLINDER
EWA13520
TIP
¢ When installing the brake hose onto the master
¢ Before installation, all internal brake com- cylinder, make sure the projection “a” on the
ponents should be cleaned and lubricated brake hose touches the projection “b” on the
with clean or new brake fluid. master cylinder.
e Never use solvents on internal brake com- ¢ While holding the brake hose, tighten the union
ponents. bolt as shown.

4-61
 FRONT BRAKE

e Turn the handlebars to the left and right to 6. Check:

make sure the brake hose does not touch other e Brake lever operation
parts (e.g., wire harness, cables, leads). Cor- Soft or spongy feeling — Bleed the brake sys-
rect if necessary. tem.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-16.

Sere
= “8,
bsay
<j
a Z

3. Fill:
¢ Brake master cylinder reservoir
(with the specified amount of the specified
brake fluid)

vy Specified brake fluid |

DOT 4

¢ 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.
ECA13540

NOTICE
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 (ABS)” on page 3-16.
5. Check:
¢ Brake fluid level
Below the minimum level mark — Add the
specified brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-13.

4-62
 REAR BRAKE

EAS20031

REAR BRAKE
Removing the rear brake pads

Order Job/Parts to remove Q'ty Remarks

Screw plug
Brake pad retaining bolt
Gc! Po

Rear brake caliper

A)

Brake pad
oO; &!}

Brake pad shim

A)

Brake pad insulator

A)
|) &!)

Brake pad spring

at)
co;

Bleed screw
me

4-63
 REAR BRAKE

Removing the rear brake master cylinder

Order Job/Parts to remove Q’ty Remarks

Rider seat Fie to “GENERAL CHASSIS (1)” on page

Fuel tank Refer to “FUEL TANK” on page 7-1.

Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)’ on page 3-16.
1 Brake fluid reservoir cap 1
2 Brake fluid reservoir diaphragm holder 1
3 Brake fluid reservoir diaphragm 1
4 Brake fluid reservoir 1
5 Brake fluid reservoir bracket 1
6 Brake fluid reservoir hose 1
7 Brake hose union bolt 1
8 Brake hose gasket 2
9 Brake hose 1

4-64
 REAR BRAKE

Removing the rear brake master cylinder

Us ta

VA
|

Order Job/Parts to remove Q'ty Remarks

10 Footrest plate
11 Cable guide
Do not disassemble the rear brake master
12 Rear brake master cylinder assembly 1

cylinder assembly.
13 Rear brake light switch coupler 1
Disconnect.
14 Rear brake light switch

4-65
 REAR BRAKE

Removing the rear brake caliper

Order Job/Parts to remove Q’ty Remarks

Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-16.
1 Brake hose union bolt 1
2 Brake hose gasket 2
3 Brake hose 1
4 Rear brake caliper 1

4-66
 REAR BRAKE

Disassembling the rear brake caliper

Order Job/Parts to remove Remarks

Screw plug
Brake pad retaining bolt
cw] ho]

Brake pad
Brake pad shim
om) om) &/]

Brake pad insulator

Brake pad spring
OO; oO; S|)

Brake caliper piston

Brake caliper piston dust seal
Brake caliper piston seal
Bleed screw
ok
©

Caliper bolt boot

4+
ok,

4-67
 REAR BRAKE

EA530183
4. Adjust:
INTRODUCTION
EWATAIO1
¢ Brake disc runout
Refer to “CHECKING THE FRONT BRAKE
DISCS” on page 4-57.
Disc brake components rarely require disas-
sembly. Therefore, always follow these pre-
ventive measures:
YX Rear brake disc bolt

¢e Never disassemble brake components un- % 27 N-m (2.7 kgf-m, 20 Ib-ft)

LOCTITE®
less absolutely necessary.
¢ If any connection on the hydraulic brake FAS S0185

system is disconnected, the entire brake REPLACING THE REAR BRAKE PADS
system must be disassembled, drained, TIP
cleaned, properly filled, and bled after reas- When replacing the brake pads, it is not neces-
sembly. sary to disconnect the brake hose or disassem-
¢ Never use solvents on internal brake com- ble the brake caliper.
ponents.
¢ Use only clean or new brake fluid for clean- 1. Measure:
ing brake components. ¢ Brake pad wear limit “a”
¢ Brake fluid may damage painted surfaces Out of specification — Replace the brake
pads as a set.

ey
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
Brake pad lining thickness limit
¢ Avoid brake fluid coming into contact with 1.0 mm (0.04 in)
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.

E4S301 84

CHECKING THE REAR BRAKE DISC

1. Check:
¢ Rear brake disc
Damage/galling — Replace.
2. Measure:
2. Install:
¢ Brake disc runout
¢ Brake pad insulators
Out of specification — Correct the brake disc
¢ Brake pad shims
runout or replace the brake disc.
(onto the brake pads)
Refer to “CHECKING THE FRONT BRAKE
¢ Brake pad spring
DISCS” on page 4-57.
(into the rear brake caliper)

a Brake disc runout limit (as mea-

sured on wheel)
0.15 mm (0.0059 in)
¢ Brake pads
TIP
Always install new brake pads, brake pad insu-
lators, brake pad shims, and brake pad spring as
3. Measure: a set.
e Brake disc thickness
Measure the brake disc thickness at a few dif- a. Connect a clear plastic hose “1” tightly to
ferent locations. the bleed screw “2”. Put the other end of
Out of specification —- Replace. the hose into an open container.
Refer to “CHECKING THE FRONT BRAKE b. Loosen the bleed screw and push the
DISCS” on page 4-57. brake caliper piston into the brake caliper
with your finger.
Brake disc thickness limit
4.5 mm (0.18 in)

4-68
 REAR BRAKE

¢ Remove any excess grease.

4. Install:
¢ Rear brake caliper
e Brake pad retaining bolts
e Screw plug

Rear brake caliper bolt (front)

27 N-m (2.7 kgf-m, 20 Ib-ft)
Rear brake caliper bolt (rear)
12 N-m (1.2 kgf-m, 8.9 Ib-ft)
LOCTITE®
c. Tighten the bleed screw.

sy
Rear brake pad retaining bolt
17 N-m (1.7 kgf-m, 13 Ib-ft)
Brake caliper bleed screw
Rear brake caliper screw plug
5 N-m (0.5 kgf-m, 3.7 Ib-ft)
2.5 N-m (0.25 kgf-m, 1.8 Ib-ft)
d. Install the brake pad insulators and brake
5. Check:
pad shims onto each brake pads.
e Brake fluid level
TIP Below the minimum level mark — Add the
Apply silicone grease between the brake pad in- specified brake fluid to the proper level.
sulator and brake pad shim. Refer to “CHECKING THE BRAKE FLUID
ECA14150 LEVEL” on page 3-13.
NOTICE 6. Check:
¢ Do not allow grease to contact the brake ¢ Brake pedal operation
pads. soft or spongy feeling > Bleed the brake sys-
e Remove any excess grease. tem.
Refer to “BLEEDING THE HYDRAULIC
e. Install the brake pads and brake pad BRAKE SYSTEM (ABS)” on page 3-16.
spring.
TIP EAS30186

REMOVING THE REAR BRAKE CALIPER

The longer tangs “a” of the brake pad spring
TIP
must point in the direction of the brake caliper
piston. Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1. Remove:
e Brake hose union bolt
e Brake hose gaskets
e Brake hose
TIP
Put the end of the brake hose into a container
and pump out the brake fluid carefully.

EAS S0187

DISASSEMBLING THE REAR BRAKE

3. Lubricate: CALIPER
¢ Rear brake caliper bolts

=
1. Remove:
e Brake caliper piston
Recommended lubricant
Silicone grease e Brake caliper piston dust seal
¢ Brake caliper piston seal
ECA14150 a. Blow compressed air into the brake hose
NOTICE joint opening “a” to force out the piston
¢ Do not allow grease to contact the brake from the brake caliper.
pads.

4-69
 REAR BRAKE

EWA13550
2. Check:
¢ Rear brake caliper bracket
¢ Cover the brake caliper piston with a rag. Cracks/damage — Replace.
Be careful not to get injured when the pis- Refer to “REAR WHEEL” on page 4-43.
ton is expelled from the brake caliper.
¢ Never try to pry out the brake caliper pis-
FASS0189

ASSEMBLING THE REAR BRAKE CALIPER

ton. EW AT FORO

¢ 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 seal and brake caliper piston
seal to swell and distort.
¢ Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seal
and brake caliper piston seal.
b. Remove the brake caliper piston dust seal
and brake caliper piston seal.
6 Specified brake fluid
EAS301 88 DOT 4
CHECKING THE REAR BRAKE CALIPER
Recommended brake component EAS30190

replacement schedule INSTALLING THE REAR BRAKE CALIPER

1. Install:
Brake pads lf necessary
¢ Rear brake caliper
Piston seal Every two years (temporarily)
Piston dust seal Every two years ¢ Brake hose gaskets XE
Brake hoses Every four years e Brake hose
Every two years and ¢ Brake hose union bolt
Brake fluid whenever the brake is
disassembled X Rear brake hose union bolt

1. Check:
% 32 N-m (3.2 kgf-m, 24 lb-ft)

¢ Brake caliper piston

Rust/scratches/wear — Replace the brake
caliper piston. Proper brake hose routing is essential to in-
¢ Brake caliper cylinder sure safe vehicle operation.
scratches/wear — Replace the brake caliper ECA1S080

assembly. NOTICE
¢ Brake caliper body When installing the brake hose onto the
Cracks/damage — Replace the brake caliper brake caliper “1”, make sure the brake pipe
assembly. “a” passes between the projections “b” on
¢ Brake fluid delivery passages the brake caliper.
(brake caliper body)
Obstruction > Blow out with compressed air.
EWA1S601

Whenever a brake caliper is disassembled,

replace the brake caliper piston dust seal
and brake caliper piston seal.

4-70
 REAR BRAKE

¢ When refilling, be careful that water does

not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
EC ATS 540

NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
5. Bleed:
2. Remove: e Brake system
¢ Rear brake caliper Refer to “BLEEDING THE HYDRAULIC
3. Install: BRAKE SYSTEM (ABS)” on page 3-16.
¢ Brake pad insulators 6. Check:
¢ Brake pad shims e Brake fluid level
(onto the brake pads) Below the minimum level mark — Add the
¢ Brake pad spring specified brake fluid to the proper level.
(into the rear brake caliper) Refer to “CHECKING THE BRAKE FLUID
¢ Brake pads LEVEL” on page 3-13.
¢ Rear brake caliper 7. Check:
Refer to “REPLACING THE REAR BRAKE ¢ Brake pedal operation
PADS” on page 4-68. Soft or spongy feeling — Bleed the brake sys-
tem.
Rear brake caliper bolt (front) Refer to “BLEEDING THE HYDRAULIC
27 N-m (2.7 kgf-m, 20 Ib-ft) BRAKE SYSTEM (ABS)” on page 3-16.
Rear brake caliper bolt (rear)
12 N-m (1.2 kgf-m, 8.9 Ib-ft) FASS0193

LOCTITE® REMOVING THE REAR BRAKE MASTER

Rear brake pad retaining bolt CYLINDER
17 N-m (1.7 kgf-m, 13 Ib-ft) 1. Remove:
Rear brake caliper screw plug ¢ Brake hose union bolt “1”
2.5 N-m (0.25 kgf-m, 1.8 lb-ft) e Brake hose gaskets “2”
¢ Brake hose “3”
4. Fill:
TIP
¢ Brake fluid reservoir
(with the specified amount of the specified To collect any remaining brake fluid, place a
brake fluid) container under the master cylinder and the end

NY
of the brake hose.
Specified brake fluid

Ne
Ne
ra
———
DOT 4
> )
EWA13090

OY, | (CD
Lb
¢ Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
2—— =>
fT 3 J |

ZY);
S=G
deteriorate, causing leakage and poor os FF
brake performance.
¢ Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
DY
es I”,
Ar
may result in a harmful chemical reaction,
leading to poor brake performance.

4-71
 REAR BRAKE

EAS30194

CHECKING THE REAR BRAKE MASTER

CYLINDER
1. Check:
¢ Brake master cylinder
Damage/scratches/wear — Replace.
¢ Brake fluid delivery passages
(brake master cylinder body)
Obstruction —> Blow out with compressed air.
2. Check:
¢ Brake fluid reservoir
2. Fill:
¢ Brake fluid reservoir diaphragm holder
e Brake fluid reservoir
Cracks/damage —> Replace.
(with the specified amount of the specified
¢ Brake fluid reservoir diaphragm
brake fluid)

NY
Damage/wear —> Replace.
3. Check: Specified brake fluid
¢ Brake hose DOT 4
¢ Brake fluid reservoir hose
Cracks/damage/wear —> Replace. EWA13090

EASS1743
¢ Use only the designated brake fluid. Other
THE REAR BRAKE MASTER CYLINDER
ECA23000 brake fluids may cause the rubber seals to
NOTICE deteriorate, causing leakage and poor
Do not disassemble the rear brake master brake performance.
cylinder. If the master cylinder malfunctions, * Refill with the same type of brake fluid that
replace the rear brake master cylinder as- is already in the system. Mixing brake fluids
sembly. may result in a harmful chemical reaction,
leading to poor brake performance.
EA&S301 96 ¢ When refilling, be careful that water does
INSTALLING THE REAR BRAKE MASTER not enter the brake fluid reservoir. Water
CYLINDER will significantly lower the boiling point of
1. Install: the brake fluid and could cause vapor lock.
¢ Brake hose gaskets JXEWG ECA13540

¢ Brake hose NOTICE

e Brake fluid reservoir hose Brake fluid may damage painted surfaces
¢ Brake hose union bolt and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
Rear brake hose union bolt
32 N-m (3.2 kgf-m, 24 Ib-ft) 3. Bleed:
e Brake system
EWAIS531
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-16.
Proper brake hose routing is essential to in- 4. Check:
sure safe vehicle operation. e Brake fluid level
ECA14160 Below the minimum level mark “a” — Add the
NOTICE specified brake fluid to the proper level.
When installing the brake hose onto the Refer to “CHECKING THE BRAKE FLUID
brake master cylinder, make sure the brake LEVEL” on page 3-13.
pipe touches the projection “a” as shown. 5. Adjust:
¢ Brake pedal position
Refer to “ADJUSTING THE REAR DISC
BRAKE” on page 3-14.

4-72
 REAR BRAKE

6. Adjust:
¢ Rear brake light operation timing
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” on page 3-35.

4-73
 ABS (Anti-lock Brake System)

ABS (Anti-lock Brake System)

Removing the hydraulic unit assembly

Order Job/Parts to remove Q’ty Remarks

Rider seat/Battery cover/Battery Pirbel to “GENERAL CHASSIS (1)” on page

Fuel tank Refer to “FUEL TANK” on page 7-1.

Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-16.
Fuel tank bracket
—

Fuse box 1
|

ff
co}

Radiator fan motor relay

Rear wheel sensor coupler
a) &|)

ABS ECU coupler Disconnect.

me

Rear brake hose bracket

~“! | @!)

mm

Hydraulic unit brake pipe (hydraulic unit to rear {

brake caliper)

4-74
 ABS (Anti-lock Brake System)

Removing the hydraulic unit assembly

Order Job/Parts to remove Q’ty Remarks

8 Hydraulic unit brake pipe (rear brake master cyl- 1
inder to hydraulic unit)
9 Hydraulic unit brake pipe (hydraulic unit to front {
brake calipers)
10 Hydraulic unit brake pipe (front brake master {
cylinder to hydraulic unit)
11 Rear brake light switch lead 1
12 Rear wheel sensor lead 1
13 Brake hose union bolt 2
14 Gasket 4
15 Brake hose (hydraulic unit to front brake cali- {
pers)
16 Brake hose (front brake master cylinder to hy- {
draulic unit)
17 Brake hose joint 1
18 Hydraulic unit tray 1
19 Hydraulic unit assembly 1

4-75
 ABS (Anti-lock Brake System)

EASS30728

ABS COMPONENTS CHART

Meter assembly
ONOahtah=

Hydraulic unit assembly

Fuse box 1
ABS solenoid fuse
YDT coupler
Starter relay
ABS motor fuse
Rear brake caliper
9. Rear wheel sensor rotor
10. Rear wheel sensor
11. Front brake caliper (left)
12. Front wheel sensor
13. Front wheel sensor rotor
14. Front brake caliper (right)
[Link] box 2
16. Signaling system fuse

4-76
 ABS (Anti-lock Brake System)

EAS30197

REMOVING THE HYDRAULIC UNIT

ASSEMBLY
ECA18230

NOTICE
Unless necessary, avoid removing and in-
stalling the brake pipes of the hydraulic unit
assembly.
EWA13930

Refill with the same type of brake fluid that is

already in the system. Mixing fluids may re- 2. Remove:
sult in a harmful chemical reaction, leading e Brake hoses
to poor braking performance. ¢ Brake pipes
ECA1S790
TIP
NOTICE ¢ Do not operate the brake lever and brake pedal
¢ Handle the ABS components with care while removing the brake hoses and brake
since they have been accurately adjusted. pipes.
Keep them away from dirt and do not sub- * Do not bend the brake pipe when loosening the
ject them to shocks. brake pipe flare nuts.
¢ Do not set the main switch to “ON” when ECA19&00

removing the hydraulic unit assembly. NOTICE

¢ Do not clean with compressed air. ¢ When removing the brake hoses and brake
¢ Do not reuse the brake fluid. pipes, cover the area around the hydraulic
¢ Brake fluid may damage painted surfaces unit assembly to catch any spilt brake fluid.
and plastic parts. Therefore, always clean Do not allow the brake fluid to contact other
up any spilt brake fluid immediately. parts.
¢ Do not allow any brake fluid to contact the ¢ Before disconnecting the brake pipes from
couplers. Brake fluid may damage the cou- the hydraulic unit assembly, do not lift up
plers and cause bad contacts. or move the brake pipes.
¢ If the brake pipe flare nuts for the hydraulic
3. Remove:
unit assembly have been removed, be sure
e Hydraulic unit assembly “1”
to tighten them to the specified torque and
bleed the brake system. TIP
To avoid brake fluid leakage and to prevent for-
1. Disconnect:
eign materials from entering the hydraulic unit
e ABS ECU coupler “1”
assembly, insert a rubber plug “a” or a bolt (M10
TIP x 1.00) into each flare nut hole.
While pushing the portion “a” of the ABS ECU ECAIS870
coupler, pull the lock lever up to release the lock. NOTICE
ECA20080
When using a bolt, do not tighten the bolt un-
NOTICE til the bolt head touches the hydraulic unit.
Do not use a tool to disconnect the ABS ECU Otherwise, the brake pipe seating surface
coupler. could be deformed.

4-77
 ABS (Anti-lock Brake System)

%
\ Hydraulic unit assembly bolt
7 N-m (0.7 kgf-m, 5.2 lb-ft)
LOCTITE®

EA&S30198

CHECKING THE HYDRAULIC UNIT

ASSEMBLY
1. Check:
¢ Hydraulic unit assembly
2. Remove:
Cracks/damage —> Replace the hydraulic unit
e Rubber plugs or bolts (M10 x 1.0)
assembly and the brake pipes that are con-
3. Install:
nected to the assembly as a set.
¢ Hydraulic unit brake pipe
E4530 99 4. Tighten:
CHECKING THE BRAKE PIPES e Hydraulic unit brake pipe flare nuts
The following procedure applies to all of the
brake pipes. XY Hydraulic unit brake pipe flare
1. Check:
¢ Brake pipe end (flare nut)
% nut
16 N-m (1.6 kgf-m, 12 Ib-ft)
Damage — Replace the hydraulic unit as- EC AISB20
sembly, brake pipes, and related parts as a NOTICE
set.
If the brake pipe flare nut does not turn easi-
EASa0200 ly, replace the hydraulic unit assembly,
INSTALLING THE HYDRAULIC UNIT brake pipes, and related parts as a set.
ASSEMBLY
1. Install: TIP
¢ Hydraulic unit assembly Do not bend the brake pipe when tightening the
ECA18260
brake pipe flare nuts.
NOTICE
5. Install:
Do not remove the rubber plugs or bolts
(M10 x 1.0) installed in the flare nut holes be- ¢ Gaskets TAM
fore installing the hydraulic unit assembly. e Brake hose union bolts
e Brake hoses “1”
TIP
Do not allow any foreign materials to enter the \y Front brake hose union bolt
hydraulic unit assembly or the brake hoses or 32 N-m (3.2 kgf-m, 24 Ib-ft)
brake pipes when installing the hydraulic unit as- EC A22800
sembly. NOTICE
a. Install the hydraulic unit assembly “1” on When installing each brake hose onto the hy-
the hydraulic unit tray “2”. draulic unit brake pipe joint, make sure that
b. Temporarily tighten the hydraulic unit as- the brake pipe “a” touches the projection “b”
sembly bolts “3”, “4”. on the joint.
c. Tighten the hydraulic unit assembly bolt
“3”, and bolt “4” to the specified torque in
this order.

4-78
 ABS (Anti-lock Brake System)

TIP ¢ When refilling, be careful that water does

There is an identifying white paint mark “c” on not enter the brake master cylinder reser-
the upper surface of the pipe of the brake hose voir or brake fluid reservoir. Water will sig-
(front brake master cylinder to the hydraulic nificantly lower the boiling point of the
unit). brake fluid and could cause vapor lock.
EC A13540

NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
o any spilt brake fluid immediately.
a 8. Bleed:
ye
1 SSA @ e Brake system

ZB RB S
3

ONS
Refer to “BLEEDING THE HYDRAULIC
I
BRAKE SYSTEM (ABS)” on page 3-16.
. Check the operation of the hydraulic unit ac-
cording to the brake lever and the brake ped-
6. Connect:
al response. (Refer to “HYDRAULIC UNIT
¢ ABS ECU coupler “1”
OPERATION TEST” on page 4-79.)
TIP ECA4770

Connect the ABS ECU coupler, and then push NOTICE

the lock lever of the coupler in the direction of the Always check the operation of the hydraulic
arrow shown. unit according to the brake lever and the
brake pedal response.
[Link] the DTC. (Refer to “SELF-DIAGNOS-
TIC FUNCTION AND DIAGNOSTIC CODE
TABLE” on page 9-32.)
[Link] a trial run. (Refer to “CHECKING
THE ABS WARNING LIGHT” on page 4-82.)
EAS30201

HYDRAULIC UNIT OPERATION TEST

The reaction-force pulsating action generated in
the brake lever and brake pedal when the ABS
7. Fill: is activated can be tested when the vehicle is
¢ Brake fluid reservoir stopped.
(with the specified amount of the specified The hydraulic unit operation can be tested using
brake fluid) the following two methods.

afl
¢ Brake line routing confirmation: this test
Specified brake fluid checks the function of the ABS after the sys-
DOT 4 tem was disassembled, adjusted, or serviced.
EWAT?T280
¢ ABS reaction-force confirmation: this test gen-
erates the same reaction-force pulsating action
that is generated in the brake lever and brake
¢ Use only the designated brake fluid. Other
pedal when the ABS is activated.
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor Brake line routing confirmation
brake performance. EWAIS120

¢ Refill with the same type of brake fluid that

is already in the system. Mixing brake fluids Securely support the vehicle so that there is
may result in a harmful chemical reaction, no danger of it falling over.
leading to poor brake performance.

4-79
 ABS (Anti-lock Brake System)

TIP 6. Start the Yamaha diagnostic tool and display

e For the brake line routing confirmation, use the the diagnosis of function screen.
diagnosis of function of the Yamaha diagnostic 7. Select code No. 2, “Brake line routing confir-
tool. mation”.
¢ Before performing the brake line routing confir- 8. Click “Actuator Check”, and then operate the
mation, make sure that no malfunctions have brake lever “1” and brake pedal “2” simulta-
been detected in the ABS ECU and that the neously.
wheels are not rotating. TIP
¢ The hydraulic unit operates 1 second after the
1. Place the vehicle on a maintenance stand.
brake lever and brake pedal are operated si-
2. Turn the main switch to “OFF”.
multaneously and continues for approximately
3. Remove:
5 seconds.
e Rider seat
¢ The operation of the hydraulic unit can be con-
Refer to “GENERAL CHASSIS (1)” on page
firmed using the indicator.
4-1.
On: The hydraulic unit is operating.
4. Check:
Flashing: The conditions for operating the hy-
* Battery voltage
draulic unit have not been met.
Lower than 12.8 V — Charge or replace the
Off: The brake lever and brake pedal are not
battery.
being operated.

il
TIP
Battery voltage
Higher than 12.8 V
J |

lf the battery voltage is lower than 12.8 V, charge

the battery, and then perform brake line routing
confirmation.
5. Removing the protective cap, and then con-
nect the Yamaha diagnostic tool to the GO88909 2
Yamaha diagnostic tool coupler (6P).
9. Check:
{/ Yamaha diagnostic tool USB (US) e Hydraulic unit operation
90890-03269 Click “Actuator Check”, a single pulse will be
Yamaha diagnostic tool (A/l) generated in the brake lever “1”, brake pedal
90890-03264 “2, and again in the brake lever “1”, in this or-
der.
TIP
¢ Yamaha diagnostic tool (A/l) (90890-03264) in-
cludes YDT sub harness (6P) (90890-03266).
e If you already have Yamaha diagnostic tool (A/
|) (90890-03262), YDT sub harness (6P)
(90890-03266) is separately required.
Y)
Refer to “YDT” on page 9-2.
>

G088911

TIP
“ON” and “OFF” on the tool screen indicate
when the brakes are being applied and released
respectively.

4-80
 ABS (Anti-lock Brake System)

ECAI7371
5. Removing the protective cap, and then con-
NOTICE nect the Yamaha diagnostic tool to the
¢ Check that the pulse is felt in the brake le- Yamaha diagnostic tool coupler (6P).
ver, brake pedal, and again in the brake le-
ver, in this order.
¢ If the pulse is felt in the brake pedal before
it is felt in the brake lever, check that the
J Yamaha diagnostic tool USB (US)
90890-03269
Yamaha diagnostic tool (A/l)
brake hoses and brake pipes are connected 90890-03264
correctly to the hydraulic unit assembly.
¢ If the pulse is hardly felt in either the brake TIP
lever or brake pedal, check that the brake e« Yamaha diagnostic tool (A/l) (90890-03264) in-
hoses and brake pipes are connected cor- cludes YDT sub harness (6P) (90890-03266).
rectly to the hydraulic unit assembly. * If you already have Yamaha diagnostic tool (A/
1) (90890-03262), YDT sub harness (6P)
[Link] the operation of the hydraulic unit is normal,
(90890-03266) is separately required.
delete all of the DTC.
Refer to “YDT” on page 9-2.
ABS reaction-force confirmation 6. Start the Yamaha diagnostic tool and display
EWAI3120
the diagnosis of function screen.
7. Select code No. 1, “ABS reaction-force con-
Securely support the vehicle so that there is firmation”.
no danger of it falling over. 8. Click “Actuator Check”, and then operate the
brake lever “1” and brake pedal “2” simulta-
TIP
neously.
e For the ABS reaction-force confirmation, use
TIP
the diagnosis of function of the Yamaha diag-
nostic tool. For more information, refer to the ¢ The hydraulic unit operates 1 second after the
operation manual of the Yamaha diagnostic brake lever and brake pedal are operated si-
tool. multaneously and continues for approximately
¢ Before performing the ABS reaction-force con- 5 seconds.
firmation, make sure that no malfunctions have ¢ The operation of the hydraulic unit can be con-
been detected in the ABS ECU and that the firmed using the indicator.
wheels are not rotating. On: The hydraulic unit is operating.
Flashing: The conditions for operating the hy-
1. Place the vehicle on a maintenance stand. draulic unit have not been met.
2. Turn the main switch to “OFF”. Off: The brake lever and brake pedal are not
3. Remove: being operated.
e Rider seat
Refer to “GENERAL CHASSIS (1)” on page
4-1.
4. Check:
* Battery voltage
Lower than 12.8 V — Charge or replace the
battery.

= Battery voltage
Higher than 12.8 V
GO88909 2

TIP 9. Areaction-force pulsating action is generated

Ifthe battery voltage is lower than 12.8 V, charge in the brake lever “1” and continues for a few
the battery, and then perform ABS reaction- seconds.
force confirmation. TIP
¢ The reaction-force pulsating action consists of
quick pulses.

4-81
 ABS (Anti-lock Brake System)

¢ Be sure to continue operating the brake lever ECAITa71

and brake pedal even after the pulsating action NOTICE

has stopped. ¢ Check that the pulse is felt in the brake le-
e “ON” and “OFF” on the tool screen indicate ver, brake pedal, and again in the brake le-
when the brakes are being applied and re- ver, in this order.
leased respectively. ¢ If the pulse is felt in the brake pedal before
it is felt in the brake lever, check that the
brake hoses and brake pipes are connected
rN correctly to the hydraulic unit assembly.
¢ If the pulse is hardly felt in either the brake
lever or brake pedal, check that the brake
hoses and brake pipes are connected cor-
rectly to the hydraulic unit assembly.
[Link] the main switch to “OFF”.
[Link] the Yamaha diagnostic tool from the
G088913 Yamaha diagnostic tool coupler, and then in-
[Link] the pulsating action has stopped in the stall the protective cap.
brake lever, it is generated in the brake pedal [Link] the main switch to “ON”.
“1” and continues for a few seconds. [Link] the start/engine stop switch to “-”.
TIP
[Link] for brake fluid leakage around the hy-
draulic unit.
e The reaction-force pulsating action consists of
Brake fluid leakage — Replace the hydraulic
quick pulses.
unit, brake pipes, and related parts as a set.
¢ Be sure to continue operating the brake lever
[Link] the operation of the hydraulic unit is normal,
and brake pedal even after the pulsating action
delete all of the DTC.
has stopped.
e “ON” and “OFF” on the tool screen indicate FAS S0202

when the brakes are being applied and re- CHECKING THE ABS WARNING LIGHT
leased respectively. 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 5 km/h
(3.1 mi/h) or performing a trial run.

3
P))=

a
1
G088914

[Link] the pulsating action has stopped in the

brake pedal, itis generated in the brake lever
and continues for a few seconds.
TIP
e The reaction-force pulsating action consists of
quick pulses.
e “ON” and “OFF” on the tool screen indicate
when the brakes are being applied and re-
leased respectively.

4-82
 HANDLEBARS

HANDLEBARS
Removing the handlebars

Order Job/Parts to remove Q’ty Remarks

Rider seat Pirbel to “GENERAL CHASSIS (1)” on page

Side cover bracket damper ioe to “GENERAL CHASSIS (7)” on page

Front panel cover oa? to “GENERAL CHASSIS (3)” on page

Front side cowling (left) Fic to “GENERAL CHASSIS (5)” on page

Side cover (left) coe to “GENERAL CHASSIS (6)” on page

Fuel tank Refer to “FUEL TANK” on page 7-1.

Air filter case Refer to “AIR FILTER CASE” on page 7-5.
1 Grip end (left) 1
2 Handlebar grip 1
3 Clutch switch connector 2 Disconnect.
4 Clutch switch 1

4-83
 HANDLEBARS

Removing the handlebars

Order Job/Parts to remove Q’ty Remarks

5 Handlebar switch coupler (left) 2 Disconnect.

6 Horn connector 2 Disconnect.
7 Horn 1
8 Handlebar switch (left) 1
9 Clutch cable 1 Disconnect.
10 Clutch lever holder 1
11 Front brake light switch connector 2 Disconnect.
12 Front brake light switch 1
13 Front brake master cylinder bracket 1
14 Front brake master cylinder holder 1
15 Front brake master cylinder assembly 1
16 Grip end (right) 1
 HANDLEBARS

Removing the handlebars

Order Job/Parts to remove Q’ty Remarks

17 Handlebar switch coupler (right) ‘4 Disconnect.

18 Handlebar switch (right) 1
19 Throttle grip 1
20 Front fork stepping motor coupler 2 Disconnect. (for YZF-R1M)
21 Main switch coupler 1 Disconnect.
22 Main switch cover 1
23 Upper bracket 1
24 Handlebar (left) 1
25 Handlebar (right) 1

4-85
 HANDLEBARS

EAS30203
N
REMOVING THE HANDLEBARS Steering stem nut
1. Stand the vehicle on a level surface.
EWAI3120 aN 115 N-m (11.5 kgf-m, 85 Ib-ft)
Upper bracket pinch bolt
26 N-m (2.6 kgf-m, 19 Ib-ft)
Securely support the vehicle so that there is Handlebar bolt
no danger of it falling over. 7 N-m (0.7 kgf-m, 5.2 lb-ft)
Handlebar pinch bolt
2. Remove:
32 N-m (3.2 kgf-m, 24 Ib-ft)
¢ Handlebar grip “1”
TIP 3. Install:
Blow compressed air between the left handlebar e Main switch cover “1”
and the handlebar grip, and gradually push the TIP
grip off the handlebar. e Pass the main switch cover “1” between the
projection “a” of the upper bracket and main
1 switch “b”, and hook the hook on one end of the
main switch cover into the hole on the other
end.

\\ « Make sure that the main switch cover “1” cov-

ers the main switch bolt head “c”.
aw

¢ The main switch cover may be facing in any di-

rection.

G088916

EAS30204

CHECKING THE HANDLEBARS a L

1. Check:
¢ Handlebar (left) 1 NI |
¢ Handlebar (right)
Bends/cracks/damage — Replace.
EWA13690
— Leet J
Do not attempt to straighten a bent handle-
4. Install:
bar as this may dangerously weaken it.
¢ Handlebar switch (right)
EASS0205
e Throttle grip
INSTALLING THE HANDLEBARS ¢ Grip end (right)
1. Stand the vehicle on a level surface.
EWAI3120 Handlebar switch screw
oN 3.5 N-m (0.35 kgf-m, 2.6 Ib-ft)
Grip end bolt
Securely support the vehicle so that there is
3.8 N-m (0.38 kgf-m, 2.8 Ib-ft)
no danger of it falling over.
2. Install: a. Fitthe slot “a” in the throttle grip “1” into the
¢ Handlebar (left) projection “b” in the handlebar switch
¢ Handlebar (right) (right, front side) “2” and the throttle grip
¢ Upper bracket “1” onto the handlebar “S”.

4-86
 HANDLEBARS

QO)
ea

2
al

b. Make sure that the throttle grip “1” turns 5. Install:

smoothly. e Front brake master cylinder assembly
Refer to “INSTALLING THE FRONT BRAKE
MASTER CYLINDER?” on page 4-61.
6. Install:
¢ Clutch lever holder “1”
e Clutch cable

sy
TIP
Clutch lever holder pinch bolt
11 N-m (1.1 kgf-m, 8.1 Ib-ft)

c. Install the handlebar switch (right, rear Align the center of slit on the clutch lever holder
side) “4”. with the punch mark “a” on the handlebar.
TIP
Align the projection “c” on the handlebar switch
(right, rear side) “4” with the hole “d” in the han-
dlebar “1”.
Tk

aa
ae
a ee
fae
j 5
=

an, \

7. Install:
¢ Handlebar switch screw (left)

TIP
d. Install the grip end (right) “5”. Sy
TIP
Handlebar switch screw
3.5 N-m (0.35 kgf-m, 2.6 Ib-ft)

There should be 1-3 mm (0.04—0.12 in) of clear-

Align the projection “a” on the handlebar switch
ance “e” between the throttle grip and the grip
(left) with the hole “b” in the handlebar.
end.

4-87
 HANDLEBARS

8. Install:
¢ Handlebar grip “1”
¢ Grip end (left) “2”

\y Grip end bolt

Qs 3.8 N-m (0.38 kgf-m, 2.8 lb-ft)

a. Apply a thin coat of rubber adhesive onto

the end of the left handlebar.
b. Side the handlebar grip over the end of the
left handlebar.
c. Wipe off any excess rubber adhesive with
a clean rag.
EWAIS700

Do not touch the handlebar grip until the rub-

ber adhesive has fully dried.
TIP
There should be 1-3 mm (0.04—0.12 in) of clear-
ance “a” between the handlebar grip and the grip
end.

G088918
\ 1
9. Adjust:
¢ Clutch lever free play
Refer to “ADJUSTING THE CLUTCH LEVER
FREE PLAY” on page 3-12.

Clutch lever free play

10.0—15.0 mm (0.39-0.59 in)

4-88
 FRONT FORK (for YZF-R1)
EAS20034

FRONT FORK (for YZF-R1)

Removing the front fork legs (for YZF-R1)

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 4-35.
Front panel cover hil to “GENERAL CHASSIS (3)” on page

1 Front fender 1
2 Upper bracket pinch bolt 1 Loosen.
3 Handlebar pinch bolt 1 Loosen.
4 Handlebar bolt 1 Loosen.
5 Cap bolt 1 Loosen.
6 Lower bracket pinch bolt 2 Loosen.
7 Front fork leg 1

4-89
 FRONT FORK (for YZF-R1)

Disassembling the front fork legs (for YZF-R1)

¢
{CC®
v

Order Job/Parts to remove Remarks

Q
Z

The following procedure applies to both of

the front fork legs.
Cap bolt
bP] —

ee

O-ring
ee

Guide
o/]

ee

Spacer
om) &/]

eeee

Fork spring
Locknut
|
co; S|

Damper adjusting rod 1

Damper adjusting rod 2
O;}

Dust seal
Oil seal clip
=k
©

Outer tube
oll,
ol,

ee

Oil seal
—_h
ho

Washer
ok
Go

Outer tube bushing

—
A

4-90
 FRONT FORK (for YZF-R1)

Disassembling the front fork legs (for YZF-R1)

Order Job/Parts to remove Q’ty Remarks

15 Inner tube bushing 1

16 Damper rod assembly 1
17 Base valve assembly 1
18 O-ring 1
19 Inner tube 1

4-91
 FRONT FORK (for YZF-R1)
EAS30206 EASS0207

REMOVING THE FRONT FORK LEGS (for DISASSEMBLING THE FRONT FORK LEGS
YZF-R1) (for YZF-R1)
The following procedure applies to both of the The following procedure applies to both of the
front fork legs. front fork legs.
1. Stand the vehicle on a level surface. 1. Turn the spring preload adjusting nut “1”
EWA13120
counterclockwise until it stops.

Securely support the vehicle so that there is

no danger of it falling over.
TIP
Place the vehicle on a maintenance stand so
that the front wheel is elevated.
2. Remove:
¢ Front brake caliper
Refer to “FRONT BRAKE” on page 4-52.
e Front wheel 2. Remove:
Refer to “FRONT WHEEL” on page 4-35. e Cap bolt “1”
3. Loosen: (from the damper rod assembly)
¢ Handlebar pinch bolt “1” ¢ Guide “2”
¢ Upper bracket pinch bolt “2” e Spacer “3”
¢ Handlebar bolt “3” e Locknut “4”
¢ Cap bolt “4” a. Press down on the spacer with the fork
¢ Lower bracket pinch bolts “5” spring compressor “5”.
EWA13640
b. Install the rod holder “6” between the lock-
nut “4” and the guide “2”.
Before loosening the upper and lower brack-

J
et pinch bolts, support the front fork leg. Fork spring compressor
90890-01441
Fork spring compressor
YM-01441
Rod holder
90890-01434
Damper rod holder double ended
YM-01434

TIP
Use the side of the rod holder that is marked “B”.

c. Hold the cap bolt “1” and loosen the lock-

4. Remove: nut “4”,
¢ Front fork leg

4-92
 FRONT FORK (for YZF-R1)
ECA17390
5. Remove:
NOTICE e Outer tube
When loosening the nut, be sure not to break a. Hold the front fork leg horizontally.
the projections on the cap bolt collar of the b. Securely clamp the brake caliper bracket
cap bolt. in a vise with soft jaws.
c. Separate the outer tube from the inner
tube by pulling the outer tube forcefully but
carefully.
ECA19680

NOTICE
Excessive force will damage the bushings.
Damaged bushings must be replaced.

d. Remove the cap bolt and guide.

e. Remove the rod holder and fork spring
compressor.
f. Remove the spacer and locknut.
3. Drain:
¢ Fork oil
TIP
Stroke the damper rod assembly “1” several 6. Remove:
times while draining the fork oil. ¢« Damper rod assembly
TIP
Remove the damper rod assembly with the
damper rod holder “1”.

Damper rod holder (@30)

90890-01506
Damper rod holder
YM-01506

G088919

4. Remove:
¢ Dust seal “1”
* Oil seal clip “2”
(with a flat-head screwdriver)
ECA19700

NOTICE
Do not scratch the outer tube.
All
7. Remove:
¢ Base valve assembly “1”
a. Secure straight part “a” of the base valve
assembly firmly in a vise with soft jaws.
b. Pull up the damper rod assembly “2” and
remove the base valve assembly “1”.

G088920

4-93
 FRONT FORK (for YZF-R1)
¢ When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
4. Check:
e Cap bolt “1”
¢ Cap bolt collar projection “2”
Cracks/damage — Replace.

EASa0208

CHECKING THE FRONT FORK LEGS (for

YZF-R1)
The following procedure applies to both of the
front fork legs.
1. Check:
¢ Inner tube
¢ Outer tube
Bends/damage/scratches — Replace. EAS30209
EWA13650 ASSEMBLING THE FRONT FORK LEGS (for
YZF-R1)
Do not attempt to straighten a bent inner The following procedure applies to both of the
tube as this may dangerously weaken it. front fork legs.
EWA18360

2. Measure:
* Spring free length “a”
If both front fork legs are not filled with the
Out of specification — Replace.
specified amount of the fork oil, it may cause
Fork spring free length poor handling and a loss of stability.
219.5 mm (8.64 in) TIP
Limit
*« When assembling the front fork leg, be sure to
215.1 mm (8.47 in)
replace the following parts:
—Inner tube bushing
—Outer tube bushing
—Oil seal
—Oil seal clip
—Dust seal
—O-ring
¢ Before assembling the front fork leg, make
sure all of the components are clean.

G088921
1. Install:
e Base valve assembly
3. Check: e Damper rod assembly
¢ Damper rod EC AS2560

Damage/wear — Replace. NOTICE

Obsiruction — Blow out all of the oil passag- Allow the damper rod assembly to slide
es with compressed air. slowly down the inner tube. Be careful not to
damage the inner tube.
ECA19110

NOTICE
¢ The front fork leg has a very sophisticated 2. Tighten:
internal construction, which are particular- ¢« Damper rod assembly
ly sensitive to foreign material. Front fork damper rod assembly
40 N-m (4.0 kgf-m, 30 Ib-ft)

4-94
 FRONT FORK (for YZF-R1)

TIP
Tighten the damper rod assembly with the
damper rod holder “1”.

i Damper rod holder (930)

y 90890-01506
Damper rod holder
YM-01506

Sy \ A

3. Lubricate: G08s922
* Inner tube’s outer surface 5. Install:

Recommended oil ° Outer tube

ai to the inner tube
Yamaha Suspension Oil 01 6. | cae r tube)

4. Install: ° Outer tube bushing “4”

in e Washer “2
* Dust seal “1” XE (with the fork seal driver “3”)
* Oil seal clip “2” TET
* Oil seal ins“3” TAN Fork seal driver
e Washer “4” 90890-01442
Adjustable fork seal driver (36—46
¢ Outer tube bushing “5” [XEN mm)
e Inner tube bushing “6” [Xtia YM-01442
ECAIS170

NOTICE
Make sure the numbered side of the oil seal
faces bottom side.

TIP 3—<—
¢ Before installing the oil seal, lubricate its lips 2
with lithium-soap-based grease.
e Lubricate the outer surface of the inner tube 1
with fork oil.
¢ Before installing the oil seal, cover the top of GO88923
the front fork leg with a plastic bag to protect 7. Install:
the oil seal during installation. © Oil seal “1”
(with the fork seal driver “2”)

Fork seal driver

90890-01442
Adjustable fork seal driver (36—46
mm)
YM-01442

4-95
 FRONT FORK (for YZF-R1)

Rod puller
90890-01437
Universal damping rod bleeding
tool set
YM-A8703
Rod puller attachment (M10)
90890-01436
Universal damping rod bleeding
tool set
G088924
YM-A8703
8. Install:
¢ Oil seal clip “1”
TIP
Adjust the oil seal clip so that it fits into the outer
tube’s groove.

G088927

[Link]:
e Front fork leg
(with the specified amount of the recom-
mended fork oil)
G088925

9. Install: Recommended oil

¢ Dust seal “1” Yamaha Suspension Oil 01
(with the fork seal driver “2”) Quantity (left)
470.0 cm? (15.89 US oz, 16.58
Fork seal driver [Link])
90890-01442 Quantity (right)
Adjustable fork seal driver (36—46 470.0 cm? (15.89 US oz, 16.58
mm) [Link])
YM-01442
EC A14240

NOTICE
¢ 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.
[Link] filling the front fork leg, slowly stroke the
damper rod “1” up and down (at least ten
G088926
times) to distribute the fork oil.
[Link]: TIP
¢ Rod puller “1”
Be sure to stroke the damper rod slowly be-
¢ Rod puller attachment (M10) “2”
cause the fork oil may spurt out.
(onto the damper rod “3”)

4-96
 FRONT FORK (for YZF-R1)

TIP
Install the fork spring with the smaller diameter
“a’ facing up “A”.

GO88929 |

[Link] measuring the fork oil level, wait ten

minutes until the oil has settled and the air
bubbles have dispersed.
G088931
TIP
C. Install the locknut all the way onto the
Be sure to bleed the front fork leg of any residual
damper rod assembly.
air.
. Install the rod puller and rod puller attach-
[Link]: ment.
¢ Front fork leg oil level “a” . Install the spacer and guide.
(from the top of the outer tube, with the outer Install the fork spring compressor.

eo
tube fully compressed and without the fork Press down on the spacer with the fork
spring) spring compressor “1”.
Out of specification — Correct. . Pull up the rod puller and install the rod
>

holder “2” between the locknut “3” and the

ax Level (left) guide “4”.
84 mm (3.3 in)
Level (right) Rod puller
84 mm (3.3 in) 90890-01437
Universal damping rod bleeding
tool set
YM-A8703
Rod puller attachment (M10)
90890-01436
Universal damping rod bleeding
cae HH tool set
1 |

YM-A8703
‘4

| Tm
MA
if

Fork spring compressor

Ps 90890-01441
G088930 Fork spring compressor
YM-01441
[Link]: Rod holder
¢ Fork spring 90890-01434
¢ Spacer Damper rod holder double ended
e Locknut YM-01434
¢ Damper adjusting rod 2
¢ Damper adjusting rod 1 TIP
* Guide Use the side of the rod holder that is marked “B”.
* Cap bolt
(along with the O-ring [XEW9)
a. Remove the rod puller and rod puller at-
tachment.
b. Install the fork spring.

4-97
 FRONT FORK (for YZF-R1)
EASS0210

INSTALLING THE FRONT FORK LEGS (for

YZF-R1)
The following procedure applies to both of the
front fork legs.
1. Install:
e Front fork leg
Temporarily tignten the upper and lower
bracket pinch bolts.
EWA13680

Remove the rod puller and rod puller at- Make sure the brake hoses are routed prop-
tachment. erly.
j. Install the damper adjusting rods and cap
TIP
bolt, and then finger tighten the cap bolt.
EWA13670 Align the outer tube with the position “a” as
shown in the illustration.
Always use a new cap bolt O-ring.
k. Hold the cap bolt “5” and tighten the lock-
nut “3” to specification.
ECA17390

NOTICE
When loosening the nut, be sure not to break
the projections on the cap bolt collar of the
cap bolt.

Dy Front fork cap bolt locknut

15 N-m (1.5 kgf-m, 11 Ib-ft) 2. Tighten:

“ e Lower bracket pinch bolts “1” and “2”

Lower bracket pinch bolt

&% 23 N-m (2.3 kgf-m, 17 Ib-ft)

TIP
Tighten each bolt to 23 N-m (2.3 kgf-m, 17 lb-ft)
in the order pinch bolt “1” > pinch bolt “2” >
pinch bolt “1” —> pinch bolt “2”.

Remove the rod holder and fork spring

compressor.
[Link]:
* Cap bolt
(to the outer tube)
TIP
e Temporarily tighten the cap bolt.
¢ When to tighten the cap bolt to the specified
torque is after installing the front fork leg to the
vehicle and tightening the lower bracket pinch 3. Tighten:
bolts. ¢ Cap bolt “1”

Sy Front fork cap bolt

23 N-m (2.3 kgf-m, 17 Ib-ft)

4-98
 FRONT FORK (for YZF-R1)
¢ Handlebar bolt “2”

\y Handlebar bolt
Q 7 N-m (0.7 kgf-m, 5.2 Ib-ft)

¢ Handlebar pinch bolt “3”

\y Handlebar pinch bolt

> 32 N-m (3.2 kgf-m, 24 Ib-ft)

¢ Upper bracket pinch bolt “4”

\y Upper bracket pinch bolt

Q 26 N-m (2.6 kgf-m, 19 Ib-ft)

TIP
When installing the front fork legs, make sure
that the spring preload adjusting nuts are posi-
tioned at the angles shown in the illustration.
Sa

4. Check:
¢ Cable routing
TIP
Make sure the brake hose, throttle cables, clutch
cable, and handlebar switch leads are routed
properly. Refer to “CABLE ROUTING?” on page
2-17.
5. Adjust:
* Spring preload
* Rebound damping
¢ Compression damping
Refer to “ADJUSTING THE FRONT FORK
LEGS (for YZF-R1)” on page 3-21.

4-99
 FRONT FORK (for YZF-R1M)
EAS20169

FRONT FORK (for YZF-R1M)

Removing the front fork legs (for YZF-R1M)

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 4-35.
Front panel cover hil to “GENERAL CHASSIS (3)” on page

1 Front fender 1
2 Upper bracket pinch bolt 1 Loosen.
3 Handlebar pinch bolt 1 Loosen.
4 Handlebar bolt 1 Loosen.
5 Front fork stepping motor coupler 1 Disconnect.
6 Cap bolt (with front fork stepping motor) 1 Loosen.
7 Lower bracket pinch bolt 2 Loosen.
8 Front fork leg 1

4-100
 FRONT FORK (for YZF-R1M)

Disassembling the front fork legs

|13

\
(
|—8
CG

Order Job/Parts to remove Remarks

Q
Z

The following procedure applies to both of

the front fork legs.
Cap bolt (with front fork stepping motor)
es
bP] —

O-ring
|

Damper adjusting rod

|
o/]

Locknut
om) &/]

Upper spring seat

|
|

Fork spring
|

|,
co; S|

Spacer
|e

Outer tube
|
O;}

Dust seal
me

Oil seal clip

=k
©

fm

Oil seal
oll,
ol,

fm

Washer
ok
ho

fm

Inner tube
—_k
Go

vem

4-101
 FRONT FORK (for YZF-R1M)
EAS33359
TIP
HANDLING THE FRONT FORK (for YZF-R1M)
EWA20910 Place the vehicle on a maintenance stand so
that the front wheel is elevated.
This front fork contains highly compressed
2. Remove:
nitrogen gas. Before handling the front fork,
e Front brake caliper
read and make sure you understand the fol-
Refer to “FRONT BRAKE” on page 4-52.
lowing information. The manufacturer can- e Front wheel
not be held responsible for property damage Refer to “FRONT WHEEL” on page 4-35.
or personal injury that may result from im- 3. Disconnect:
proper handling of the front fork. e Front fork stepping motor coupler
¢ Do not tamper or attempt to open the front 4. Loosen:
fork. ¢ Handlebar pinch bolt “1”
¢ Do not subject the front fork to an open ¢ Upper bracket pinch bolt “2”
flame or any other source of high heat. High
¢ Handlebar bolt “3”
heat can cause an explosion due to exces-
e Cap bolt “4”
sive gas pressure.
e Lower bracket pinch bolts “5”
¢ Do not deform or damage the front fork in EW A1S640

any way. Front fork damage will result in

poor damping performance. Before loosening the upper and lower brack-
et pinch bolts, support the front fork leg.
EASS3360

DISPOSING OF FRONT FORK LEG (for

YZF-R1M)
1. Gas pressure must be released before dis-
posing of a front fork. To release the gas
pressure, drill a 2—3 mm (0.08—0.12 in) hole
through the front fork as shown.
EWAI3760

Wear eye protection to prevent eye damage

from released gas or metal chips.

TIP
Loosen the cap bolt “4” using the front fork cap
bolt wrench “6”.

J Front fork cap bolt wrench 42mm

90890-01575
YM-01575

EAS31 648

REMOVING THE FRONT FORK LEGS (for

YZF-R1M)
The following procedure applies to both of the
front fork legs.
1. Stand the vehicle on a level surface.
EWAIS120

Securely support the vehicle so that there is

no danger of it falling over.

4-102
 FRONT FORK (for YZF-R1M)

5 Remove: b. Hold the spring preload adjusting bolt “5”

¢ Front fork leg and loosen the locknult.

EASa1649

DISASSEMBLING THE FRONT FORK LEGS

(for YZF-R1M)
The following procedure applies to both of the
front fork legs.
1. Turn the spring preload adjusting bolt “1”
counterclockwise until it stops.
TIP
Turn the spring preload adjusting bolt “1” before
removing the front fork from the vehicle. c. Remove the cap bolt, damper adjusting
rod, upper spring seat and fork spring.
3. Drain:
¢ Fork oil
TIP
Separately from the fork oil in the inner tube, fork
oil is in the inside cartridge of the lower part of
the inner tube. The fork oil of the cartridge in the
inner tube cannot be replaced.
4. Remove:
e Outer tube
2. Remove: 5. Remove:
¢ Cap bolt “1” ¢ Dust seal
¢ Locknut “2” ¢ Oil seal clip “1”
¢ Upper spring seat “3” (with a flat-head screwdriver)
¢ Damper adjusting rod ¢ Oil seal
a. Loosen the cap bolt “1” using the front fork e Washer
cap bolt wrench “4” and then remove it
from the outer tube.

Front fork cap bolt wrench 42mm

90890-01575
YM-01575

4-103
 FRONT FORK (for YZF-R1M)
EA531650
1. Lubricate:
CHECKING THE FRONT FORK LEGS (for
e Inner tube’s outer surface
YZF-R1M)
The following procedure applies to both of the — Recommended oil
front fork legs. | | Ohlins R&T 43
1. Check:
¢ Inner tube 2. Install:
¢ Outer tube e Dust seal “1” [XAG
Bends/damage/scratches — Replace. ¢ Oil seal clip “2”
EW A13650
° Oil seal “3” JAW
e Washer “4”
Do not attempt to straighten a bent inner BC AIS170

tube as this may dangerously weaken it. NOTICE

2. Measure: Make sure the numbered side of the oil seal
* Spring free length “a” faces bottom side.
Out of specification — Replace.
TIP
Fork spring free length * Before installing the oil seal, lubricate its lips
260.0 mm (10.24 in) with lithium-soap-based grease.
Limit ¢ Lubricate the outer surface of the inner tube
254.8 mm (10.03 in) 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.

G088921

3. Check:
* Cap bolt
Cracks/damage —> Replace.
E4S31651

ASSEMBLING THE FRONT FORK LEGS (for

YZF-R1M)
The following procedure applies to both of the
front fork legs.
EWA18360

lf both front fork legs are not filled with the

specified amount of the fork oil, it may cause
GO088922
poor handling and a loss of stability.
3. Install:
TIP
¢ Outer tube
e When assembling the front fork leg, be sure to (to the inner tube)
replace the following parts: 4. Install:
—Oil seal e Washer
—Dust seal e Oil seal “1”
—O-ring (with the fork seal driver “2”)
¢ Before assembling the front fork leg, make
sure all of the components are clean.

4-104
 FRONT FORK (for YZF-R1M)
7. Fill:
CS, Fork seal driver e Front fork leg
90890-01442 (with the specified amount of the recom-
Adjustable fork seal driver (36—46 mended fork oil)
mm)
YM-01442 4 Recommended oil
Ohlins R&T 43
Quantity (left)
263 cm? (8.89 US oz, 9.26
[Link])
Quantity (right)
263 cm? (8.89 US oz, 9.26
[Link])
ECA14230

NOTICE
Goss8924 ¢ Be sure to use the recommended fork oil.
5. Install: Other oils may have an adverse effect on
* Oil seal clip “1” front fork performance.
¢ When disassembling and assembling the
TIP
front fork leg, do not allow any foreign ma-
Adjust the oil seal clip so that it fits into the outer terial to enter the front fork.
tube’s groove.
8. Before measuring the fork oil level, wait ten
minutes until the oil has settled and the air
bubbles have dispersed.
9. Measure:
e Front fork leg oil level “a”
(from the top of the outer tube, with the outer
tube fully compressed and without the fork
spring)
Out of specification — Correct.
G088925
Level (left)
6. Install: 180 mm (7.1 in)
* Dust seal “1” Level (right)
(with the fork seal driver “2”) 180 mm (7.1 in)

J Fork seal driver —

90890-01442
Adjustable fork seal driver (36—46
mm) a
=|—_—

YM-01442
MA

[ *| |

GO088930

[Link]:
e Spacer
¢ Fork spring
e Upper spring seat
G088926
¢ Locknut
e Damper adjusting rod

4-105
 FRONT FORK (for YZF-R1M)
* Cap bolt d. Hold the spring preload adjusting bolt “3”
(along with the O-ring [XEW9) and tighten the locknut “4” to specification.
a. Install the spacer and fork spring.
Front fork cap bolt locknut
TIP
Install the fork spring with the marks “a” facing
up “A”.
~& 19 N-m (1.9 kgf-m, 14 Ib-ft)

t
[Link]:
¢ Cap bolt
b. Install the locknut “1”, upper spring seat
(to the outer tube)
“2 and damper adjusting rod.
TIP
TIP
¢ Temporarily tighten the cap bolt.
Touch the locknut “1” to the upper spring seat
¢ When to tighten the cap bolt to the specified
“2, and install the locknut “1” until the upper
torque is after installing the front fork leg to the
spring seat “2” contacts with the width across
vehicle and tightening the lower bracket pinch
flats “b” of the inner tube.
bolts.

A
EFAS31652

1 INSTALLING THE FRONT FORK LEGS

The following procedure applies to both of the
2 sy
front fork legs.
1. Install:
b
¢ Front fork leg
Temporarily tighten the upper and lower
bracket pinch bolts.
EWA13680

c. Install the cap bolt “3”.

EWAIS870 Make sure the brake hoses are routed prop-
erly.
Always use a new cap bolt O-ring.
TIP
TIP Align the outer tube with the position “a” as
Tighten the cap bolt “3” by hand while holding shown in the illustration.
the width across flats “b” of the inner tube.

4-106
 FRONT FORK (for YZF-R1M)
2. Tighten: e Upper bracket pinch bolt “5”
¢ Lower bracket pinch bolts “1” and “2”
\y Upper bracket pinch bolt
Lower bracket pinch bolt | | | 26 N-m (2.6 kgf-m, 19 Ib-ft)
oN 23 N-m (2.3 kgf-m, 17 Ib-ft)

TIP
Tighten each bolt to 23 N-m (2.3 kgf-m, 17 lb-ft)
in the order pinch bolt “1” —> pinch bolt “2” >
pinch bolt “1” — pinch bolt “2”.

TIP
When installing the front fork legs, make sure
that the front fork stepping motor couplers are
positioned at the angles shown in the illustration.

3. Tighten:
¢ Cap bolt “1”
TIP
Tighten the cap bolt “1” using the front fork cap
bolt wrench “2”.

Front fork cap bolt wrench 42mm

90890-01575
YM-01575
4. Check:
e Cable routing
Front fork cap bolt | TIP
20 N-m (2.0 kgf-m, 15 Ib-ft) Make sure the brake hose, throttle cables, clutch
cable, and handlebar switch leads are routed
properly. Refer to “CABLE ROUTING?” on page
2-17.
5. Adjust:
e Spring preload
¢ Rebound damping
¢« Compression damping
Refer to “ADJUSTING THE PRELOAD OF
THE FRONT FORK LEGS (for YZF-R1M)”
on page 3-23 and “ADJUSTING THE DAMP-
; ty ING FORCE OF THE FRONT FORK LEGS
permsva! Don AND REAR SHOCK ABSORBER ASSEM-
\y Handiebarbol BLY (for YZF-R1M)” on page 3-23.
ON 7 N-m (0.7 kgf-m, 5.2 |b-ft)

* Handlebar pinch bolt “4”

Handlebar pinch bolt

32 N-m (3.2 kgf-m, 24 lb-ft)

4-107
 STEERING HEAD

EAS20035

STEERING HEAD
Removing the lower bracket

“ Loosen the lower ring nut completely, and then tighten it to specification.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (3)” on page

Front panel cover
4-9.
Refer to “GENERAL CHASSIS (4)” on page
Windshield
4-13.

Front side cowling Refer to “GENERAL CHASSIS (5)” on page

4-16.
Refer to “GENERAL CHASSIS (6)” on page
Front cowling assembly
4-23.
Refer to “GENERAL CHASSIS (7)” on page
Air intake duct
4-28.
Front wheel Refer to “FRONT WHEEL’ on page 4-35.
Upper bracket/Handlebars Refer to “HANDLEBARS’” on page 4-83.
Refer to “FRONT FORK (for YZF-R1)” on
Front fork legs page 4-89 or refer to “FRONT FORK (for
YZF-R1M)’ on page 4-100.

4-108
 STEERING HEAD

Removing the lower bracket

“ Loosen the lower ring nut completely, and then tighten it to specification.

Order Job/Parts to remove Remarks

Q
Zz

Front brake hose

hs
—

|
hm]

Horn bracket
cw]

Lower bracket cover

fe

Steering damper solenoid coupler

&]

Disconnect.

Steering damper solenoid

mm) oy)

Lock washer
co; ~s|

Upper ring nut

fm

Rubber washer
Lower ring nut
0;

Lower bracket
—k
a

Bearing cover
|
ak.
ool,

Lower bearing dust seal

=k
No

Upper bearing
lk
Go

fm

Lower bearing
—k

mm
a

4-109
 STEERING HEAD

EAS30213
e Bearing race
REMOVING THE LOWER BRACKET
Damage/pitting — Replace the bearings and
1. Stand the vehicle on a level surface.
EWAI3120
bearing races as a Set.
3. Replace:
¢ Bearing
Securely support the vehicle so that there is
¢ Bearing race
no danger of it falling over.
a. Remove the bearing races from the steer-
2. Remove: ing head pipe “1” with a long rod “2” and
¢ Upper ring nut “1” hammer.
e Rubber washer b. Remove the bearing race “3” from the low-
¢ Lower ring nut “2” er bracket with a floor chisel “4” and ham-
¢ Lower bracket mer.
EWA13730
c. Install a new dust seal and new bearing
races.
Securely support the lower bracket so that ECA14270

there is no danger of it falling. NOTICE

TIP If the bearing race is not installed properly,
the steering head pipe could be damaged.
¢ Hold the lower ring nut with steering nut
wrench, and then remove the upper ring nut TIP
with the ring nut wrench “3”. * Always replace the bearings and bearing races
e Remove the lower ring nut with the steering nut as a set.
wrench “4”. « Whenever the steering head is disassembled,
replace the dust seal.
Ring nut wrench
90890-01268
Spanner wrench
YU-01268
Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472

Ss
J 4 3 \
G088933

Y /
~)
Xf ON
WZ
bh sz
3 4
| oN
G088932 | 2
\(i
J
EAS30214

CHECKING THE STEERING HEAD GO088934

1. Wash:
4. Check:
¢ Bearing
¢ Upper bracket
¢ Bearing race
e Lower bracket
= Recommended cleaning solvent (along with the steering stem)
Kerosene Bends/cracks/damage — Replace.

2. Check:
* Bearing

4-110
 STEERING HEAD

EAS30216

INSTALLING THE STEERING HEAD

1. Lubricate:
¢ Upper bearing
* Lower bearing

= Recommended lubricant
Lithium-soap-based grease |

2. Install:
¢ Lower ring nut “1”
¢ Rubber washer “2”
¢ Upper ring nut “3”
¢ Lock washer “4”
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-19.

p L

mY A 3
QW Wt
ao RS
GO088935 ]

3. Install:
* Upper bracket
¢ Steering stem nut
Refer to “HANDLEBARS” on page 4-83.
TIP
Temporarily tighten the steering stem nut.
4. Install:
¢ Front fork legs
Refer to “FRONT FORK (for YZF-R1)” on
page 4-89 or “FRONT FORK (for YZF-R1M)”
on page 4-100.
TIP
Temporarily tighten the upper and lower bracket
pinch bolts.

EASS0215

CHECKING THE STEERING DAMPER

1. Check:
* Steering damper body
Damage/oil leaks — Replace the steering
damper assembly.
¢ Steering damper rod
Bends/scratch — Replace the steering
damper assembly.
¢ Bearing
Damage/pitting — Replace the steering
damper assembly.

4-111
 REAR SHOCK ABSORBER ASSEMBLY

EAS20036

REAR SHOCK ABSORBER ASSEMBLY

Removing the rear shock absorber assembly (for YZF-R1)

Order Job/Parts to remove Q’ty Remarks

Rider seat Pirbel to “GENERAL CHASSIS (1)” on page

Fuel tank Refer to “FUEL TANK” on page 7-1.

Rear brake caliper Refer to “REAR BRAKE” on page 4-63.
Rear wheel Refer to “REAR WHEEL’ on page 4-43.
Exhaust chamber Refer to “ENGINE REMOVAL’ on page 5-11.
1 Connecting arm upper nut/Washer/Bolt 1/1/1
2 Rear shock absorber assembly lower nut/Bolt 1/1
3 Connecting arm lower nut/Washer/Bolt 1/1/1
4 Connecting arm 2
5 Rear shock absorber assembly upper nut/Col- 4/1/1
lar/Bolt

4-112
 REAR SHOCK ABSORBER ASSEMBLY

Removing the rear shock absorber assembly (for YZF-R1)

Order Job/Parts to remove Q’ty Remarks

6 Relay arm nut/Bolt 1/1

7 Collar 1
8 Relay arm 1
9 Rear shock absorber assembly 1
10 Oil seal/Bearing 2/1
11 Collar/Oil seal/Bearing 1/2/2
12 Collar/Oil seal/Bearing 1/2/1
13 Collar/Dust seal/Circlip/Bushing 2/2/1/1
14 Collar/Oil seal/Bearing 1/2/2

4-113
 REAR SHOCK ABSORBER ASSEMBLY

Removing the rear shock absorber assembly (for YZF-R1M)

6g reer

Order Job/Parts to remove Q’ty Remarks

Rider seat Fie to “GENERAL CHASSIS (1)” on page

Fuel tank Refer to “FUEL TANK” on page 7-1.

Rear brake caliper Refer to “REAR BRAKE” on page 4-63.
Rear wheel Refer to “REAR WHEEL’ on page 4-43.
Exhaust chamber Refer to “ENGINE REMOVAL’ on page 5-11.
Rear shock absorber assembly stepping motor ;
1 coupler 2 Disconnect.

2 Connecting arm upper nut/Washer/Bolt 1/1/1

3 Rear shock absorber assembly lower nut/Bolt 1/1
4 Connecting arm lower nut/Washer/Bolt 1/1/1
5 Connecting arm 2
6 Rear shock absorber assembly upper nut/Col- 4/1/1
lar/Bolt

4-114
 REAR SHOCK ABSORBER ASSEMBLY

Removing the rear shock absorber assembly (for YZF-R1M)

iff ai

FH
EC Sul

Order Job/Parts to remove Q’ty Remarks

7 Relay arm nut/Bolt 1/1

8 Collar 1
9 Relay arm 1
10 Rear shock absorber assembly 1
11 Oil seal/Bearing 2/1
12 Collar/Oil seal/Bearing 1/2/2
13 Collar/Oil seal/Bearing 1/2/1
14 Collar/Dust seal/Circlip/Bushing 2/2/2/1
15 Collar/Oil seal/Bearing 1/2/2

4-115
 REAR SHOCK ABSORBER ASSEMBLY

EASS30826

HANDLING THE REAR SHOCK ABSORBER

EWATST40
a Ae i
a |

[i
OQ | r)

|]
This rear shock absorber contains highly

J
compressed nitrogen gas. Before handling

T]
i}
the rear shock absorber, read and make sure
you understand the following information.
The manufacturer cannot be held responsi-
ble for property damage or personal injury
that may result from improper handling of
the rear shock absorber. A. YZF-R1
¢ Do not tamper or attempt to open the rear B. YZF-RiM
shock absorber.
¢ Do not subject the rear shock absorber to EAS30219

an open flame or any other source of high REMOVING THE REAR SHOCK ABSORBER
heat. High heat can cause an explosion due ASSEMBLY
to excessive gas pressure. 1. Stand the vehicle on a level surface.
EWAI3120
¢ Do not deform or damage the rear shock
absorber in any way. Rear shock absorber
securely support the vehicle so that there is
damage will result in poor damping perfor-
no danger of it falling over.
mance.
TIP
EASSOT29
Place the vehicle on a maintenance stand so
DISPOSING OF A REAR SHOCK ABSORBER
that the rear wheel is elevated.
1. Gas pressure must be released before dis-
posing of a rear shock absorber. To release 2. Remove:
the gas pressure, drill a 2—3 mm (0.08—0.12 ¢ Connecting arm upper nut
in) hole through the rear shock absorber as ¢« Connecting arm upper bolt “1”
shown. e Rear shock absorber assembly lower nut
EWAI3760
e Rear shock absorber assembly lower bolt “2”
¢ Connecting arm lower nut
Wear eye protection to prevent eye damage ¢« Connecting arm lower bolt “3”
from released gas or metal chips. ¢ Connecting arm “4”
TIP
A
When removing the bolt, hold the swingarm so
that it does not drop down.

Cot

3. Remove:
e« Rear shock absorber assembly upper nut
¢ Rear shock absorber assembly upper bolt
4, Remove:
e Relay arm nut “1”
e Relay arm bolt “2”

4-116
 REAR SHOCK ABSORBER ASSEMBLY

e Collar “3S”
¢ Relay arm “4” v
TIP CLL i
Pull out the collar “3” from the left side of the ve- \
hicle. ~~

4. Remove:
e Oil seal
¢ Bearing “1”
TIP
Remove the bearing with a socket “2” that
matches its outside diameter.
5. Remove:
¢« Rear shock absorber assembly

DISASSEMBLING THE REAR SHOCK 2- ¥

ABSORBER ASSEMBLY Yo
1. Remove: ie
¢ Collar 1
¢ Dust seal
2. Remove:
* Circlip “1”
(with a flat-head screwdriver)

CHECKING THE REAR SHOCK ABSORBER

ASSEMBLY
1. Check:
e Rear shock absorber rod
Bends/damage — Replace the rear shock
absorber assembly.
e Rear shock absorber assembly
Gas leaks/oil leaks — Replace the rear shock
absorber assembly.
3. Remove: ° Spring
° Bushing “1” ¢ Bushings |
Damage/wear —> Replace the bushings.
Lad * Bolts
Remove the bushing with a socket “2” that
eagch ae Bends/damage/wear —> Replace.
matches its outside diameter.
FAS S0221

CHECKING THE CONNECTING ARM AND

RELAY ARM
1. Check:
¢« Connecting arms
e Relay arm
Damage/wear — Replace.
2. Check:
e Bearings

4-117
 REAR SHOCK ABSORBER ASSEMBLY

* Oil seals EAS S222

INSTALLING THE RELAY ARM

Damage/pitting — Replace.
1. Lubricate:
3. Check:
¢ Collars
* Collars
e Oil seals
Damage/scratches — Replace.
EA531654
= Recommended lubricant
ASSEMBLING THE REAR SHOCK | | Lithium-soap-based grease
ABSORBER ASSEMBLY
1. Install: 2. Install:
* Bearing “1” ¢ Bearings “1”
(to the relay arm)
* Oil seal DEW
TIP
e Oil seals “2” EWG
(to the relay arm)
Install the bearing with a socket “2” that matches
its outside diameter. Installed depth “a”
4.5 mm (0.18 in)
Installed depth “a” Installed depth “b”
4.0 mm (0.16 in) 3.5 mm (0.14 in)

TIP
¢ When installing the oil seals “2” to the relay
arm, face the character stamp of the oil seals
2 ey ¥. outside.
¢ Press in the oil seal so it does not protrude
from the end surface of the relay arm.

2. Install:
¢ Bushing “1”
° Circlip [EWG (for YZF-R1)
¢ Circlip (for YZF-R1M)

ee...
¢ Dust seal DEG
TIP
Install the bushing with a socket “2” that matches B r A

|| fe
its outside diameter.

a Installed depth “a”

YZF-R1 6.0 mm (0.24 in)
YZF-R1M 3.0 mm (0.12 in)
es
—) 5

¥ i [so H
HY Ta
| MT\_la Relay arm
Drow &

ryt
Q) DP
Connecting arm
Rear shock absorber assembly
|
Frame
. Left side
Right side

4-118
 REAR SHOCK ABSORBER ASSEMBLY

EASs0225

INSTALLING THE REAR SHOCK

ABSORBER ASSEMBLY
1. Install:
¢ Rear shock absorber assembly
¢« Relay arm
¢ Connecting arm
TIP
e Install the rear shock absorber assembly upper
bolt, relay arm bolt, connecting arm lower bolt
and connecting arm upper bolt from the left.
¢ When installing the rear shock absorber as-
sembly, lift up the swingarm.
2. Tighten:
¢ Relay arm nut
¢ Rear shock absorber assembly upper nut
¢ Connecting arm lower nut
¢ Rear shock absorber assembly lower nut
¢« Connecting arm upper nut

\y Relay arm nut

> 40 N-m (4.0 kgf-m, 30 Ib-ft)
Rear shock absorber assembly
upper nut
40 N-m (4.0 kgf-m, 30 Ib-ft)
Connecting arm lower nut
40 N-m (4.0 kgf-m, 30 Ib-ft)
Rear shock absorber assembly
lower nut
40 N-m (4.0 kgf-m, 30 Ib-ft)
Connecting arm upper nut
40 N-m (4.0 kgf-m, 30 Ib-ft)

4-119
 SWINGARM

EAS200a7

SWINGARM
Removing the swingarm

Order Job/Parts to remove Q’ty Remarks

Rear brake caliper Refer to “REAR BRAKE” on page 4-63.
Rear wheel Refer to “REAR WHEEL’ on page 4-43.

Rear shock absorber assembly SEMBLY” on page 4 CIS ABSORBER AS-

Drive sprocket Refer to “CHAIN DRIVE” on page 4-125.

1 Drive chain guard 1
2 Rear fender 1
3 Drive chain guide 1
4 Rear wheel sensor lead cover 1
5 Pivot shaft nut/Washer 1/1
6 Pivot shaft ring nut/Washer 1/1
7 Pivot shaft 1

4-120
 SWINGARM

Removing the swingarm

Order Job/Parts to remove Q’ty Remarks

8 Rear wheel sensor lead hook 1

9 Swingarm 1
10 Drive chain 1
11 Dust cover 2
12 Washer 1
13 Bushing 1
14 Bearing 2

4-121
 SWINGARM

EAS30226
5. Remove:
REMOVING THE SWINGARM
e Pivot shaft nut
1. Stand the vehicle on a level surface.
EWAI3120
e Pivot shaft ring nut “1”
TIP
Securely support the vehicle so that there is Loosen the pivot shaft ring nut with the ring nut
no danger of it falling over. wrench “2”.

TIP
Ring nut wrench
Place the vehicle on a maintenance stand so 90890-01507
that the rear wheel is elevated. Ring nut wrench
2. Remove: YM-01507
¢ Rear shock absorber assembly
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 4-112.
3. Measure:
¢ Swingarm side play
¢ Swingarm vertical movement
a. Measure the tightening torque of the pivot
shaft nut.

N Pivot shaft nut

% 105 N-m (10.5 kgf-m, 77 Ib-ft)
Pivot shaft ring nut
6. Remove:
65 N-m (6.5 kgf-m, 48 Ib-ft)
e Pivot shaft “1”
Pivot shaft
7 N-m (0.7 kgf-m, 5.2 Ib-ft) TIP
Loosen the pivot shaft with the damper rod hold-
b. Check the swingarm side play “A” by mov- er ale

ing the swingarm from side to side.

lf the swingarm has side-to-side play, hh Damper rod holder (@22)
check the collars, bearings, and dust cov- 90890-01365
ers.
c. Check the swingarm vertical movement
“B” by moving the swingarm up and down.
lf the swingarm vertical movement is not
smooth or if there is binding, check the piv-
ot shaft, collars, bearings, and dust cov-
ers.

7. Remove:
e Swingarm
EAS S0227

CHECKING THE SWINGARM

G088936 1. Check:
4. Remove: ¢ Swingarm
¢ Drive chain Bends/cracks/damage —> Replace.
Refer to “REMOVING THE DRIVE CHAIN” 2. Check:
on page 4-126. e Pivot shaft
Roll the pivot shaft on a flat surface.

4-122
 SWINGARM

Bends —> Replace.

EWAIST7O = Recommended lubricant
| | Lithium-soap-based grease
Do not attempt to straighten a bent pivot
shaft. 2. Install:
¢ Bearings “1”
3. Wash: (to the swingarm)
e Pivot shaft
¢ Oil seals “2” TENG
e Dust covers
(to the swingarm)
° Collar
¢ Bushing Installed depth “a”
e Washer 0—1.0 mm (0—0.04 in)
Installed depth “b”
| Recommended cleaning solvent | 4.0 mm (0.16 in)
Kerosene

4. Check:
¢ Dust covers “1” °+ Whee installing the oil seals to the swingarm,
e Oil seals “2” face the character stamp of the oil seals out-
Damage/wear — Replace. side.
¢ Collar “3” * Press in the oil seal so it does not protrude
Damage/scratches — Replace. from the end surface of the swingarm.
* Bearings “4”
Damage/pitting — Replace.
¢ Bushing “5”
Damage/pitting — Replace.

A. Left side
B. Right side

3. Install:
EAS30228
e Swingarm
INSTALLING THE SWINGARM e Pivot shaft “1”
1. Lubricate:
Pivot shaft
« Dust covers
ON 7 N-m (0.7 kgf-m, 5.2 lb-ft)
e Pivot shaft
e Oil seals
e Collar
¢ Bushing

4-123
 SWINGARM

TIP e Rear shock absorber assembly

Tighten the pivot shaft with the damper rod hold- Refer to "REAR SHOCK ABSORBER AS-
er “2”. SEMBLY” on page 4-112.
¢ Rear wheel
Refer to “REAR WHEEL” on page 4-43.
7. Adjust:
e Drive chain slack
Refer to “Adjusting the drive chain slack” on
page 3-19.

Drive chain slack (When perform-

ing maintenance/Maintenance
stand)
25.0-—35.0 mm (0.98—1.38 in)
Drive chain slack (When replac-
ing with a new one/Maintenance
stand)
20.0—30.0 mm (0.79—1.18 in)
Drive chain slack limit (Mainte-
4. Install: nance stand)
¢ Pivot shaft ring nut “1” 35.0 mm (1.38 in)
Pivot shaft ring nut
ON 65 N-m (6.5 kgf-m, 48 Ib-ft)

TIP
Tighten the pivot shaft ring nut with the ring nut
wrench “2”.

Ring nut wrench

90890-01507
Ring nut wrench
YM-01507

5. Install:
© Pivot shaft nut

Pivot shaft nut

105 N-m (10.5 kgf-m, 77 Ib-ft)
6. Install:
e Drive chain
Refer to “INSTALLING THE DRIVE CHAIN”
on page 4-127.

4-124
 CHAIN DRIVE

EAS20038

CHAIN DRIVE
Removing the drive chain

Order Job/Parts to remove Q'ty Remarks

Shift sensor coupler Disconnect.

—.

Locknut
Gc! Po

ee

Shift sensor
ee

Shift rod
&/}

ee

Shift arm
oy]

Shift rod joint

&!)

ee
co; S|)

Shift pedal
Drive sprocket cover
Drive chain guide
;

Drive sprocket nut

—_h
oS

Washer
ak.
ol,

Drive sprocket
—_h
ho

Drive chain
ok
Go

4-125
 CHAIN DRIVE

EAS30229

REMOVING THE DRIVE CHAIN

1. Stand the vehicle on a level surface. 123 4 5 6121314
15 16
Te
EWAI3120

Securely support the vehicle so that there is

no danger of it falling over.
TIP
Place the vehicle on a maintenance stand so
G088937
that the rear wheel is elevated.
b. Calculate the 15-link section length “c” of
2. Straighten the drive sprocket nut rib “a”
the drive chain using the following formula.
Drive chain 15-link section length “c” =
(length “a” between pin inner sides +
length “b” between pin outer sides)/2
TIP
¢ When measuring a 15-link section of the drive
chain, make sure that the drive chain is taut.
¢ Perform this procedure 2-3 times, at a different
location each time.

3. Remove:
© Drive chain
EGAT410

NOTICE
Be sure to put on safety goggles when work-
ing.
TIP
Cut the drive chain with the drive chain cut & riv- G088938

et tool. 2. Check:
¢ Drive chain
Drive chain cut & rivet tool Stiffness — Clean and lubricate or replace.
90890-01550
Drive chain cut & rivet tool
YM-01550

EASa0230

CHECKING THE DRIVE CHAIN

1. Measure:
¢ 15-link section length “a” of the drive chain
Out of specification — Replace the drive
chain.

Ay
G088939

15-link length limit 3. Clean:

239.3 mm (9.42 in) e Drive chain
a. Wipe the drive chain with a clean cloth.
a. Measure the length “a” between the inner b. Put the drive chain in kerosene and re-
sides of the pins and the length “b” be- move any remaining dirt.
tween the outer sides of the pins on a 15- c. Remove the drive chain from the kerosene
link section of the drive chain as shown in and completely dry it.
the illustration.

4-126
 CHAIN DRIVE

ECA1S050

NOTICE
¢ This vehicle has a drive chain with small a * a |
rubber O-rings “1” between the drive chain Nf
side plates. Never use high-pressure water
or air, steam, gasoline, certain solvents 2 sy
(e.g., benzine), or a coarse brush to clean Pa
the drive chain. High-pressure methods } | LZ
| | | {
could force dirt or water into the drive
Goss943 —— ——
chain’s internals, and solvents will deterio-
rate the O-rings. A coarse brush can also 5. Lubricate:
damage the O-rings. Therefore, use only e Drive chain
kerosene to clean the drive chain.
¢ Do not soak the drive chain in kerosene for Recommended lubricant
more than ten minutes, otherwise the O- Chain lubricant suitable for O-
rings can be damaged. ring chains

EASS0231

CHECKING THE DRIVE SPROCKET

1. Check:
¢ Drive sprocket
More than 1/4 tooth “a” wear > Replace the
drive sprocket, the rear wheel sprocket and
the drive chain as a set.
Bent teeth — Replace the drive sprocket, the
rear wheel sprocket and the drive chain as a
set.

G088941 GO0s8s8904

4. Check: b. Correct
¢ O-rings “1” 1. Drive chain roller
Damage — Replace the drive chain. 2. Drive sprocket
¢ Drive chain rollers “2”
EAS S232
Damage/wear — Replace the drive chain. CHECKING THE REAR WHEEL SPROCKET
¢ Drive chain side plates “3” Refer to “CHECKING AND REPLACING THE
Damage/wear/cracks — Replace the drive REAR WHEEL SPROCKET” on page 4-47.
chain.
FASS0233

CHECKING THE REAR WHEEL DRIVE HUB

Refer to “CHECKING THE REAR WHEEL
DRIVE HUB” on page 4-47.
FAS S0234

INSTALLING THE DRIVE CHAIN

1. Install:
e Drive chain

4-127
 CHAIN DRIVE

ECAI7410

NOTICE
Be sure to put on safety goggles when work-
ing.
TIP
Install the drive chain joint with the drive chain BS Sa
cut & rivet tool.

hls Drive chain cut & rivet tool

p 90890-01550
Drive chain cut & rivet tool 2. Lubricate:
YM-01550 e Drive chain

a. When press fitting the connecting plate Recommended lubricant

“1”, make sure the space “a” between the Chain lubricant suitable for O-
ring chains
end of the connecting pin “2” and the con-
necting plate is 1.3-1.4 mm (0.05—0.06
3. Install:
in).
¢ Drive sprocket
TIP ¢ Washer “1”
Apply lithium soap-based grease onto the con- ¢ Drive sprocket nut “2” [XE
necting pin “2”.
\y Drive sprocket nut
ONY 140 N-m (14 kgf-m, 103 Ib-ft)

7 TIP
¢ While applying the rear brake, tighten the drive
sprocket nut.
¢ Install washer “1” with the “OUT” mark “a” fac-
ing out.
{ a ¢ Stake the drive sprocket nut “2” at cutouts “b”
{ in the drive axle.

b. After riveting, make sure the diameter be-

tween the edges “b” of the connecting pin
“2” is 5.5-5.8 mm (0.22—0.23 in).

4. Install:
b e Shift arm “1”
TIP
c. After riveting, make sure the space “c”, Before installing, make sure to align the mark “a”
which is inside of the connecting link “3” of the shift shaft with the slot “b” of the shift arm.
and inside of the connecting plate “1”, is
15.10—15.30 mm (0.594—0.602 in). \y Shift arm bolt
10 N-m (1.0 kgf-m, 7.4 Ib-ft)

4-128
 CHAIN DRIVE

6. Adjust:
¢ Installed shift rod length
Refer to “ADJUSTING THE SHIFT PEDAL”
on page 4-129.
7. Adjust:
¢ Drive chain slack
Refer to “Adjusting the drive chain slack” on
page 3-19.

Drive chain slack (When perform-

ing maintenance/Maintenance
5. Install: stand)
© Shift rod joint “1” 25.0-—35.0 mm (0.98—1.38 in)
e Shift sensor “2” Drive chain slack (When replac-
¢ Shift rod “3” ing with a new one/Maintenance
TIP stand)
20.0—30.0 mm (0.79—1.18 in)
e Install the shift rod joint and shift sensor in the
Drive chain slack limit (Mainte-
direction shown in the illustration. nance stand)
e The allowable twist of the shift rod joint and 35.0 mm (1.38 in)
shift sensor is +5°.
Install the shift rod so that the side “b” faces up- ECA13550

ward as shown in the illustration. NOTICE

A drive chain that is too tight will overload
Shift rod joint bolt the engine and other vital parts, and one that
10 N-m (1.0 kgf-m, 7.4 Ib-ft) is too loose can skip and damage the swing-
LOCTITE® arm or cause an accident. Therefore, keep
Shift sensor locknut the drive chain slack within the specified lim-
7 N-m (0.7 kgf-m, 5.2 Ib-ft) its.

FASS1729

ADJUSTING THE SHIFT PEDAL

al WR ~ TIP
=H The shift pedal position is determined by the in-
stalled shift rod length.
1. Measure:
e Installed shift rod length “a”
Incorrect — Adjust.

a Installed shift rod length

258.5-—260.5 mm (10.18—10.26 in)

a. 24 mm (0.94 in)

2. Adjust:
¢ Installed shift rod length

4-129
 CHAIN DRIVE

a. Loosen both locknuts “1”.

b. Turn the shift rod until the specified in-
stalled shift rod length is obtained.
c. Tighten both locknuts.
TIP
Be sure to place the shift rod joints in parallel.
The allowable twist of the shift rod joints is +5°.

Shift rod locknut

| 7 Nem (0.7 kgf-m, 5.2 lb-ft)
d. Make sure the installed shift rod length is
within specification.

4-130
 CHAIN DRIVE

4-131
 ENGINE

LUBRICATION SYSTEM CHART AND DIAGRAMG................0..00000000. ee Be

ENGINE OIL LUBRICATION CHART ...... 00... e cece ee eeeee eee eaeeeeee eee DOT
LUBRICATION DIAGRAMS ... 00... cece ee cece eee cece ee ee eee ca eee eee caeeeeeeeaeene OTD

ENGINE INSPECTION
.. faadiedundedtebwenhed
ces evtacscanncenl=O!
MEASURE THE COMPRESSION PRESSURE... wie hited SdvamideSatenacedae

ENGINE REMOVAL.. ga ie Sucew'ed wet sae fs cbed deh ae Ca sd ssiauuade''sfowvannawonwsasswsanassd= T

REMOVING THE ENGINE. dint id visa bowiatiataeeeisateeeaipaiaedivet dates tdeiatensce > 1
INSTALLING THE ENGINE... {stad nandensenvasrvevexen C= 1)
INSTALLING THE EXHAUST PIPE AND MUFFLER... piveawieiveiwtveesenoe Da

CAMSHAFTS... dea afems esses s Seviadiseivets deeds dau segexmieessyeeadensssvenxeecl=1G

REMOVING THE CAMSHAFTS.. Leeeeeee D724
REMOVING THE ROCKER ARMS AND ROCKER ARM SHAFTS. seuss D-24
CHECKING THE CAMSHAFTS .. beseeeee D724
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS. reeneee D726
CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET .........5-26
CHECKING THE TIMING CHAIN GUIDES..........000 eee eee B26
CHECKING THE TIMING CHAIN TENSIONER... eee eee O27
ASSEMBLING THE TIMING CHAIN COVER .. seein OST
INSTALLING THE ROCKER ARMS AND ROCKER ARM SHAFTS vores One
INSTALLING THE TIMING CHAIN COVER... cece eee B28
INSTALLING THE CAMSHAPTS. ............ccccsccececeeeeeeeneeceeeeaeneeesesseasseeeeeees OOO

CYLINDER HEAD... denne eeeeeeeeeeeaeaenseeaeeeeeeeseeeeeteeseesenees OMG

REMOVING THE CYLINDER HEAD... Seda sttivs de nwetibn adi uwdeniwseniss cost wand Ene
CHECKING THE CYLINDER HEAD cvcscssssssssssssssstussississassasustaseaeeseeeeeee 5-34
INSTALLING THE CYLINDER HEAD... cece cece ee eeeeee eee eeeeeeeeeeees DOF

VALVES AND VALVE SPRINGS ....0.00.000 0c cece cece cette eee eeeee eee eeeeeeeees DOGO
REMOVING THE VALVES.. setanessseesercceaenecsersessses OUGO
CHECKING THE VALVES AND VALVE GUIDES ... Seudusdetuevesceversesgae
CHECKING THE VALVE SEATS voccccccsccscsssssssssssssssessssesssssessssssssssseseseeses 5°40
CHECKING THE VALVE SPRINGS .....00..0.... cc ceccee cece cee eee ee eee eee eee eee eees DAD
CHECKING THE VALVE SPRING SEAT..0..... cece ccce cee eeeeeeeeeeeeeeeeeeee OMAD
INSTALLING THE VALVES 0.00... c cece cece cee cee eenee eee eea enue eeeeeseeeeeeeees DAD

GENERATOR .. Geutsaans ituattveadiuviaidauaestiseateasetdtvesi cass iexan el ee

REMOVING THE GENERATOR... sence eetee eee ea eeaeee cee eaeeeeeeeseeeeeeeeeet sees DAG
INSTALLING THE GENERATOR veseccceccccsssssssscsssssssssssssssssssssssesseeresseeeeeee 5-46

STARTER CLUTCH .. we eae eects eeseaaeeneeeeseeeeeeeeeeseeeeteeseeseeees DAG

REMOVING THE STARTER CLUTCH gS cesta seVeseWius aes naneeneeankess sessceasvesss Sere?
CHECKING THE STARTER CLUTCH... eee cee c cece eee eee setae DAY
INSTALLING THE STARTER CLUTCH... eee ccc c eee eeeee cee eee tees eeees DAY
ELECTRIC STARTER.. se eaa ee eee eae aaaeeeeeeesaeaeneedsesaeaeneeeeesaeees
DDO
CHECKING THE STARTER MOTOR. bevwes efoseensawcntewsecferseetenpsosee
Se
ASSEMBLING THE STARTER MOTOR vvvecccsccsccsssssssssssssssessssssseseeeseeeeeee 5-52

OIL PUMP... pag chug oath Sap Sh eegde eee motes eee Meret aw'ean'hwtes Uebageet seach neds TOPE
REMOVING THE OIL PAN... jodeteanstdsaeadedeahsiuauedsasinviaieasa O50
CHECKING THE SPROCKET AND CHAIN... be eeeeeeeeeeeeaseeeeeeeeeeseeeeees PDT
CHECKING THE OIL PUMP... ssccsesssssssssssssssassssssssssssssesssesesesssssseseens 557
CHECKING THE RELIEF VALVE .. stgafyoeeGineeee, cepa cagceeceivenete petease Oe
CHECKING THE OIL DELIVERY PIPES. sis iw sn ens ps gant den ndvesanensss'eensse aE
CHECKING THE OIL STRAINER csccssssssssssssssssisessisssasisaseasassssssssssssesseee 557
ASSEMBLING THE OIL PUMP. ...... 0.0... eee cee ee eeeeee eee DOT
INSTALLING THE: OIL PUMP wiccceccccicccnscescsissetincviessnsnssescctwenneas sensensesserss D7OO
INSTALLING THE OIL PAN 2.22.22. 0:0...5.200..iccceccosecicceeee seen ectteecesseeeeteescteese ODO

REMOVING THE CLUTCH... tga dadgabesetweeceras teqnteae leven [Link]-2e0e Oe

CHECKING THE FRICTION PLATES... ce ceeedenneeeceeaaaeeeeesesaaeeeseesesaaees 0704
CHECKING THE CLUTCH PLATES cvossssssssssssssssssssssssassassisiisseasaeessseeeee5-O4
CHECKING THE CLUTCH SPRINGS... ceecee eect eee ee ees aeneeeeeeeeaeees DOD
CHECKING THE CLUTCH HOUSING ...00. leet ee eee B65
CCUG THE CLT EC casi cesccecss perce ceecaeeae sae teestadeiessscncctisatieees OOO
CHECKING THE PRESSURE PLATE ...000. eee cece cece eee eee reese eee 66
CHECKING THE PRIMARY DRIVE GEAR.. feasevasendaebwed atudenesevsseieask OOO
CHECKING THE PRIMARY DRIVEN GEAR... atieceadins eeratei OU
CHECKING THE PULL LEVER SHAFT AND PULL ROD saseeeteesesaeeeerees 0700
PS TAIN TB GEG occ ceceedccceteeveecececes arcceadecte duets cer adieetetueteenveseee 00

SHIFT SHAFT... pademnanemssevaseinintisface sins (onmigdeds en adenssswseree cl aoe

CHECKING THE SHIFT SHAFT. sdeeeuveeri sedeeade at sds ceeceutviveveduadewsevseeee =? U
CHECKING THE STOPPER LEVER... ssesssssssssssssssssassisisessssssssessesesssssssessns 5°70
INSTALLING THE SHIFT SHAPT ...000 2... eee eecce cece eceeeenee eee eeeeeeeeeee es DVO

CRANKCASE .. cee eee cece eaeeaeeaeeeseesaeeeeeeeeseaseeeeeeeees OUT

DISASSEMBLING THE CRANKCASE... poeenean dadwonbauenatiatedsieetaced toactennes OST
CHECKING THE CRANKCASE.. sccssssssssssssssssssssiasisssasesasssssaeesseseeee 5°74
ASSEMBLING THE CRANKCASE... we eeteeeeeeeeeeseeeeeee OTA
INSTALLING THE CRANKCASE BREATHER COVER... Heddvedviveveettiewsee eFC
INSTALLING THE OIL PRESSURE SWITCH.........0.0.0 occ DTT
INSTALLING THE GEAR POSITION SENSOR............ ccc ceeeeeeeeeeteeee eee OTT

CONNECTING RODS AND PISTONS.. atieceadiasdesea ere

REMOVING THE CONNECTING RODS AND PISTONS .ccssssssssssesesseeeee5+79
CHECKING THE CYLINDER AND PISTON .....0000 eee 9°80
CHECKING THE PISTON RINGS... 2... ccc e cee ceeteee eee eaeeneeeeeeeeeeeeee
es OPO T
CHECKING THE PISTON PIN.. save bease ese cecewve dunes soeteadestececuss
OSG
CHECKING THE CONNECTING RODS... eisuevattiveeetctsatanasd
Sy oene
INSTALLING THE CONNECTING ROD AND PISTON .. sadder edeeenseniseseses O80
CRANKSHAFT AND BALANCER SHAFT .. venee D-91
REMOVING THE CRANKSHAFT AND BALANCER SHAFT... Lee 5-92
CPIECRING TE COIL NZ ieee cs cescctecs cevnacenzevsanseeceenstcanenteeahetecieisat 9-92
CHECKING THE CRANKSHAPT ...00 oo... e cee ccee cece eee eeeeee eee eaeea eee eeeeeeane 9-92
CHECKING THE BALANCER SHAPT ....0... cece cece ceeee ee eeeenneee ee eee anaes 9-94
INSTALLING THE CRANKSHAFT ......2.. 2... cc eect eee cece eceeeeeeeeeeaeeeneeeeeees 9-95
INSTALLING THE THRUST BEARING .....00000 0c cece eee cece eeeeeeeeeees 5-96
INSTALLING THE BALANCER ASSEMBLY ................:ccccsceseeeeeeeeeeeeeeeees 9-96

TRANSMISSION... sesseeee 5°98

REMOVING THE TRANSMISSION .. w.11-5°102
CHECKING THE SHIFT FORKS... ......5-102
CHECKING THE SHIFT DRUM ASSEMBLY... wee 9°102
CHECKING THE TRANSMISSION.. “voccesssssssstssssssssssssene 5-103
ASSEMBLING THE MAIN AXLE AND DRIVE AXLE defo ceed gee seeme sen etense 9-103
INSTALLING THE TRANSMISSION . 20. eee eee ee enneneeeeeeeaeeeeees 5-104
 LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS20298

LUBRICATION SYSTEM CHART AND DIAGRAMS

EASa2 382

ENGINE OIL LUBRICATION CHART

js

1. Oil strainer [Link] camshaft

2. Oil pump 18. Shift fork guide bar (upper)
3. Relief valve 19. Main axle
4. Oil cooler 20. Drive axle
5. Oil filter cartridge [Link] shower
6. Main gallery
7. Oil pressure switch
8. Crankshaft
9. Generator rotor
10. Balancer shaft
11. Oil nozzle
12. Sub gallery
13. Timing chain tensioner
14. Intake rocker arm
15. Intake camshaft
16. Exhaust rocker arm

o-1
 LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS32363

LUBRICATION DIAGRAMS
Crankcase, cylinder, and cylinder head (left side view)

Intake camshaft
=

Oil nozzle
pany

Oil delivery pipe 2

Oil filter cartridge
Crankshaft
NOoa

Exhaust camshaft
Sub gallery
 LUBRICATION SYSTEM CHART AND DIAGRAMS

Crankcase and cylinder (right side view)

11 eat? 12
pak ee

Timing chain tensioner

ONOarah =

Intake camshaft
Exhaust camshaft
Crankshaft
Relief valve
Oil pipe 1
Oil delivery pipe 1
Oil pan
9. Oil strainer
10. Oil pump
11. Shift fork guide bar
12. Shift fork-C
13. Drive axle
 LUBRICATION SYSTEM CHART AND DIAGRAMS

Timing chain cover and oil pipe (right side view)

Timing chain cover

akon =

Oil pipe 3
Oil pipe 2
Crankshaft
Crankcase
 LUBRICATION SYSTEM CHART AND DIAGRAMS

Oil pump and oil cooler (bottom view)

13——__!

Oil cooler
ONOarah =

Oil delivery pipe 1

Oil cooler outlet hose
Oil filter cartridge
Oil pressure switch
Oil delivery pipe 2
Oil strainer
Oil pump
9. Oil pipe 1
10. Main gallery
11. Relief valve
12. Oil pipe 2
13. Oil pipe 3
14. Oil cooler inlet hose
 LUBRICATION SYSTEM CHART AND DIAGRAMS

Camshaft and balancer shaft (top view)

Cylinder head
oh =

Exhaust camshaft
Intake camshaft
Balancer shaft
 LUBRICATION SYSTEM CHART AND DIAGRAMS

Crankshaft (rear view)

Oil nozzle
ONOarah =

Oil pipe 3
Timing chain cover
Crankshaft
Oil pipe 2
Oil pressure switch
Generator rotor
Shaft
 LUBRICATION SYSTEM CHART AND DIAGRAMS

Crankshaft and transmission (top view)

1

1. Oil pump
Main axle
© he

Clutch housing
ob

Drive axle
Oil delivery pipe 3
 ENGINE INSPECTION

EAS20041

ENGINE INSPECTION
EASa0249

MEASURE THE COMPRESSION PRESSURE

The following procedure applies to all of the cyl-
inders.
TIP
Insufficient compression pressure will resultina
loss of performance.
1. Measure:
5. Measure:
* Valve clearance
¢« Compression pressure
Out of specification — Adjust.
Out of specification — Refer to steps (c) and
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-6.
(d).
a: Start the engine, warm it up for several min- Compression pressure
utes, and then turn it off. 1261-1624 kPa/210 r/min (12.6-
3 . Remove: 16.2 kgf/cm?/210 r/min, 179.4—
¢ Rider seat 231.0 psi/210 r/min)
Refer to “GENERAL CHASSIS (1)” on page
4-1. a. Set the main switch to “ON”.
¢ Fuel tank b. With the throttle wide open, crank the en-
Refer to “FUEL TANK” on page 7-1. gine until the reading on the compression
* Air filter case gauge stabilizes.
EWAITTIOO
Refer to “AIR FILTER CASE” on page 7-5.
e Air cut-off valve
Refer to “AIR INDUCTION SYSTEM” on To prevent sparking the plug, remove all ig-
page 7-20. nition coil couplers and fuel injector cou-
* Ignition coils plers before cranking the engine.
¢ Spark plugs TIP
Refer to “CAMSHAFTS’” on page 5-18.
ECA13340
The difference in compression pressure be-
NOTICE tween cylinders should not exceed 100 kPa (1
kgi/cm?, 15 psi).
Before removing the spark plugs, use com-
pressed air to blow away any dirt accumulat- c. If the compression pressure is above the
ed in the spark plug wells to prevent it from maximum specification, check the cylinder
falling into the cylinders. head, valve surfaces and piston crown for
4. Install: carbon deposits.
« Compression gauge “1” Carbon deposits —> Eliminate.
. If the compression pressure is below the
Compression gauge minimum specification, pour a teaspoonful
90890-03081 of engine oil into the spark plug bore and
Engine compression tester measure again.
YU-33223 Refer to the following table.
Compression pressure (with oil applied into the
cylinder)
Reading Diagnosis
Piston ring(s) wear or
Higher than without oil damage — Repair.
Piston, valves, cylinder
Same as without oil head gasket possibly
defective — Repair.
 ENGINE INSPECTION

6. Install:
¢ Spark plugs

Spark plug
> 13 N-m (1.3 kgf-m, 9.6 Ib-ft)
Spark plug (new)
18 N-m (1.8 kgf-m, 13 Ib-ft)

TIP
¢ Before installing the spark plug, clean the
spark plug and gasket surface.
e If the spark plug is a new one, tighten it to 18
N-m (1.8 kgf-m, 13 lb-ft).
7. Install:
* Ignition coils
Refer to “CAMSHAFTS” on page 5-18.
e Air cut-off valve
Refer to “AIR INDUCTION SYSTEM” on
page 7-20.
¢ Air filter case
Refer to “AIR FILTER CASE” on page 7-5.
¢ Fuel tank
Refer to “FUEL TANK” on page 7-1.
e Rider seat
Refer to “GENERAL CHASSIS (1)” on page
4-1.

9-10
 ENGINE REMOVAL

EAS20042

ENGINE REMOVAL
Removing the muffler and exhaust pipe

GOH

Order Job/Parts to remove Q’ty Remarks

Rider seat/Passenger seat/Battery cover/Tail Refer to “GENERAL CHASSIS (1)” on page
cover 4-1,
Front panel cover Fi to “GENERAL CHASSIS (3)” on page

Front side cowling yd to “GENERAL CHASSIS (5)” on page

Side cover/Front side cowling inner panel aoe to "GENERAL CHASSIS (6)" on page

Side cover bracket cae to “GENERAL CHASSIS (8)” on page

Electrical components tray fae to “GENERAL CHASSIS (9)” on page

Fuel tank Refer to “FUEL TANK” on page 7-1.

Radiator Refer to “RADIATOR” on page 6-3.
Oil cooler Refer to “OIL COOLER’ on page 6-7.
1 Muffler protector 1
2 Muffler joint 1
3 Muffler 1

5-11
 ENGINE REMOVAL

Removing the muffler and exhaust pipe

Order Job/Parts to remove Q’ty Remarks

4 Ring 1
5 Gasket 1
6 EXUP valve pulley cover 1
7 EXUP cable 2 1
8 EXUP cable 1 1

9 Os sensor coupler 2 Disconnect.

10 Exhaust pipe 1
11 Exhaust chamber 1
12 Gasket 4
13 Gasket 2
14 EXUP servo motor coupler 1 Disconnect.
15 EXUP servo motor bracket 1
16 EXUP servo motor 1
17 EXUP servo motor cover 1

9-12
 ENGINE REMOVAL

Disconnecting the leads and hoses

Order Job/Parts to remove Q’ty Remarks

Air filter case Refer to “AIR FILTER CASE” on page 7-5.

Air filter case duct/Air cut-off valve naeo 720. INDUCTION SYSTEM" on

.; Refer to “FUEL TANK” on page 7-1.

Canister For California only.
Throttle bodies oon to “THROTTLE BODIES” on page

Thermostat assembly Refer to “THERMOSTAT” on page 6-9.

Shift rod/Drive sprocket Refer to “CHAIN DRIVE” on page 4-125.
1 Clutch cable 1 Disconnect.
2 Starter motor lead 1 Disconnect.
3 Cylinder identification sensor coupler 1 Disconnect.
4 Ignition coil coupler 4 Disconnect.

5 Coolant
harness) temperature sensor coupler (sub-wire 1 Disconnect.

6 Neutral switch connector 1 Disconnect.

9-13
 ENGINE REMOVAL

Disconnecting the leads and hoses

Order Job/Parts to remove Q’ty Remarks

7 Stator coil coupler 1 Disconnect.
8 Crankshaft position sensor coupler 1 Disconnect.
9 Oil pressure switch connector 1 Disconnect.
10 Gear position sensor coupler 1 Disconnect.

5-14
 ENGINE REMOVAL

Removing the engine

Order Job/Parts to remove Remarks

Engine mounting bolt (right front side)

w) hol —

Collar
Se

Collar
Engine mounting bolt (left front side)
on | &/

Engine mounting bolt (rear upper side)/Engine

1
mounting nut (rear upper side)
Engine mounting bolt (rear lower side)/Engine
1/1
mounting nut (rear lower side)
Oo

Engine
Engine mounting adjust bolt

9-15
 ENGINE REMOVAL

DEN 6. Tighten:
REMOVING THE ENGINE ¢ Engine mounting adjust bolt “1”
1. Loosen:
¢ Engine mounting adjust bolt TIP
TIP ¢ Tighten the engine mounting adjust bolt to
specification with the pivot shaft wrench.
Loosen the engine mounting adjust bolt with the
¢ Make sure that the flange on the engine
pivot shaft wrench “1”.
mounting adjust bolt contacts the engine.

y nee Engine mounting adjust bolt

- Frame mount insert wrench ® 8 N-m (0.8 kgf-m, 5.9 lb-ft)
YM-01485
Pivot shaft wrench
90890-01485
Frame mount insert wrench
YM-01485

7. Install:
e Engine mounting nut (rear lower side) “8”
e Engine mounting nut (rear upper side) “9”
8. Tighten:
¢ Engine mounting nut (rear lower side) “8”

Engine mounting nut

) 56 N-m (5.6 kgf-m, 41 Ib-ft)

9. Tighten:
¢ Engine mounting nut (rear upper side) “9”

\y Engine mounting nut

56 N-m (5.6 kgf-m, 41 Ib-ft)

10. Tighten:
¢ Engine mounting bolt (left front side) “4”

EAsa0251 \y Engine mounting bolt

INSTALLING THE ENGINE } 70 N-m (7.0 kgf-m, 52 Ib-ft)
[Link]:
: | | | _
¢ ech
Engine mounting adjust bolt “1”
(temporarily tighten) Engine mounting bolt (right front side) “7’
2. Install: \y Engine mounting bolt
* Engine | | 70 N-m (7.0 kgf-m, 52 Ib-ft)
3. Install:
¢ Engine mounting bolt (rear lower side) “2”
*¢ Engine mounting bolt (rear upper side) “S”
4. Install:
¢ Engine mounting bolt (left front side) “4”
(temporarily tighten)
5. Install:
¢ Collar “5”
¢ Collar “6”
¢ Engine mounting bolt (right front side) “7”
(temporarily tighten)

3-16
 ENGINE REMOVAL

EASs0252

INSTALLING THE EXHAUST PIPE AND

MUFFLER
1. Install:
¢ Exhaust pipe
¢ Gasket “1” KEW
(to exhaust chamber)
e Muffler
TIP
When installing the gasket, install it so that the
chamfered side “a” of the gasket faces the ex-
haust pipe side as shown in the illustration.

Installed depth of gasket “b”

5.0 mm (0.20 in)
-f

fy |
_
b . ES) "ag 4
i
1
—

TT te F
=H ; WW
j Tt T. | |
WS |

a
|

\ ~
oO
Me Ty | |
°
1) os
Sa
aan of

tas |

9-17
 CAMSHAFTS

EAS20043

CAMSHAFTS
Removing the cylinder head cover

GOH

Order Job/Parts to remove Q’ty Remarks

Rider seat Pirbel to “GENERAL CHASSIS (1)” on page

Front panel cover Fi to “GENERAL CHASSIS (3)” on page

Front side cowling yd to “GENERAL CHASSIS (5)”" on page

Side cover/Front side cowling inner panel Refer to “GENERAL CHASSIS (6)" on page
4-23.
Side cover bracket cae to “GENERAL CHASSIS (8)” on page

Electrical components tray fae to “GENERAL CHASSIS (9)” on page

Fuel tank Refer to “FUEL TANK” on page 7-1.

Air filter case Refer to “AIR FILTER CASE” on page 7-5.
Radiator Refer to “RADIATOR” on page 6-3.
Refer to “AIR INDUCTION SYSTEM?” on
Air cut-off valve page 7-20.

3-18
 CAMSHAFTS

Removing the cylinder head cover

GOH

Order Job/Parts to remove Q’ty Remarks

1 Ignition coil coupler ‘4 Disconnect.

2 Ignition coil 4
3 Spark plug 4 If the spark plug is a new one, tighten it to 18
N-m (1.8 kgf-m,
13 lb-ft).
Cylinder identification sensor coupler Disconnect.
&

||

Cylinder identification sensor

mm) cy]

Cylinder head cover

|)
oO) “|

Cylinder head cover gasket

Cylinder head cover gasket
(oO)

Timing chain guide (top side)

me

9-19
 CAMSHAFTS

Removing the camshafts

GOH

Order Job/Parts to remove Q’ty Remarks

Crankshaft end cover/Timing mark accessing Refer to “GENERATOR?” on page 5-44
bolt
1 Timing chain tensioner 1
2 Timing chain tensioner gasket 1
« If the camshaft cap bolt is a new one, itis
not necessary to apply engine oil onto the
3 Camshaft cap 1 4 mating surface and threads of the bolt.
e If the camshaft cap bolt is a new one, tight-
en it to 10 N-m (1.0 kgf-m, 7.4 Ib-ft).
« lf the camshaft cap bolt is a new one, itis
not necessary to apply engine oil onto the
4 Camshaft cap 2 1 mating surface and threads of the bolt.
« lf the camshaft cap bolt is a new one, tight-
en it to 10 N-m (1.0 kgf-m, 7.4 Ib-ft).
Intake camshaft
Exhaust camshaft

9-20
 CAMSHAFTS

Removing the timing chain and timing chain guide

GOH

* Following the tightening order, loosen the bolt one by one, and then retighten it to the specific
torque.
Order Job/Parts to remove Q’ty Remarks
Tani Install the oil pipe to the timing chain cover,
; Ol pipe 3 ' and then install them to the crankcase.
a Install the oil pipe to the timing chain cover,
2 Timing chain cover ' and then install them to the crankcase.
3 Timing chain cover gasket 1
4 Dowel pin 2
5 Timing chain guide (intake side) 1
6 Timing chain guide (exhaust side) 1
7 Timing chain 1
8 Timing chain sprocket bolt 1
9 Timing chain sprocket 1

9-21
 CAMSHAFTS

Removing the timing chain and timing chain guide

GOH

* Following the tightening order, loosen the bolt one by one, and then retighten it to the specific
torque.
Order Job/Parts to remove Q’ty Remarks

10 Straight key 1
11 Circlip 1
12 Washer 1
13 Oil seal 1

Re
When removing the oil pipe 2, also remove
14 Oil pipe 2 1 the water pump inlet
Refer to “WATER PUMP” on page 6-13.

9-22
 CAMSHAFTS

Removing the rocker arms

Order Job/Parts to remove Q’ty Remarks

Engine Refer to “ENGINE REMOVAL’ on page 5-11.

Intake camshaft/Exhaust camshaft Refer to “CAMSHAFTS” on page 5-18.
1 Rocker arm shaft bolt 4
2 Straight plug (rocker arm shaft) 3
3 Rocker arm shaft 4
4 Rocker arm 16

9-23
 CAMSHAFTS

EAS30256

REMOVING THE CAMSHAFTS

1. Remove:
¢ Timing mark accessing bolt
¢ Crankshaft end cover
Refer to “GENERATOR?’ on page 5-44.
2. Align:
¢ Mark “a” on the generator rotor
(with the generator rotor cover slot “b”)
a. Turn the crankshaft counterclockwise.
b. When piston #1 is at BTDC105° on the
compression stroke, align the BTDC105° EFAS31655

mark “a” on the generator rotor with the REMOVING THE ROCKER ARMS AND
generator rotor cover slot “b”. ROCKER ARM SHAFTS
TIP 1. Remove:
e Rocker arm shaft bolt
BTDC105° on the compression stroke can be
¢ Straight plug
found when the camshaft lobes are turned away
e Rocker arm shaft
from each other.
¢ Rocker arm
EASM257

CHECKING THE CAMSHAFTS

1. Check:
e Camshaft lobes
Blue discoloration/pitting/scratches — Re-
place the camshaft.
2. Measure:
e Camshaft lobe dimensions “a”
Out of specification — Replace the camshaft.

3. Remove: Camshaft lobe dimensions

Lobe height (Intake)
¢ Timing chain tensioner
35.291-35.391 mm (1.3894—-
¢ Timing chain tensioner gasket
1.3933 in)
4. Remove: Limit
¢ Camshaft cap 35.191 mm (1.3855 in)
EGA 720
Lobe height (Exhaust)
NOTICE
34.745-34.845 mm (1.3679-
To prevent damage to the cylinder head, 1.3718 in)
camshafts or camshaft caps, loosen the Limit
camshaft cap bolts in stages and in a criss- 34.645 mm (1.3640 in)
cross pattern, working from the outside in.
5. Remove:
* Intake camshaft
* Exhaust camshaft
TIP
To prevent the timing chain from falling into the
crankcase, fasten it with a wire “1”.

GO088946

3. Measure:
¢ Camshaft runout
Out of specification — Replace.

9-24
 CAMSHAFTS

Camshaft runout limit

0.050 mm (0.0020 in)

hs
a. Camshaft cap bolt (black): 40 mm (1.57 in)
b. Camshaft cap bolt (silver): 35 mm (1.38 in)
A. Intake side
B. Exhaust side
4. Measure:
¢ Camshaft-journal-to-camshaft-cap clearance TIP
Out of specification - Measure the camshaft
If the camshaft cap bolt is a new one, it is not
journal diameter.
necessary to apply engine oil onto the mating
Camshaft-journal-to-camshaft- surface and threads of the bolt.
cap clearance * If the camshaft cap bolt is a new one, tighten it
0.028—0.062 mm (0.0011—0.0024 to 10 N-m (1.0 kgf-m, 7.4 lb-ft).
in) * Tighten the camshaft cap bolts in stages and in
Limit a crisscross pattern, working from the inner
0.080 mm (0.0032 in) caps out.
* Do not tum the camshaft when measuring the
a. Install the camshaft into the cylinder head camshaft journal-to-camshaft-cap clearance
(without the camshaft caps). with the Plastigauge®.
b. Position strip of Plastigauge® “1” onto the
camshaft journal as shown.
\ Camshaft cap bolt
% 8 N-m (0.8 kgf-m, 5.9 Ib-ft)
Camshaft cap bolt (new)
10 N-m (1.0 kgf-m, 7.4 Ib-ft)

d. Remove the camshaft caps and then mea-

sure the width of the Plastigauge® “1”.

G088947

c. Install the dowel pins and camshaft caps.

ECA23010

NOTICE
There are two kinds of camshaft cap bolts
with different lengths. Be sure to install each
bolt onto the correct position. G088948

5. Measure:
¢ Camshaft journal diameter “a”
Out of specification — Replace the camshaft.
Within specification — Replace the cylinder
head and the camshaft caps as a set.

9-25
 CAMSHAFTS

Camshaft journal diameter Rocker arm shaft outside diame-

25.459-—25.472 mm (1.0023— ter
1.0028 in) 7.967-—7.979 mm (0.3137-0.3141
in)
Limit
7 7.936 mm (0.3124 in)

G088949

EASS0259

CHECKING THE ROCKER ARMS AND

ROCKER ARM SHAFTS nomiene
The following procedure applies to all of the FAS30258
rocker arms and rocker arm shafts. CHECKING THE TIMING CHAIN AND
1. Check: CAMSHAFT SPROCKET
¢ Rocker arm 1. Check:
Damage/wear —> Replace. ¢ Timing chain
2. Check: Damage/stiffness — Replace the timing
e Rocker arm shaft chain and camshaft and camshaft sprocket
Blue discoloration/excessive wear/pitting/ as a set.
scratches —> Replace or check the lubrication 2. Check:
system. ¢ Camshaft sprocket
3. Measure: More than 1/4 tooth wear “a” — Replace the
e Rocker arm inside diameter “a” camshaft sprockets and the timing chain as a
Out of specification — Replace. set.

Rocker arm inside diameter

7.987—8.002 mm (0.3144—0.3150
in)
Limit
8.017 mm (0.3156 in)

G088950

a. 1/4 tooth
b. Correct
1. Timing chain
2. Camshaft sprocket

FASS0265

CHECKING THE TIMING CHAIN GUIDES

The following procedure applies to all of the
4. Measure:
camshaft sprockets and timing chain guides.
¢ Rocker arm shaft outside diameter “a”
1. Check:
Out of specification — Replace.
¢ Timing chain guide (exhaust side)
e Timing chain guide (intake side)

0-26
 CAMSHAFTS

¢ Timing chain guide (top side)

Damage/wear — Replace the defective
part(s).
EAS30266

CHECKING THE TIMING CHAIN TENSIONER

1. Check:
¢ Timing chain tensioner
Cracks/damage/rough movement —> Re-
place.
a. Using the valve spring compressor “1”,
push and insert timing chain tensioner rod EASS1744

“2 into the timing chain tensioner housing. ASSEMBLING THE TIMING CHAIN COVER
TIP 1. Install:
Push the timing chain tensioner rod in direction ° Oil seal “1” KEW
“a’, and turn the timing chain tensioner body “3” TIP
in direction “b” until it stops. Install the oil seal with a socket “2” that matches
its outside diameter.

A
Valve spring compressor
90890-04019 Installed depth “a”
Valve spring compressor 4.0—4.5 mm (0.16—0.18 in)
YM-04019

Det Nd
c=

LL
(A

|
|
.
td iJ
Va

2. Install:
e Washer
* Circlip DE

INSTALLING THE ROCKER ARMS AND

ROCKER ARM SHAFTS
1. Install:
e Rocker arm
e Rocker arm shaft “1”
e Rocker arm shaft bolt “2”
b. Keep pressing the timing chain tensioner ¢ Straight plug “3”
rod, mount clip “4” into groove “5”, and TIP
lock the timing chain tensioner rod.
¢ Align the end surface “a” of the rocker arm
c. Push the timing chain tensioner rod in di-
shaft with the surface “b” of the cylinder head.
rection “c’.
¢ After installing the rocker arm shaft bolt, make
d. Make sure that the timing chain tensioner
sure that the rocker arm shaft turns smoothly.
rod can smoothly move out from the timing
chain tensioner housing in direction “d”. If
not smooth, replace the timing chain ten-
sioner assembly.

0-27
 CAMSHAFTS

Rocker arm shaft bolt

6 N-m (0.6 kgf-m, 4.4 Ib-ft)
LOCTITE®
Straight plug (rocker arm shaft)
10 N-m (1.0 kgf-m, 7.4 Ib-ft)
LOCTITE®

c. Install the oil pipe bolt “3” and tighten it

temporarily until there is no clearance at
a” (timing chain cover to oil pipe) and “b”
(oil pipe to oil pipe bolt).
TIP
Apply locking agent (LOCTITE®) onto the oil
pipe bolt.
2 : “ g :
|

} a a) emt
,

‘ HK )
r

2 ~\
phat
FE e
‘| a
]

EASS1I715

INSTALLING THE TIMING CHAIN COVER d. Install the timing chain cover assembly
1. Install: and a new timing chain cover gasket.
¢ Timing chain cover e. Install new timing chain cover bolts and
* Oil pipe 3 tighten them.
a. Install new O-rings to the oil pipe.
TIP Timing chain cover bolt
Apply lithium-soap-based grease evenly on new ES 1st: 6 N-m (0.6 kgf-m, 4.4 lb-ft)
"2nd: 3.0 N-m (0.30 kgf-m, 2.2
O-rings.
lb-ft)
b. Install the oil pipe “1” to the timing chain Specified angle 90°
cover “2”.
TIP " Following the tightening order, loosen the
e While turning the oil pipe, install it to the timing bolt one by one and then retighten it to the
chain cover so that the grease applied to the O- specific torque and the specific angle.
rings is distributed. TIP
¢ If the oil pipe is not turned smoothly, the O- Tighten the timing chain cover bolts in the tight-
rings might be caught. ening sequence as shown.

9-28
 CAMSHAFTS

a. Turn the crankshaft counterclockwise.

b. When piston #1 is at BTDC105°, align the
BTDC105° mark “a” on the generator rotor
with the generator rotor cover slot “b”.

f. Install the oil pipe bolts “4” and tighten

them temporarily.
TIP
Apply locking agent (LOCTITE®) onto the oil
pipe bolts. 3. Install:
e Exhaust camshaft “1”
e Intake camshaft “2”
TIP
* Hang the timing chain on the sprocket from the
exhaust camshaft to the intake camshaft.
¢ The intake camshaft sprocket timing mark “a”
and exhaust camshaft sprocket timing mark “b”
should align with the cylinder head surface “c”.
¢ Check the timing mark position of the camshaft
sprocket using a mirror.
¢ The timing chain (exhaust side) should be
g. Tighten the oil pipe bolts to the specified stretched and the timing chain (intake side)
torque following the tightening order should be sagged.
shown in the illustration.

Oil pipe 3 bolt ca « 1 bc

10 N-m (1.0 kgf-m, 7.4 Ib-ft)
LOCTITE®
VAS, 28s
i¢ my"
i RO?
1

te
he

a
oh,
h
A.
== =
c
i
1 ih

Be
fe #

ae == "
if
i) a

4. Install:
¢ Camshaft cap
TIP
Make sure each camshaft cap is installed in its
original place. Refer to the identification marks
EASSa0289
as follows:
INSTALLING THE CAMSHAFTS
“1”: camshaft cap mark for cylinder #1
1. Remove:
“2 : camshaft cap mark for cylinder #2
¢ Timing mark accessing bolt
“3”: camshaft cap mark for cylinder #3
¢ Crankshaft end cover
“4”: camshaft cap mark for cylinder #4
Refer to “GENERATOR?” on page 5-44.
2. Align:
¢ Mark “a” on the generator rotor
(with the generator rotor cover slot “b”)

9-29
 CAMSHAFTS

5. Tighten: a. Camshaft cap bolt (black): 40 mm (1.57 in)

¢ Camshaft cap bolts b. Camshaft cap bolt (silver): 35 mm (1.38 in)
A. Intake side
Camshaft cap bolt B. Exhaust side
8 N-m (0.8 kgf-m, 5.9 Ib-ft)
Camshaft cap bolt (new) 6. Install:
10 N-m (1.0 kgf-m, 7.4 Ib-ft) ¢ Timing chain tensioner
¢ Timing chain tensioner gasket IXEWG
TIP a. Using the valve spring compressor “1”,
e If the camshaft cap bolt is a new one, it is not push and insert timing chain tensioner rod
necessary to apply engine oil onto the mating “2. into the timing chain tensioner housing.
surface and threads of the bolt. TIP
e If the camshaft cap bolt is a new one, tighten it
Push the timing chain tensioner rod in direction
to 10 N-m (1.0 kgf-m, 7.4 lb-ft).
“a’, and turn the timing chain tensioner body “3”
e Tighten the camshaft cap bolts in stages and in
in direction “b” until it stops.
a crisscross pattern, working from the inner
caps out.
Va Valve spring compressor
| 90890-04019
ECA1T440

NOTICE
Valve spring compressor
¢ Lubricate the camshaft cap bolts with the YM-04019
engine oil.
¢ The camshaft cap bolts must be tightened
evenly or damage to the cylinder head,
camshaft caps, and camshafts will result.
¢ Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.
ECA23010

NOTICE
There are two kinds of camshaft cap bolts
with different lengths. Be sure to install each
bolt onto the correct position.

9-30
 CAMSHAFTS

b. Keep pressing the timing chain tensioner

rod, mount clip “4” into groove “5”, and
lock the timing chain tensioner rod.

c. In the status of step (b), install the rod as-

sembly in the cylinder block.
TIP
Always use a new gasket.

\y Timing chain tensioner bolt

10 N-m (1.0 kgf-m, 7.4 Ib-ft)
LOCTITE® 9. Measure:
e Valve clearance
d. Unlock the timing chain tensioner by turn-
Out of specification — Adjust.
ing the crankshaft clockwise, and tension
Refer to “ADJUSTING THE VALVE CLEAR-
the timing chain.
ANCE?” on page 3-6.
7. Turn:
[Link]:
¢ Crankshaft
¢ Timing mark accessing bolt
(several turns counterclockwise)
8. Check:
¢ Mark “a”
Make sure the mark “a” on the generator rotor
is aligned with the generator rotor cover slot e Crankshaft end cover
“Db”.
¢ Camshaft sprocket timing mark “c” Crankshaft end cover
Make sure the camshaft sprocket timing mark > 15 N-m (1.5 kgf-m, 11 Ib-ft)
“c” is aligned with the cylinder head mating
Refer to “GENERATOR?” on page 5-44.
surface “d”.
[Link]:
Out of alignment — Adjust.
¢ Timing chain guide (top side)
Refer to the installation steps above.
TIP
¢ Cylinder head cover gasket “1” IXEWa
Check the timing mark position of the camshaft ¢ Cylinder head cover gasket “2” [XW
sprocket using a mirror. e Cylinder head cover

Cylinder head cover bolt

~& 10 N-m (1.0 kgf-m, 7.4 Ib-ft)
TIP
¢ Apply Three Bond No. 1541C® onto the mat-
ing surfaces of the cylinder head cover and cyl-
inder head cover gasket.

9-31
 CAMSHAFTS

e After installing the cylinder head cover gasket

“2 to the cylinder head cover, cut off the “a”
section.

12.|nstall:
¢ Spark plugs
* Ignition coils “1”

Spark plug
13 N-m (1.3 kgf-m, 9.6 Ib-ft)
Spark plug (new)
18 N-m (1.8 kgf-m, 13 Ib-ft)

TIP
¢ Before installing the spark plug, clean the
spark plug and gasket surface.
e If the spark plug is a new one, tighten it to 18
N-m (1.8 kgf-m, 13 Ib-ft).
e Install the ignition coils “1” in the direction
shown in the illustration.

9-32
 CYLINDER HEAD

EAS20044

CYLINDER HEAD
Removing the cylinder head

* Following the tightening order, loosen the bolt one by one, and then retighten it to the specific
torque.
Order Job/Parts to remove Q’ty Remarks
Engine Refer to “ENGINE REMOVAL’ on page 5-11.
Intake camshaft/Exhaust camshaft Refer to “CAMSHAFTS” on page 5-18.
Coolant temperature sensor
—

he)
on) &/; cd); ho]

Cylinder head
Cylinder head gasket
|
FD)

Dowel pin
Oil delivery pipe
—)

0-33
 CYLINDER HEAD

EAS30276

REMOVING THE CYLINDER HEAD

1. Remove:
« Intake camshaft
e Exhaust camshaft
Refer to “REMOVING THE CAMSHAFTS”
on page 5-24.
2. Remove:
Y
¢ Cylinder head bolt (M6) (x 2)
¢ Cylinder head bolt (M9) (x 10) GO088956

TIP a. Place a straightedge “1” and a thickness

e Loosen the bolts in the proper sequence as gauge “2” across the cylinder head.
shown.
e Loosen each bolt 1/2 of a turn at a time. After UL, Thickness gauge
all of the bolts are fully loosened, remove them. 90890-03268
Feeler gauge set
YU-26900-9

EASs30277 GO088957
CHECKING THE CYLINDER HEAD
1. Eliminate: b. Measure the warpage.
¢ Combustion chamber carbon deposits c. If the limit is exceeded, resurface the cylin-
(with a rounded scraper) der head as follows.
d. Place a 400—600 grit wet sandpaper on
TIP
the surface plate and resurface the cylin-
Do not use a sharp instrument to avoid damag- der head using a figure-eight sanding pat-
ing or scratching:
tern.
¢ Spark plug bore threads
TIP
e Valve seats
To ensure an even surface, rotate the cylinder
2. Check: head several times.
¢ Cylinder head
Damage/scratches — Replace. EFAS S0282

¢ Cylinder head water jacket INSTALLING THE CYLINDER HEAD

Mineral deposits/rust — Eliminate. 1. Install:
3. Measure: ¢ Cylinder head gasket [YEW
¢ Cylinder head warpage ¢ Dowel pins
Out of specification — Resurface the cylinder 2. Install:
head. e Cylinder head

a
¢ Cylinder head bolt (M6) (x 2)
Warpage limit
0.10 mm (0.0039 in) ¢ Cylinder head bolt (M9) (x 10) DXA
TIP
¢ Pass the timing chain through the timing chain
cavity.

0-34
 CYLINDER HEAD

e Lubricate the cylinder head bolt (M9) thread

and mating surface with engine oil.
3. Tighten:
¢ Cylinder head bolt “1”—“10”
¢ Cylinder head bolt “11”, “12”

\y Cylinder head bolt “1”—“10”

‘>| Ist: 10 N-m (1.0 kgf-m, 7.4 Ib-ft)
2nd: 25 N-m (2.5 kgf-m, 18 Ib-ft)
3rd: 45 N-m (4.5 kgf-m, 33 Ib-ft)
*A4th: 15 N-m (1.5 kgf-m, 11 Ib-ft)
Specified angle 160°
Cylinder head bolt “11”, “12”
9 N-m (0.9 kgf-m, 6.6 Ib-ft)

* Following the tightening order, loosen the

bolt one by one and then retighten it to the
specific torque and the specific angle.
TIP
Tighten the cylinder head bolts in the tightening
sequence as shown and torque them in 4 stag-
es.

ey Ao Aer)

O72 O—_O27 0 |
Oo YOx 9 fim
= 1 - ee

4. Install:
e Exhaust camshaft
© Intake camshaft
Refer to “INSTALLING THE CAMSHAFTS”
on page 5-29.

9-35
 VALVES AND VALVE SPRINGS

EAS20045

VALVES AND VALVE SPRINGS

Removing the valves and valve springs

Order Job/Parts to remove Remarks

Q
Zz

Cylinder head Refer to “CYLINDER HEAD” on page 5-33.

Exhaust valve pad
Oo
—
hp|

Exhaust valve cotter

oO
—

Exhaust valve spring retainer

ol]

©
ow;

Exhaust valve spring (outer)

&;

wo,

Exhaust valve spring (inner)

om!)
om)

wo; ©;

Exhaust valve
ns |

Exhaust valve stem seal

cw)
co;

Exhaust valve spring seat

Exhaust valve guide
(};

©!)
CO;

Intake valve pad

—k
©

Intake valve cotter

mo
—_
—

0-36
 VALVES AND VALVE SPRINGS

Removing the valves and valve springs

Order Job/Parts to remove Q’ty Remarks

12 Intake valve spring retainer 8

13 Intake valve spring (outer) 8
14 Intake valve spring (inner) 8
15 Intake valve 8
16 Intake valve stem seal 8
17 Intake valve spring seat 8
18 Circlip 8
19 Intake valve guide 8

0-37
 VALVES AND VALVE SPRINGS

EAS30283

REMOVING THE VALVES Valve spring compressor

The following procedure applies to all of the 90890-04019
valves and related components. Valve spring compressor
TIP YM-04019
Before removing the internal parts of the cylinder Valve spring compressor attach-
ment (026)
head (e.g., valves, valve springs, valve seats),
90890-01243
make sure the valves properly seal.
Valve spring compressor attach-
1. Remove: ment (026)
¢ Valve pad YM-01253-1
TIP
Make a note of the position of each valve pad so
that they can be reinstalled in their original place.
2. Check:
e 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 5-40. ts

Ke
GO88959
a. Pouraclean solvent “a” into the intake and
exhaust ports. 4. Remove:
b. Check that the valves properly seal. e Valve spring retainer
TIP e Valve spring (outer)
e Valve spring (inner)
There should be no leakage at the valve seat “1”.
e Valve
e Valve stem seal
e Valve spring seat
TIP
Identify the position of each part very carefully so
that it can be reinstalled in its original place.

FAS S0284

CHECKING THE VALVES AND VALVE

GUIDES
G088958
The following procedure applies to all of the
3. Remove: valves and valve guides.
« Valve cotters 1. Measure:
TIP e Valve-stem-to-valve-guide clearance
Remove the valve cotters by compressing the Out of specification — Replace the valve
valve spring with the valve spring compressor guide.
“1” and the valve spring compressor attachment * Valve-stem-to-valve-guide clearance =
or
Valve guide inside diameter “a” -
Valve stem diameter “b”

0-38
 VALVES AND VALVE SPRINGS

b. Install the new valve guide with the valve

Valve-stem-to-valve-quide clear- guide installer “2” and valve guide remov-
ance (intake) er “qe

0.010—0.037 mm (0.0004—0.0015
in) Valve guide position (intake)
Limit 12.0—12.4 mm (0.47-0.49 in)
0.080 mm (0.0032 in) Valve guide position (exhaust)
Valve-stem-to-valve-guide clear- 17.5—17.9 mm (0.69-0.70 in)
ance (exhaust)
0.025—0.052 mm (0.0010—0.0020
in)
Limit
0.100 mm (0.0039 in)

GO088963

a. Valve guide position

c. After installing the valve guide, bore the

valve guide with the valve guide reamer
G088960
“3” to obtain the proper valve-stem-to-
valve-guide clearance.

SX
2. Replace:
¢ Valve guide
GO088964

TIP
TIP After replacing the valve guide, reface the valve
To ease valve guide removal and installation, seat.
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”.

GO088962

0-39
 VALVES AND VALVE SPRINGS

Valve guide remover (04.5)

©
90890-04116
Valve guide remover (4.5 mm)
YM-04116
Valve guide remover (25)
90890-04097
is Fs
Valve guide remover (5.0 mm)
YM-04097
I _|
Valve guide installer (@4.5) aostada 1 CTI II I ILIS FITTS SS SE
90890-04117
Valve guide installer (4.5 mm) EFAS S0285

YM-04117 CHECKING THE VALVE SEATS

Valve guide installer (@5) The following procedure applies to all of the
90890-04098 valves and valve seats.
Valve guide installer (5.0 mm) 1. Eliminate:
YM-04098 ¢ Carbon deposits
Valve guide reamer (@4.5) (from the valve face and valve seat)
90890-04118
2. Check:
Valve guide reamer (4.5 mm)
e Valve seat
YM-04118
Valve guide reamer (@5) Pitting/wear — Replace the cylinder head.
90890-04099 3. Measure:
Valve guide reamer (5.0 mm) ¢ Valve seat contact width “a”
YM-04099 Out of specification — Replace the cylinder
head.
3. Eliminate:
¢ Carbon deposits Valve seat contact width (intake)
(from the valve face and valve seat) 0.90—1.10 mm (0.0354—0.0433 in)
4. Check: Limit
1.6 mm (0.06 in)
* Valve face
Valve seat contact width (ex-
Pitting/wear — Grind the valve face.
haust)
¢ Valve stem end 1.10—1.30 mm (0.0433-—0.0512 in)
Mushroom shape or diameter larger than the Limit
body of the valve stem — Replace the valve. 1.8 mm (0.07 in)
5. Measure:
¢ Valve stem runout
Out of specification — Replace the valve.
TIP
e When installing a new valve, always replace
the valve guide.
¢ If the valve is removed or replaced, always re-
place the valve stem seal.

Valve stem runout GO088966

0.010 mm (0.0004 in)
a. Apply blue layout fluid “b” onto the valve
face.

9-40
 VALVES AND VALVE SPRINGS

css
eS SS aoe
nnn nena
OH
b

ge
eect
——

G088967 GO088968

b. Install the valve into the cylinder head. b. Apply molybdenum disulfide oil onto the
c. Press the valve through the valve guide valve stem.
and onto the valve seat to make a clear c. Install the valve into the cylinder head.
impression. d. Turn the valve until the valve face and
d. Measure the valve seat contact width. valve seat are evenly polished, then clean
TIP off all of the lapping compound.
Where the valve seat and valve face contacted TIP
one another, the blue layout fluid will have been For the best lapping results, lightly tap the valve
removed. seat while rotating the valve back and forth be-
tween your hands.

be
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. SES 7
ECA22580
ao
NOTICE oe

This model uses titanium intake valves. Gos8969

Titanium valves that have been used to lap e. Apply a fine lapping compound to the
the valve seats must not be used. Always re- valve face and repeat the above steps.
place lapped valves with new valves. f. After every lapping procedure, be sure to
TIP clean off all of the lapping compound from
the valve face and valve seat.
e When replacing the intake valves, replace the
g. Apply blue layout fluid “b” onto the valve
intake valves without lapping the valve seats
face.
and valve faces.
e When replacing the cylinder head or intake
valve guides, use new valves to lap the valve
seats, and then replace them with new intake
valves.
a. Apply a coarse lapping compound “a” to
the valve face.
ECA 790

NOTICE
Do not let the lapping compound enter the GOS8967

gap between the valve stem and the valve . Install the valve into the cylinder head.
guide. Press the valve through the valve guide
and onto the valve seat to make a clear
impression.

5-41
 VALVES AND VALVE SPRINGS

j. Measure the valve seat contact width “c” 1. Check:

again. If the valve seat width is out of spec- e Valve spring seat
ification, reface and lap the valve seat. Damage/scratches — Replace the valve
spring seat.
FAS 30288

INSTALLING THE VALVES

The following procedure applies to all of the
valves and related components.
1. Deburr:
e Valve stem end
(with an oil stone)
GO088970

EASS0286

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. GO088972

Inner spring 2. Lubricate:

Free length (intake) e Valve stem
34.52 mm (1.36 in) e Valve stem seal
Limit (with the recommended lubricant)

i
32.79 mm (1.29 in)
Free length (exhaust) Recommended lubricant
36.94 mm (1.45 in) Molybdenum disulfide oil
Limit
35.09 mm (1.38 in) 3. Install:
Outer spring e Valve spring seat “1”
Free length (intake) ¢ Valve stem seal “2” [XEN
35.72 mm (1.41 in) e Valve “3”
Limit e Valve spring (inner) “4”
33.93 mm (1.34 in)
e Valve spring (outer) “5”
Free length (exhaust)
e Valve spring retainer “6”
36.85 mm (1.45 in)
Limit (into the cylinder head)
35.01 mm (1.38 in) TIP
¢ Make sure each valve is installed in its original
place.
* Install the valve springs with the larger pitch “a”
facing up.

Goss971 he = ~>| a
EASS1716

CHECKING THE VALVE SPRING SEAT

The following procedure applies to all of the
valve lifters.

9-42
 VALVES AND VALVE SPRINGS

G088975

b. Smaller pitch 6. Lubricate:

e Valve pad
4. Install:
(with the recommended lubricant)
° Valve coitters
TIP a= Recommended lubricant
Install the valve cotters by compressing the | | Molybdenum disulfide oil
valve spring with the valve spring compressor
“1” and the valve spring compressor attachment 7. Install:
“or e Valve pad
TIP

Valve spring compressor Each valve pad must be reinstalled in its original
90890-04019 position.
Valve spring compressor
YM-04019
Valve spring compressor attach-
ment (926)
90890-01243
Valve spring compressor attach-
ment (626)
YM-01253-1

G088959

5. To secure the valve cotters onto the valve

stem, lightly tap the valve tip with a soft-face
hammer.
ECA13800

NOTICE
Hitting the valve tip with excessive force
could damage the valve.

9-43
 GENERATOR

EAS20134

GENERATOR
Removing the stator coil and generator rotor

GOH

" Following the tightening order, loosen the bolt one by one, and then retighten it to the specific
torque.
Order Job/Parts to remove Q’ty Remarks
Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL’ on
page 3-29.
1 Stator coil coupler 1 Disconnect.
2 Crankshaft position sensor coupler 1 Disconnect.
3 Generator cover 1
4 Generator cover gasket 1
5 Dowel pin 2
6 Stator coil lead holder 1
7 Stator coil assembly (stator coil/crankshaft posi- {
tion sensor)

9-44
 GENERATOR

Removing the stator coil and generator rotor

GOH

* Following the tightening order, loosen the bolt one by one, and then retighten it to the specific
torque.
Order Job/Parts to remove Q’ty Remarks
8 Shaft 1
9 Generator rotor 1
10 Woodruff key 1
11 Crankshaft end cover 1
12 Timing mark accessing bolt 1

9-45
 GENERATOR

J
EAS30829

REMOVING THE GENERATOR Flywheel puller

1. Remove: 90890-01404
¢« Generator rotor bolt “1” Flywheel puller
e Washer YM-01404
TIP
While holding the generator rotor “2” with the
15mm pin type rotor holding tool “3”, loosen the
generator rotor bolt.

15mm pin type rotor holding tool

90890-04171
YM-04171

GO88977

EAS30830

INSTALLING THE GENERATOR

1. Install:
¢ Woodruff key
e Generator rotor
e Washer “1”
e Shaft “2”
e Generator rotor bolt “3”
TIP
2. Install: ¢ Clean the tapered portion of the crankshaft and
¢ Crankshaft protector “1” the generator rotor hub.
TIP ¢ When installing the generator rotor, make sure
Install the crankshaft protector to the hole “a” of the woodruff key is properly seated in the key-
the crankshaft. way of the crankshaft.
¢ Lubricate the washer with engine oil.
é{5| Crankshaft protector * Install the shaft to the hole of the generator ro-
ff 90890-01382 tor bolt.
Crankshaft protector ¢ Lubricate the generator rotor bolt threads and
YM-01382 washer mating surfaces with engine oil.

3. Remove:
2. Tighten:
e Generator rotor bolt “1”

KA
e Generator rotor “1”
(with the flywheel puller “2”) Generator rotor bolt
¢ Woodruff key 85 N-m (8.5 kgf-m, 63 Ib-ft)
TIP
Install the flywheel puller to the generator rotor.

9-46
 GENERATOR

TIP TIP
While holding the generator rotor “2” with the Tighten the generator cover bolts in the tighten-
15mm pin type rotor holding tool “3”, tighten the ing sequence as shown.
generator rotor bolt.

15mm pin type rotor holding tool

90890-04171
YM-04171

5. Connect:
e Stator coil coupler
Ai — e Crankshaft position sensor coupler
SF 3 1 TIP
To route the stator coil lead, refer to “CABLE
3. Apply: ROUTING” on page 2-17.
¢ Sealant
(onto the stator coil assembly lead grommet)

(¢Z,| Yamaha bond No. 1215

3 90890-85505
Three bond No. 1215®

4. Install:
¢ Generator cover gasket [TET
e Generator cover
e Generator cover bolt JXEG
\y Generator cover bolt
, 1st: 6 N-m (0.6 kgf-m, 4.4 Ib-ft)
“2nd: 3.0 N-m (0.30 kgf-m, 2.2
lb-ft)
Specified angle 90°

Following the tightening order, loosen the

bolt one by one and then retighten it to the
specific torque and the specific angle.

9-47
 STARTER CLUTCH

EAS20049

STARTER CLUTCH
Removing the starter clutch

GOH

Order Job/Parts to remove Q'ty Remarks

Clutch housing assembly Refer to “CLUTCH” on page 5-60.

Starter clutch gear
ek
ow) hm) —

Bearing
mmemf

Starter clutch assembly

Circlip
on) &)

Starter clutch idle gear

0-48
 STARTER CLUTCH

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

Sheave holder
Z 90890-01701
Primary clutch holder
YS-01880-A
EASS0309

INSTALLING THE STARTER CLUTCH

1. Install:
e Starter clutch

XS Starter clutch holder bolt

Ay 14 N-m (1.4 kgf-m, 10 lb-ft)
LOCTITE®

TIP
¢ Install the starter clutch so that the side of the
starter clutch roller assembly with the arrow
EASSa0206 mark is toward the clutch housing.
CHECKING THE STARTER CLUTCH ¢ While holding the clutch housing assembly “1”
1. Check: with the sheave holder “2”, tighten the starter
¢ Starter clutch rollers clutch holder bolt “3”.
Damage/wear —> Replace. ¢ Fix the flat surface of the clutch housing as-
2. Check: sembly with the sheave holder.
* Starter clutch gear
* Starter clutch idle gear CZ Sheave holder
Burrs/chips/roughness/wear — Replace the pf 90890-01701
defective part(s). Primary clutch holder
3. Check: YS-01880-A
* Starter clutch gear’s contacting surfaces
Damage/pitting/wear — Replace the starter
clutch gear.
4. Check:
¢ Starter clutch operation
a. Install the starter clutch gear “1” onto the
clutch housing assembly “2” and hold the
clutch housing assembly.
b. When turning the starter clutch gear clock-
wise “A”, the starter clutch and the starter
clutch gear should engage, otherwise the
starter clutch is faulty and must be re-
placed.

9-49
 ELECTRIC STARTER

EAS20052

ELECTRIC STARTER
Removing the starter motor

Order Job/Parts to remove Q’ty Remarks

Rider seat Pirbel to “GENERAL CHASSIS (1)” on page

Fuel tank Refer to “FUEL TANK” on page 7-1.

Air filter case Refer to “AIR FILTER CASE” on page 7-5.
Refer to “FUEL TANK” on page 7-1.
Canister For California only.
Throttle bodies a to “THROTTLE BODIES” on page

1 Starter motor lead 1 Disconnect.

2 Starter motor 1

9-90
 ELECTRIC STARTER

Disassembling the starter motor

Order Job/Parts to remove Q'ty Remarks

O-ring
Ww) ho) —

Starter motor front cover

Starter motor yoke

Armature assembly
1) &;)

Gasket
ee
|)

Brush holder set

a
“|

Starter motor rear cover

9-51
 ELECTRIC STARTER

a
EAS30325

CHECKING THE STARTER MOTOR Brush overall length limit

1. Check: 5.5 mm (0.22 in)
¢ Commutator
Dirt > Clean with 600 grit sandpaper.
2. Measure:
¢ Mica undercut “a”
Out of specification — Scrape the mica to the
proper measurement with a hacksaw blade
that has been grounded to fit the commutator.

A
TIP
Mica undercut (depth)
2.40 mm (0.09 in)
|

Goss9s9

5. Measure:
a

The mica of the commutator must be undercut to ¢ Brush spring force

ensure proper operation of the commutator. Out of specification — Replace the brush
holder set.

Brush spring force

4.80-—7.20 N (489-734 of, 17.28-
25.92 oz)

G088986

3. Check:
e« Armature assembly
a. Connect the digital circuit tester and check
the continuity.

Digital circuit tester (CD732)

‘eo 90890-03243 6. Check:
Model 88 Multimeter with ta- e Gear teeth
chometer Damage/wear —> Replace the starter motor.
YU-A1927 7. Check:
¢ Bearing
b. If there is no continuity, replace the starter e Oil seal
motor. Damage/wear — Replace the starter motor
—_ | front cover.
OL EFAS S0326

oD oO ASSEMBLING THE STARTER MOTOR

1. Install:
e Starter motor rear cover “1”
St |S =|_ e Starter motor yoke “2”
= Wl QO e Starter motor front cover “3”
TIP
Align the match mark “a” on the starter motor
4. Measure: yoke with the match mark “b” on the starter mo-
* Brush length “a” tor front cover.
Out of specification — Replace the brush
holder set.

9-52
 ELECTRIC STARTER

9-93
 OIL PUMP

EAS20054

OIL PUMP
Removing the oil pan and oil pump

GOH

Order Job/Parts to remove Q’ty Remarks

Rider seat Pirbel to “GENERAL CHASSIS (1)” on page

Front panel Fi to “GENERAL CHASSIS (3)” on page

Refer to “GENERAL CHASSIS (5)” on page

Front side cowling/Front muffler protector
4-16.

Side cover/Front side cowling inner panel Refer to “GENERAL CHASSIS (6)” on page
4-23.

Side cover bracket

Refer to “GENERAL CHASSIS (8)” on page
4-32.
Refer to “GENERAL CHASSIS (9)” on page
Electrical components tray
4-34.
Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL’ on
page 3-29.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Radiator Refer to “RADIATOR” on page 6-3.
Oil cooler Refer to “OIL COOLER?” on page 6-7.
Exhaust pipe/Muffler Refer to “ENGINE REMOVAL’ on page 5-11.

9-54
 OIL PUMP

Removing the oil pan and oil pump

GOH

Order Job/Parts to remove Q’ty Remarks

1 Oil pan 1
2 Oil pan gasket 1
3 Oil strainer 1
4 Oil delivery pipe 1 1
5 Oil pipe 1 1
6 Relief valve assembly 1
7 Oil delivery pipe 2 1
8 Oil pump drive chain guide 1
9 Collar 1
10 Oil pump drive sprocket 1
11 Washer 1
12 Oil pump drive chain 1
13 Oil pump 1
14 Dowel pin 2
15 Baffle plate 1

9-59
 OIL PUMP

Disassembling the oil pump

Order Job/Parts to remove Q'ty Remarks

Oil pump cover

me| OO]

Dowel pin
Gc! Po

Oil pump outer rotor

Oil pump inner rotor
1] &]

Pin
Oil pump housing
—~J}; &)

Oil pump driven sprocket

mf

0-56
 OIL PUMP

EAS30333

REMOVING THE OIL PAN

1. Remove:
¢ Oil pan
¢ Gasket
* Dowel pins
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.
EFAS S0339
EAS30336

CHECKING THE SPROCKET AND CHAIN CHECKING THE OIL DELIVERY PIPES
1. Check: The following procedure applies to all of the oil
¢ Oil pump drive sprocket delivery pipes.
Cracks/damage/wear —> Replace. 1. Check:
2. Check: e Oil delivery pipe 1
¢ Oil pump drive chain e Oil delivery pipe 2
Damage/stiffness — Replace the oil pump ¢ Oil pipe 1
drive chain and oil pump drive sprocket as a Damage — Replace.
set. Obstruction > Wash and blow out with com-
pressed air.
EASaoaa7

CHECKING THE OIL PUMP EFAS S0340

1. Check: CHECKING THE OIL STRAINER

¢ Oil pump driven sprocket 1. Check:
¢ Oil pump housing e Oil strainer
¢ Oil pump inner rotor Damage — Replace.
¢ Oil pump outer rotor Contaminants — Clean with solvent.
¢ Oil pump cover FASS0S42

Cracks/damage/wear — Replace the oil ASSEMBLING THE OIL PUMP

pump assembly. 1. Lubricate:
2. Check: ¢ Inner rotor
¢ Oil pump operation ¢ Outer rotor
Rough movement — Repeat steps (1) and ¢ Oil pump shaft
(2) or replace the oil pump assembly. (with the recommended lubricant)

= 2. Install:
Recommended
Engine oil
lubricant

¢ Oil pump driven sprocket “1”

e Pin “2”
e Inner rotor “3”
e Outer rotor “4”
GO088997 No 9 ¢ Oil pump cover “5”
e Oil pump housing bolt

Dy
EAS303358

CHECKING THE RELIEF VALVE

Oil pump housing bolt
1. Check: 10 N-m (1.0 kgf-m, 7.4 Ib-ft)
* Relief valve body “1”
* Relief valve “2”
¢ Spring “3”
« Damage/wear — Replace the defective
part(s).

0-97
 OIL PUMP

TIP
When installing the inner rotor, align the pin “2”
in the oil pump shaft with the groove in the inner
rotor “3”.

3. Install:
e Oil pump drive chain guide

Oil pump drive chain guide bolt

10 N-m (1.0 kgf-m, 7.4 lb-ft)
3. Check: LOCTITE®
¢ Oil pump operation
Refer to “CHECKING THE OIL PUMP” on 4. Install:
page 5-57. ¢ O-ring DEW
¢ Oil pipe 1
INSTALLING THE OIL PUMP Oil pipe 1 bolt
1. Install: 10 N-m (1.0 kgf-m, 7.4 lb-ft)
8 mao pin LOCTITE®
¢ Oil pump “1”
© Oil pump bolt “2” ° O-ring DOTY
. ¢ Oil delivery pipe 1
Oll pump bolt ¢ Oil strainer
10 N-m (1.0 kgf-m, 7.4 Ib-ft)
Oil strainer bolt
10 N-m (1.0 kgf-m, 7.4 lb-ft)
LOCTITE®

° O-ring KEM
¢ Relief valve assembly

Relief valve assembly bolt

10 N-m (1.0 kgf-m, 7.4 Ib-ft)
LOCTITE®

2. Install: 2 eee
e Washer ° O-ring KE
© Oil pump drive chain “1” ° Oil delivery pipe 2
¢ Oil pump drive sprocket “2” Oil delivery pipe 2 bolt
° Collar Ay 10 N-m (1.0 kgf-m, 7.4 lb-ft)
TIP LOCTITE®
Install the oil pump drive chain “1” onto the oil
pump drive sprocket “2”. EASI0045
INSTALLING THE OIL PAN
NOTICE 1. Install
After installing the oil pump drive chain and " = pan gasket [KEM
drive sprocket, make sure the oil pump turns . Oil eek 7
smoothly. il pan bolt (x 12)

0-98
 OIL PUMP

° M6 x 25 mm (0.98 in) bolts: “1”—“6”, “9”—"12”

2. Tighten:
¢ Oil pan bolt

Oil pan bolt

10 N-m (1.0 kgf-m, 7.4 Ib-ft)
LOCTITE®

3. Install:
¢ Engine oil drain bolt
¢ Gasket DEW

0-59
 CLUTCH

EAS20055

CLUTCH
Removing the clutch cover

GOH

" Following the tightening order, loosen the bolt one by one, and then retighten it to the specific
torque.
Order Job/Parts to remove Q’ty Remarks
Front side cowling (right) Fite to “GENERAL CHASSIS (3)” on page

Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL’ on
page 3-29.
1 Clutch cable 1 Disconnect.
2 Clutch cover 1
3 Clutch cover gasket 1
4 Dowel pin 2
5 Oil filler cap 1

9-60
 CLUTCH

Removing the pull lever shaft

Order Job/Parts to remove Q’ty Remarks

1 Circlip 1
2 Pull lever 1
3 Pull lever spring 1
4 Circlip 1
5 Pull lever shaft 1
6 Oil seal 1
7 Bearing 1
8 Bearing 1
9 Clutch cover damper plate 1
10 Clutch cover damper 1

2-61
 CLUTCH

Removing the clutch

GOH

Order Job/Parts to remove Q’ty Remarks

1 Pressure plate 1 1
2 Compression spring 3
3 Pressure plate 2 1
4 Pull rod 1
5 Bearing 1 Press the bearing into pressure plate 2.
6 Friction plate 1 3 Blackish shoe
7 Clutch plate 1 1 Inside diameter: 110.2 mm (4.34 in)
8 Clutch plate 2 8 Inside diameter: 103.5 mm (4.07 in)
9 Friction plate 2 7 Whitish shoe

9-62
CLUTCH

csa
=
®
ce

SF leij-J-|-|—-|—-|/—-|—- /-
o

0-63
2
6
S
2 _—

2 S >
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g\2\2| |sco 5on

Cc liolo o =
SB |ala
5 | ®\|®!W/s o
7 |olol/ze|o2 S
o/;/a & =
wo |;)o; ow
wert
EIE/nalaluo\ieis
SiMe aie isz/e
the clutch

DD /|oa |}_ oS | oe
£lc|<|/Slexliais\icie
SPIZIZI(EIZLZ(/S/\2i15/|@
Sis lis ia lslielzlia|ss
Ol /OIO/IOlFA /Olals
Removing

fee

B |S \x [No |+ |w |o |n |@
6 yyy yey
 CLUTCH

EAS30346

REMOVING THE CLUTCH

1. Remove:
¢ Clutch cover
e Gasket
TIP
Loosen each bolt 1/4 of a tun at a time, in stag-
es and in a crisscross pattern.
After all of the bolts are fully loosened, remove
them. GO088993

2. Remove: 6. Remove:
* Compression spring bolts e Clutch boss nut
¢ Pressure plate 1 ¢ Conical spring washer
¢ Compression springs e Clutch boss
¢ Pressure plate 2 e Thrust plate
¢ Pull rod e Clutch housing assembly
3. Remove: ¢ Bearing
¢ Friction plates 1 e Washer
¢ Clutch plate 1 FAS 30348

* Clutch plates 2 CHECKING THE FRICTION PLATES

* Friction plates 2 The following procedure applies to all of the fric-
¢ Clutch damper spring tion plates.
¢ Clutch damper spring seat 1. Check:
TIP e Friction plate 1 (blackish shoe)
Be sure to mark the friction plates and clutch e Friction plate 2 (whitish shoe)
plates or note the position of each part so that Damage/wear —> Replace the friction plates
they are installed in their original positions. as a set.
2. Measure:
4. Straighten the clutch boss nut rib “a”. e Friction plate 1, 2 thickness
Out of specification — Replace the friction

(7?
plates as a set.
TIP
Measure the friction plate at four places.

Friction plate 1 thickness

2.72—2.88 mm (0.107-0.113 in)
Wear limit
G088991 2.62 mm (0.103 in)
Friction plate 2 thickness
5. Loosen:
2.72—2.88 mm (0.107—0.113 in)
¢ Clutch boss nut “1” Wear limit
TIP 2.62 mm (0.103 in)
e While holding the clutch boss “2” with the uni-
versal clutch holder “3”, loosen the clutch boss EAS30349

nut.
CHECKING THE CLUTCH PLATES
The following procedure applies to all of the
e Do not use an impact wrench for removing the
clutch boss nut. clutch plates.
1. Check:
¢ Clutch plate 1, 2
Universal clutch holder Damage — Replace the clutch plates as a
90890-04086
set.
Universal clutch holder
YM-91042

0-64
 CLUTCH

2. Measure: Clutch plate “1”

¢ Clutch plate 1, 2 warpage
(with a surface plate and thickness gauge) Part No. Thickness
Out of specification — Replace the clutch 2CR-16325-10 2.0 mm (0.079 in)
plates as a set.
2CR-16325-00 2.3 mm (0.091 in) STD
Thickness gauge 2CR-16325-20 2.6 mm (0.102 in)
90890-03268
Feeler gauge set
YU-26900-9

Clutch plate 1 thickness

2.46-2.74 mm (0.097—0.108 in)
Warpage limit
0.10 mm (0.004 in)
Clutch plate 2 thickness
2.18—2.42 mm (0.086—0.095 in)
Warpage limit
0.10 mm (0.004 in) EAS30351

CHECKING THE CLUTCH SPRINGS

3. Measure: The following procedure applies to all of the
¢ Assembly width “a” of the friction plates and clutch springs.
clutch plates 1. Check:
Out of specification — Adjust. e Clutch spring
Damage — Replace the clutch springs as a
Assembly width
48.3-—49.3 mm (1.90-1.94 in) set.
2. Measure:
TIP
¢ Clutch spring free length
Out of specification — Replace the clutch
e Perform the thickness measurement without
springs as a set.
applying the oil.
e This step should be performed only if the fric- Clutch spring free length
tion plates and clutch plates were replaced. 47.36 mm (1.86 in)
¢ To measure the total width of the friction plates Limit
and clutch plates, combine 10 friction plates 44.99 mm (1.77 in)
and 9 clutch plates as shown.
FAS S0352

Ges
! /) CHECKING THE CLUTCH HOUSING
SK 1. Check:
¢ Clutch housing dogs
——V SS : rn

Damage/pitting/wear — Deburr the clutch

housing dogs or replace the clutch housing.
TIP
Pitting on the clutch housing dogs will cause er-
ratic clutch operation.

“4 a

b. Select the clutch plate from the following

table.

0-65
 CLUTCH

EASS0357

CHECKING THE PRIMARY DRIVEN GEAR

1. Check:
e Primary driven gear
Damage/wear — Replace the clutch housing
and crankshaft as a set.
Excessive noise during operation > Replace
the clutch housing and crankshaft as a set.
FAS 30358
G088994 CHECKING THE PULL LEVER SHAFT AND
2. Check: PULL ROD
¢ Bearing 1. Check:
Damage/wear —> Replace the bearing and ¢ Pull lever shaft pinion gear teeth
clutch housing. e Pull rod teeth
Damage/wear — Replace the pull rod and
pull lever shaft as a set.
EASSa0353

CHECKING THE CLUTCH BOSS

2. Check:
1. Check:
e Pull rod bearing
¢ Clutch boss splines
Damage/wear — Replace.
Damage/pitting/wear — Replace the clutch
boss. FAS S0363

TIP INSTALLING THE CLUTCH

Pitting on the clutch boss splines will cause er- TIP
ratic clutch operation. After assembling the clutch assembly, the noise
like a dry-type clutch might occur with the gear
position in neutral and half clutch. This is due to
the clutch dragging by engine oil when assem-
bled. The pressure plate makes chattering by
the clutch dragging and noise occurs between
pressure plate cam and clutch boss cam. This
noise will disappeared after riding few mileage
as engine oil between clutch plate and friction
plate will be reduced to optimum condition by
G088995
clutch operation.

EASa0a54
1. Install:
CHECKING THE PRESSURE PLATE e Washer
1. Check: ¢ Bearing
¢ Pressure plate 1 e Clutch housing assembly “1”
¢ Pressure plate 2 EC AS2570

NOTICE
Cracks/damage — Replace.
¢ Bearing Make sure to fit the projections “a” of the oil
Damage/wear — Replace. pump drive sprocket to the concave “b” of
the clutch housing assembly.
EAS30356

CHECKING THE PRIMARY DRIVE GEAR TIP

1. Check: When installing the clutch housing assembly,
¢ Primary drive gear turn the crankshaft so that the crankshaft web “c”
Damage/wear —> Replace the crankshaft and cannot be seen.
clutch housing as a set.
Excessive noise during operation — Replace
the crankshaft and clutch housing as a set.

0-66
 CLUTCH

SY ~
> — 4 NIMs

b EBS

2. Install: 3. Lubricate:
¢ Thrust plate e Friction plates
¢ Clutch boss “1” e Clutch plates
* Conical spring washer “2” (with the recommended lubricant)

=
° Clutch boss nut “3” [Xt
Recommended lubricant
\y Clutch boss nut Engine oil
| 125 Nem (12.5 kgf-m, 92 Ib-ft)
4. Install:
TIP
e Clutch damper spring seat
e Clutch damper spring
e Install the conical spring washer on the main
¢ Friction plates 1
axle with the “OUT” mark “a” facing away from
e Clutch plates 2
the vehicle.
¢ Friction plates 2
¢ While holding the clutch boss “1” with the uni-
e Clutch plate 1
versal clutch holder “4”, tighten the clutch boss
TIP
nut.
¢ Do not use an impact wrench for installing the ¢ First, install a friction plate and then alternate
clutch boss nut. between a clutch plate and a friction plate.
e Stake the clutch boss nut at cutouts “b” in the * Install the last friction plate “1” offset from the
main axle. other friction plates “2”, making sure to align a
projection on the friction plate with the punch
mark “a” on the clutch housing.
Universal clutch holder
90890-04086
Universal clutch holder
YM-91042

0-67
 CLUTCH

5. Install:
¢ Pull rod
¢ Pressure plate 2
¢ Clutch springs
* Pressure plate 1
¢ Clutch spring bolts

KS
©)) 8
Clutch spring bolt SSK
10 N-m (1.0 kgf-m, 7.4 Ib-ft) | © He)
©)
TIP
e Tighten the clutch spring bolts in stages and in 8. Install:
a crisscross pattern. e Pull lever spring “1”
e Apply lithium-soap-based grease onto the pull e Pull lever “2”
rod. e Washer
e Position the pull rod so that the teeth “a” face ¢ Circlip DE
towards the rear of the vehicle. Then, install the TIP
clutch cover. ¢ The end of the pull lever should be closest to
the clutch cover match mark “a” when there is
no free play of the pull lever.
¢ Make sure that the pull rod teeth and pull lever
shaft pinion gear are engaged.

6. Install:
* Dowel pins
¢ Clutch cover gasket DEY
¢ Clutch cover
* Clutch cover bolt EN 9. Adjust:
7. Tighten: ¢ Clutch lever free play
¢ Clutch cover bolt Refer to “ADJUSTING THE CLUTCHLEVER

4
FREE PLAY” on page 3-12.

a
Clutch cover bolt
1st: 6 N-m (0.6 kgf-m, 4.4 lb-ft) Clutch lever free play
"2nd: 3.0 N-m (0.30 kgf-m, 2.2 10.0-—15.0 mm (0.39-0.59 in)
lb-ft)
Specified angle 180°

‘ Following the tightening order, loosen the

bolt one by one and then retighten it to the
specific torque and the specific angle.
TIP
Tighten the clutch cover bolts in the tightening
sequence as shown.

0-68
 SHIFT SHAFT

EAS20057

SHIFT SHAFT
Removing the shift shaft and stopper lever

GOH

Order Job/Parts to remove Remarks

Clutch assembly Refer to “CLUTCH” on page 5-60.

Shift arm Refer to “CHAIN DRIVE” on page 4-125.
Circlip
—

le

Washer
ew! hy]

ie

Shift shaft
el

Washer
&/]

ee
om)

Circlip
@)

Washer
Stopper lever
co;

Stopper lever spring

Oo;

Collar
Shift shaft spring
ff
—_k
©

Shift shaft spring stopper

ol,
—4+

Bearing
ho
—

fmf

Oil seal
—k
ta

Bearing
—_k
om

mm

0-69
 SHIFT SHAFT

a
EASS3O377

CHECKING THE SHIFT SHAFT

1. Check: Lubricate the oil seal lips with lithium-soap-
e Shift shaft based grease.
Bends/damage/wear —> Replace.
¢ Shift shaft spring
¢ Collar
Damage/wear — Replace.
EASa0a78

CHECKING THE STOPPER LEVER

1. Check:
¢ Stopper lever
Bends/damage —> Replace.
Roller turns roughly — Replace the stopper
lever.
EAS30381

INSTALLING THE SHIFT SHAFT

1. Install:
¢ Shift shaft spring stopper “1”
* Shift shaft assembly
¢ Stopper lever spring “2”

Shift shaft spring stopper

SON 22 N-m (2.2 kgf-m, 16 Ib-ft)
LOCTITE®

TIP
¢ Hook the end of the shift shaft spring “3” onto
the shift shaft spring stopper “1”.
¢ Hook the ends of the stopper lever spring “2”
onto the stopper lever “4” and the crankcase
boss “5”.
¢ Mesh the stopper lever with the shift drum seg-
ment assembly.

2. Install:
¢ Bearing
* Oil seal DEW
e Washer
¢ Circlip DEW

9-70
 CRANKCASE

EAS20059

CRANKCASE
Removing the crankcase breather cover and switches

" Following the tightening order, loosen the bolt one by one, and then retighten it to the specific
torque.
“ Apply Three Bond No. 1215B®
Order Job/Parts to remove Q’ty Remarks

Engine Refer to “ENGINE REMOVAL’ on page 5-11.

Cylinder head cover/Intake camshaft/Exhaust Refer to “CAMSHAFTS’” on page 5-18.
camshaft
Cylinder head Refer to “CYLINDER HEAD” on page 5-33.
Generator rotor Refer to “GENERATOR?” on page 5-44.

Starter motor
Refer to “ELECTRIC STARTER’ on page
5-50.
Water pump Refer to “WATER PUMP” on page 6-13.
Clutch housing assembly Refer to “CLUTCH” on page 5-60.
Oil strainer/Oil pump/Relief valve assembly Refer to “OIL PUMP” on page 5-54.

o-71
 CRANKCASE

Removing the crankcase breather cover and switches

* Following the tightening order, loosen the bolt one by one, and then retighten it to the specific
torque.
™ Apply Three Bond No. 1215B®
Order Job/Parts to remove Remarks
Q
Z

Gear position sensor

lh

Oil pressure switch

hy}

eel
Go]

Oil pressure switch joint

Oil filter cartridge
&]

Oil filter cartridge union bolt

|
oO) SI) om)

Crankcase breather cover

Crankcase breather cover gasket

Damper plate (upper crankcase)
(};

Clutch cable holder

fmm

Neutral switch
=k
©

Gasket
ok,
ok

mm

9-72
 CRANKCASE

Separating the crankcase

* Following the tightening order, loosen the bolt one by one, and then retighten it to the specific
torque.
Order Job/Parts to remove Q’ty Remarks
1 Plug (oil gallery) 2
2 Plug (balancer shaft end) 2
3 Lower crankcase 1
4 Dowel pin 4

9-73
 CRANKCASE

EAS30389
TIP
DISASSEMBLING THE CRANKCASE
1. Place the engine upside down. Identify the position of each part very carefully so
2. Remove: that it can be reinstalled in its original place.
e Crankcase bolt (x 40)
FAS S039)
TIP
CHECKING THE CRANKCASE
e Loosen each bolt 1/4 of a turn at a time, in stag- 1. Thoroughly wash the crankcase halves in a
es and in acrisscross pattern. After all of the mild solvent.
bolts are fully loosened, remove them. iz Thoroughly clean all the gasket surfaces and
e Loosen the bolts in the proper sequence as crankcase mating surfaces.
shown. 3 . Check:
e The numbers embossed on the crankcase in- e Crankcase
dicate the crankcase tightening sequence. Cracks/damage — Replace.
e Oil delivery passages
Obstruction > Blow out with compressed air.
EFAS S039?

ASSEMBLING THE CRANKCASE

1. Lubricate:
¢ Crankshaft journal bearing inner surface
(with the recommended lubricant)

Recommended lubricant
Engine oil

2. Apply:
e Sealant
(onto the crankcase mating surfaces)

Yamaha bond No. 1215

90890-85505
Three bond No. 1215®

TIP
¢ Do not allow any sealant to come into contact
3. Remove: with the oil gallery or crankshaft journal bear-
e Lower crankcase ings, or balancer shaft journal bearings.
ECA13900
* Remove the sealant from the area “a” as
NOTICE
shown in the illustration.
Tap on one side of the crankcase with a soft- ¢ Make sure that the sealant does not get into
face hammer. Tap only on reinforced por- the groove “b” in the crankcase.
tions of the crankcase, not on the crankcase
mating surfaces. Work slowly and carefully
and make sure the crankcase halves sepa-
rate evenly.
4. Remove:
* Dowel pins
5. Remove:
¢ Crankshaft journal lower bearing
¢ Balancer shaft journal bearing
(from the lower crankcase)

0-74
 CRANKCASE

¢ Lubricate the bolts “28”, “40” mating surfaces

with engine oil.
¢ Apply the bolts “28”, “40” thread with LOC-
TITE®.
e M9 x 100 mm (3.94 in) bolts with washers:
44 Q” |New |

e M8 x 58 mm (2.28 in) bolts with new O-rings:

“11"—"18"
¢ M8 x 60 mm (2.36 in) bolts: “19”, “20”
e M6 x 65 mm (2.56 in) bolts: “21”, “22”
¢ M6 x 70 mm (2.76 in) bolt: “23”
¢ M6 x 60 mm (2.36 in) bolts: “24’—“27”, “35”,
“39”
¢ M6 x 50 mm (1.97 in) bolts: “81”—“34”
¢ M6 x 50 mm (1.97 in) bolts (LOCTITE®):
“28”, “40”
¢ M6 x 40 mm (1.57 in) bolts: “29”, “30”, “36”,
“37”, “39”

3. Install:
* Dowel pins
4. Setthe shift drum assembly and transmission
gears in the neutral position.
5. Install:
e Lower crankcase “1”
(onto the upper crankcase “2”)
ECA13980

NOTICE
Before tightening the crankcase bolts, make
sure the transmission gears shift correctly
when the shift drum assembly is turned by
hand.

7. Tighten:
e Crankcase bolts “1°—“10”

yy, Crankcase bolts “1—"10°

1st: 20 N-m (2.0 kgf-m, 15 Ib-ft)
6. Install: *2nd: 15 N-m (1.5 kgf-m, 11 Ib-ft)
e Crankcase bolt (x 40) 3rd: Specified angle 75°
TIP
* Following the tightening order, loosen the
e Lubricate the bolts “1”—“10” thread, mating sur- bolt one by one and then retighten it to the
faces and washers with engine oil. specific torque.
e Lubricate the bolts “11°—“18” thread, mating
surfaces and O-rings with engine oil.
¢ Lubricate the bolts “19”—“27”, “29"—“39” thread
and mating surfaces with engine oil.

9-75
 CRANKCASE

EWA16610

If the bolt is tightened more than the speci-

fied angle, do not loosen the bolt and then re-
tighten it. Instead, replace the bolt with a new
one and perform the procedure again.
ECA20890

NOTICE
Do not use a torque wrench to tighten the
bolt to the specified angle.
TIP
Tighten the bolts in the tightening sequence cast
on the crankcase.

°/ i
EAS31718

INSTALLING THE CRANKCASE BREATHER

COVER
1. Install:
e Crankcase breather cover
e Crankcase breather cover bolt EWG
2. Tighten:
e Crankcase breather cover bolt
\
Crankcase breather cover bolt
4 1st: 6 N-m (0.6 kgf-m, 4.4 lb-ft)
*2nd: 3.0 N-m (0.30 kgf-m, 2.2
lb-ft)
Specified angle 90°

8. Tighten: ° Following the tightening order, loosen the

¢ Crankcase bolts “11”—“40” bolt one by one and then retighten it to the
specific torque and the specific angle.
Crankcase bolts “11”—"20"
24 N-m (2.4 kgf-m, 18 Ib-ft) TIP
Crankcase bolts “21’—"40" Tighten the crankcase breather cover bolts in
10 N-m (1.0 kgf-m, 7.4 Ib-ft) the tightening sequence as shown.

TIP
Tighten the bolts “11”—“18” in the tightening se-
quence cast on the crankcase.

0-76
 CRANKCASE

EASS1071

INSTALLING THE OIL PRESSURE SWITCH Gear position sensor bolt

1. Install: AON 4.0 N-m (0.40 kgf-m, 3.0 Ib-ft)
¢ Oil pressure switch “1” LOCTITE®
* Oil pressure switch lead “2”
TIP
Oil pressure switch
¢ Lubricate the O-ring with lithium-soap-based
% 13 N-m (1.3 kgf-m, 9.6 Ib-ft)
Oil pressure switch lead bolt grease.
1.8 N-m (0.18 kgf-m, 1.3 lb-ft) ¢ Fit the end “a” of the shift drum assembly into
the opening “b” in the gear position sensor “1”.
TIP
e Apply Three Bond No. 1215B® to the threads
“a’ of the oil pressure switch. However, do not
apply Three Bond No. 1215B® to the portion
“b” of the oil pressure switch.
e Install the oil pressure switch lead so that it is
routed within the range shown in the illustra-
tion.

EAS31658

INSTALLING THE GEAR POSITION SENSOR

ECA22630

NOTICE
To prevent damage to the gear position sen-
sor, keep magnets (including any pickup tool
with a magnet, magnetized screwdrivers,
etc.) away from the gear position sensor.
1. Install:
° O-ring KEM
¢ Gear position sensor “1”
 CONNECTING RODS AND PISTONS

EAS20132

CONNECTING RODS AND PISTONS

Removing the connecting rods and pistons

Order Job/Parts to remove Remarks

Q
Zz

Lower crankcase Refer to “CRANKCASE’ on page 5-71.

Connecting rod cap
—

S
hp|

Big end lower bearing

S|

Big end upper bearing

ol]

|
BS)

Connecting rod
&;

Piston pin clip

om!)

wo!)
om)

Piston pin
S|
ns |

BB) B!)

Piston
co;

Top ring
2nd ring
B)
(};

Oil ring
S|)
oO
a

Cylinder
|
oll,
—_—

ro} —)

Cylinder gasket
ok
ho

Dowel pin
Go
—

0-78
 CONNECTING RODS AND PISTONS

EAS30745

REMOVING THE CONNECTING RODS AND Piston pin clip rotation tool
PISTONS 90890-04175
The following procedure applies to all of the con- YM-04175
necting rods and pistons.
1. Remove:
¢ Connecting rod cap
¢« Connecting rod
¢ Big end bearings
TIP ‘\é
Sl
¢ Identify the position of each big end bearing so
that it can be reinstalled in its original place. (_. f | ~\|
e After removing the connecting rods and con-
necting rod caps, care should be taken not to [ \
damage the mating surfaces of the connecting
rods and connecting rod caps. c. Turn the piston pin clip rotation tool “2” so
2 Remove: that the piston pin clip ends are positioned
¢ Piston pin clip “1” at “a” or "b”.
a. Make sure that the piston pin clip ends are
in either the “a” or “b” position in relation to
the cutout “c”.
TIP
lf the piston pin clip ends are not positioned at
“a’ or “b”, adjust the piston pin clip ends position
by following steps (b) to (c).

d. Remove the piston pin clip “1” using long-

nose pliers or a similar tool.
TIP
When removing the piston pin clip, hold the pis-
ton pin clip in place with your fingers because it
can easily spring.

b. Install the piston pin clip rotation tool “2” to

the piston pin clip.
TIP
When installing the piston pin clip rotation tool,
align the projection “d” on the piston pin clip ro-
tation tool with the clip ends “e”

9-79
 CONNECTING RODS AND PISTONS

3. Remove:
\/
¢ Piston pin “1”
G088999

EASS07a?

CHECKING THE CYLINDER AND PISTON

1. Check:
© Piston “2”
ECA1a810
e Piston wall
NOTICE e Cylinder wall
Do not use a hammer to drive the piston pin Vertical scratches — Replace the cylinder
out. block, and replace the pistons and piston
rings as a set.
TIP 2. Measure:
e For reference during installation, put identifica- e Piston-to-cylinder clearance
tion marks on the piston crown. a. Measure cylinder bore “C” with the cylin-
¢ Before removing the piston pin, deburr the pis- der bore gauge.
ton pin clip groove and the piston pin bore ar- TIP
ea. If both areas are deburred and the piston Measure cylinder bore “C” by taking side-to-side
pin is still difficult to remove, remove it with the and front-to-back measurements of the cylinder.
piston pin puller set “3”.
Bore
(Z,| Piston pin puller set 79.000-—79.010 mm (3.1102-
~ 90890-01304 3.1106 in)
Piston pin puller Wear limit
YU-01304 79.060 mm (3.1126 in)

“C” = maximum of Dy, Do, Ds, Da, Ds, Dg

Goss998 3
4. Remove:
¢ Top ring GOs9000

¢ 2nd ring b. If out of specification, replace the cylinder,

¢ Oil ring and replace the piston and piston rings as
TIP a set.
When removing a piston ring, open the end gap c. Measure piston skirt diameter “P” with the
with your fingers and lift the other side of the ring micrometer.
over the piston crown.

0-80
 CONNECTING RODS AND PISTONS

Piston Piston ring

Diameter Top ring
78.961—78.994 mm (3.1087- Ring side clearance
3.1100 in) 0.030—0.065 mm (0.0012-
0.0026 in)
Side clearance limit
0.115 mm (0.0045 in)
2nd ring
Ring side clearance
0.020—0.055 mm (0.0008-
0.0022 in)
Side clearance limit
0.115 mm (0.0045 in)

a. 8.0 mm (0.31 in) from the bottom edge of the

piston

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.
Piston-to-cylinder clearance = Cylinder bore “C” -
Piston skirt diameter “P”
2. Install:

a
e Piston ring
Piston-to-cylinder clearance (into the cylinder)
0.006—0.049 mm (0.0002-—0.0019 TIP
in)
Use the piston crown to level the piston ring near
bottom of cylinder “a”, where cylinder wear is
f. lf out of specification, replace the cylinder,
lowest.
and replace the piston and piston rings as
a set. 3. Measure:
e Piston ring end gap
EASSa0T
4a

CHECKING THE PISTON RINGS Out of specification — Replace the piston

1. Measure: ring.
* Piston ring side clearance TIP
Out of specification — Replace the piston The oil ring expander spacer’s end gap cannot
and piston rings as a set. be measured. If the oil ring rail’s gap is exces-
TIP sive, replace all three piston rings.
Before measuring the piston ring side clearance,
eliminate any carbon deposits from the piston Top ring
ring grooves and piston rings. End gap limit
0.50 mm (0.0197 in)
2nd ring
End gap limit
1.15 mm (0.0453 in)

0-81
 CONNECTING RODS AND PISTONS

GO089005

b. Upper of cylinder 3. Calculate:

e Piston-pin-to-piston-pin-bore clearance
EAS30749 Out of specification — Replace the piston pin
CHECKING THE PISTON PIN and piston as a set.
The following procedure applies to all of the pis- Piston-pin-to-piston-pin-bore clearance = Piston
ton pins. pin bore inside diameter “b” - Piston pin outside
1. Measure: diameter “a”
¢ Piston pin outside diameter “a”
Out of specification — Replace the piston pin. Piston-pin-to-piston-pin-bore
clearance
Piston pin outside diameter
0.002—0.022 mm (0.0001—0.0009
16.991—17.000 mm (0.6689-—
in)
0.6693 in)
Limit
16.971 mm (0.6681 in)
EAS S0750

CHECKING THE CONNECTING RODS

1. Measure:
¢ Crankshaft-pin-to-big-end-bearing clearance
Out of specification — Replace the big end
bearings.

Oil clearance
0.033—0.057 mm (0.0013—0.0022
in)

The following procedure applies to all of the

GoOs9004
connecting rods.
2. Measure: FCA13990
¢ Piston pin bore inside diameter “b” NOTICE
Out of specification — Replace the piston. Do not interchange the big end bearings and
connecting rods. To obtain the correct
Piston pin bore inside diameter crankshaft-pin-to-big-end-bearing clear-
tx 17.002—17.013 mm (0.6694— ance and prevent engine damage, the big
hina in) end bearings must be installed in their origi-
17.043 mm (0.6710 in) nal positions.
a. Clean the big end bearings, crankshaft
pins, and the connecting rods with oil
cleaner.
TIP
When cleaning the connecting rod, clean the
bearing surface “a” of the connecting rod bolt
and threads “b”.

9-82
 CONNECTING RODS AND PISTONS

b. Wait five minutes to dry the remaining oil

cleaner component.
c. Install the big end upper bearing into the
connecting rod and the big end lower
bearing into the connecting rod cap with
the connecting rod big end metal installer
“1”.
TIP
¢« From the 3 types, choose the connecting rod
big end metal installer “1” that fits exactly, and
install it to the connecting rod and connecting d. Put a piece of Plastigauge® “1” on the
rod cap as shown in the illustration. crankshaft pin.
e Align the projections “a” on the big end bear-
ings with the notches “b” in the connecting rod
and connecting rod cap.
¢ Push the big end bearing “2” down and install it
to the connecting rod and connecting rod cap.

Connecting rod big end bearing

installer
90890-04193 GO89008
Connecting rod big end bearing
installer e. Assemble the connecting rod halves.
EC A18390
YM-04193
NOTICE
Tighten the connecting rod bolts using the
plastic-region tightening angle method. Al-
ways install new bolts.
TIP
* Install the new connecting rod bolt without
cleaning and without any oil.
¢ Make sure that the projection “a” on the con-
necting rod cap faces the same direction as the
“o” mark “b” on the connecting rod.
¢ After installing the big end bearing, assemble
the connecting rod and connecting rod cap
without installing them onto the crankshaft.

0-83
 CONNECTING RODS AND PISTONS

e Make sure the “o” marks “b” on the connecting

rods face towards the left side of the crank-
shaft.
* Install the connecting rod so that the Plasti-
gauge® is in position “c” or “d”.

TIP Qi =) iff
Install by carrying out the following procedures in
order to assemble in the most suitable condition. (SE fy
f. Tighten the connecting rod bolt while
checking that the sections shown “a” and
“b” are flush with each other by touching
the surface.

\y Connecting rod bolt

30 N-m (3.0 kgf-m, 22 Ib-ft)

TIP
To install the connecting rod cap, care should be
taken not to install it at an angle and the position
should not be out of alignment.
h. Tighten the connecting rod bolts with a
torque wrench.

\y Connecting rod bolt (1st)

| 25 N-m (2.5 kgf-m, 18 Ib-ft)
i. Puta mark “1” on the corner of the con-
necting rod bolt “2” and the connecting rod
cap “3”.

a. Side machined face

b. Thrusting faces

g. Loosen the connecting rod bolt, remove

the connecting rod and connecting rod
cap and install these parts to the crank-
shaft with the big end bearing kept in the \
current condition.
TIP
¢ Do not move the connecting rod or crankshaft to
J. Tighten the connecting rod bolts further
until the clearance measurement has been reach the specified angle 175°—-185° with
completed. torque wrench, and then confirm that the
¢ Make sure that the projection “a” on the con- torque value is within the range of 40 N-m
necting rod cap faces the same direction as the (4.0 kgf-m, 30 Ib-ft) to 85 N-m (8.5 kgf-m,
“o” mark “b” on the connecting rod. 63 Ib-ft) with keeping the torque wrench

0-84
 CONNECTING RODS AND PISTONS

175°—185°. If torque is out of range, re- 2. Select:

place the connecting rod bolt to new one ¢ Big end bearings (P;—P,)
and repeat from step (h). TIP

N Connecting rod bolt (final) | « The numbers “A” stamped into the crankshaft
web and the numbers “1” on the connecting
% Specified angle 175°-185°
rods are used to determine the replacement
big end bearings sizes.
e “P,”—"P,” refer to the bearings shown in the
crankshaft illustration.
For example, if the connecting rod “P,” and
the crankshaft web “P,” numbers are 6 and 2
respectively, then the bearing size for “P,” is:
“P” (connecting rod) - “P,” (crankshaft web)
= 6 -2=4 (green)
EWA16610

Bearing color code

If the bolt is tightened more than the speci- Code 1
fied angle, do not loosen the bolt and then re- Blue
Code 2
tighten it. Instead, replace the bolt with a new
Black
one and perform the procedure again.
Code 3
k. After the installation, check that the sec- Brown
tion shown “a” is flush with each other by Code 4
touching the surface. Green
Code 5
Yellow
Code 6
Pink

|. Remove the connecting rod and big end

bearings.
m. Measure the compressed Plastigauge®
width on the crankshaft pin. If the crank-
shaft-pin-to-big-end-bearing clearance is
out of specification, select replacement A} P: P2 Ps Ps
big end bearings. =|

93332 C

0-85
 CONNECTING RODS AND PISTONS

EASSaoT51

INSTALLING THE CONNECTING ROD AND

PISTON
The following procedure applies to all of the con-
necting rods and pistons.
1. Install:
¢ Big end bearings
¢ Connecting rod cap
(onto the connecting rod)
TIP
e Clean the big end bearings, crankshaft pins,
and the connecting rods with oil cleaner, and
then wait five minutes to dry the remaining oil
cleaner component.
e When cleaning the connecting rod, clean the
bearing surface “a” of the connecting rod bolt
and threads “b”.
¢ Be sure to reinstall each big end bearing in its
original place.
e From the 3 types, choose the connecting rod
big end metal installer “1” that fits exactly, and
install it to the connecting rod and connecting
rod cap as shown in the illustration.
e Align the projections “c” on the big end bear-
ings with the notches “d” in the connecting rods
and connecting rod caps.
e Push the big end bearing “2” down and install it
to the connecting rod and connecting rod cap.
e Make sure that the projection “e” on the con-
necting rod cap faces the same direction as the
“o mark “f’ on the connecting rod.

Connecting rod big end bearing

installer
90890-04193
Connecting rod big end bearing
installer
YM-04193

0-86
 CONNECTING RODS AND PISTONS

2. Tighten: 3. Install:
* Connecting rod bolts DEG ¢ Top ring “1”
ECA1B8390 (into the piston)
NOTICE e 2nd ring “2”
Tighten the connecting rod bolts using the e Upper oil ring rail “3”
plastic-region tightening angle method. Al- ¢ Oil ring expander “4”
ways install new bolts. ¢ Lower oil ring rail “5”
TIP
TIP
Be sure to install the piston rings so that the
e Install by carrying out the following procedures
manufacturer’s marks or numbers “a” face up.
in order to assemble in the most suitable con-
dition.
¢ Install the new connecting rod bolt without
cleaning and without any oil.
a. Replace the connecting rod bolts with new
ones.
b. After installing the big end bearing, as-
semble the connecting rod and connecting
rod cap without installing them onto the
wy
crankshaft. GO089011
c. Tighten the connecting rod bolt while
4. Install:
checking that the sections shown “a” and
e Piston “1”
“b” are flush with each other by touching
(onto the respective connecting rod “2”)
the surface.
e Piston pin “3”
\y Connecting rod bolt TIP
oS 30 N-m (3.0 kgf-m, 22 Ib-ft) ¢ Apply engine oil onto the piston pin.
¢ Make sure that the “o” mark “a” on the connect-
TIP ing rod faces left when the punch mark “b” on
To install the connecting rod cap, care should be the piston is pointing up as shown.
taken not to install it at an angle and the position ¢ Reinstall each piston into its original cylinder.
should not be out of alignment.

5. Install:
a. Side machined face ¢ Piston pin clip “1” DEG
b. Thrusting faces a. Install the piston pin clip “1” in the piston as
shown in the illustration.
d. Loosen the connecting rod bolt, remove
the connecting rod and connecting rod TIP
cap and install these parts to the crank- When installing the first piston pin clip, place oth-
shaft with the big end bearing kept in the er piston pin “2” under the piston pin as shown in
current condition. the illustration.

0-87
 CONNECTING RODS AND PISTONS

TIP d. Make sure the piston pin clip “1” is posi-

tioned as shown in the illustration.

e. Install the piston pin clip installer tool “4”

b. Push the piston pin clip insertion tool “3” in onto the piston.
the direction as shown in the illustration
and place the piston pin clip into the piston Piston pin clip installer tool
pin bore. 90890-04174
TIP YM-04174

Push in the piston pin clip insertion tool while f. While holding the piston pin clip installer
holding it parallel with the upper surface of the tool, turn it counterclockwise “c”, to com-
piston and rear surface of the piston pin clip in- pletely install the piston pin clip in the pis-
sertion tool. ton.

kh, Piston pin clip insertion tool

f 90890-04173
YM-04173

g. Make sure that the piston pin clip “1” is in

the groove “d”.

c. Install the piston pin clip to the piston by

pressing the portion “b” on the piston pin
clip insertion tool “3” in the direction shown
in the illustration.

0-88
 CONNECTING RODS AND PISTONS

TIP
¢ While holding the piston rings with the hand, in-
stall the piston assembly into the cylinder from
underneath.
* Install the piston assembly into the cylinder so
that the piston ring end gap is aligned with the
cylinder skirt “a”.

6. Lubricate:
e Piston
e Piston rings
¢ Cylinder
(with the recommended lubricant)

=, Recommended lubricant
Engine oil
[Link]:
7. Offset:
¢ Cylinder gasket DEN
¢ Piston ring end gaps
¢ Dowel pins
e Cylinder assembly
¢ Connecting rod caps
e Connecting rod bolts
TIP
e Make sure the “>” marks “a” on the connecting
rods face towards the left side of the crank-
shaft.
¢ Make sure that the projection “b” on the con-
necting rod cap faces the same direction as the
“o” mark “a” on the connecting rod.
a. Top ring
b. 2nd ring
a
c. Upper oil ring rail
d. Oil ring expander
LES
e. Lower oil ring rail ‘ EY
A. Exhaust side

8. Lubricate:
¢ Crankshaft pins
* Connecting rod big end bearing inner surface (Wy 92
and side surface
(with the recommended lubricant)
[Link]:
Recommended lubricant ¢ Connecting rod bolts “1”
Engine oil

9. Install:
* Piston assemblies “1”
(into the cylinder “2”)

0-89
 CONNECTING RODS AND PISTONS

EWA16610

TIP If the bolt is tightened more than the speci-

Tighten the connecting rod bolts using the fol- fied angle, do not loosen the bolt and then re-
lowing procedure. tighten it. Instead, replace the bolt with anew
a. Tighten the connecting rod bolts with a one and perform the procedure again.
torque wrench. d. After the installation, check that the sec-
tion shown “a” is flush with each other by
Connecting rod bolt (1st) touching the surface.
25 N-m (2.5 kgf-m, 18 Ib-ft) EWAIT1I20

b. Put a mark “1” on the corner of the con- If the connecting rod and cap are not flush
necting rod bolt “2” and the connecting rod with each other, remove the connecting rod
cap “3” .

bolts and big end bearing and restart from

step (1). In this case, make sure to replace
the connecting rod bolts.

c. Tighten the connecting rod bolts further to

reach the specified angle 175°—185° with
torque wrench, and then confirm that the
torque value is within the range of 40 N-m
(4.0 kgf-m, 30 lb-ft) to 85 N-m (8.5 kgf-m,
63 |b-ft) with keeping the torque wrench
175°—185°. If torque is out of range, re-
place the connecting rod bolt to new one
and repeat from step (a).

\y Connecting rod bolt (final)

> Specified angle 175°-—185°

9-90
 CRANKSHAFT AND BALANCER SHAFT

EAS20176

CRANKSHAFT AND BALANCER SHAFT

Removing the crankshaft and balancer shaft

Order Job/Parts to remove Remarks

Lower crankcase Refer to “CRANKCASE’ on page 5-71.

Refer to “REMOVING THE CONNECTING
Connecting rod
RODS AND PISTONS’ on page 5-79.
Balancer shaft
ow] ht}

Balancer shaft journal lower bearing

|

Balancer shaft journal upper bearing

Bl
S|
om) &]

Crankshaft
Crankshaft journal lower bearing
oy
om)

Ph) oO)

Crankshaft journal upper bearing

Thrust bearing
oO) S|)

&)

Oil nozzle 1
Oo)

ny)

Oil nozzle 2

3-91
 CRANKSHAFT AND BALANCER SHAFT

EASS1174
2. Check:
REMOVING THE CRANKSHAFT AND
¢ Crankshaft journal surfaces
BALANCER SHAFT
¢ Crankshaft pin surfaces
1. Remove:
Scratches/wear — Replace the crankshaft.
e Balancer shaft “1”
¢ Bearing surfaces
¢ Balancer shaft journal bearing
Scratches/wear — Replace the crankshaft
¢ Crankshaft assembly “2”
journal bearing.
¢ Crankshaft journal bearings
3. Measure:
TIP ¢ Crankshaft-journal-to-crankshaft-journal-
Identify the position of each balancer shaft jour- bearing clearance
nal bearings and crankshaft journal bearings so Out of specification — Replace the crank-
that it can be reinstalled in its original place. shaft journal bearings.

Journal oil clearance

0.025—0.043 mm (0.0010—0.0017
in)
ECA13920

NOTICE
Do not interchange the crankshaft journal
bearings. To obtain the correct crankshaft-
journal-to-crankshaft-journal-bearing clear-
ance and prevent engine damage, the crank-
shaft journal bearings must be installed in
EAS31 174

CHECKING THE OIL NOZZLES their original positions.

The following procedure applies to all of the oil a. Clean the crankshaft journal bearings,
nozzles. crankshaft journals, and bearing portions
1. Check: of the crankcase.
¢ Oil nozzle 1 b. Place the upper crankcase upside down
¢ Oil nozzle 2 on a bench.
Damage/wear —> Replace the oil nozzle. c. Install the crankshaft journal upper bear-
* Oil passage ings “1” and the crankshaft into the upper
Obstruction —> Blow out with compressed air. crankcase.
EASS1075
TIP
CHECKING THE CRANKSHAFT Align the projections “a” on the crankshaft jour-
1. Measure: nal upper bearings with the notches “b” in the up-
¢ Crankshaft runout per crankcase.
Out of specification — Replace the crank-
shaft.

Runout limit
0.030 mm (0.0012 in)

_ —
G089019 _

a LL x d. Put a piece of Plastigauge® “1” on each

crankshaft journal.
TIP

G089018
Do not put the Plastigauge® over the oil hole in
the crankshaft journal.

9-92
 CRANKSHAFT AND BALANCER SHAFT

1
4. Select:
¢ Crankshaft journal bearings (J4—Js)
TIP
« The numbers “A” stamped into the crankshaft
web and the numbers “B” stamped into the
lower crankcase are used to determine the re-
placement crankshaft journal bearing sizes.
e “J,"-“Js” refer to the bearings shown in the
G089020 crankshaft and lower crankcase illustration.
e. Install the crankshaft journal lower bear- For example, if the crankcase “J,” and crank-
ings “1” into the lower crankcase and as- shaft web “J,” numbers are 5 and 2 respec-
semble the crankcase halves.
tively, then the bearing size for “J,” is:
TIP
“J,” (crankcase) - “J,” (crankshaft web) + 3
e Align the projections “a” of the crankshaft jour-
5 - 2+ 3=6 (pink)
nal lower bearings with the notches “b” in the
lower crankcase.
¢ Do not move the crankshaft until the clearance Bearing color code
measurement has been completed. Code 0
White
Code 1
Blue
Code 2
N\A WS a . Black
Code 3
Brown
Code 4
Green
Code 5
G089019 Yellow
Code 6
f. Tighten the bolts to specification in the Pink
tightening sequence cast on the crank-
case.
Refer to “CRANKCASE” on page 5-71.
. Remove the lower crankcase and the
crankshaft journal lower bearings.
. Measure the compressed Plastigauge®
width “a” on each crankshaft journal.
lf the crankshaft-journal-to-crankshaft-
journal-bearing clearance is out of specifi-
cation, select replacement crankshaft
journal bearings.

Sea
Ji Je Js Ja ds

2393932 2222

GO089021

9-93
 CRANKSHAFT AND BALANCER SHAFT

ing clearance and prevent engine damage,

the balancer shaft journal bearings must be
installed in their original positions.
a. Clean the balancer shaft journal bearings,
balancer shaft journals, and bearing por-
tions of the crankcase.
b. Place the upper crankcase upside down
ona bench.
c. Install the balancer shaft journal upper
B] Ji Je Js da ds bearings “1” and the balancer shaft into
the upper crankcase.
EASS1076

CHECKING THE BALANCER SHAFT TIP

1. Measure: Align the projections “a” on the balancer shaft
e Balancer shaft runout journal upper bearings with the notches “b” in the
Out of specification — Replace the balancer upper crankcase.
shaft.

Balancer shaft runout limit

lx 0.030 mm (0.0012 in)

G0s9019

FI | A d. Put a piece of Plastigauge® “1” on each

balancer shaft journal.
TIP
Do not put the Plastigauge® over the oil hole in
2. Check: the balancer shaft journal.
¢ Balancer shaft journal surfaces
Scratches/wear — Replace the balancer
shaft.
¢ Bearing surfaces
scratches/wear — Replace the balancer
shaft journal bearing.
3. Measure:
¢ Balancer shaft journal-to-balancer shaft jour-
nal bearing clearance
Out of specification — Replace the balancer GO089020

shaft journal bearings. e. Install the balancer shaft journal lower

a
bearings “1” into the lower crankcase and
Balancer shaft journal to balanc-
er shaft bearing clearance assemble the crankcase halves.
0.028—0.046 mm (0.0011—0.0018 TIP
in) ¢ Align the projections “a” of the balancer shaft
journal lower bearings with the notches “b” in
ECA18400

NOTICE the crankcase.

¢ Do not move the balancer shaft until the clear-
Do not interchange the balancer shaft jour-
ance measurement has been completed.
nal bearings. To obtain the correct balancer
shaft-journal-to-balancer shaft-journal-bear-

0-94
 CRANKSHAFT AND BALANCER SHAFT

Bearing color code

Code 0
White
Code 1
Blue
Code 2
Black
Code 3
Brown
G089019 a |
Code 4
f. Tighten the bolts to specification in the Green
tightening sequence cast on the crank- Code 5
case. Refer to “CRANKCASE” on page Yellow
5-71. Code 6
g. Remove the lower crankcase and the bal- Pink
ancer shaft journal lower bearings.
h. Measure the compressed Plastigauge®
width “a” on each balancer shaft journal. If
the balancer shaft-journal-to-balancer
shaft-journal-bearing clearance is out of
specification, select replacement balancer
Ji
shaft journal bearings.

G089021

4. Select:
¢ Balancer shaft journal bearing (J,—J,)
TIP
e The numbers “A” stamped into the balancer
shaft web and the numbers “B” stamped into
the lower crankcase are used to determine the
replacement balancer shaft journal bearing siz-
es.
e “J,"—-“J,” refer to the bearings shown in the bal-
ancer shaft and lower crankcase illustration.

For example, if the crankcase “J,” and bal-

ancer shaft web “J,” numbers are 6 and 2 re-
spectively, then the bearing size for “J,” is:
Ji Jo Js Ja
“J,” (crankcase) - “J,” (balancer shaft web) - 1 =
6 -2-1=3 (brown) FASSiOr?

INSTALLING THE CRANKSHAFT

1. Install:
e Crankshaft journal upper bearings
(into the upper crankcase)

0-95
 CRANKSHAFT AND BALANCER SHAFT

¢ Crankshaft journal lower bearings TIP

(into the lower crankcase) When installing the thrust bearing, shift the
e Crankshaft crankshaft to the left to widen the gap between
TIP the crankshaft and the crankcase.
e Align the projections “a” on the crankshaft jour-
nal bearings “1” with the notches “b’” in the
crankcase.
¢ Be sure to install each crankshaft journal bear-
ings in its original place.

b. Insert the thrust bearing “2” into the slot of

the upper crankcase as shown in the illus-
tration and slide it in the direction of the ar-
G089019 row.
TIP
EAS31799

INSTALLING THE THRUST BEARING When installing thrust bearing “2”, shift the
1. Install: crankshaft to the right to widen the gap between
¢ Thrust bearing “1” the crankshaft and the crankcase.
TIP
¢ Install the thrust bearings to the both side of the
journal #4 of the upper crankcase.
e The thickness of the thrust bearing is only one.
No need to adjust the clearance between the
thrust bearing and the crankshaft.
e Install the thrust bearing with the grooves “a”
side is facing the crankshaft.
e Apply engine oil on the grooves “a” side of the
thrust bearing.
c. Check that the thrust bearing is inserted
properly into the groove of the crankcase.

a. Insert the thrust bearing “1” into the slot of

the upper crankcase as shown in the illus-
tration and slide it in the direction of the ar- EAS31172

row. INSTALLING THE BALANCER ASSEMBLY

1. Install:
¢ Balancer shaft journal upper bearings
(into the upper crankcase)

0-96
 CRANKSHAFT AND BALANCER SHAFT

¢ Balancer shaft journal lower bearings

(into the lower crankcase)
TIP
e Align the projections “a” on the balancer shaft
journal bearings “1” with the notches “b” in the
crankcases.
¢ Be sure to install each balancer shaft journal
bearing in its original place.

Gos9019 “ \

2. Install:
*¢ Balancer shaft
TIP
Install by aligning the crankshaft match mark “a”
and the balancer shaft match marks “b”.

9-97
 TRANSMISSION

EAS20062

TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks

Order Job/Parts to remove Q'ty Remarks

Lower crankcase Refer to “CRANKCASE’ on page 5-71.

Drive axle assembly
—

OD]
hp|

Shift drum retainer

Spring
ol]

e OA] A]

Shift fork guide bar

&;

Shift fork-L
| et)
om!)

ee
om)

Shift fork-R
ns |

Shift drum assembly

Shift fork-C
co;

Main axle assembly

(};

Oil delivery pipe 3

—k
©

me

O-ring
oll,
—_—

Oil baffle plate

Po} mee
—h
ho

Bearing
Go
—

0-98
 TRANSMISSION

Disassembling the main axle assembly

Order Job/Parts to remove Q’ty Remarks

{ 2nd pinion gear 1 secretes Wehr alas side of the pinion

2 Toothed lock washer 1

3 Toothed lock washer retainer 1
4 6th pinion gear 1
5 Collar 1
6 Washer 1
7 Circlip 1
8 3rd pinion gear 1
9 Circlip 1
10 Washer 1
11 5th pinion gear 1
12 Collar 1
13 Bearing housing 1
14 Bearing 1
15 Main axle 1

9-99
 TRANSMISSION

Disassembling the drive axle assembly

Order Job/Parts to remove Q’ty Remarks

1 Circlip 1
2 Bearing 1
3 Washer 1
4 1st wheel gear 1
5 Collar 1
6 5th wheel gear 1
7 Circlip 1
8 Washer 1
9 3rd wheel gear 1
10 Collar 1
11 Toothed lock washer 1
12 Toothed lock washer retainer 1

5-100
 TRANSMISSION

Disassembling the drive axle assembly

“6
‘6 ‘New

Order Job/Parts to remove Q’ty Remarks

13 4ih wheel gear 1

14 Collar 1
15 Washer 1
16 Circlip 1
17 6th wheel gear 1
18 Circlip 1
19 Washer 1
20 2nd wheel gear 1
21 Collar 1
22 Collar 1
23 Oil seal 1
24 Circlip 1
25 Bearing 1
26 Drive axle 1

9-101
 TRANSMISSION

EA530430 EASS0431

REMOVING THE TRANSMISSION CHECKING THE SHIFT FORKS

1. Remove: The following procedure applies to all of the shift
¢ Drive axle assembly “1” forks.
¢ Shift drum retainers “2” 1. Check:
¢ Shift fork guide bars e Shift fork cam follower “1”
¢ Shift fork-L e Shift fork pawl “2”
¢ Shift fork-R Bends/damage/scoring/wear — Replace the
¢ Shift drum assembly shift fork.
¢ Shift fork-C

1
GO89022

2. Check:
2. Remove: e Shift fork guide bar
¢ Bearing housing “1” Roll the shift fork guide bar on a flat surface.
¢ Main axle assembly “2” Bends —> Replace.
a. Insert two bolts “3” of the proper size, as EWAI2840

shown in the illustration, into the main axle

assembly bearing housing. Do not attempt to straighten a bent shift fork
guide bar.
3. Check:
e Shift fork movement
(along the shift fork guide bar)
Rough movement —> Replace the shift forks
and shift fork guide bar as a set.

b. Tighten the bolts until they contact the

crankcase surface.
c. Continue tightening the bolts until the main
axle assembly comes free from the upper
an
crankcase.
3. Remove: GO0B9023

* Oil delivery pipe 3 “1” 4. Check:

¢ Bearings “2” e Shift fork guide bar (for the shift fork-C) oil
passage
Clogging/damage —> Replace the shift fork
guide bar (for the shift fork-C).
FAS S442

CHECKING THE SHIFT DRUM ASSEMBLY

1. Check:
e Shift drum groove
Damage/scratches/wear — Replace the shift
drum assembly.

9-102
 TRANSMISSION

¢ Shift drum segment “1” 3. Check:

Damage/wear — Replace the shift drum as- ¢ Transmission gears
sembly. Blue discoloration/pitting/wear — Replace
¢ Shift drum bearing “2” the defective gear(s).
Damage/pitting — Replace the shift drum as- e Transmission gear dogs
sembly. Cracks/damage/rounded edges — Replace
the defective gear(s).

Go0s9024

GO0s89025
EASSO433

CHECKING THE TRANSMISSION 4. Check:

1. Measure: e Transmission gear engagement
e Main axle runout (each pinion gear to its respective wheel
(with a centering device and dial gauge “1”) gear)
Out of specification — Replace the main axle. Incorrect — Reassemble the transmission
axle assemblies.
Main axle runout limit 5. Check:
0.08 mm (0.0032 in)
e Transmission gear movement
Rough movement — Replace the defective
part(s).
6. Check:
¢ Circlips
Bends/damage/looseness — Replace.
EFAS 30435

ASSEMBLING THE MAIN AXLE AND DRIVE

AXLE
1. Install:
e Toothed washer “1”
2. Measure:
* Circlip “2” TE
« Drive axle runout TIP
(with a centering device and dial gauge “1”) ¢ Be sure the circlip sharp-edged corner “a” is
Out of specification — Replace the drive axle. positioned opposite side to the toothed washer

Ay
and gear.
Drive axle runout limit * Install the circlip so that a spline “b” is in the
0.08 mm (0.0032 in) center of the gap between the circlip ends “c”
as shown.

5-103
 TRANSMISSION

A. Main axle
B. Drive axle

EAS30438

INSTALLING THE TRANSMISSION

1. Install:
¢ Bearings “1”
¢ Oil delivery pipe 3 “2”
TIP
Face the seal side of bearing to the outside.
2. Install:
¢ Toothed lock washer retainer “1” \y . ; :
. a Oil delivery pipe 3 bolt
Toothed lock washer “2 &, 10 N-m (1.0 kgf-m, 7.4 Ib-ft)
TIP LOCTITE®
e With the toothed lock washer retainer in the
groove “a” in the axle, align the projection on
the retainer with an axle spline, and then install
the toothed lock washer. 2
¢ Be sure to align the projection on the toothed
lock washer that is between the alignment
marks “b” with the alignment mark “c’” on the re-
tainer.

2. Install:
e Main axle assembly “1”
¢ Bearing housing “2”

Main axle bearing housing bolt

> 12 N-m (1.2 kgf-m, 8.9 lb-ft)
LOCTITE®

9-104
 TRANSMISSION

3. Install: * Oil seal DEW

¢ Shift fork-C “1”
° Circlip “4” TENG
¢ Shift drum assembly “2”
e Drive axle assembly “5”
¢ Shift fork guide bar “3”
TIP \y Shift drum retainer bolt
e The embossed marks on the shift forks should &)} 10 N-m (1.0 kgf-m, 7.4 Ib-ft)
face towards the right side of the engine and be LOCTITE®
in the following sequence: “R”, “C’”, “L”.
¢ Carefully position the shift forks so that they TIP
are installed correctly into the transmission * Install shift fork-R into the groove “a” in the 5th
gears. wheel gear and shift fork-L into the groove “b”
e Install shift fork-C into the groove “a” in the 3rd in the 6th wheel gear on the drive axle.
pinion gear on the main axle. ¢ Install the shift drum retainer with its “OUT”
e Install the shift fork guide bar “3” in the crank- mark “c” facing outward.
case with the cap “b” facing toward the direc- ¢ Make sure that the projection “d” on the drive
tion shown in the illustration. axle assembly is inserted into the slot in the
crankcase.
——|>4 Qo re ¢ Make sure that the drive axle bearing circlip “4”
° is inserted into the groove “e” in the upper
a
crankcase.

Cy

ory
Oo oO
Kop I

0
é

Qg
|
SH | | [ d | e

e Transmission
Rough movement —> Reparr.
TIP
Oil each gear, shaft, and bearing thoroughly.

4. Install:
e Shift fork-R “1”
e Shift fork-L “2”
¢ Shift fork guide bar
¢ Shift drum retainers “3”
* Bearing

5-105
 COOLING SYSTEM

COOLING SYSTEM DIAGRAMS ......00.000. ooo cc eee cece cee cece eee e cece eee ee sean eeeeeeeee

RADIATOR..
REMOVING THE RADIATOR ..
CHECKING THE Se rn
INSTALLING THE RADIATOR ....0. 2c cece ccc cece eee e eee eee e eee ee aeaeeeeeeeaeeeee

OIL COOLER...
CHECKING THE OIL COOLER ..
INSTALLING THE OIL COOLER acceso

THERMOSTAT..
REMOVING THE THERMOSTAT ASSEMBLY... sees B= 11
CHECKING THE THERMOSTAT... ...6-11
ASSEMBLING THE THERMOSTAT ASSEMBLY. cnn .6-11
INSTALLING THE THERMOSTAT ASSEMBLY eccescecccecccceecccceecceeceeeee .6-11

WATER PUMP... wee 6-13

DISASSEMBLING THE WATER PUMP.. 6-15
CHECKING THE WATER BB aca neeemtnt tarts .6-15
ASSEMBLING THE WATER PUMP ooccccccoccococceccceeeeeceeceeeeeeeecece .6-15
INSTALLING THE WATER PUMP cecesccccccccccccccccceccesceccseccceseccesseeceeeceseee .6-16
 COOLING SYSTEM DIAGRAMS

COOLING SYSTEM DIAGRAMS

/[

Radiator outlet hose

ONOMPhroaAN™=

Cooling system air bleed hose

Thermostat assembly
Radiator inlet hose
Radiator
Water pump outlet pipe
Water pump
Water pump inlet pipe

6-1
 COOLING SYSTEM DIAGRAMS

Cooling system air bleed hose

ANOarwaN=

Radiator
Radiator outlet hose
Radiator inlet hose
Water pump inlet pipe
Water pump outlet pipe
Water pump
Thermostat assembly
 RADIATOR

EAS20063

RADIATOR
Removing the radiator

Order Job/Parts to remove Q’ty Remarks

Front panel cover cao to “GENERAL CHASSIS (3)” on page

Front side cowling ie to “GENERAL CHASSIS (5)” on page

Side cover/Front side cowling inner panel oe to “GENERAL CHASSIS (6)" on page
Side cover bracket tas to “GENERAL CHASSIS (8)” on page

Electrical components tray car to “GENERAL CHASSIS (9)” on page

Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-32.
 RADIATOR

Removing the radiator

Order Job/Parts to remove Q’ty Remarks

1 Coolant reservoir hose 1 Disconnect.

2 Coolant reservoir 1
3 Coolant reservoir cap 1
4 Radiator cap 1
5 Radiator fan motor coupler 2 Disconnect.
6 Cooling system air bleed hose 1 Disconnect.
7 Radiator outlet hose 1 Disconnect.
8 Radiator inlet hose 1 Disconnect.
9 Radiator 1
10 Radiator fan 2
 RADIATOR

EAS31659
3. Measure:
REMOVING THE RADIATOR
¢ Radiator cap valve opening pressure
1. Remove:
Below the specified pressure —> Replace the
¢ Hose clamp (Clic-R) “1”
radiator cap.
TIP
« Remove the hose clamp using the hose clamp Radiator cap valve opening pres-
pliers “2”. sure
¢e When removing the hose clamp, make sure 107.9-137.3 kPa (1.08—1.37 kgf/
that the thick tip “a” of the hose clamp pliers is cm?, 15.6—19.9 psi)
directed as shown in the illustration.
a. Install the radiator cap tester “1” and radi-
ator cap tester adapter “2” to the radiator
cap a”

Radiator cap tester

90890-01325
Mityvac cooling system tester kit
YU-24460-A
Radiator cap tester adapter
90890-01352
G089027
Pressure tester adapter
YU-33984
2. Disconnect:
e Radiator inlet hose
e Radiator outlet hose
3. Remove:
e Radiator
EASa0439

CHECKING THE RADIATOR

1. Check:
¢ Radiator fins
Obstruction > Clean.
GO89029
Apply compressed air to the rear of the radia-
tor. b. Apply the specified pressure for ten sec-
Damage — Repair or replace. onds and make sure there is no drop in
TIP pressure.
4, Check:
Straighten any flattened fins with a thin, flat-head
e Radiator fan
screwdriver.
Damage — Replace.
Malfunction — Check and repair.
Refer to “COOLING SYSTEM” on page 8-27.

BY
| !\
FAS S040
\

INSTALLING THE RADIATOR

———_
1. Install:
e Radiator
2. Connect:
e Radiator inlet hose
G089028
¢ Radiator outlet hose
3. Install:
2. Check:
¢ Radiator hoses
¢ Hose clamp (Clic-R) “1” TYE
Cracks/damage — Replace. TIP
* Install the hose clamp using the hose clamp pli-
ers “2”.
 RADIATOR

¢ When installing the hose clamp, make sure

that the thin tip “a” of the hose clamp pliers is Cooling system leak test pres-
directed as shown in the illustration. sure
¢ For more information about installing the hose, 137.3 kPa (1.37 kgf/cm?, 19.9
refer to “CABLE ROUTING” on page 2-17. psi)
ECAS4270

NOTICE
¢ Do not apply such a high pressure as ex-
ceeds the test pressure.
¢ Make sure that a checkup after the cylinder
head gasket is replaced is made after 3 min-
utes of warm-up.
¢ Make sure that coolant is filled up to the up-
per level beforehand.
G089030
c. Remove the radiator cap tester and radia-
4. Fill: tor cap tester adapter.
* Cooling system EWA19090

(with the specified amount of the recom-

mended coolant) When the radiator cap tester is removed,
Refer to “CHANGING THE COOLANT” on coolant will spout; therefore, cover it with a
page 3-32. cloth beforehand.
5. Check:
¢ Radiator
¢ Radiator hose connections
Coolant leaks — Correct or replace.
¢ Radiator hoses
Bulges — Replace.
a. Attach the radiator cap tester “1” and radi-
ator cap tester adapter “2” to the radiator.

Radiator cap tester

90890-01325
Mityvac cooling system tester kit
YU-24460-A
Radiator cap tester adapter
90890-01352
Pressure tester adapter
YU-33984

G089031

b. Apply the specified pressure for 5—10 sec-

onds and make sure there are no coolant
leaks or bulging radiator hose.
 OIL COOLER

EAS20064

OIL COOLER
Removing the oil cooler

Order Job/Parts to remove Q’ty Remarks

Front side cowling ca to “GENERAL CHASSIS (5)” on page

Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL’ on
page 3-29.
1 Oil cooler cover 1
2 Damper 2
Disconnect.
When removing the oil cooler inlet hose,
3 Oil cooler inlet hose ' also remove the water pump inlet pipe.
Refer to “WATER PUMP” on page 6-13.
Oil cooler outlet hose 1
5 Oil cooler 1
 OIL COOLER

EAS30441

CHECKING THE OIL COOLER

1. Check:
¢ Oil cooler
Cracks/damage —> Replace.
¢ Oil cooler fins
Obstruction — Clean.
Apply compressed air to the rear of the oil
cooler.
Damage — Repair or replace.
TIP
Straighten any flattened fins with a thin, flat-head
screwdriver.

2. Tighten:
e Oil cooler bolt (upper) “2”
6089028

2. Check: \y Oil cooler bolt

* Oil cooler inlet hose | 4 10 N-m (1.0 kgf-m, 7.4 Ib-ft)
¢ Oil cooler outlet hose
3. Tighten:
Cracks/damage/wear —> Replace. * Oil cooler bolt (lower) “3”

INSTALLING THE OIL COOLER Yy Oil cooler bolt

1. Install: > 10 N-m (1.0 kgf-m, 7.4 lb-ft)
¢ Oil cooler “1” 4 Tan
oe . Tighten:
O-ring New e Radiator bolt “4”
* Oil cooler bolt (upper) “2”
¢ Oil cooler bolt (lower) “3” Radiator bolt
FA

¢ Radiator bolt “4” oy 10 N-m (1.0 kgf-m, 7.4 Ib-ft)

TIP
Apply lithium-soap-based grease to the O-ring. 5. Fill:
e Crankcase
(with the specified amount of the recom-
mended engine oil)
Refer to “CHANGING THE ENGINE OIL” on
page 3-29.
6. Measure:
e Engine oil pressure
Refer to “MEASURING THE ENGINE OIL
PRESSURE” on page 3-30.
 THERMOSTAT

EAS20065

THERMOSTAT
Removing the thermostat

Order Job/Parts to remove Q'ty Remarks

Rider seat
Refer to “GENERAL CHASSIS (1)” on page
4-1,

Front panel cover Refer to “GENERAL CHASSIS (3)” on page

4-9,
Refer to “GENERAL CHASSIS (5)” on page
Front side cowling
4-16.

Side cover/Front side cowling inner panel Refer to “GENERAL CHASSIS (6)” on page
4-23.

Side cover bracket

Refer to “GENERAL CHASSIS (8)” on page
4-32.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Refer to “FUEL TANK” on page 7-1.
Canister
For California only.
Air filter case Refer to “AIR FILTER CASE” on page 7-5.
Se to “THROTTLE BODIES” on page
Throttle bodies
7-11.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-32.
 THERMOSTAT

Removing the thermostat

Order Job/Parts to remove Q'ty Remarks

Cooling system air bleed hose Disconnect.

fh

Radiator inlet hose

es
Gc! Po

ff

Thermostat housing cover

O-ring
1] &]

Thermostat
Thermostat housing
—~J}; &)

fm

O-ring
mm

6-10
 THERMOSTAT

EAS31660
2. Check:
REMOVING THE THERMOSTAT ASSEMBLY
¢ Thermostat housing
1. Remove:
¢ Thermostat housing cover
* Hose clamp (Clic-R)
Cracks/damage — Replace.
Refer to “REMOVING THE RADIATOR?” on
page 6-5. FAS S044

¢ Radiator inlet hose ASSEMBLING THE THERMOSTAT

2. Remove: ASSEMBLY
¢ Thermostat assembly 1. Install:
¢ Thermostat housing “1”
EAS30443
e Thermostat “2”
CHECKING THE THERMOSTAT
1. Check: ° O-ring “3” TET
¢ Thermostat e Thermostat housing cover “4”
Does not open at 69-73 °C (156-163 °F) >
\y Thermostat housing cover nut
Replace. ON 10 N-m (1.0 kgf-m, 7.4 lb-ft)
a. Suspend the thermostat “1” in a container
“2° filled with water. TIP
b. Slowly heat the water “3”.
Install the thermostat with its breather hole “a”
c. Place a thermometer “4” in the water.
facing up.
d. While stirring the water, observe the ther-
mostat and thermometer’s indicated tem-
perature.

FAS S045
G089032 INSTALLING THE THERMOSTAT
ASSEMBLY
1. Install:
¢« Thermostat assembly
2. Install:
¢ Radiator inlet hose
¢ Hose clamp (Clic-R) [XE
Refer to “INSTALLING THE RADIATOR?” on
A page 6-5.
TIP
G089033 Cc D
For more information about installing the hose,
A. Fully closed refer to “CABLE ROUTING?” on page 2-17.
B. Fully open
C. 71°C (159.8 °F)
3. Fill:
D. 85 °C (185.0 °F)
¢ Cooling system
E. 8 mm (0.31 in) (with the specified amount of the recom-
mended coolant)
TIP Refer to “CHANGING THE COOLANT?” on
lf the accuracy of the thermostat is in doubt, re- page 3-32.
place it. A faulty thermostat could cause serious 4. Check:
overheating or overcooling. ¢ Cooling system
Leaks — Repair or replace any faulty part.

6-11
 THERMOSTAT

Refer to “INSTALLING THE RADIATOR?” on

page 6-5.
5. Measure:
¢ Radiator cap valve opening pressure
Below the specified pressure > Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR?’ on
page 6-5.

6-12
 WATER PUMP

EAS20066

WATER PUMP
Removing the water pump

Order Job/Parts to remove Q’ty Remarks

Rider seat Pirbel to “GENERAL CHASSIS (1)” on page

Front panel cover Fi to “GENERAL CHASSIS (3)” on page

Front side cowling yd to “GENERAL CHASSIS (5)” on page

Side cover/Front side cowling inner panel aoe to "GENERAL CHASSIS (6)" on page

Side cover bracket cae to “GENERAL CHASSIS (8)” on page

Fuel tank Refer to “FUEL TANK” on page 7-1.

Radiator Refer to “RADIATOR” on page 6-3.
Oil cooler Refer to “OIL COOLER?” on page 6-7.
Muffler/Exhaust pipe Refer to “ENGINE REMOVAL’ on page 5-11.
1 Water pump inlet pipe 1
2 Water pump outlet pipe 1
3 Water pump assembly 1
4 Oil cooler stay 3

6-13
 WATER PUMP

Disassembling the water pump

Order Job/Parts to remove Q’ty Remarks

1 Water pump housing cover 1

2 O-ring 1
3 Circlip 1
4 Impeller shaft 1
5 Mechanical seal 1
6 Bearing 1
7 Oil seal 1

6-14
 WATER PUMP

EAS30446 EASS447

DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP

1. Remove: 1. Check:
¢ Mechanical seal (housing side) “1” ¢ Water pump housing cover
TIP e Impeller shaft
Remove the mechanical seal (housing side) Cracks/damage/wear —> Replace.
from the inside of the water pump housing “2”. e Water pump housing
Cracks/damage/wear — Replace the water
pump assembly.
2. Check:
¢ Bearing
Rough movement —> Replace.
3. Check:
e Water pump inlet pipe
e Water pump outlet pipe
Cracks/damage/wear — Replace.
FAS S048

ASSEMBLING THE WATER PUMP

2. Remove: 1. Install:
¢ Bearing “1” ° Oil seal “1” DEW
* Oil seal “2”
¢ Bearing “2” KEW
TIP
(into the water pump housing “3”)

ey
Remove the oil seal and bearing from the out-
side of the water pump housing “3”. Installed depth “a”
0.5—1.0 mm (0.02-0.04 in)

TIP
Install the oil seal with a socket “4” that matches
ND

its outside diameter.

pe
qj

—
3. Remove:
* Mechanical seal (impeller side) “1”
(from the impeller, with a thin, flat-head
screwdriver)
O
TIP
Do not scratch the impeller shaft. 2. Install:
¢ Mechanical seal (housing side) “1” [XW
EC A20330

NOTICE
Never lubricate the mechanical seal (hous-
ing side) surface with oil or grease.
TIP
Use the special tools and a press to press the
mechanical seal (housing side) straight in until it
G089034
touches the water pump housing.

6-15
 WATER PUMP

Mechanical seal installer (033)

90890-04132
Water pump seal installer (933)
YM-33221-A
Middle driven shaft bearing driv-
er
90890-04058
Middle drive bearing installer 40
& 50 mm
YM-04058
2. Fill:
¢ Cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-32.
3. Check:
¢ Cooling system
Leaks — Repair or replace the faulty part.
4. Measure:
e Radiator cap valve opening pressure
Water pump housing Below the specified pressure — Replace the
radiator cap.
Pp Pwr

Mechanical seal installer

Middle driven shaft bearing driver Refer to “CHECKING THE RADIATOR?” on
. Push down page 6-5.

3. Install:
* Mechanical seal (impeller side) “1” JYENY
TIP
¢ Before installing the mechanical seal (impeller
side), apply tap water or coolant onto its outer
surface.
¢ If the top of the mechanical seal is dirty, clean
it.

1 EM
G089035

EASa0449

INSTALLING THE WATER PUMP

1. Install:
¢ Water pump assembly “1”
TIP
Align the slit “a” on the impeller shaft with the
projection “b” on the oil pump driven sprocket.

6-16
 WATER PUMP

6-17
 FUEL SYSTEM

FUEL TANK... seve TOT

REMOVING THE FU EL TANK..
REMOVING THE FUEL PUMP ..sp Sect venbdeec bea gseeetecercecesee, cececegctesciveesbeeeatee 7-3
CHECKING THE FUEL PUMP BODYV.....0... oo. ce cece e eee e eee eeeetees 7-3
CHECKING THE FUEL PUMP OPERATION .......... cee cecceetteeeeeeeeeeneeeee
INSTALLING THE FUEL PUMP.....0000. eee cece eee eee eee ee eee eee eeeeaeeee 7-4
INSTALLING THE FUEL TANK... ....:.0ccccesssiissesccsnsissntvecriesrsessnrasensserecenssce 7-4

AIR FILTER CASETHE

.. SECONDARY iNICETOES. we eeeeeeeneeeaeecueeseeeeeueeeeeeeee f-5
CHECKING
(BEFORE REMOVING)... ween fof
REMOVING THE FUEL HOSE (PRIMARY INJECTOR JOINT SIDE.
AND SECONDARY INJECTOR JOINT SIDE) ...
REMOVING THE SECONDARY INJECTORS .scscccsccccccccsccsscesssssssssssesesve
REMOVING THE AIR FILTER CASE... pees PoE
REMOVING THE INTAKE FUNNEL ASSEMBLY ..
CHECKING THE SECONDARY INJECTORS ...000.. cee eects 7-8
CHECKING THE AIR FILTER CASE SEAL.. wee lB
CHECKING THE INTAKE FUNNEL.. we 1B
INSTALLING THE INTAKE FUNNEL AND AIR FILTER CASE... eee lB
CHECKING THE INTAKE FUNNEL OPERATION .occssscssssssssssssssssssseseeeee
INSTALLING THE SECONDARY INJECTORS .. ween EY
INSTALLING THE UPPER AIR FILTER CASE... etee FO
INSTALLING THE FUEL HOSE (PRIMARY INJECTOR JOINT SIDE
AND SECONDARY INJECTOR JOINT SIDE) ... ee ... f-1Q

THROTTLE BODIES.. wees f@11

CHECKING THE PRIMARY INJECTORS (BEFORE REMOVING)... .f-15
REMOVING THE PRIMARY INJECTORS.. jeveuuduyverusves sanieT 15
CHECKING THE PRIMARY INJECTORS... wee 715
CHECKING AND CLEANING THE THROTTLE BODIES. stbaesetenecs PONS
REPLACING THE THAGT ILE BODIES cs. 2 ccccscecccectec
testes cecerhsceetee chiens: 7-17
INSTALLING THE PRIMARY INJECTORS........ cece ceeeeceeeeeeeeeeeeees 7-17
CHECKING THE INJECTOR PRESSURE... raven Foe
CHECKING THE FUEL PRESSURE .. wee 18
ADJUSTING THE THROTTLE POSITION SEN SOR... 7-19

AIR INDUCTION SYSTEM... weueee 120

CHECKING THE AIR INDUCTION SYSTEM...
INSTALLING THE AIR INDUCTION SYSTEM. ccccsccssssssssssssssssssvssvsssvsveee 7-24
 FUEL TANK

EAS20067

FUEL TANK
Removing the fuel tank

* Hook-and-loop fastener

Order Job/Parts to remove Q'ty Remarks

Rider seat yeh to “GENERAL CHASSIS (1)” on page

Fuel tank side cover (left)

Gc) ho] —

||

Fuel tank side cover (right)

|

Fuel hose connector Disconnect.

|

Fuel pump coupler Disconnect.

om) &|

ft

Fuel tank breather hose Disconnect.

Oo) SN) mm)

Fuel tank drain hose Disconnect.

|

Fuel tank
|

Fuel tank top cover (rear)

mt
0)

Fuel tank top cover (front)

|
|

Fuel pump bracket

—_h
oS

fm

Fuel pump
oll,
ol,

Fuel tank cap

A]
—k

fm

Fuel tank protector

Go
=k

em
 FUEL TANK

Removing the rollover valve and canister (for California only)

Order Job/Parts to remove Q'ty Remarks

Refer to “GENERAL CHASSIS (1)” on page

Rider seat
4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Canister purge hose (hose joint to canister)
ek
ow) hm) —

ef

Fuel tank breather hose (fuel tank to canister)

Canister holder
on) &)

Canister
|
me

Canister bracket
ve

7-2
 FUEL TANK

EA530450

REMOVING THE FUEL TANK

1. Extract the fuel in the fuel tank through the
fuel tank cap with a pump.
2. Remove:
¢ Rider seat
Refer to “GENERAL CHASSIS (1)” on page
4-1.
3. Disconnect:
¢ Fuel hose (fuel tank side)
¢ Fuel pump coupler
¢ Fuel tank drain hose
* Fuel tank breather hose
EWAITa20

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 hose.
ECATT490

NOTICE
4. Remove:
Be sure to disconnect the fuel hose by hand.
e Fuel tank
Do not forcefully disconnect the hose with
tools. TIP
Do not set the fuel tank down so that the instal-
TIP lation surface of the fuel pump is directly under
¢ While pushing the ends “a” of the fuel hose the tank. Be sure to lean the fuel tank in an up-
connector cover “1” in direction “b’, slide the right position.
fuel hose connector cover in direction “c”, and
then remove the hose from the fuel pump. EASS0451

¢ Before removing the hose, place a few rags in REMOVING THE FUEL PUMP
the area under where it will be removed. 1. Remove:
¢ It is prohibited to wear the cotton work gloves ¢ Fuel pump
or equivalent coverings. ECA ?21

NOTICE
¢ Do not drop the fuel pump or give ita
strong shock.
* Do not touch the base section of the fuel
sender.

FAS S454

CHECKING THE FUEL PUMP BODY

1. Check:
¢ Fuel pump body
Obstruction > Clean.
Cracks/damage —> Replace fuel pump as-
sembly.
FAS S455

CHECKING THE FUEL PUMP OPERATION

1. Check:
¢ Fuel pump operation
Refer to “CHECKING THE FUEL PRES-
SURE” on page 7-18.

7-3
 FUEL TANK

EAS30456
TIP
INSTALLING THE FUEL PUMP
1. Install: * Install the fuel hose onto the fuel pump secure-
ly, and slide the fuel hose connector cover “1”
* Fuel pump gasket KEY
in the direction shown in the illustration.
* Fuel pump
* It is prohibited to wear the cotton work gloves
¢ Fuel pump bracket
or equivalent coverings.
¢ Fuel pump bolts

\ Fuel pump bolt

% 4.0 N-m (0.40 kgf-m, 3.0 Ib-ft)
1
TIP
¢ Do not damage the installation surfaces of the
\
fuel tank when installing the fuel pump.
e Always use a new fuel pump gasket.
e Install the fuel pump gasket so that the lip side
turns to the inside of the fuel tank.
¢ Install the fuel pump as shown in the illustra-
3. Connect:
tion.
¢ Fuel tank breather hose
e Align the projection “a” on the fuel pump with
the slot in the fuel pump bracket. ¢ Fuel tank drain hose
¢ Fuel pump coupler
e Tighten the fuel pump bolts in the proper tight-
ening sequence as shown. 4. Tighten:
¢ Front fuel tank bolt

%
\
5. Tighten:
Front fuel tank bolt
6 N-m (0.6 kgf-m, 4.4 Ib-ft)

e Rear fuel tank bolt

\y Rear fuel tank bolt

4.0 N-m (0.40 kgf-m, 3.0 Ib-ft)

A. Forward

EASSO457

INSTALLING THE FUEL TANK

1. Install:
* Fuel tank
© Rear fuel tank bolt
e Fuel tank nut
TIP
Temporarily tighten the rear fuel tank bolt.
2. Connect:
¢ Fuel hose (fuel tank side)
ECATTS00

NOTICE
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.

7-4
 AIR FILTER CASE

EAS20068

AIR FILTER CASE

Removing the air filter case and secondary injectors

Order Job/Parts to remove Q’ty Remarks

Rider seat Pirbel to “GENERAL CHASSIS (1)” on page

Fuel tank Refer to “FUEL TANK” on page 7-1.

1 Air filter case cover 1
2 Fuel hose 2 (secondary injector fuel rail side) 1
3 Fuel hose 1 (fuel tank to fuel hose 2) 1
4 Fuel hose 3 (fuel hose 2 to throttle body) 1 Disconnect.
5 Secondary injector coupler 4 Disconnect.
6 Fuel rail/Secondary injector joint 2/1
7 Secondary injector 4
8 Upper air filter case 1
9 Air filter element 1
10 Crankcase breather hose 1 Disconnect.

7-5
 AIR FILTER CASE

Removing the air filter case and secondary injectors

Order Job/Parts to remove Q’ty Remarks

11 Air induction system hose 1 Disconnect.
12 Intake funnel servo motor coupler 1 Disconnect.
13 Intake funnel assembly bolt 6 Loosen.
14 Air filter case 1
15 Intake funnel servo motor rod assembly 1
16 Intake funnel assembly 1
17 Intake funnel servo motor 1
18 a shock absorber assembly stepping motor { for YZE-R1M

19 Coolant temperature sensor lead 1

20 Throttle servo motor lead 1
21 Cross bar 1

7-6
 AIR FILTER CASE

EAS30458

CHECKING THE SECONDARY INJECTORS

(BEFORE REMOVING)
1. Check:
¢ Injectors
Use the diagnostic code numbers “40”—“43”.
Refer to “SELF-DIAGNOSTIC FUNCTION
AND DIAGNOSTIC CODE TABLE?” on page
9-32.
EAS30459

REMOVING THE FUEL HOSE (PRIMARY

INJECTOR JOINT SIDE AND SECONDARY
INJECTOR JOINT SIDE)
1. Remove:
* Fuel hose (primary injector joint side and sec-
ondary injector joint side)
EWAITa20

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 hose. EASS0460

REMOVING THE SECONDARY INJECTORS

ECATT490 EWA? 330

NOTICE
Be sure to disconnect the fuel hose by hand. ¢ Check the injectors in a well-ventilated area
Do not forcefully disconnect the hose with free of combustible materials. Make sure
tools. that there is no smoking or use of electric
tools in the vicinity of the injectors.
TIP
¢ Be careful when disconnecting the fuel
¢ While pushing the ends “a” of the fuel hose hose. Any remaining pressure in the fuel
connector cover “1” in direction “b”, slide the hose may cause the fuel to spray out. Place
fuel hose connector cover in direction “c’, and a container or rag under the hose to catch
then remove the hose from the fuel pump. any fuel that spills. Always clean up any
¢ Before removing the hose, place a few rags in spilt fuel immediately.
the area under where it will be removed. ¢ Turn the main switch to “OFF” and discon-
¢ It is prohibited to wear the cotton work gloves nect the negative battery lead from the bat-
or equivalent coverings. tery terminal before removing the injectors.
1. Remove:
e Fuel tank
e Fuel hose
Refer to “REMOVING THE FUEL TANK” on
page 7-3.
2. Remove:
e Fuel rail screw
¢ Fuel rail
e Secondary injector joint
e Secondary injector
EFAS31663

REMOVING THE AIR FILTER CASE

1. Remove:
e Upper air filter case

7-7
 AIR FILTER CASE

2. Loosen: Damage — Replace.

¢ Intake funnel assembly bolt “1” 2. Check:
e Injector resistance
Refer to “CHECKING THE FUEL INJEC-
TORS’ on page 8-51.
EAS31664

CHECKING THE AIR FILTER CASE SEAL

1. Check:
e Air filter case seal
Damage — Replace.

3. Disconnect: CHECKING THE INTAKE FUNNEL

e« Crankcase breather hose
1. Check:
¢ Air induction system hose ¢ Intake funnel servo motor rod assembly
¢ Intake funnel servo motor coupler Damage/scratches — Replace.
4. Remove: e Intake funnel assembly
* Air filter case Cracks/damage — Replace.
2. Check:
Es«Sa0461 e Intake funnel movement
REMOVING THE INTAKE FUNNEL Sticks — Replace the intake funnel assem-
ASSEMBLY bly.
1. Remove: ECA17550

¢ Intake funnel servo motor rod assembly NOTICE

¢ Intake funnel servo motor ¢ Make sure that the intake funnel smoothly
2. Remove: moves to the contacting surface between
¢ Intake funnel assembly upper stopper and lower seating position
ECA26860
when it is moved by hand.
NOTICE
¢ Make sure that the intake funnel smoothly
e Do not disassemble the intake funnel as- strokes from the upper position to the seat-
sembly. ing position by its own weight.
¢ Do not remove the intake funnel bolts from
the intake funnel joint. A B
a. Keep the two tabs “a” pushed in the direc-
tion shown in the illustration and separate
the intake funnel assembly from air filter
case.

A. Upper
B. Lower

EAS 1665

INSTALLING THE INTAKE FUNNEL AND AIR

FILTER CASE
EASSO462
1. Install:
CHECKING THE SECONDARY INJECTORS ¢ Cross bar “1”
1. Check: ¢ Intake funnel servo motor
* Injectors e Intake funnel servo motor rod assembly
Obstruction — Replace and check the fuel ° Air filter case “2”
pump/fuel supply system. e Intake funnel assembly “3”
Deposit > Replace. a. Install the cross bar “1”.

7-8
 AIR FILTER CASE

b. Temporary tighten the cross bar bolts “a”.

c. Install the intake funnel assembly and air
filter case.
d. Tighten the Intake funnel assembly bolt
“bp” and air filter case bolt “c”.

\y Intake funnel assembly bolt

8 N-m (0.8 kgf-m, 5.9 Ib-ft)
Air filter case bolt
8 N-m (0.8 kgf-m, 5.9 Ib-ft)

e. Tighten the cross bar bolt “a”. A. Upper

B. Lower
N Cross bar bolt
%
EAS30466
23 N-m (2.3 kgf-m, 17 Ib-ft)
INSTALLING THE SECONDARY INJECTORS
ECA21550

NOTICE
e Always use new O-rings.
¢ When installing the injectors, do not allow
any foreign material to enter or adhere to
the injectors, fuel rails, or O-rings.
¢ Be careful not to twist or pinch the O-rings
when installing the injectors.
¢ When installing the injector, install it at the
same position as the removed cylinder.
* If an injector is subject to strong shocks or
EAS30465
excessive force, replace it.
CHECKING THE INTAKE FUNNEL
* If installing the original fuel rail and bolts,
OPERATION
remove the white paint marks using a
1. Check:
cleaning solvent. Otherwise, paint chips on
¢ Intake funnel servo motor operation
the bolt seats could prevent the bolts from
a. Activate the diagnostic mode and select
being tightened to the specified torque.
the diagnostic code number “34”.
Refer to “SELF-DIAGNOSTIC FUNC- 1. Install a new seal onto the end of each injec-
TION AND DIAGNOSTIC CODE TABLE” tor.
on page 9-32. . Install the injectors to the fuel rails.
NO

b. Set the start/engine stop switch to “Q”. . Install the secondary injector joint, making
Go

c. Check that the stopper lever “a” contacts sure to install them in the correct direction.
the lever “b” (figure “A”). . Install the injector assemblies to the upper air
d. Check that the intake funnel seal mates filter case.

TIP
with the fixed intake funnel (figure “B”).
yy, Fuel rail screw (secondary injec-
tor)
The intake funnels should move smoothly and 3.5 N-m (0.35 kgf-m, 2.6 lb-ft)
should not make any unusual sound.
5. Check the injector pressure after the injectors
are installed.
Refer to “CHECKING THE INJECTOR
PRESSURE” on page 7-17.
FASS0467

INSTALLING THE UPPER AIR FILTER CASE

1. Install:
e Upper air filter case

7-9
 AIR FILTER CASE

Upper air filter case screw

an 2.0 N-m (0.20 kgf-m, 1.5 Ib-ft)
EASSaO0468

INSTALLING THE FUEL HOSE (PRIMARY

INJECTOR JOINT SIDE AND SECONDARY
INJECTOR JOINT SIDE)
1. Connect:
¢ Fuel hose (primary injector joint side and sec-
ondary injector joint side)
ECAT?500

NOTICE
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
¢ While pushing the ends “a” of the fuel hose
connector cover “1” in direction “b”, slide the
fuel hose connector cover in direction “c”, and
then remove the hose from the fuel pump.
¢ Before removing the hose, place a few rags in
the area under where it will be removed.
¢ It is prohibited to wear the cotton work gloves
or equivalent coverings.
—

7-10
 THROTTLE BODIES

THROTTLE BODIES
Removing the throttle bodies

Order Job/Parts to remove Q’ty Remarks

Rider seat Fie to “GENERAL CHASSIS (1)” on page

Front side cowling aoe to “GENERAL CHASSIS (5)" on page

Side cover ioe to “GENERAL CHASSIS (6)” on page

Side cover bracket hi to “GENERAL CHASSIS (8)” on page

Fuel tank Refer to “FUEL TANK” on page 7-1.
Air filter case Refer to “AIR FILTER CASE” on page 7-5.
Refer to “FUEL TANK” on page 7-1.
Canister For California only.
1 Throttle position sensor coupler 1 Disconnect.
2 Intake air pressure sensor coupler 1 Disconnect.
3 Coupler holder 1

7-11
 THROTTLE BODIES

Removing the throttle bodies

Order Job/Parts to remove Q’ty Remarks

4 Throttle servo motor coupler 1 Disconnect.
5 Fuel hose 3 (fuel hose 2 to throttle body) 1
6 Primary injector coupler 4 Disconnect.
7 Intake solenoid vacuum hose 1 Disconnect.
8 ane uueneiae sensor coupler (sub-wire { Disconnect.

9 Throttle body joint clamp screw 4 Loosen.

10 Throttle body assembly 1
11 Neutral switch connector 1 Disconnect.
12 Heat protector 1
13 Throttle body joint 2

7-12
 THROTTLE BODIES

Removing the primary injectors (except for California)

Order Job/Parts to remove Q’ty Remarks

1 Negative pressure hose 5
2 Hose joint 2
3 Service hose 1
4 Intake air pressure sensor 1
5 Throttle position sensor 1
6 Fuel rail 2
7 Primary injector joint 1
8 Primary injector 4

7-13
 THROTTLE BODIES

Removing the primary injectors (for California)

Order Job/Parts to remove Q'ty Remarks

Canister purge hose

ow] ho; —

f&}/ =| pl =| =) =| pl a! wl o

Hose joint
Negative pressure hose
Hose joint
|
“S| om) om)

Service hose
Intake air pressure sensor
Throttle position sensor
OO; oO;

Fuel rail
Primary injector joint
Primary injector
lk
oO

7-14
 THROTTLE BODIES

EAS31666
¢ Throttle body joints
CHECKING THE PRIMARY INJECTORS
« Fuel hoses
(BEFORE REMOVING)
¢ Air induction system
1. Check:
¢« Exhaust system
¢ Injectors
e Crankcase breather hose
Use the diagnostic code numbers “36”—“39”.
« Vacuum hose
Refer to “SELF-DIAGNOSTIC FUNCTION
AND DIAGNOSTIC CODE TABLE?” on page EWAIT340

9-32.
lf the throttle bodies are subjected to strong
EAS31667
shocks or dropped during cleaning, replace
REMOVING THE PRIMARY INJECTORS
EWAI?T330 them as a set.
1. Check:
¢ Check the injectors in a well-ventilated area ¢ Throttle bodies
free of combustible materials. Make sure Cracks/damage —> Replace the throttle bod-
that there is no smoking or use of electric ies as a Set.
tools in the vicinity of the injectors. 2. Clean:
¢ Be careful when disconnecting the fuel ¢ Throttle bodies
hose. Any remaining pressure in the fuel ECAS1540

hose may cause the fuel to spray out. Place NOTICE

a container or rag under the hose to catch ¢ Observe the following precautions; other-
any fuel that spills. Always clean up any wise, the throttle bodies may not operate
spilt fuel immediately. properly.
¢ Turn the main switch to “OFF” and discon- * Do not subject the throttle bodies to exces-
nect the negative battery lead from the bat- sive force.
tery terminal before removing the injectors. ¢ Clean the throttle bodies in the recom-
mended cleaning solvent.
1. Remove:
¢ Do not use any caustic carburetor cleaning
® Fuel rail
solution.
a. Remove the fuel rail screws.
* Do not apply cleaning solvent directly to
EASS31 688 any plastic parts, sensors, or seals.
CHECKING THE PRIMARY INJECTORS ¢ Be careful not to remove the white paint
1. Check: mark that identifies the standard throttle
* Injectors body.
Obstruction — Replace and check the fuel *¢ Do not turn the bypass air screws “a”; oth-
pump/fuel supply system. erwise, the throttle body synchronization
Deposit — Replace. will be affected.

=
Damage — Replace.
2. Check: Recommended cleaning solvent
* Injector resistance Yamaha Oil & Brake Cleaner
Refer to “CHECKING THE FUEL INJEC-
TORS’ on page 8-51.
EASSaOT
aa

CHECKING AND CLEANING THE THROTTLE

BODIES
TIP
Clean the throttle bodies only if they cannot be
synchronized using the bypass air screws. Be-
fore cleaning the throttle bodies, check the fol-
lowing items:
e Valve clearance
a. Place the throttle bodies on a flat surface
e Spark plugs
with the air filter case side facing up.
e Air filter element

7-15
 THROTTLE BODIES

b. Install the caps (895-14169-00) onto the ECA17590

hose fittings “a”. NOTICE

¢ Do not use a tool, such as a wire brush, to
remove the carbon deposits; otherwise, the
inside of the throttle bodies may be dam-
aged.
¢ Do not allow carbon deposits or other for-
eign materials to enter any of the passages
in each throttle body or in the space be-
tween the throttle valve shaft and the throt-
tle body.
f. After removing the carbon deposits, clean
c. Hold the throttle valves in the open posi- the inside of the throttle bodies with the
tion. recommended cleaning solvent, and then
EWA15940
dry the throttle bodies using compressed
air.
When cleaning the throttle bodies, be careful
g. Make sure that there are no carbon de-
not to injure yourself on the throttle valves or
posits or other foreign materials in any of
other components of the throttle bodies. the passages “a” in each throttle body or in
ECA20380
the space “b” between the throttle valve
NOTICE shaft and the throttle body.
¢ Do not open the throttle valves by supply- a.

ing electrical power to the throttle bodies.

¢ Do not use tools to open the throttle valves
or to keep them in the open position.
¢ Do not open the throttle valves quickly.

=~;
|
AF, 3. Install the throttle bodies.
4. Connect the intake air pressure sensor Cou-
pler “1”.
G089040
TIP
After connecting intake air pressure sensor cou-
d. Apply the recommended cleaning solvent
pler “1”, press corner portion “a” of coupler cover
to the throttle valves and the inside of the
“2, then make sure that the intake air pressure
throttle bodies to remove any carbon de-
sensor is not exposed.
posits.
TIP
¢ Do not allow any cleaning solvent to enter the
opening for the injectors.
¢ Do not apply any cleaning solvent to the por-
tions of the throttle valve shafts between the
throttle bodies.

e. Remove the carbon deposits from the in-

side of each throttle body in a downward
direction, from the air filter case side of the
throttle body to the engine side. 5. Reset:
¢ ISC (Idle Speed Control) learning values
Use the diagnostic code number “67”.

7-16
 THROTTLE BODIES

Refer to “SELF-DIAGNOSTIC FUNCTION ¢ Be careful not to twist or pinch the O-rings

AND DIAGNOSTIC CODE TABLE?” on page when installing the injectors.
9-32. ¢ When installing the injector, install it at the
6. Reset: same position as the removed cylinder.
¢ A/F control learning value * If an injector is subject to strong shocks or
Use the DTC number “87”. excessive force, replace it.
Refer to “SELF-DIAGNOSTIC FUNCTION ° If installing the original fuel rail and bolts,
AND DIAGNOSTIC CODE TABLE?” on page remove the white paint marks using a
9-32. cleaning solvent. Otherwise, paint chips on
7. Adjust: the bolt seats could prevent the bolts from
¢ Throttle bodies synchronizing being tightened to the specified torque.
Out of specification — Replace the throttle 1. Install primary injector joint “1” so that damper
bodies.
part “a” faces the rib “b” side of fuel rail “2” as
Refer to “SYNCHRONIZING THE THROT- shown in the illustration.
TLE BODIES” on page 3-9.
EAS31160

REPLACING THE THROTTLE BODIES

1. Remove the throttle bodies from the vehicle.
2. Install a new throttle bodies to the vehicle.
3. Reset:
¢ |SC (Idle Speed Control) learning values
Use the diagnostic code number “67”.
Refer to “SELF-DIAGNOSTIC FUNCTION
AND DIAGNOSTIC CODE TABLE?” on page
9-32. 2. Install a new seal onto the end of each injec-
4. Reset: tor.
e A/F control learning value Install the injectors to the fuel rails.
Use the diagnostic code number “87”. . Install the primary injector joint, making sure
Refer to “SELF-DIAGNOSTIC FUNCTION to install them in the correct direction.
AND DIAGNOSTIC CODE TABLE?” on page 5. Install the injector assemblies to the throttle

¥
9-32. bodies.
5. Adjust:
¢ Throttle bodies synchronizing NN Fuel rail screw (throttle body)
Refer to “SYNCHRONIZING THE THROT- 3.5 N-m (0.35 kgf-m, 2.6 Ib-ft)
TLE BODIES” on page 3-9.
6. Place the vehicle on a maintenance stand so 6. Check the injector pressure after the injectors
that the rear wheel is elevated. are installed.
7. Check: Refer to “CHECKING THE INJECTOR
PRESSURE” on page 7-17.
¢ Engine idling speed
Start the engine, warm it up, and then mea- EASS0481

sure the engine idling speed. CHECKING THE INJECTOR PRESSURE

TIP
(or ¥ Engine idling speed
After installing the injectors, perform the follow-
1200-1400 r/min
ing steps to check the injector pressure.
EAS31689
¢ Do not allow any foreign materials to enter the
INSTALLING THE PRIMARY INJECTORS fuel lines.
ECA21550

NOTICE 1. Check:
e Injector pressure
¢ Always use new O-rings.
a. Connect the fuel injector pressure adapter
¢ When installing the injectors, do not allow
“1” to the injector joint “2”, and then con-
any foreign material to enter or adhere to
nect an air compressor “3” to the adapter.
the injectors, fuel rails, or O-rings.

7-17
 THROTTLE BODIES

b. Connect the pressure gauge “4” to the fuel e Fuel tank cover
injector pressure adapter “1”. Refer to “FUEL TANK” on page 7-1.
2. Check:
Pressure gauge e Fuel pressure
90890-03153 a. Remove the fuel tank bolts and hold up the
Pressure gauge fuel tank.
YU-03153
b. Disconnect the fuel hose “1” from the fuel
Fuel injector pressure adapter
90890-03210 pump.
Fuel injector pressure adapter Refer to “FUEL TANK” on page 7-1.
EWA? 320
YU-03210
Cover fuel hose connections with a cloth
(yy 4 when disconnecting them. Residual pres-
sure in the fuel lines could cause fuel to
spurt out when removing the hose.
EC AT?490

NOTICE

7"
Be sure to disconnect the fuel hose by hand.
Do not forcefully disconnect the hose with
tools.
G089041 3 r 2

c. Close the valve on the injector pressure

adapter.
d. Apply air pressure with the air compres-
sor.
e. Open the valve on the injector pressure
adapter until the specified pressure is
reached.

Specified air pressure

490 kPa (5.0 kgf/cm?2, 71.1 psi)
c. Connect the pressure gauge “2” and fuel
NOTICE pressure adapter “3” to the fuel hose.

J
Never exceed the specified air pressure or Pressure gauge
damage could occur. 90890-03153
f. Close the valve on the injector pressure Pressure gauge
adapter. YU-03153
Fuel pressure adapter
g. Check that the specified air pressure is
90890-03176
held at least one minute.
Fuel pressure adapter
Pressure drops — Check the pressure YM-03176
gauge and adapter.
Check the seals and O-rings and then re-
install.
Out of specification — Replace the fuel in-
jectors.
EASa04a2

CHECKING THE FUEL PRESSURE

1. Remove:
e Rider seat
Refer to “GENERAL CHASSIS (1)” on page
4-1.
d. Start the engine.

7-18
 THROTTLE BODIES

e. Measure the fuel line pressure. f. Adjust the position of the throttle position
Faulty — Replace the fuel pump. sensor angle so that 11-21 can appear in

a
the Yamaha diagnostic tool screen.
Fuel line pressure (at idle) g. After adjusting the throttle position sensor
300-390 kPa (3.0-—3.9 kgf/cm, angle, tighten the throttle position sensor

%
43.5—56.6 psi) bolts “1”.
3. Install:
¢ Fuel tank
IN Throttle position sensor bolt
3.5 N-m (0.35 kgf-m, 2.6 Ib-ft)
¢ Fuel tank cover
Refer to “FUEL TANK” on page 7-1.
¢ Rider seat
Refer to “GENERAL CHASSIS (1)” on page
4-1.
EAS30485

ADJUSTING THE THROTTLE POSITION

SENSOR
ECA1T540

NOTICE
¢ Handle the throttle position sensor with
special care.
¢ Never subject the throttle position sensor
to strong shocks. If the throttle position
sensor is dropped, replace it.
1. Check:
¢ Throttle position sensor
Refer to “DIAGNOSTIC CODE: SENSOR
OPERATION TABLE” on page 9-59.
2. Adjust:
¢ Throttle position sensor angle
TIP
Before adjusting the throttle position sensor, the
throttle bodies must be removed.
a. Temporary tighten the throttle position
sensor screws.
b. Check that the throttle valves are fully
closed.
c. Connect the throttle position sensor to the
wire harness.
d. Remove the protective cap, and then con-
nect the Yamaha diagnostic tool to cou-
pler.
TIP
For information about using the Yamaha diag-
nostic tool, refer to the operation manual that is
included with the tool.
Refer to “SELF-DIAGNOSTIC FUNC-
TION AND DIAGNOSTIC CODE TABLE”
on page 9-32.
e. Diagnostic code number “01” is selected.

7-19
 AIR INDUCTION SYSTEM

EAS2O071

AIR INDUCTION SYSTEM

1. Ajr filter case

2. Aljr cut-off valve
3. Air induction system hose (air filter case to air
cut-off valve)
4. Cylinder head cover
Air induction system hose (air cut-off valve to
=

reed valve cover)

7-20
 AIR INDUCTION SYSTEM

Removing the air cut-off valve assembly and reed valves

Order Job/Parts to remove Q’ty Remarks

Rider seat Friel to “GENERAL CHASSIS (1)” on page

Fuel tank Refer to “FUEL TANK” on page 7-1.

Air filter case Refer to “AIR FILTER CASE” on page 7-5.
1 Atmospheric pressure sensor coupler 1 Disconnect.
2 Intake air temperature sensor coupler 1 Disconnect.
3 Air filter case duct 1
4 Atmospheric pressure sensor hose 1
5 Atmospheric pressure sensor 1
6 Damper 1
7 Intake air temperature sensor holder 1
8 Intake air temperature sensor 1

7-21
 AIR INDUCTION SYSTEM

Removing the air cut-off valve assembly and reed valves

Order Job/Parts to remove Q’ty Remarks

9 Air cut-off valve coupler 1 Disconnect.
10 Air induction system hose (air cut-off valve to j
reed valve cover)
14 Air induction system hose (air filter case to air {
cut-off valve)
42 Air induction system hose (air cut-off valve to 1
reed valve cover)
13 Air cut-off valve 1
14 Reed valve cover 2
15 Reed valve assembly 2
16 Reed valve plate 4

7-22
 AIR INDUCTION SYSTEM

EAS30488

CHECKING THE AIR INDUCTION SYSTEM

Air injection
The air induction system burns unburned ex-
haust gases by injecting fresh air (secondary air)
into the exhaust port, reducing the emission of
hydrocarbons. When there is negative pressure
at the exhaust port, the reed valve opens, allow-
ing secondary air to flow into the exhaust port.
The required temperature for burning the un-
burned exhaust gases is approximately 600 to
700 °C (1112 to 1292 °F).

Air cut-off valve

The air cut-off valve is controlled by the signals
from the ECU in accordance with the combus-
tion conditions. Ordinarily, the air cut-off valve
opens to allow the air to flow during idle and
closes to cut-off the flow when the vehicle is be-
ing driven. However, if the coolant temperature
is below the specified value, the air cut-off valve
remains open and allows the air to flow into the
exhaust pipe until the temperature becomes
higher than the specified value.

A. From the air filter case

B. To the cylinder head

1. Check:
e Hoses
Loose connections — Connect properly.
Cracks/damage —> Replace.
2. Check:
¢ Reed valve
e Reed valve stopper
e Reed valve seat
Cracks/damage —> Replace the reed valve
assembly.
3. Measure:
¢ Reed valve bending limit “a”
Out of specification — Replace the reed
valve assembly.

Reed valve bending limit

0.4 mm (0.02 in)

7-23
 AIR INDUCTION SYSTEM

3. Install:

“ « Reed valve cover

Reed valve cover bolt

Se % 10 N-m (1.0 kgf-m, 7.4 Ib-ft)
LOCTITE®

>|
so

G089044

4. Check:
e Air cut-off valve
Cracks/damage — Replace.
5. Check:
e Air induction system solenoid
Refer to “CHECKING THE AIR INDUCTION
SYSTEM SOLENOID?” on page 8-49.
EAS30489

INSTALLING THE AIR INDUCTION SYSTEM

1. Install:
¢ Reed valve plate
TIP
Align the projection “a” on the cylinder head cov-
er “1” with the hole “b” in the reed valve plate.

2. Install:
¢ Reed valve assembly
TIP
Install the reed valve assembly so that the open
side turns to the exhaust side of the engine.

A
—
—_

GO0s89045

A. Exhaust side

7-24
 AIR INDUCTION SYSTEM

7-25
 ELECTRICAL SYSTEM

IGNITION SYSTEM .. eee BHT

CIRCUIT DIAGRAM... eee OPT
ENGINE STOPPING DUE TO SIDESTAND OPERATION... tietdvee
tev
I TNE occ cence ess eet nee eee knee nani eneeseies een oe 8-4

ELECTRIC STARTING SYSTEM. ....00000... 0... e cee ceecee ee eee eeeeeeeeeeaeeee

CIRCUIT DIAGRAM.. wee Oof
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION .. idetveeviees OFS
TROUBLESHOOTING ..... oo. cce ec cece cece eect ea ce acne eee eae ca eee eee saeaaeeeeeeeaeas 8-10

CHARGING SYSTEM. ..00 22.0... ce cece eee eee c nee eee cea tees seaeee eee eneeeeeees 8-12
CIRCUIT DIAGRAM ..0.... cece cece cee cere ae cae ene ee eee cae ended eesaua nena eeeaael 8-12
TROUBLESHOOTING ........e cc cecc cece cece cece e ceca eee eee aee eee ee aeaeeeeeesaeeeeeeaaees 8-13

8-15
CIRCUIT DIAGRAM . 2.2.0... cece cece eee e cece cere eee cae eee ee sea aaa eee eesaaaeeeeeeeeaaee 8-15
TRIQUBLE aC TING icy cece secanes cites decent ctect svat ies nt ecanadseisenacenasettenseaenstest 8-17

SIGNALING SYSTEM ..00 20.00... c eee e eee eee cae eee cea ee ee aeaeeeeeeeaeeeeeees 8-19
CTPAU ITT EXTAGAM ccc i sen: tases de cecs cceas ses antes ca yaauaescaeseaesntaciceatecesiscaahedsai tives 8-19
TROUBLESHOOTING... 2. ...ee cece cece cee cece eee eee ee eee cee ee ee aea eee eeeeaeeeeeeeaaes 8-21

8-27
CIRCUIT DIAGRAM .... 2... cece cece eee e eee eect cece ae ene ee cea aaa eee eeeesauaeeeeeeeeaaee 8-27
TIN otis oes ce eeceivwes cates tenenccses rave ceattiaae ds nanvaniessatateniiess 8-29

FUEL PUMP SYSTEM.....00..00..c..c ccc ee cece cece eee eee cea eee ee aea eee eeeeneeeeees 8-31
CUPID TTC sic ie esecent snes esses ative nate «cece cen vaniewes aces ewes enstvensevacet 8-31
ee TINGE seccces ater Sec tiaies tevinm tye patanncdte dea saeveeteis snieeinanbentigves beesat 8-33

COMMUNICATION CONTROL SYSTEM itor YZF-R1 me ‘i O30

CIRCUIT DIAGRAM..
TROUBLESHOOTING ..ge gis ie ieee odode es ems sven ryfosind'aeiveas aes ue gwnenie nasonex denne 8-37
ELECTRICAL COMPONENTS. ......0...... 0.00... ccec cee ce eee e eee eeeeeeee eee saa aaa eeeeseasaas ees O7OG
CHECKING THE SWITCHES..... 0... ce eee ee ceeeee eee cease eeeeeeeseee es BMAD
CHECKING THE FUSES.. sauawitaewedsneidieadedasisicassesanl eed
REPLACING THE ECU (Engine Control Unit) .. seeeeeeeseaaeaeeeeeteeeeeeeees OAT
CHECKING AND CHARGING THE BATTERY... siewdeied sedate ected rei Sea
CHECKING THE RELAYS... scecssssssssssssssssissisissiasssasessseeeee 842
CHECKING THE RELAY UNIT (DIODE)... sapiusewhi dnhawenséuesaitsdeaesanedt~peca es
CHECKING THE IGNITION COILS... sscsssssssssssssssssissssissisasseasseeeee 844
CHECKING THE IGNITION SPARK GAP... we eeaeeeeeeeeeeseeeeee BAG
CHECKING THE CRANKSHAFT POSITION SENSOR... pawbaanst aetdderstecash ee
CHECKING THE STARTER MOTOR OPERATION ...................2.2222..-- 8-46
CHECKING THE STATOR COIL .. dene eeeeeecaeceeeeeeseeeseeseteeseesees OT AG
CHECKING THE RECTIFIER/REGULATOR... fos dewts covey iweddeuevesszeesces OPO)
CHECKING THE HORN.. ssccssssssssssssssssssssssssssssssasecesssssssessssessess 8°47
CHECKING THE FUEL SENDER .. etewdaniuiti Webensehevect-nsae OEE
CHECKING THE FUEL LEVEL WARNING LIGHT... sig Sites ddgachtiestsceac erred
CHECKING THE RADIATOR FAN MOTORS... acca teseeeeeeeeeeees BAB
CHECKING THE COOLANT TEMPERATURE SENSOR... seeneceteseeeeeeeees OM 4G
CHECKING THE THROTTLE SERVO MOTOR .. beeeeseteeeeeeees ees BPAY
CHECKING THE AIR INDUCTION SYSTEM SOLENOID. seeeeseeseseeeeeeeees OPA
CHECKING THE CYLINDER IDENTIFICATION SENSOR ....................8-50
CHECKING THE INTAKE AIR TEMPERATURE SENSOR ....................8-50
CHECKING THE STEERING DAMPER SOLENOID .........00000.0.02...... 8°51
CHECKING THE FUEL INJECTORS... cee cccesseeeeeeeeeaeeeneeeeseaeeeeees OUD I
CHECKING THE WHEEL SWITCH .....0. 00... c eee e eee eee eee eee eee OPD2
 IGNITION SYSTEM

EAS20072

IGNITION SYSTEM
EA530490

CIRCUIT DIAGRAM

OG
a &
ee ee

got I]
bau : : -

Ue a

ootht - oe em = octet : -

|+—S+ |
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8-1
 IGNITION SYSTEM

3. Main switch
4. Main fuse
9. Backup fuse
12. Ignition fuse
[Link] ground
[Link]
[Link] coupler
[Link] switch (right)
[Link]/engine stop switch
[Link] unit
[Link] switch
[Link] switch
[Link] identification sensor
[Link] position sensor
[Link] (Engine Control Unit)
[Link] plug
[Link] coil #1
[Link] coil #2
[Link] coil #3
[Link] coil #4
[Link] (Inertial Measurement Unit)
“, Joint coupler for YZF-R1
“*, Joint coupler for YZF-R1M
 IGNITION SYSTEM

EAS30491

ENGINE STOPPING DUE TO SIDESTAND OPERATION

When the engine is running and the transmission is in gear, the engine will stop if the sidestand is
moved down. This is because the electric current from the ECU does not flow to the ignition coils or fuel
injectors when the neutral switch or sidestand switch is open. However, the engine continues to run
under the following conditions:
e The transmission is in gear (the neutral switch is open) and the sidestand is up (the sidestand switch
circuit is closed).
e The transmission is in neutral (the neutral switch is closed) and the sidestand is down (the sidestand
switch circuit is open).

2
——O
Q ®
a5 1

+ 4

9 5
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I 6
11 \10 [*

Pt
1. Battery
2. Main fuse
3. Main switch
4. Ignition fuse
5. Start/engine stop switch
6. Ignition coil
7. Spark plug
8. ECU (Engine Control Unit)
9. Relay unit (diode)
10. Sidestand switch
11. Neutral switch
 IGNITION SYSTEM

EASs0492

TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP
¢ Before troubleshooting, remove the following part(s):
1. Front side cowling/Front panel
2. Rider seat
3. Fuel tank cover
4. Fuel tank
5. Ai r filter case

1. Check the fuses. NG-

(Main, ignition and backup)
Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 8-41.

OKL
. Check the battery. NG-
Refer to “CHECKING AND ¢ Clean the battery terminals.
CHARGING THE BATTERY” on e Recharge or replace the battery.
page 8-42.
OKJ
. Check the spark plugs. NG-
Refer to “CHECKING THE SPARK Re-gap or replace the spark plug(s).
PLUGS’ on page 3-5.

OKL
. Check the ignition spark gap. OK >
Refer to “CHECKING THE SPARK Ignition system is OK.
PLUGS’ on page 3-5.

NGJ
. Check the ignition coils. NG-
Refer to “CHECKING THE IGNI- Replace the ignition coil(s).
TION COILS” on page 8-44.

OKJ
. Check the crankshaft position sen- NG-
sor.
Refer to “CHECKING THE CRANK- Replace the crankshaft position sensor.
SHAFT POSITION SENSOR’ on
page 8-45.
OKJ
. Check the cylinder identification NG-
sensor.
Refer to “CHECKING THE CYLIN- Replace the cylinder identification sensor.
DER IDENTIFICATION SENSOR”
on page 8-50.
OKJ
 IGNITION SYSTEM

8. Check the main switch. NG-

Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 8-40.

OKJ
9. Check the start/engine stop switch. NG-
Refer to “CHECKING THE Replace the handlebar switch (right).
SWITCHES” on page 8-40.

OKJ
[Link] the neutral switch. NG-
Refer to “CHECKING THE Replace the neutral switch.
SWITCHES” on page 8-40.

OKL
[Link] the sidestand switch. NG-
Refer to “CHECKING THE Replace the sidestand switch.
SWITCHES” on page 8-40.

OKL
[Link] the relay unit (diode). NG-
Refer to “CHECKING THE RELAY Replace the relay unit.
UNIT (DIODE)” on page 8-43.

OKJ
[Link] the entire ignition system’s NG-
wiring. Properly connect or repair the ignition sys-
Refer to “CIRCUIT DIAGRAM” on tem’s wiring.
page 8-1.

OKJ
Replace the ECU or IMU.
Refer to “REPLACING THE ECU (En-
gine Control Unit)” on page 8-41.
IGNITION SYSTEM
 ELECTRIC STARTING SYSTEM

EAS20073

ELECTRIC STARTING SYSTEM

EAS30493

CIRCUIT DIAGRAM

ries

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oir‘n

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fan

roTy
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hon cme fs oa sc re

8-7
 ELECTRIC STARTING SYSTEM

3. Main switch
4. Main fuse
9. Backup fuse
12. Ignition fuse
[Link] ground
[Link]
[Link] relay
[Link] motor
[Link] coupler
[Link] switch (right)
[Link]/engine stop switch
[Link] unit
[Link] circuit cut-off relay
[Link] switch
[Link] switch
[Link] (Engine Control Unit)
[Link] switch (left)
[Link] switch
 ELECTRIC STARTING SYSTEM

EAS30494

STARTING CIRCUIT CUT-OFF SYSTEM OPERATION

lf the main switch is turned to “ON” and the “@” side of the start/engine stop switch is pushed, the starter
motor can only operate if at least one of the following conditions is met:
e The transmission is in neutral (the neutral switch is closed).
¢ The clutch lever is pulled to the handlebar (the clutch switch is closed) and the sidestand is up (the
sidestand switch is closed).
The starting circuit cut-off relay prevents the starter motor from operating when neither of these condi-
tions has been met. In this instance, the starting circuit cut-off relay is open so current cannot reach the
starter motor. When at least one of the above conditions has been met, the starting circuit cut-off relay
is closed and the engine can be started by pressing the “@” side of the start/engine stop switch.

WHEN THE TRANSMISSION IS IN NEUTRAL

oS p

WHEN THE SIDESTAND IS UP AND THE

CLUTCH LEVER IS PULLED TO THE
HANDLEBAR
Battery
=

Main fuse
Poh

Main switch
Ignition fuse
Starting circuit cut-off relay
ONOaA

Relay unit (diode)

Clutch switch
Sidestand switch
9. Neutral switch
10. Start/engine stop switch
11. Starter relay
12. Starter motor
 ELECTRIC STARTING SYSTEM

EAS30495

TROUBLESHOOTING
The starter motor fails to turn.
TIP
¢ Before troubleshooting, remove the following part(s):
Front side cowling/Front panel/Side cover
=

Rider seat
wh

Fuel tank cover

Fuel tank
OonrP

Air filter case

Throttle bodies

1. Check the fuses. NG >

(Main, ignition and backup)
Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 8-41.

OKJ
2. Check the battery. NG -
Refer to “CHECKING AND ¢ Clean the battery terminals.
CHARGING THE BATTERY” on ¢« Recharge or replace the battery.
page 8-42.

OKL
3. Check the starter motor operation. OK >
Starter motor is OK. Perform the electric
Refer to “CHECKING THE START-
starting system troubleshooting, starting
ER MOTOR OPERATION” on page
with step (5).
8-46.

NGJ
4. Check the starter motor. NG >
Refer to “CHECKING THE START- Repair or replace the starter motor.
ER MOTOR’ on page 5-52.

OKL
5. Check the relay unit (starting circuit NG -
cut-off relay).
Replace the relay unit.
Refer to “CHECKING THE RE-
LAYS” on page 8-42.

OKJ
6. Check the relay unit (diode). NG ->
Refer to “CHECKING THE RELAY Replace the relay unit.
UNIT (DIODE)” on page 8-43.

OKJ
7. Check the starter relay. NG ->
Refer to “CHECKING THE RE- Replace the starter relay.
LAYS” on page 8-42.

OKJ

8-10
 ELECTRIC STARTING SYSTEM

8. Check the main switch. NG-

Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 8-40.

OKJ
9. Check the neutral switch. NG-
Refer to “CHECKING THE Replace the neutral switch.
SWITCHES” on page 8-40.

OKJ
[Link] the sidestand switch. NG-
Refer to “CHECKING THE Replace the sidestand switch.
SWITCHES” on page 8-40.

OKL
[Link] the clutch switch. NG-
Refer to “CHECKING THE Replace the clutch switch.
SWITCHES” on page 8-40.

OKL
[Link] the start/engine stop switch. NG-
Refer to “CHECKING THE Replace the handlebar switch (right).
SWITCHES” on page 8-40.

OKJ
[Link] the entire starting system’s NG-
wiring. Properly connect or repair the starting sys-
Refer to “CIRCUIT DIAGRAM” on tem’s wiring.
page 8-7.

OKJ
Replace the ECU.
Refer to “REPLACING THE ECU (En-
gine Control Unit)” on page 8-41.

8-11
 CHARGING SYSTEM

EAS2o0r4

CHARGING SYSTEM
EASSa0496

CIRCUIT DIAGRAM

1. AC magneto
2. Rectifier/regulator
4. Main fuse
[Link] ground
[Link]

8-12
 CHARGING SYSTEM

EAS30497

TROUBLESHOOTING
The battery is not being charged.
TIP
¢ Before troubleshooting, remove the following part(s):
1. Front side cowling/Front panel/Side cover bracket/Electrical components tray
2. Rider seat

1. Check the fuse. NG-

(Main)
Replace the fuse.
Refer to “CHECKING THE FUS-
ES” on page 8-41.

OKJ
2. Check the battery. NG-
Refer to “CHECKING AND ¢ Clean the battery terminals.
CHARGING THE BATTERY” on ¢« Recharge or replace the battery.
page 8-42.

OKL
3. Check the stator coil. NG-
Refer to “CHECKING THE STATOR Replace the stator coil assembly.
COIL’ on page 8-46.

OKJ
4. Check the rectifier/regulator. NG-
Refer to “CHECKING THE RECTI- Replace the rectifier/regulator.
FIER/REGULATOR?’ on page 8-46.

OKJ
5. Check the entire charging system’s NG-
wiring. Properly connect or repair the charging
Refer to “CIRCUIT DIAGRAM” on system’s wiring.
page 8-12.

OKL
The charging system circuit is OK.

8-13
 CHARGING SYSTEM

8-14
 LIGHTING SYSTEM

EAS20075

LIGHTING SYSTEM
EA530498

CIRCUIT DIAGRAM

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@) fi
he me ep del dd deh ee ee ee eee dekh des - - ek - - - - - ai. ._-.- LL, |:

ab a aoe:

Be

: ~~

So
A

8-15
 LIGHTING SYSTEM

3. Main switch
4. Main fuse
9. Backup fuse
12. Ignition fuse
[Link] system fuse
[Link] fuse
[Link] ground
[Link]
[Link] coupler
[Link] (Engine Control Unit)
[Link] assembly
[Link]-function meter
[Link] light
[Link] beam indicator light
[Link] switch (left)
[Link]/LAP switch
[Link] switch
[Link] turn signal/position light (right)
[Link] turn signal/position light (left)
[Link] control unit
[Link] (high beam)
[Link] (low beam)
[Link]/brake light
[Link] plate light
[Link] light

8-16
 LIGHTING SYSTEM

EAS30499

TROUBLESHOOTING
Any of the following fail to light: headlight, auxiliary light, high beam indicator light, tail/orake light, li-
cense plate light or meter light.
TIP
¢ Before troubleshooting, remove the following part(s):
1. Front side cowling/Front panel/Side cover
2. Passenger seat/Rider seat/Tail cover/Rear side cover
3. Headlight assembly

1. Check the fuses. NG ->

(Main, headlight, backup, ignition
and signaling system) Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 8-41.

OKL
2. Check the battery. NG -
Refer to “CHECKING AND ¢ Clean the battery terminals.
CHARGING THE BATTERY” on e Recharge or replace the battery.
page 8-42.

OKJ
3. Check the main switch. NG >
Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 8-40.

OKJ
4. Check the dimmer switch. NG > ; Le
Refer to “CHECKING THE The dimmer switch is faulty. Replace the
SWITCHES’ on page 8-40. handlebar switch (left).

OKJ
5. Check the Pass/LAP switch. NG -
The Pass/LAP switch is faulty. Replace the
Refer to “CHECKING THE
handlebar switch (left).
SWITCHES” on page 8-40.

OKL
6. Check the entire lighting system’s NG-
wiring. Properly connect or repair the lighting sys-
Refer to “CIRCUIT DIAGRAM” on tem’s wiring.
page 8-15.

OKJ
Replace the ECU, meter assembly,
headlight assembly, front turn signal/
position light, tail/brake light, license
plate light or auxiliary light.
Refer to “REPLACING THE ECU (En-
gine Control Unit)” on page 8-41.

8-17
 LIGHTING SYSTEM

8-18
 SIGNALING SYSTEM

EAS20076

SIGNALING SYSTEM

CIRCUIT DIAGRAM
On
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@ if
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(bury
8H
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elon
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itil

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[<1]

8-19
 SIGNALING SYSTEM

3. Main switch
4. Main fuse
9. Backup fuse
12. Ignition fuse
[Link] system fuse
[Link] ECU fuse
[Link] lighting fuse
[Link] ground
[Link]
[Link] coupler
[Link] brake light switch
[Link] switch (right)
[Link] unit
[Link] switch
[Link] sender
[Link] position sensor
[Link] sensor
[Link] temperature sensor
[Link] (Engine Control Unit)
[Link] unit assembly (ABS ECU)
[Link] wheel sensor
[Link] assembly
[Link] level warning light
[Link] indicator light
[Link] indicator light
[Link]-function meter
[Link] pressure and coolant temperature warning
light
80. Turn signal indicator light (right)
[Link] signal indicator light (left)
[Link] pressure switch
[Link] switch (left)
[Link] switch
94. Turn signal switch
[Link] switch
[Link]
[Link] turn signal light (right)
[Link] turn signal light (left)
[Link] turn signal/position light (right)
[Link] turn signal/position light (left)
[Link] brake light switch
[Link]/brake light
A. Wire harness
C. Sub-wire harness (coolant temperature sensor)
F. Sub-wire harness (oil pressure switch)
“, Joint coupler for YZF-R1
“*. Joint coupler for YZF-R1M

8-20
 SIGNALING SYSTEM

EAS30501

TROUBLESHOOTING
e Any of the following fail to light: turn signal light, brake light or an indicator light.
¢ The horn fails to sound.
e The speedometer fails to operate.
TIP
¢ Before troubleshooting, remove the following part(s):
Front side cowling/Front panel/Side cover
=

Passenger seat/Rider seat/Tail cover/Rear side cover

Wh

Fuel tank cover

Fuel tank
NOOP

Air filter case

Throttle bodies
Drive sprocket cover

1. Check the fuses. NG-

(Main, ignition, signaling system,
backup, ABS ECU and hazard light-
Replace the fuse(s).
ing)
Refer to “CHECKING THE FUS-
ES” on page 8-41.

OKJ
2. Check the battery. NG-
Refer to “CHECKING AND ¢ Clean the battery terminals.
CHARGING THE BATTERY” on ¢« Recharge or replace the battery.
page 8-42.

OKL
3. Check the main switch. NG-
Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 8-40.

OKJ
4. Check the entire signaling sys- NG-
tem’s wiring. Properly connect or repair the signaling
Refer to “CIRCUIT DIAGRAM” on system's wiring.
page 8-19.

OKJ
Check the condition of each of the sig-
naling system circuits.
Refer to “Checking the signaling sys-
tem”.

Checking the signaling system

The horn fails to sound.
1. Check the horn switch. NG-
Refer to “CHECKING THE Replace the handlebar switch (left).
SWITCHES” on page 8-40.

OKL

8-21
 SIGNALING SYSTEM

2. Check the horn. NG -

Refer to “CHECKING THE HORN” Replace the horn.
on page 8-47.

OKJ
3. Check the entire signaling sys- NG ->
tem’s wiring. Properly connect or repair the signaling
Refer to “CIRCUIT DIAGRAM” on system's wiring.
page 8-19.

OK J

This circuit is OK.

The tail/brake light fails to come on.

1. Check the front brake light switch. NG-

Refer to “CHECKING THE Replace the front brake light switch.
SWITCHES” on page 8-40.

OKL
2. Check the rear brake light switch. NG >
Refer to “CHECKING THE Replace the rear brake light switch.
SWITCHES” on page 8-40.

OKJ
3. Check the entire signaling sys- NG ->
tem’s wiring. Properly connect or repair the signaling
Refer to “CIRCUIT DIAGRAM” on system's wiring.
page 8-19.

OKL
Replace the tail/brake light.

The tur signal light, turn signal indicator light or both fail to blink.

1. Check the turn signal switch. NG->

Refer to “CHECKING THE Replace the handlebar switch (left).
SWITCHES” on page 8-40.

OKJ
2. Check the hazard switch. NG -
Refer to “CHECKING THE Replace the handlebar switch (left).
SWITCHES” on page 8-40.

OKJ

8-22
 SIGNALING SYSTEM

3. Check the entire signaling sys- NG-

tem’s wiring. Properly connect or repair the signaling
Refer to “CIRCUIT DIAGRAM” on system's wiring.
page 8-19.

OKJ
Replace the meter assembly, front turn
signal/position light or rear turn signal
light.

The neutral indicator light fails to come on.

1. Check the neutral switch. NG-

Refer to “CHECKING THE Replace the neutral switch.
SWITCHES” on page 8-40.

OKL
2. Check the relay unit (diode). NG-
Refer to “CHECKING THE RELAY Replace the relay unit.
UNIT (DIODE)” on page 8-43.

OKJ
3. Check the entire signaling sys- NG-
tem’s wiring. Properly connect or repair the signaling
Refer to “CIRCUIT DIAGRAM” on system’s wiring.
page 8-19.

OKJ
Replace the meter assembly.

The oil pressure and coolant temperature warning light fails to come on, or the oil pressure warning icon
flashes when the main switch is set to “ON”.

1. Check the entire signaling sys- NG-

tem’s wiring. Properly connect or replace the wiring har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-19.

OKJ
2. Disconnect the oil pressure switch NG-
lead from the oil pressure switch,
and then check whether the oil
pressure and coolant temperature Replace the meter assembly.
warning light comes on when the
lead is connected to the engine
ground.

OKJ
Replace the oil pressure switch.

8-23
 SIGNALING SYSTEM

The oil pressure and coolant temperature warning light remains on after the engine is started.

1. Check the entire signaling sys- NG ->

tem’s wiring. Properly connect or replace the wiring har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-19.

OKL
2. Measure the engine oil pressure. NG -
Refer to “MEASURING THE EN- Check the engine oil leakage, oil viscosity,
GINE OIL PRESSURE?” on page oil seal, oil filter, or oil pump.
3-30.

OKJ
Replace the oil pressure switch.

The fuel level warning light fails to come on.

1. Check the fuel sender. NG-

Refer to “CHECKING THE FUEL Replace the fuel pump assembly.
SENDER?” on page 8-47.

OKJ
2. Check the entire signaling sys- NG -
tem’s wiring. Properly connect or repair the signaling
Refer to “CIRCUIT DIAGRAM” on system's wiring.
page 8-19.

OKL
Replace the meter assembly.

The oil pressure and coolant temperature warning light fails to come on.

1. Check the coolant temperature sen- NG -

sor.
Refer to “CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR”
on page 8-48.

OK J
2. Check the entire signaling sys- NG -
tem’s wiring. Properly connect or replace the wiring har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-19.

OK
Replace the ECU or meter assembly.
Refer to “REPLACING THE ECU (En-
gine Control Unit)” on page 8-41.

8-24
 SIGNALING SYSTEM

QSS (Quick Shift System) does not operate.

1. Check that the malfunction indicator NG-

Repair the faulty parts.
light does not come on.

OKJ
2. Check that the QSS is working un- NG- Check the QSS operating conditions ex-
der normal QSS operating condi- plained in the owner’s manual and operate
tions. the QSS accordingly.

OKJ
3. Make sure that the QSS is effective. NG-
Activate the QSS. (Set the QSS to a set-
(Check whether the “QS g w’ icon
ting other than “OFF”.)
is displayed at the top of the meter.)

OKJ
4. Are you operating while the NG-
Operate while the “QS g w’ iconis lit.
“QS a W° icon is lit?
OKL
5. Is the transmission gear display NG-
Repair the gear position sensor.
normal?

OKL
6. Check the connection of the cou- NG-
pler between the gear position sen- Connect the gear position sensor coupler.
sor and the ECU.

OKJ
7. Are the clutch and neutral switches NG-
Repair the switch if it is not normal.
normal?

OKJ
8. Check the shift sensor value in the NG-
DIAG mode.
2.5 V when the shift pedal is not be-
ing operated.
Replace the shift sensor.
4.5 V when the shift pedal is
pressed fully in.
0.5 V when the shift pedal is
pushed fully up.

OKJ
9. Check the entire signaling sys- NG-
tem’s wiring. Properly connect or repair the signaling
Refer to “CIRCUIT DIAGRAM” on system’s wiring.
page 8-19.

OKL
Replace the ECU.
Refer to “REPLACING THE ECU (En-
gine Control Unit)” on page 8-41.

8-25
 SIGNALING SYSTEM

The speedometer fails to operate.

1. Check the rear wheel sensor. NG ->

Refer to “MAINTENANCE OF THE
REAR WHEEL SENSOR AND Replace the rear wheel sensor.
SENSOR ROTOR?’ on page 4-49.

OK J
2. sie the entire wheel sensor wir- NG > Properly connect or repair the wheel sen-

Refer to TIP. Sor wiring.

OKJ
Replace the hydraulic unit assembly,
ECU, meter assembly.
Refer to “REPLACING THE ECU (En-
gine Control Unit)” on page 8-41.

TIP
Repair or replace if there is an open or short circuit.
¢ Between rear wheel sensor coupler and ABS ECU coupler.
(white—white)
(black—black)
¢e Between ABS ECU coupler and ECU coupler.
(gray/black—gray/black)
(white/blue—white/blue)
¢ Between joint coupler and ECU coupler.
(blue/white—blue/white)
(blue/black—blue/black)
¢ Between joint coupler and meter assembly coupler.
(blue/white—blue/white)
(blue/black—blue/black)

8-26
 COOLING SYSTEM

EAS20077

COOLING SYSTEM
EAS30502

CIRCUIT DIAGRAM

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ele beech o Peles pat
pehuiwieD
epee
“

saee ly eseaemens 11 eae Gl ale leet ning Fi

& 2H
iL gat Ul dels oh ok ie ee a ee eee abel, —--“t aa |

| : oe

c :

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—

=o

8-27
 COOLING SYSTEM

Main switch
oe Main fuse
Radiator fan motor relay
9. Backup fuse
[Link] radiator fan motor fuse
[Link] fan motor fuse
12. Ignition fuse
[Link] ground
[Link]
[Link] temperature sensor
[Link] (Engine Control Unit)
[Link] radiator fan motor (right)
[Link] fan motor (left)
A. Wire harness
C. Sub-wire harness (coolant temperature sensor)

8-28
 COOLING SYSTEM

EAS30503

TROUBLESHOOTING
TIP
¢ Before troubleshooting, remove the following part(s):
Front side cowling/Front panel/Side cover bracket/Electrical components tray
Rider seat
Fuel tank cover
ll ol

Fuel tank
Ai r filter case
Throttle bodies

1. Check the fuses. NG-

(Main, ignition, backup, radiator fan
motor and sub radiator fan motor) Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 8-41.

OKJ
. Check the battery. NG-
Refer to “CHECKING AND ¢ Clean the battery terminals.
CHARGING THE BATTERY” on e Recharge or replace the battery.
page 8-42.
OKJ
. Check the main switch. NG-
Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 8-40.

OKL
. Check the radiator fan motor. NG-
Refer to “CHECKING THE RADIA- Replace the radiator fan motor.
TOR FAN MOTORS’ on page 8-48.

OKJ
. Check the radiator fan motor relay. NG-
Refer to “CHECKING THE RE- Replace the radiator fan motor relay.
LAYS” on page 8-42.

OKJ
. Check the coolant temperature sen- NG-
sor.
Refer to “CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR”
on page 8-48.
OKL

8-29
 COOLING SYSTEM

7. Check the entire cooling system’s NG -

wiring. Properly connect or repair the cooling sys-
Refer to “CIRCUIT DIAGRAM” on tem’s wiring.
page 8-27.

OK L
Replace the ECU.
Refer to “REPLACING THE ECU (En-
gine Control Unit)” on page 8-41.

8-30
 FUEL PUMP SYSTEM

EAS20081

FUEL PUMP SYSTEM

EAS30513

CIRCUIT DIAGRAM

rae

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fe) fi
+ -b dh de titpiiil ... it - 4 whee bake = eo debeh— deed = = be 2 dg dhakedels |:

—| ae ref:
—

ie

8-31
 FUEL PUMP SYSTEM

Main switch
“NFO Main fuse
Fuel injection system fuse
9. Backup fuse
12. Ignition fuse
[Link] ground
[Link]
[Link] coupler
[Link] switch (right)
[Link]/engine stop switch
[Link] unit
[Link] pump relay
[Link] pump
[Link] (Engine Control Unit)

8-32
 FUEL PUMP SYSTEM

EA530514

TROUBLESHOOTING
lf the fuel pump fails to operate.
TIP
¢ Before troubleshooting, remove the following part(s):
1. Front side cowling/Front panel
2. Rider seat
3. Fuel tank cover
4. Fuel tank

1. Check the fuses. NG ->

(Main, ignition, backup and fuel in-
jection system) Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 8-41.

OKL
2. Check the battery. NG -
Refer to “CHECKING AND ¢ Clean the battery terminals.
CHARGING THE BATTERY” on e Recharge or replace the battery.
page 8-42.

OKJ
3. Check the main switch. NG >
Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 8-40.

OKJ
4. Check the start/engine stop switch. NG ->
Refer to “CHECKING THE Replace the handlebar switch (right).
SWITCHES” on page 8-40.

OKJ
5. Check the relay unit (fuel pump re- NG >
|
lay).
Refer to “CHECKING THE RE- Replace the relay unit.
LAYS” on page 8-42.

OKJ
6. Check the fuel pump. NG >
Refer to “CHECKING THE FUEL Replace the fuel pump.
PUMP OPERATION” on page 7-3.

OKJ

8-33
 FUEL PUMP SYSTEM

7. Check the entire fuel pump sys- NG -

tem’s wiring. Properly connect or repair the fuel pump
Refer to “CIRCUIT DIAGRAM” on system's wiring.
page 8-31.

OK L
Replace the ECU.
Refer to “REPLACING THE ECU (En-
gine Control Unit)” on page 8-41.

8-34
 COMMUNICATION CONTROL SYSTEM (for YZF-R1M)
EAS20212

COMMUNICATION CONTROL SYSTEM (for YZF-R1M)

EASS6T1

CIRCUIT DIAGRAM

5
ae WT tT TT See eee TTT E
@ oof
LIMA ___- 41-4... l.-..-- a a wo mo i
=o

=
ie
Lt i FS 6 t= he
Itz
1 cerca == ney = S1f |

a) se] Ke
i = ; :
i &
=H |
—-F !

!eee —(morn ci
1 =a |) I

[tet
© fi|
Lo _t

___ bs oe |
| ae \

| '@
Sele)Je]!
ai EL: dei)

ss
i

[uu]
=F

es (=

8-35
 COMMUNICATION CONTROL SYSTEM (for YZF-R1M)
Main switch
“NFO Main fuse
Fuel injection system fuse
9. Backup fuse
12. Ignition fuse
[Link] ground
[Link]
[Link] coupler
[Link] (Engine Control Unit)
[Link] (Inertial Measurement Unit)
[Link] assembly
[Link]-function meter
[Link] coupler
[Link] (Communication Control Unit)
[Link] unit
A. Wire harness
E. Sub-wire harness (CCU (Communication
Control Unit))

8-36
 COMMUNICATION CONTROL SYSTEM (for YZF-R1M)
EASS1672

TROUBLESHOOTING
The communication control system failed to function.
TIP
¢ Before troubleshooting, remove the following part(s):
1. Front side cowling/Front panel/Side cover
2. Rider seat/Passenger seat/Battery cover/Tail cover

1. Check the fuses. NG ->

(Main, ignition and backup)
Refer to “CHECKING THE FUS- Replace the fuse(s).
ES” on page 8-41.

OKJ
2. Check the battery. NG ->
Refer to “CHECKING AND ¢ Clean the battery terminals.
CHARGING THE BATTERY” on ¢« Recharge or replace the battery.
page 8-42.

OKL
3. Check the main switch. NG >
Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 8-40.

OKJ
4. Check the entire communication NG >
contro! system’s wiring. Properly connect or repair the communica-
Refer to “CIRCUIT DIAGRAM” on tion control system’s wiring.
page 8-35.

OKJ
Replace the ECU, CCU, GPS unit,
IMU or meter assembly.
Refer to “REPLACING THE ECU (En-
gine Control Unit)” on page 8-41.

8-37
 ELECTRICAL COMPONENTS

EAS20089

ELECTRICAL COMPONENTS

Accelerator position sensor [Link] (Engine Control Unit)

SGNOghah=

Intake funnel servo motor 19. Radiator fan motor

Throttle position sensor [Link]
Primary injector [Link] control unit
Intake air pressure sensor [Link] damper solenoid
Throttle servo motor [Link] (Suspension Control Unit) (for YZF-R1M)
Secondary injector 24. Front brake light switch
Fuel pump [Link] switch
9 Battery 26. Main switch
[Link] unit (for YZF-R1M)
[Link] (Communication Control Unit)
(for YZF-R1M)
[Link] servo motor
13. IMU (Inertial Measurement Unit)
14. Hydraulic unit assembly (ABS ECU)
15. Shift sensor
16. Stator coil
17. Crankshaft position sensor

8-38
 ELECTRICAL COMPONENTS

1. Intake solenoid [Link] wheel sensor

2. Front fork stepping motor (for YZF-R1M) [Link] identification sensor
3. Air induction system solenoid [Link] box 3 (SCU fuse) (for YZF-R1M)
4. Ignition coll [Link]/regulator
5. Atmospheric pressure sensor 24.\Intake air temperature sensor
6. Coolant temperature sensor [Link] box 2
7. Neutral switch
8. Rear shock absorber assembly stepping motor
(for YZF-R1M)
9. Main fuse
10. Starter relay
11. Relay unit
12. Fuse box 1
13. Radiator fan motor relay
14. Rear wheel sensor
15. Rear brake light switch
16. Gear position sensor
[Link] switch
18.05 sensor
19. Oil pressure switch

8-39
 ELECTRICAL COMPONENTS

EAS30549

CHECKING THE SWITCHES

Check each switch for continuity with the digital circuit tester. If the continuity reading is incorrect, check
the wiring connections and if necessary, replace the switch.

1. Start/engine stop switch

2. Mode switch
3. Pass/LAP switch
4. Dimmer switch
5. Horn switch
6. Turn signal switch
7. Hazard switch
8. Main switch
9. Sidestand switch
10. Clutch switch
11. Front brake light switch
12. Neutral switch
13. Rear brake light switch

8-40
 ELECTRICAL COMPONENTS

EAS30551

CHECKING THE FUSES Fuses ae Q’ty

The following procedure applies to all of the fus-
es. ABS ECU 7.54 1
ECA13680
ABS solenoid 15A 1
NOTICE
Auxiliary 2A 1
To avoid a short circuit, always set the main
switch to “OFF” when checking or replacing Backup TOA 1
a fuse. Electronic throttle valve 7.5A 1
1. Remove: SCU (for YZF-R1M) 7.54 1
e Passenger seat/Rider seat Spare 30A 1
Refer to “GENERAL CHASSIS (1)” on page Spare 15A 1
4-1.
Spare 10A 1
¢ Front panel (left)
Refer to “GENERAL CHASSIS (8)” on page Spare 7.54 1
4-9. Spare 2A 1
2. Check: EWAIS310

¢ Fuse
a. Connect the digital circuit tester to the fuse
Never use a fuse with an amperage rating
and check the continuity.
other than that specified. Improvising or us-
TIP ing a fuse with the wrong amperage rating
Set the digital circuit tester selector to “Q ”. may cause extensive damage to the electri-
cal system, cause the lighting and ignition
(Z| Digital circuit tester (CD732) systems to malfunction and could possibly
go 90890-03243 cause a fire.
Model 88 Multimeter with ta-
4. Install:
chometer
e Rider seat/Passenger seat
YU-A1927
Refer to “GENERAL CHASSIS (1)” on page
b. If the digital circuit tester indicates “O.L’, 4-1.
replace the fuse. ¢ Front panel (left)
3. Replace: Refer to “GENERAL CHASSIS (3)” on page
¢ Blown fuse 4-9.
a. Set the main switch to “OFF”. EFAS 1006

b. Install a new fuse of the correct amperage REPLACING THE ECU (Engine Control Unit)
rating. 1. Turn the main switch to “OFF”.
c. Set on the switches to verify if the electri- 2. Replace the ECU (Engine Control Unit).
Cal circuit is operational. 3. Clean the throttle bodies and reset the ISC
d. Ifthe fuse immediately blows again, check (Idle Speed Control) learning value.
the electrical circuit. Refer to “CHECKING AND CLEANING THE
Amperage ' THROTTLE BODIES?” on page 7-15.
Fuses rating Q’ty 4 . Check:
¢ Engine idling speed
Main 50 A 1
Start the engine, warm it up, and then mea-
Headlight 7.5A 1 sure the engine idling speed.
Signaling system 7.5A 1
Ur ¥ Engine idling speed
Ignition 15A 1
1200-1400 r/min
Radiator fan motor 15A 1
Sub radiator fan motor 10A 1
Hazard 15A 1
Fuel injection system 15A 1
ABS motor 30 A 1

8-41
 ELECTRICAL COMPONENTS

EAS30552

CHECKING AND CHARGING THE BATTERY

TIP
Refer to “CHECKING AND CHARGING THE
BATTERY” in “BASIC INFORMATION” (sepa-
rate volume).
1. Remove:
¢ Rider seat/Battery cover
Refer to “GENERAL CHASSIS (1)” on page
4-1.
2. Disconnect: TIP
* Battery leads Route the positive battery lead “1” to the outside
(from the battery terminals) of the EXUP servo motor lead “3” and starter re-
ECA13640
lay lead “4”.
NOTICE
First, disconnect the negative battery lead
“1”, and then positive battery lead “2”.

8. Check:
e Battery terminals
Dirt > Clean with a wire brush.
3. Remove:
¢ Battery Loose connection — Connect properly.
9. Lubricate:
Refer to “GENERAL CHASSIS (1)” on page
e Battery terminals

=
4-1.
4. Check: Recommended lubricant
* Battery charge Dielectric grease
5. Charge:
¢ Battery [Link]:
6. Install: ¢ Battery cover/Rider seat
¢ Battery Refer to “GENERAL CHASSIS (1)” on page
Refer to “GENERAL CHASSIS (1)” on page 4-1.
4-1.
7. Connect:
FASS30553

CHECKING THE RELAYS

* Battery leads
Check each switch for continuity with the digital
(to the battery terminals)
ECA13630
circuit tester. If the continuity reading is incor-
NOTICE rect, replace the relay.

J
First, connect the positive battery lead “1”, Digital circuit tester (CD732)
and then the negative battery lead “2”. 90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927

8-42
 ELECTRICAL COMPONENTS

1. Disconnect the relay from the wire harness. Relay unit (fuel pump relay)
2. Connect the digital circuit tester (Q2) and bat-
tery (12 V) to the relay terminal as shown.
Check the relay operation. 3 2 1 4
Out of specification — Replace. |

Starter relay | ESL |

Briw | LW RW| L | RIL
or LIR|UWIRAYLIBILY | Sb | BY |Sbiw
eee ee Z|

6 eo RIW my 1. Positive battery terminal

7 R/W| LAW 2. Negative battery terminal
=|-=F 3. Positive tester probe
2
6Ch Ce ee nee
1:2
eee
4. Negative tester probe
4
Result
1. Positive battery terminal Continuity
2. Negative battery terminal (between “3” and “4”)
3. Positive tester probe

4.. Negative tester probe Radiator fan motor relay

= | Relay operation 7
Continuity A
(between “3” and “4”) R if
4
CUMMMMY | R/B TL
Relay unit (starting circuit cut-off relay) RW GIy lL. |

3 1 2 4 2 1
\_\ |
Tl rT 1. Positive battery terminal
2. Negative battery terminal
aoe Ore TG re er 3. Positive tester probe
4. Negative tester probe

C_] Result
1. Positive battery terminal Continuity
2. Negative battery terminal (between “3” and “4”)
3. Positive tester probe
4. Negative tester probe EAS20795
CHECKING THE RELAY UNIT (DIODE)
[] Result 1. Check: | |

(between “3” and “4”) Out of specification — Replace.

(Z| Digital circuit tester (CD732)

o 90890-03243
: Model 88 Multimeter with ta-
chometer
YU-A1927

8-43
 ELECTRICAL COMPONENTS

TIP a. Disconnect the relay unit coupler from the

The digital circuit tester readings are shown in wire harness.
the following table. b. Connect the digital circuit tester (Q) to the
relay unit terminal as shown.

ai
Check the relay unit (diode) for continuity.
Continuity

a9
. Check the relay unit (diode) for no continu-
Positive tester probe
sky blue “1” ity.
Negative tester probe EAS30558

black/yellow “2” CHECKING THE IGNITION COILS

No continuity The following procedure applies to all of the igni-
Positive tester probe tion coils.
black/yellow “2” 1. Check:
Negative tester probe e Primary coil resistance
sky blue “1”
Out of specification — Replace.
Continuity
Positive tester probe L_] Primary coil resistance
sky blue “1” 0.85-1.15 ©
Negative tester probe
blue/yellow “3” a. Disconnect the ignition coil coupler from
No continuity
the ignition coil.
Positive tester probe
b. Connect the digital circuit tester (©) to the
blue/yellow “3”
Negative tester probe ignition coil as shown.
sky blue “1”
Digital circuit tester (CD732)
Continuity
90890-03243
Positive tester probe
Model 88 Multimeter with ta-
sky blue “1”
chometer
Negative tester probe
YU-A1927
sky blue/white “4”
No continuity
Positive tester probe « Positive tester probe
sky blue/white “4” Ignition coil terminal “1”
* Negative tester probe
Negative tester probe
Ignition coil terminal “2°
sky blue “1”
Continuity
Positive tester probe
blue/black “5”
Negative tester probe
blue/yellow “3”
No continuity
Positive tester probe
blue/yellow “3”
Negative tester probe
blue/black “5”

c. Measure the primary coil resistance.

2. Check:
e Secondary coil resistance
Out of specification — Replace.

L_] Secondary coil resistance

Bri | LW RW} Lo} RL 8.50-11.50 kQ

a. Connect the digital circuit tester (Q) to the

ignition coil as shown.

8-44
 ELECTRICAL COMPONENTS

Digital circuit tester (CD732)

90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927

« Negative tester probe

Ignition coil terminal “1”
¢ Positive tester probe
Spark plug terminal “2”
2. Ignition coil

c. Turn the main switch to “ON”.

d. Measure the ignition spark gap “a”.
e. Crank the engine by pushing the “@” side
of the start/engine stop switch and gradu-
ally increase the spark gap until a misfire
occurs.
EAS 30560

CHECKING THE CRANKSHAFT POSITION

SENSOR
b. Measure the secondary coil resistance. 1. Disconnect:
EAS30556
e Crankshaft position sensor coupler
CHECKING THE IGNITION SPARK GAP (from the wire harness)
1. Check: 2. Check:
¢ Ignition spark gap ¢ Crankshaft position sensor resistance
Out of specification — Perform the ignition Out of specification — Replace the crank-
system troubleshooting, starting with step (5). shaft position sensor.
Refer to “TROUBLESHOOTING?” on page
8-4. Crankshaft position sensor resis-

a
tance
Minimum ignition spark gap 189-231 ©
6.0 mm (0.24 in)
a. Connect the digital circuit tester (Q) to the
TIP crankshaft position sensor coupler as
shown.
lf the ignition spark gap is within specification,

J
the ignition system circuit is operating normally. Digital circuit tester (CD732)
a. Remove the ignition coil from the spark 90890-03243
plug. Model 88 Multimeter with ta-
chometer
b. Connect the ignition checker “1” as
YU-A1927
shown.

J Ignition checker
90890-06754
Oppama pet—4000 spark checker
¢ Positive tester probe
black “1”
¢ Negative tester probe
gray “no

YM-34487

8-45
 ELECTRICAL COMPONENTS

2. Check:
¢ Stator coil resistance
Out of specification — Replace the stator coil.

[| Stator coil resistance

0.112—0.168 ©

a. Connect the digital circuit tester to the sta-

tor coil coupler as shown.

Digital circuit tester (CD732)

b. Measure the crankshaft position sensor 90890-03243
resistance. Model 88 Multimeter with ta-
chometer
EASS0582

CHECKING THE STARTER MOTOR YU-A1927

OPERATION
1. Check: « Positive tester probe
white “1”
¢ Starter motor operation * Negative tester probe
Does not operate — Perform the electric white “2”
starting system troubleshooting, starting with
step (4). « Positive tester probe
Refer to “TROUBLESHOOTING” on page white “1”
8-10. ¢ Negative tester probe
white “3”
a. Connect the positive battery terminal “1”
and starter motor lead “2” with a jumper
* Positive tester probe
lead “3”. white “2”
EWA13810
¢ Negative tester probe
white “3”
¢ A wire that is used as a jumper lead must
have at least the same capacity of the bat-
tery lead, otherwise the jumper lead may
burn.
¢ This check is likely to produce sparks,
therefore, make sure no flammable gas or
fluid is in the vicinity.

b. Measure the stator coil resistance.

FAS S0680

CHECKING THE RECTIFIER/REGULATOR

1. Check:
¢ Rectifier/regulator input voltage
Out of specification — Correct the stator coil
condition.
b. Check the starter motor operation. Refer to “CHECKING THE STATOR COIL”
EAS30566 on page 8-46.
CHECKING THE STATOR COIL
1. Disconnect: = | Rectifier/regulator input voltage
¢ Stator coil coupler above 14 V at 5000 r/min
(from the wire harness)
a. Connect the digital circuit tester (AC V) to
the rectifier/regulator coupler as shown.

8-46
 ELECTRICAL COMPONENTS

Digital circuit tester (CD732)

90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927

¢ Positive tester probe

white “1”
¢ Negative tester probe
white “2”
b. Start the engine and let it run at approxi-
¢ Positive tester probe mately 5000 r/min.
white “1” c. Measure the charging voltage.
¢ Negative tester probe
white “3” EASS0569

CHECKING THE HORN

¢ Positive tester probe 1. Check:
white “2” e Horn sound
¢ Negative tester probe
Faulty sound — Replace.
white “3”
EASS0573

CHECKING THE FUEL SENDER

1. Disconnect:
¢ Fuel pump coupler

nl (from the wire harness)

¢ Fuel hose
(from the fuel tank)
2. Remove:
e Fuel tank
Refer to “FUEL TANK” on page 7-1.
3. Remove:
b. Start the engine and let it run at approxi- e Fuel pump
mately 5000 r/min. (from the fuel tank)
c. Measure the rectifier/regulator input volt- 4. Connect:
age. ¢ Fuel pump coupler
2. Check: e Fuel hose
¢ Rectifier/regulator output voltage 5. Turn the main switch to “ON”.
Out of specification — Replace the rectifier/ 6. Check:
regulator. ¢ Fuel level warning light

il
Out of specification — Replace the fuel
Regulated voltage (DC)
pump.
14.3-14.7 V
« Fuel pump is atmosphere “A”
— Fuel level warning light is come on
a. Connect the digital circuit tester (DC V) to
* Fuel pump is soaked in fuel “B”
the battery as shown. — Fuel level warning light is goes off
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”

8-47
 ELECTRICAL COMPONENTS

12V

EASSaO574 c. Measure the radiator fan motor move-

CHECKING THE FUEL LEVEL WARNING ment.
LIGHT
EFAS S0578
This model is equipped with a self-diagnosis de- CHECKING THE COOLANT TEMPERATURE
vice for the fuel level detection circuit. SENSOR
1. Check: 1. Remove:
* Fuel level warning light “1” ¢ Coolant temperature sensor
(Turn the main switch to “ON”.) Refer to “CYLINDER HEAD” on page 5-33.
Warning light comes on for a few seconds, EW AI41740

then goes off — Warning light is OK.

Warning light does not come on —> Replace ¢ Handle the coolant temperature sensor
the meter assembly. with special care.
Warning light flashes eight times, then goes ¢ Never subject the coolant temperature sen-
off for 3 seconds in a repeated cycle (mail- sor to strong shocks. If the coolant tem-
function detected in fuel sender) — Replace perature sensor is dropped, replace it.
the fuel pump assembly.
2. Check:
¢ Coolant temperature sensor resistance
Out of specification — Replace.

Coolant temperature sensor re-

sistance
CNBESC: 2513-2777 Q at 20 °C (2513-
oh
2777 Q at 68 °F)
Coolant temperature sensor re-
‘ sistance
210-221 © at 100 °C (210-221 ©
at 212 °F)
EASSaO57?

CHECKING THE RADIATOR FAN MOTORS a. Connect the digital circuit tester (Q) to the
1. Check: coolant temperature sensor as shown.
¢ Radiator fan motor
Faulty/rough movement — Replace.
a. Disconnect the radiator fan motor coupler
from the wire harness.
J Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
b. Connect the battery (DC 12 V) as shown. chometer
¢ Positive tester probe
YU-A1927
blue “1”
¢ Negative tester probe b. Immerse the coolant temperature sensor
black “2” “1” in a container filled with coolant “2”.
TIP
Make sure the coolant temperature sensor ter-
minals do not get wet.
c. Place a thermometer “3” in the coolant.

8-48
 ELECTRICAL COMPONENTS

d. Heat the coolant or let it cool down to the

specified temperatures.
e. Measure the coolant temperature sensor
resistance.
3. Install:
¢ Coolant temperature sensor

YX Coolant temperature sensor

% 16 N-m (1.6 kgf-m, 12 Ib-ft)
3V
EASa0592 A. Check that the throttle valves “2” open.
CHECKING THE THROTTLE SERVO MOTOR B. Check that the throttle valves “2” fully close.
1. Remove:
e Air filter case EAS S0587

CHECKING THE AIR INDUCTION SYSTEM

Refer to “AIR FILTER CASE” on page 7-5.
SOLENOID
2. Check:
1. Check:
¢ Throttle valve operation
e Air induction system solenoid resistance
Throttle valves do not fully close — Replace
Out of specification — Replace.

[ell
the throttle bodies.
a. Connect two C-size batteries to the throttle Solenoid resistance
servo motor terminals “1” as shown. 18-22 QO
ECA17660

NOTICE a. Remove the air induction system solenoid

Do not use a 12 V battery to operate the throt- coupler from the air induction system sole-
tle servo motor. noid.
b. Connect the digital circuit tester (Q) to the
TIP
air induction system solenoid terminal as
Do not use old batteries to operate the throttle
shown.
servo motor.

Ve Digital circuit tester (CD732)

90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927

¢ Positive tester probe

orange “1”
*« Negative tester probe
green “2”

8-49
 ELECTRICAL COMPONENTS

« Positive tester probe

white/black (wire harness color)
¢ Negative tester probe
black/blue (wire harness color)

c. Measure the air induction system solenoid

EAS30589
resistance. SA\
CHECKING THE CYLINDER LO I nA \
IDENTIFICATION SENSOR c. Turn the main switch to “ON”.
1. Remove: d. Rotate the crankshaft.
¢ Fuel tank e. Measure the voltage. With each full rota-
Refer to “FUEL TANK” on page 7-1. tion of the crankshaft, the voltage reading
* Air filter case should cycle from 0.8 V to 4.8 V to 0.8 V to
Refer to “AIR FILTER CASE” on page 7-5. 4.8 V.
e Air filter case duct
FASS0594
Air cut-off valve CHECKING THE INTAKE AIR
Refer to “AIR INDUCTION SYSTEM” on TEMPERATURE SENSOR
page 7-20. 1. Remove:
2. Check: e Intake air temperature sensor
¢ Cylinder identification sensor output voltage EWAIA110

Out of specification — Replace.

* Handle the intake air temperature sensor
| Cylinder identification sensor
with special care.
output voltage (ON)
4.8V ¢ Never subject the intake air temperature
Cylinder identification sensor sensor to strong shocks. If the intake air
output voltage (OFF) temperature sensor is dropped, replace it.
0.8 V 2. Check:
e Intake air temperature sensor resistance
a. Connect the test harness— speed sensor
Out of specification — Replace.
(3P) “1” to the rear speed sensor coupler
and wire harness as shown. Intake air temperature sensor re-
b. Connect the digital circuit tester (DC V) to sistance
the test harness— speed sensor (3P). 5400-6600 © at 0 °C (5400-6600
QO at 32 °F)
Digital circuit tester (CD732) Intake air temperature sensor re-
90890-03243 sistance
Model 88 Multimeter with ta- 289-391 © at 80 °C (289-391 ©
chometer at 176 °F)
YU-A1927
Test harness— speed sensor (3P) a. Connect the digital circuit tester (Q) to the
90890-03208 intake air temperature sensor terminal as
Test harness— speed sensor (3P) shown.
YU-03208

8-50
 ELECTRICAL COMPONENTS

Digital circuit tester (CD732) Digital circuit tester (CD732)

90890-03243 90890-03243
Model 88 Multimeter with ta- Model 88 Multimeter with ta-
chometer chometer
YU-A1927 YU-A1927

b. Immerse the intake air temperature sen- * Positive tester probe

sor “1” in a container filled with water “2”. black “1”
TIP * Negative tester probe
black “2”
Make sure that the intake air temperature sensor
terminals do not get wet.
c. Place a thermometer “3” in the water.

c. Measure the steering damper solenoid re-

sistance.
d. Slowly heat the water, then let it cool down
EAS 30681
to the specified temperature. CHECKING THE FUEL INJECTORS
e. Measure the intake air temperature sen-
The following procedure applies to all of the fuel
sor resistance. injectors.
3. Install: 1. Remove:
e Intake air temperature sensor ¢ Fuel injector
EASa0598 Refer to “THROTTLE BODIES’ on page 7-11
CHECKING THE STEERING DAMPER or “AIR FILTER CASE” on page 7-5.
SOLENOID 2. Check:
1. Remove: ¢ Fuel injector resistance
¢ Front upper cowling Out of specification — Replace the fuel injec-
Refer to “GENERAL CHASSIS (4)” on page tor.

ail
4-13.
2. Check: Resistance
* Steering damper solenoid resistance 12.0 ©
Out of specification — Replace the steering
a. Disconnect the fuel injector coupler from
damper assembly.
the fuel injector.

s. Steering damper solenoid resis-

tance
b. Connect the digital circuit tester (Q) to the
fuel injector coupler as shown.

Ve
49.82-56.18 ©
Digital circuit tester (CD732)
a. Disconnect the steering damper lead cou- 90890-03243
pler from wire harness. Model 88 Multimeter with ta-
b. Connect the digital circuit tester (Q) to the chometer
YU-A1927
steering damper lead coupler.
* Positive tester probe
Injector terminal “1”
*« Negative tester probe
Injector terminal “2”

8-51
 ELECTRICAL COMPONENTS

« Positive tester probe

white/black “4”
¢ Negative tester probe
black/yellow “3”

e. When turning the wheel switch in direction

“a’, check that the output voltage is within
the specified values.

c. Measure the fuel injector resistance.

i f.
Output voltage
More than 5 V

When turning the wheel switch in direction

EASS1673

CHECKING THE WHEEL SWITCH “b”, check that the output voltage is within
the specified values.

si
1. Check:
¢ Wheel switch “1” output voltage Output voltage
Out of specification — Replace the handlebar Less than 0.5 V
switch (right).
a. Connect the digital circuit tester (DC V) to
the handlebar switch coupler (right) as
shown.

Digital circuit tester (CD732)

90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927

¢ Positive tester probe

white/green “2”
¢ Negative tester probe
black/yellow “3”

b. Turn the main switch to “ON”.

c. When turning the wheel switch in direction
“a” and “b”, check that the output voltage is
within the specified values.

Output voltage reading cycle

More than 5 V to less than 0.5 V
then back to more than 5 V to
less than 0.5 V

d. Connect the digital circuit tester (DC V) to

the handlebar switch coupler (right) as
shown.

425! Digital circuit tester (CD732)

eo 90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927

8-52
 ELECTRICAL COMPONENTS

8-53
 SELF DIAGNOSTIC

SELF-DIAGNOSTIC FUNCTION ....0 200.000. cece eee eee e eee ee sana eeeeeaes 9-7
GLOSSARY... weaeee= 1
OUTLINE.. wee GOT
CHECKING THE WARNING LIGHT .. 9-7
YDT..
PARTS CONNECTED TO THE ECU... 12112 9-3
PARTS CONNECTED TO THE SCU (for YZF-R4x1M) renee
PARTS CONNECTED TO THE ABS ECU..
PRECAUTIONS FOR ROAD TEST 1.00... cecc cece ceeceeee eee ee ccna neers seeaaaeeeeeeesaaas 9-4

SYSTEM DIAGRAM.. 1220 9-5

ECU CIRCUIT DIAGRAM...
By Ce eet EPA CMT oi, scccedeseesccveccevesseceecs
asceteds oe cductscevedeuedetesveevervecs .9-8

FUEL INJECTION SYSTEM... veveee 9°17

CIRCUIT DIAGRAM.. veoee 9°11
BASIC PROCESS FOR TROUBLESHOOTING .. rere 9°13
[A] THE MIL COMES ON/FLASHES AND ENGINE OPERATION Is
NOT NORMAL... ...9-14
[B] THE MIL DOES NOT COME ON, BUT THE ENGINE
OPERATION IS NOT NORMAL.. 9-14

ABS (Anti-lock Brake System)..........................ccccccccece ceeesceseeeseeeeseeeeeesnees .9-15

CIRCUIT DIAGRAM.. veoeee 9215
ABS COMPONENTS CHART ..
ABS COUPLER LOCATION CHART ..gi we nie'e ye Vee vndiveiviuegexnofeanaeenesvacensensyrvoser 9-18
MAINTENANCE OF THE ABS ECU.. 112 9-19
ABS TROUBLESHOOTING OUTLINE... wee 9-19
BASIC INSTRUCTIONS FOR TROUBLESHOOTING... wae. 9-20
[A] CHECKING THE ABS WARNING LIGHT... ceaneneee P22
[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON... peneree P22
[A-2] ALL INDICATOR LIGHTS FAIL TO COME ON.. soesseses 9-22
[A-3] THE ABS WARNING LIGHT COMES ON.. saan 22
[A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE... ...9°22
[A-5] ABS ECU AND FI ECU FAIL TO COMMUNICATE ....sssscscscccccseee . 9-23
[B-1] MALFUNCTION ARE CURRENTLY DETECTED..........00000.. .9-23
[B-2] DIAGNOSIS USING THE DTC...... 0... eee eee ee ec eee eee eeeeeeeee .9-23
(3) DEBE TINGS Ti De res ctce cece cicegctenteteapeceeeseespuewetes tavasvnetevsstecsatiad: .9-24
[(O-1] FINAL CHECK (000... cece cece eee ee eee eae ca neces eae ea eee eee eaaeaeeaeeeeeaeea . 9-24

STEERING DAMPER SYSTEM...00...... cece ccc ceecee ee eee cesses eeaeeeeeseasaaeeees 9-25
CIRCUIT DIAGRAM.. s1aeee 9°20
BASIC INSTRUCTIONS FOR TROUBLESHOOTING... -.9-2f
ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM
(for YZF-R1M) ... sofas Sn bs deen peteeneg eb og eb ems ws dene nate omnes Cat aweweewnaeiks aoaes owes ee
CIRCUIT DIAGRAM... sasaaeessaseeeeseeee DOO
MAINTENANCE OF THE SCU (suspension control unit. beseeeseeeeee O71
BASIC INSTRUCTIONS FOR TROUBLESHOOTING... “voecessssssssnsee 9°31

SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE..........9-32

DTC TABLE... sd ¥eiat Yeah eesautecewdeeuedsnutdeucecceateese OS
SELF-DIAG NOSTIC FU NCTION TABLE
(FOR FUEL INJECTION SYSTEM).......... cece eee ce eee eeeeeeeeeessaseeeeeas O°
SELF-DIAGNOSTIC FUNCTION TABLE
(FOR ABS (Anti-lock Brake System))... .. 9-52
SELF-DIAGNOSTIC FUNCTION TABLE (FOR STEERING DAMPER
SYSTEM)... ... 9-56
SELF-DIAG NOSTIC FU NCTION TABLE (FOR ELECTRONICALLY >
ADJUSTABLE SUSPENSION SYSTEM (for YZF-R1M)).......................9-56
COMMUNICATION ERROR WITH THE METER cesssstisassiseesssssssssssssssane 9°59
DIAGNOSTIC CODE: SENSOR OPERATION TABLE............................ 9°59
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE ...................... 9-62
DIAGNOSTIC CODE TABLE (SCU) (for YZF-R1M) .........00. 9-64

Ee Ce TP ase cineca tits te pene ceca Sete nd Pewee atuaets teases dates ceteantiesnsceas OO

~ TROUBLESHOOTING Fide Gases id ahbu cians caus sacasfevad tesa yedusss tases dsieacicasstiasnszecs ae

~ TROUBLESHOOTING Piast Geue's dd atbu ci daase cane sacasfevad tewseyadusns tases dsiesciasctiasssiccs te

TROUBLESHOOTING Fide Seuss deaths ci daase caus sacas feed tesa veduass teases dsieacieesstiassszccn tad

C0520 (Fl)............-- seccsucsucsucssssssssessussussussucssessessesstssessssussassscsesseseeseeee

9°71
TROUBLESHOOTING oocccccccsssssssssssssseccesssssssssssssisecessesssssssssssseeeessssesssssss
9°71

CO520 (SCU)........ccccseccccsccsessessucssecusssesscsecssessessussssussussassscssessessessesssssessscsseeee
9°75
TROUBLESHOOTING osccccccsssssssssssssceesesssssssssssesevesessssssssesssssseessesseeseess 9°75

TROUBLESHOOTING Fie deta doha'vde thsile Suu Valea evant beanie sadvadsduvdadevedduvvateslens’ OTE

TROUBLESHOOTING Fie dia eine ahaa taila Su Valea vant beanies Sad ads duvaadevadduvvatesdanes’ OPI)

TROUBLESHOOTING Fie da eiadivi ahaa tise Su Valea ant Gaver ace Sad ade duvadeveaewvvatesdawes’ OME)
C1007 ..
TROUBLESHOOTING sans i nna bw'e wisipits wees ewes pws e saints cm au'innidc'asuiiwes naan 9-86

P0030...
TROUBLESHOOTING sans i neal bw'e wens wanes ewes wee saints cm aun nidc'asuiiees naan 9-87

P0050...
TROUBLESHOOTING sans i neal bw'e wei acne wane avs tweens a nsatuns cmie'innidc'asuites naan 9-971

P0069...
TROUBLESHOOTING sans pune alm ibe wei wcna's wanes ave tne assent ns cmiwinnitc'asuits asap 9-95

PO0D1, P2195...
TROUBLESHOOTING gee eee pega don ote eet node dpe yadsawaneperes eeu yfycesdonedeeseevesess 9-97

POOD3, P2197...
TROUBLESHOOTING pa pie ecg gee dgfen edu ewde ec eesaegeyavensuaseeteegeeeeyessycceenes eetene 9-101

P0107, P0108 ..
TROUBLESHOOTING pepe eee gee egfen eeu ewee made aed geyaveneuas cote gueedyes sy cceenee eetene 9-105

P0112, P0113 ..
TROUBLESHOOTING pepe eee gee egfen eeu ewee made aed geyaveneuas cote gueedyes sy cceenee eetene 9-109

P0117, P0118 .. ee D113

TROUBLESHOOTING .. ...9-113

P0122, P0123, P0222, PQO2Z2ZS, P2135. .............ccscscccsssssscenecccsesseeneesenesserseetes 9-117

TROUBLESHOOTING 000... eee ccc cece cece eee e ee eae ena ee eee cee eas eaeeeeaeaaeeeeeeees 9-117

P0132...
TROUBLESHOOTING pega ete eae g ee egfe eafun weno sees vote aeuau peu ee caedyes ey cceegeseeeese 9-121

P0152...
TROUBLESHOOTING bee ceed eee ee eec eee eeeeeesauaeeceeeesaueeneeeceseueeaeeseaeeuseeeeeeeeaes 9-124

P0201..
TROUBLESHOOTING bee cee eee eee ea eee cece eeaauaeeeeeeesaueeeeeeeesauaeaeeseeeeuaeeeeeeeeaes 9-127

P0202...
TROUBLESHOOTING bee cee eeeeee ea eae eeeeeeaaaueceeeeeseueeeeeeeeseuaecseeeesauueeeeseaseus 9-130

P0203...
TROUBLESHOOTING bee cae eee eee ea eae eeeeeeaaeueceeeeeseuaeeeeseesaaueeseseesauueeeeseesaus 9-133
P0204...
TROUBLESHOOTING sens i ek seme ssid s am Wes ory dn ewes Karam nein nabs wes 9-136

P0335...
TROUBLESHOOTING sens i ek seme wisinit s am Weis owen sofas Karam nein maha we 9-139

P0340...
TROUBLESHOOTING sens i ink nem bw'eswjsisit s hah wernes owen sofas karan sueine panies wes 9-142

P0351..
TROUBLESHOOTING eens i ink nineteen sa wens arya sof Kasra une pate wes 9-145

P0352...
TROUBLESHOOTING pape aap ee dpfen eeu wee nede se egeyaveneeas cede caedyes ey cceedee tease 9-149

P0353...
TROUBLESHOOTING pepe ete apg egfen efun weeeede se egeyetsaeuae peu os ceeedyes ey cceeguseeeese 9-153

P0354...
TROUBLESHOOTING pega ete ape g ee epfe dade weno sees vats eane peu ee gaeedyes eveenedesedseee 9-157

PO475, PO47G, POAGE. ...........:ccsessecsncccsessersesecsarsessoracseneesssrccsesensserccsansecserens 9-161

TROUBLESHOOTING 0000... ceee ccc cece eee e cee eee eee eae ea eee eee ea eaaeeeeeeeaeaaeeees 9-161

P0480...
TROUBLESHOOTING pega eben pe wpie eafue wee ceteegu ee vats aeans peu os gasedyenevesneausedsese 9-165

P048D, PO46E ..
TROUBLESHOOTING pega eben pe wpie eafue wee ceteegu ee vats aeans peu os gasedyenevesneausedsese 9-168

PO500 (FI), P1500.........ccccscescecceccecsscssessessessessessucsecsecsucssesseseessussessacsncsseseee 9-171

TROUBLESHOOTING. ......cscescsssscssesseseessssessussecsucssesestsetsstsseseesesseesees 9-171

P0500 (SCU)...
TROUBLESHOOTING bee cee eeeeee ea eae eeeeeeaaaueceeeeeseueeeeeeeeseuaecseeeesauueeeeseaseus 9-183

PO560 (Fl), PO5G3..........[Link] 9-184

TROUBLESHOOTING ......cccsecsecscsscssessessessssssusstesessssssssssatsaeareaesesee 9-184

P0560 (SCU)...
TROUBLESHOOTING bee cae eee eee ea eae eeeeeeaaeueceeeeeseuaeeeeseesaaueeseseesauueeeeseesaus 9-185

P0601..
TROUBLESHOOTING bee eae eee eee ea eae eeeeeeeaaeue cece eeseaueeeeeeeaaaueeseseesaaueeeeseesaas 9-186
P0606...
TROUBLESHOOTING sens i ek seme ssid s am Wes ory dn ewes Karam nein nabs wes 9-187

PO62F ..
TROUBLESHOOTING sens i ek seme ssid s am Wes ory dn ewes Karam nein nabs wes 9-188

P0638...
TROUBLESHOOTING sens i ek seme wisinit s am Weis owen sofas Karam nein maha we 9-189

P0657...
TROUBLESHOOTING sens i ink nem bw'eswjsisit s hah wernes owen sofas karan sueine panies wes 9-193

P0916, P0917 ..
TROUBLESHOOTING pa pie ecg gee dgfen edu ewde ec eesaegeyavensuaseeteegeeeeyessycceenes eetene 9-197

P1400...
TROUBLESHOOTING pepe eee gee egfen eeu ewee made aed geyaveneuas cote gueedyes sy cceenee eetene 9-201

P1600...
TROUBLESHOOTING pape aap ee dpfen eeu wee nede se egeyaveneeas cede caedyes ey cceedee tease 9-205

P1601..
TROUBLESHOOTING pepe ete apg egfen efun weeeede se egeyetsaeuae peu os ceeedyes ey cceeguseeeese 9-209

P1602...
TROUBLESHOOTING pega ete ape g ee epfe dade weno sees vats eane peu ee gaeedyes eveenedesedseee 9-213

P1806, P1807 .. eee O17

TROUBLESHOOTING .. 9-217

P2122, P2123, P2127, P2Z1ZG, P2VSS ........0cccscsessorscsescesserscseseneserseseasenserses 9-221

TROUBLESHOOTING 200.0... eeeee eee cece cece eee e eee eae cea aaa ee eeeeaa ea eeeeeeaaaeeeeeees 9-221

P2158 (Fi)...
TROUBLESHOOTING bee eee eee eee ea aaa cece eesaeae cece eesaueeeeeeeesaueeaeeseeseuaeeeeeeeeaes 9-225

P2158 (SCU)...
TROUBLESHOOTING bee cee eeeeee ea eae eeeeeeaaaueceeeeeseueeeeeeeeseuaecseeeesauueeeeseaseus 9-229

P21CF..
TROUBLESHOOTING bee cee eeeeee ea eae eeeeeeaaaueceeeeeseueeeeeeeeseuaecseeeesauueeeeseaseus 9-230

P21D0..
TROUBLESHOOTING bee cee eeeeee ea eae eeeeeeaaaueceeeeeseueeeeeeeeseuaecseeeesauueeeeseaseus 9-233
P21D1..
TROUBLESHOOTING sens i ink sem conesinit is fam We eers wy dn ewes aaecram nian satan wes 9-236

P21D2..
TROUBLESHOOTING sens i ink sem conesinit is fam We eers wy dn ewes aaecram nian satan wes 9-239

P2228, P2229 ..
TROUBLESHOOTING sens i ek seme ssid s am Wes ory dn ewes Karam nein nabs wes 9-242

U0100 ..
TROUBLESHOOTING sens i ek seme ssid s am Wes ory dn ewes Karam nein nabs wes 9-246

U0121.
TROUBLESHOOTING pepe eee gniegfen eeu eed eeeeten evgeyavenee ts ete geeeeyesevecuedeeeetene 9-249

U0125 (FI)...
TROUBLESHOOTING pepe eee gniegfen eeu eed eeeeten evgeyavenee ts ete geeeeyesevecuedeeeetene 9-252

U0125 (SCU)....
TROUBLESHOOTING pepe eee gniegfen edu ewdemeeeen egeyavensuaseeteegeeeeyesevcceedeeeetene 9-256

U0155 or Err (Fl)...

TROUBLESHOOTING pepe eee gniegfen edu ewdemeeeen egeyavensuaseeteegeeeeyesevcceedeeeetene 9-259

0155. OFr EFr (SOU) tcc 5nccc seve. cence sete ces cess tend std tea dateceeee seed, Se cctee gcdven tes sctens 9-263
TROUBLESHOOTING ...... occ cc ce ceeeeeceseeeeeceeseeeecessaeeeesaeeeeseeaees 9-263

11_ABS..
TROUBLESHOOTING pepe eee gniegfen edu ewdemeeeen egeyavensuaseeteegeeeeyesevcceedeeeetene 9-266

12_ABS..
TROUBLESHOOTING pepe eee gniegfen edu ewdemeeeen egeyavensuaseeteegeeeeyesevcceedeeeetene 9-267

13, 26_ABS. ..
TROUBLESHOOTING becca eeeee eee cea eaaeeeeeeaaaueeeeeeeaeaueeeeeseaeaueeeeeeeeaeaeneeeeesaees 9-268

14, 27_ABS..
TROUBLESHOOTING becca eeeee eee cea eaaeeeeeeaaaueeeeeeeaeaueeeeeseaeaueeeeeeeeaeaeneeeeesaees 9-269

15_ABS..
TROUBLESHOOTING becca eeeee eee cea eaaeeeeeeaaaueeeeeeeaeaueeeeeseaeaueeeeeeeeaeaeneeeeesaees 9-270

16_ABS..
TROUBLESHOOTING becca eeeee eee cea eaaeeeeeeaaaueeeeeeeaeaueeeeeseaeaueeeeeeeeaeaeneeeeesaees 9-272
21_ABS ...9-274
~ TROUBLESHOOTING ..sssssossssssssnssssnsssneesnnntinessnnnsinnesnnsesneese .9-274

31_ABS..
TROUBLESHOOTING sens i ink sem conesinit is fam We eers wy dn ewes aaecram nian satan wes 9-275

33_ABS..
TROUBLESHOOTING sens i ink sem conesinit is fam We eers wy dn ewes aaecram nian satan wes 9-277

34_ABS 9-279
~ TROUBLESHOOTING ...sssssossssssssnsessnsssneesnnntineesnantinnesnnstsneese .9-279

41_ABS ...9-280
~ TROUBLESHOOTING .sssssossssssssnsessssssneesnnntineesnasinnesnnsesneese . 9-280

42 ABS..
TROUBLESHOOTING pape eae gniegie teu ewdeeeeetea evgecaveneeesevedsgaeeeyesavecuedeeetene 9-281

43, 45_ABS ..
TROUBLESHOOTING pepe ee ea eg niegie teu ewde ee eetea evgeuaveneeesevedsgaeeeyesavecuedyenetene 9-282

44, 46_ABS ... 9-283

"TROUBLESHOOTING o..scscsssssssstsnssssstsstsnstnessnstnetientnntsneeneee .9-283

51_ABS..
TROUBLESHOOTING pepe ee ea eg niegie teu ewde ee eetea evgeuaveneeesevedsgaeeeyesavecuedyenetene 9-284

53_ABS..
TROUBLESHOOTING pepe ee ea eg niegie teu ewde ee eetea evgeuaveneeesevedsgaeeeyesavecuedyenetene 9-285

55 ABS ... 9-287

~ TROUBLESHOOTING ...sssssossssssssnssssssssneesinnntinessnaninnesnnsesnneee .9-287

56_ABS ... 9-288

~ TROUBLESHOOTING o..sssssossssssssnsessnsssneesinantinessnantnsesnnsssnesen . 9-288

57_ABS..
TROUBLESHOOTING be eeeeeeeeeee cea ee eee eeeeaaaueeeceeeaeaueeeeeeesaaueeeeeeesaeaeeseseesaees 9-289

62_ABS..
TROUBLESHOOTING be eeeeeeeeeee cea ee eee eeeeaaaueeeceeeaeaueeeeeeesaaueeeeeeesaeaeeseseesaees 9-293

68_ ABS ... 9-294

~ TROUBLESHOOTING o..sosssossssssssnssssnsssseesnantinessnanssnsesnnsesneeen .9-294
89 ABS... veeeee 9-295
TROUBLESHOOTING .. ...9-295

90 ABS... 1121 9-298

TROUBLESHOOTING .. ...9-298

91_ABS.. w.11 9-301

TROUBLESHOOTING .. ...9-301
 SELF-DIAGNOSTIC FUNCTION

EAS20437

SELF-DIAGNOSTIC FUNCTION
EAS33142

GLOSSARY
Word Description

‘Maltunction iadecatae MIL is an indicator light that comes on when a control unit determines a malfunc-
light) tion.

ae nostic rouble DTC is a code that is saved within a control unit’s memory when the control unit
is de) determines a malfunction.

Current malfunction A DTC for an unrecovered, current malfunction.

Recovered malfunc-
A DTC for a previously determined but now recovered malfunction.
tion
OBD
Self-diagnostic system is equipped in a control unit for the emission control sys-
(On-board diagnos-
tem.
tics)
GST
Generic diagnostic tool that complies with OBD standards.
(Generic scan tool)
YDT
(Yamaha diagnostic Diagnostic tool developed especially for Yamaha vehicles.
tool)

EASa2858

OUTLINE
The control unit is equipped with a self-diagnostic function in order to ensure that the system is operat-
ing normally. If this function detects a malfunction in the system, it immediately operates the system
under substitute characteristics and illuminates the warning light to alert the rider that a malfunction has
occurred in the system. Once a malfunction has been detected, a DTC is stored in the memory of the
control unit.
EASa2859

CHECKING THE WARNING LIGHT

The warning light comes on after the main switch has been set to “ON”. Refer to the following table for
lighting up time.
lf the warning light still comes on, refer to a check item of a troubleshooting of each system, check and
repair it. If the warning light does not come on, the warning light (LED) may be defective.
TIP
¢ This engine equips self-diagnostic function. It’s controlled delicately for detecting defective and mal-
function of the exhaust emission control system. Therefor, the vehicle modifying, poor maintenance,
and improper using of the vehicle may also become the cause of the MIL come on. These events may
cause the occurrence of the warning light coming on without malfunction.
e Reprogramming of the ECU software.
e Using the electrical accessory which may affect the ECU.
e Using the incorrect specification of spark plug and fuel injector. Using the third party accessories such
as suspension and exhaust system.
¢ Change of specifications of drive chain, sprocket, wheel and tire.
e Removing or modifying the Os sensor, the air induction system, the exhaust system part (catalyst, EX-
UP, etc.).
¢« Poor maintenance of the drive chain and tire air pressure.
e Incorrect brake pedal height, rear brake dragging.
e Excessive opening and closing of the throttle grip, frequently used of burnout, wheelie and half clutch.
e Air mixture by fuel supply badness.

9-1
 SELF-DIAGNOSTIC FUNCTION

System Lighting up warning light Lighting time

FUEL INJECTION SYSTEM MIL “2” 2.0 seconds
ABS (Anti-lock Brake System) | ABS warning light “1” .

oe DAMPER SYS- Auxiliary system warning light “3” 2.0 seconds

ELECTRONICALLY ADJUST-
ABLE SUSPENSION SYS- Auxiliary system warning light “3” 2.0 seconds
TEM (for YZF-R1M)

TIP
*: The ABS warning light goes off when the vehicle is judged to normal with running.

EAS32806

YDT
This model uses the YDT to identify malfunctions.
For information about using the YDT, refer to the operation manual that is included with the tool.

hh Yamaha diagnostic tool USB (US)

ff 90890-03269
Yamaha diagnostic tool (A/l)
90890-03264

TIP
e Yamaha diagnostic tool (A/l) (90890-03264) includes YDT sub harness (6P) (90890-03266).
e lf you already have Yamaha diagnostic tool (A/I) (90890-03262), YDT sub harness (6P) (90890-
03266) is separately required.
eA GST can also be used to identify malfunctions.
 SELF-DIAGNOSTIC FUNCTION

Connecting the YDT

Remove the protective cap “1”, and then connect the YDT to the coupler.

EASS2884

PARTS CONNECTED TO THE ECU

The following parts are connected to the ECU.
When checking for a power short circuit, the couplers must be disconnected from all of the following
parts beforehand.
¢ Crankshaft position sensor ¢ Oo sensor 1 (left side)
¢ Primary injector #1 ¢ Fuel pump
¢e Primary injector #2 ¢ Auxiliary light
¢ Primary injector #3 ¢ O» sensor 2 (right side)
e Primary injector #4 ¢ Hydraulic unit assembly (ABS ECU)
¢ Secondary injector #1 ¢ Air induction system solenoid
¢ Secondary injector #2 ¢ Throttle servo motor
¢ Secondary injector #3 « Relay unit
¢ Secondary injector #4 ¢ Starter relay
* Ignition coil #1 ¢« Radiator fan motor relay
* Ignition coil #2 ¢« Meter assembly
* Ignition coil #3 « Steering damper solenoid
* Ignition coil #4 e EXUP servo motor
¢ Throttle position sensor ¢ Cylinder identification sensor
¢ Accelerator position sensor ¢ Intake funnel servo motor
¢ Intake air pressure sensor ¢ Intake solenoid
« Atmospheric pressure sensor ¢ Headlight control unit
¢ Coolant temperature sensor ¢ Handlebar switch (left and right)
¢ Gear position sensor ¢ IMU (Inertial Measurement Unit)
e Shift sensor ¢ SCU (Suspension Control Unit) (YZF-R1M)
¢ Intake air temperature sensor ¢ CCU (Communication Control Unit) (YZF-R1M)

EASa2H85

PARTS CONNECTED TO THE SCU (for YZF-R1M)

The following parts are connected to the SCU.
When checking for a power short circuit, the couplers must be disconnected from all of the following
parts beforehand.
¢ Front fork stepping motor (left) ¢ Sub radiator fan motor
¢ Front fork stepping motor (right) ¢ Auxiliary DC connector
 SELF-DIAGNOSTIC FUNCTION

¢« Rear shock absorber assembly stepping motor ¢ Sidestand switch

(compression damping)
e Rear shock absorber assembly stepping motor (re- * Fuel sender
bound damping)
¢ Steering damper solenoid (OPTION) ¢ Fuel pump
¢ ECU (Engine Control Unit) ¢ Handlebar switch (left)
¢ Hydraulic unit assembly (ABS ECU) ¢ Headlight control unit
« Meter assembly © Auxiliary light
¢ IMU (Inertial Measurement Unit) ¢ Front turn signal/position light (right and left)
¢ CCU (Communication Control Unit) * Steering damper solenoid
e Radiator fan motor

EAS32916

PARTS CONNECTED TO THE ABS ECU

The following parts are connected to the hydraulic unit assembly (ABS ECU).
When checking for a power short circuit, the couplers must be disconnected from all of the following
parts beforehand.
¢ SCU (Suspension Control Unit) (YZF-R1M) ¢ Front wheel sensor
¢ Meter assembly ¢ Rear wheel sensor
¢ IMU (Inertial Measurement Unit) ¢ Handlebar switch (right and left)
e ECU (Engine Control Unit) ¢ Rear brake light switch
¢ CCU (Communication Control Unit) (YZF-R1M) ¢ Tail/brake light

EASa3137

PRECAUTIONS FOR ROAD TEST

EWA20860

When test riding the vehicle, always comply with local traffic regulations.
 SYSTEM DIAGRAM

EAS20387

EAS 32920

ECU CIRCUIT DIAGRAM

| 2. Electronic| throttle valve fuse

> 1A
—>/B
—— 34. Primary injector #1
$
10. Fuel pump 6) eS .
¢ 3. Backup fuse relay 9 35. Primary injector #2

| 4. Fuel injection 9. Start/engine 36. Primary injector #3

system fuse stop switch 11. Fuel pump @)
* = ‘
f=) ai
.
5. Ignition fuse , it:
eet
12. Starter
rela
Nedra
indicator ‘<
a) a)
SE UIERY
—
mes |
. ” light @ 38. Secondary injector #1
6. Main switch 66)
24) =
++ +

7. Main fuse 15. Starter 39. Secondary injector #2

G motor @) — |
= 40. Secondary injector #3
8. Battery =
| (Ces 14. Starting circuit 22) At Senne he
= yd. cut-off relay yin)

19. Rectifier/regulator IA 16. Clutch 1. ECARTLUn

i switch
a + oe *

* 9. Start/engine
60) (8A
Stop switch 7 42. Throttle servo motor
17. Sidestand y ¥ 18. Neutral 1 O |
switch switch 10)

B _..., 43. Ignition

ok.
alg coil #1

__.., 44. Ignition

; coil #2

position
:<} ® o——*
sensor = o= ">" _..., 45. Ignition
* ale coil #3
. 6} | <———____________#

22. EXUP servo motor +6 os

7 ——e ----, 46. Ignition
23. Atmospheric: 1 ! coil #4
| pressure sensor | es {>+1+-—69)
24. Intake air pressure ip<—r
sensor ¢ +

= @
25. Coolant temperature sensor

26. Intake air temperature sensor 7

* arc

2/7. Shift sensor

 SYSTEM DIAGRAM

59 80) O
a, 47. Intake funnel servo motor
28. Gear position sensor {03

fOrn__ 65),
&)

Q'S
29. Oz sensor TOF (64) O
¢ (left side) 5 22. EXUP servo motor
*

30. Ozsensor2 |}-—({00 a

. (right side) 4

48. Steering damper solenoid

88 69) — 1

31. Throtte postion 43) 49. Intake solenoid $

31. Throttle position veneer a1) =
sensor a ?
| 49 50. Air induction system
~ solenoid
® 20) c= :
65) 51. Radiator fan
32. Accelerator position : @ motor relay
sensor 49) pee a cea C
32. Accelerator position 2 51) tL 7
sensor e) 68)
a
53. Pass/LAP
52. Dimmer switch
33. Hydraulic unit assembly fon switch |
(ABS ECU) .

"54. Headlight
! control unit |
ee ee ee

56. CAN communication

circuit
 SYSTEM DIAGRAM

ECU (Engine Control Unit) 54. Headlight control unit

ONOahtah= Electronic throttle valve fuse 55. Meter assembly
Backup fuse 56. CAN communication circuit
Fuel injection system fuse
Ignition fuse
Main switch
Main fuse
Battery
9. Start/engine stop switch
10. Fuel pump relay
11. Fuel pump
12. Starter relay
13. Neutral indicator light
14. Starting circuit cut-off relay
15. Starter motor
16. Clutch switch
[Link] switch
18. Neutral switch
19. Rectifier/regulator
20. Cylinder identification sensor
21. Crankshaft position sensor
[Link] servo motor
[Link] pressure sensor
24.\Intake air pressure sensor
25. Coolant temperature sensor
26. Intake air temperature sensor
27. Shift sensor
28. Gear position sensor
29.Qp5 sensor 1 (left side)
30.O». sensor 2 (right side)
31. Throttle position sensor
32. Accelerator position sensor
33. Hydraulic unit assembly (ABS ECU)
34. Primary injector #1
35. Primary injector #2
36. Primary injector #3
[Link] injector #4
38. Secondary injector #1
39. Secondary injector #2
[Link] injector #3
[Link] injector #4
42. Throttle servo motor
43. Ignition coil #1
44. Ignition coil #2
45. Ignition coil #3
46. Ignition coil #4
47.|Intake funnel servo motor
[Link] damper solenoid
[Link] solenoid
50. Air induction system solenoid
51. Radiator fan motor relay
[Link] switch
[Link]/LAP switch
 SYSTEM DIAGRAM

EAS33369

ECU COUPLER LAYOUT

| = | = ee ee
1/2/3141516|71819) (35/36137138/39/40141
10/11|12/13/14/15116|17) |(42l43/44/45|46|47)X|_ | ||61 162 [63 |64 65 66 |67 |68|69| 70/71 |72/73/74|75/76
18/19120/21/2223/04125) \\agiag'50[51\52153_|
52 (77178|79|80|81|82/83|84|85| 86/87/88] 89/90|91]92
99 100101/1021031041051061071108
26|27|28]29/30]31]32133]34) '54/55156/57/58/59|60| {[ (9319495|96|97/98|

Wire harness Wire harness

No. Connected parts eeag No. Connected parts cnln

1 Throttle servo motor Y/R Pass/LAP switch, dim-

9 _ _ 28 | mer switch, headlight Y/B
control unit
: _ _ 29 =| Fuel pump relay L/W
4 | Oz sensor 2 (right PAW 30 _| Intake funnel servo V/L
side) motor
31 Intake funnel servo Sh
5 | Qos sensor 1 (left side) P/B motor

6 | Ignition coil #3 O/G 32 | Fuel pump relay R/L

7 | Ignition coil #4 Gy/G 83 | Ground B/W
8 | Ignition coil #1 O 384 | Ground B/W
9 7
Ignition coil #2 Gy/R 35 | Accelerator
Sensor position L/Y
10 | Throttle servo motor Lg/R 36 = —
11. | Intake solenoid L/R _ Throttle position sen- ;
12 —_ — sor
13 | Primary injector #3 L/B 38 — _
14 | Primary injector #4 O/B 39 Steering damper sole- via
15 | Primary injector #1 R/B noid
16 | Primary injector #2 G/B 40 —_ —
17. | Ground B 41 | Ignition fuse R/W
Electronic throttle 42 _ | Accelerator position W
18 | valve fuse RIL sensor
19 _ fan motor re zi G/Y 43 Throttle
aay position sen- W

Air induction system 44 a —_

20 : y Br/R ~
Accelerator position LG
solenoid 45
21 | Secondary injector #3 Br/Y Sensor
22 | Secondary injector #4 Br/B 46 — -—
23 | Secondary injector #1 W/L 47 | EXUP servo motor B/R
24 | Secondary injector #2 Sb/W 48 | —_
25 | Ground B AQ a position sen- B/G
26 =| Backup fuse R/G i
27 — — a
54 Accelerator position B
sensor
 SYSTEM DIAGRAM

Wire harness Wire harness

No. Connected parts aalag No. Connected parts color

52 — — 83 — —
53 | EXUP servo motor B/G
84 | QO. sensor 1 (left side) Gy/G
54 a position B/L
85 — —
55 — Intake air tempera-
86 ture sensor BriW
56 Throttle position sen- B
sor 87 — —
57 Accelerator position B/Y Cylinder identification
sensor, crankshaft po-
sition sensor, EXUP
58 a
servo motor, atmo-
59 — spheric pressure sen-
60 | EXUP servo motor W/Y sor, intake air
88 | pressure sensor, cool- B/L
64 i aaa UB ant temperature sen-
sor, intake air
62 — temperature sensor,
shift sensor, Oo sen-
63 — sor 1 (left side), O,
64 — sensor 2 (right side)
65 a 89 | Gear position sensor W
66 — 90 — —
67 — — 91 — _—
68 ee pressure PW Cylinder identification
92 sensor WiB
69 Atmospheric pres- p 93 — _—
sure sensor
94 — —
70 —
Clutch switch, relay
71 +| Shift sensor V 95 unit L/Y

Cylinder identification 96 Starter relay, relay LW

sensor, EXUP servo unit
70 motor, atmospheric L
pressure sensor, in- 97 — —
take air pressure sen- 98 — —
sor, shift sensor
99 — _—
73 | Gear position sensor L/R
100 Oz sensor 2 (right Gy/Y
74 —
side)
75 —
101 — —
76 a position Gy
Coolant temperature
yy oe LW 102 sensor GW
103 | Gear position sensor G
78 a 104 — —
79 — Hydraulic unit assem-
105 | bly (ABS ECU) Gy/B
20 | Staring crouteurort | BN 106 — _—
81 — — Hydraulic unit assem-
82 — — 107 | bly (ABS ECU) mi.
108 — _
 SYSTEM DIAGRAM

9-10
 FUEL INJECTION SYSTEM

EAS20440

FUEL INJECTION SYSTEM

EAS32871

CIRCUIT DIAGRAM

& io]

a |<]

42 )< le]

9-11
 FUEL INJECTION SYSTEM

Main switch 69. Throttle position sensor

oN Main fuse [Link] (Inertial Measurement Unit)
Radiator fan motor relay 7 [Link] assembly
a

Fuel injection system fuse [Link] (Malfunction indicator light)

Electronic throttle valve fuse [Link]-function meter
9. Backup fuse [Link] system warning light
12. Ignition fuse [Link] coupler
[Link] ECU fuse [Link] switch (left)
[Link] ground [Link] switch
[Link] [Link] control unit
[Link] coupler
A. Wire harness
[Link] switch (right)
B. Sub-wire harness (Intake solenoid)
[Link]/engine stop switch
C. Sub-wire harness (Coolant temperature
[Link] position sensor sensor)
[Link] unit D. Sub-wire harness (Intake air temperature
[Link] circuit cut-off relay sensor)
[Link] pump relay . Joint coupler for YZF-R1

o
[Link] switch **, Joint coupler for YZF-R1M
[Link] switch
[Link] pump
[Link] solenoid
[Link] position sensor
38.0.5 sensor 1 (left side)
39.0, sensor 2 (right side)
[Link] sensor
[Link] air pressure sensor
[Link] pressure sensor
[Link] identification sensor
[Link] servo motor
[Link] position sensor
[Link] temperature sensor
47.|ntake air temperature sensor
[Link] (Engine Control Unit)
[Link] plug
[Link] coil #1
[Link] coil #2
[Link] coil #3
[Link] coil #4
[Link] induction system solenoid
[Link] injector #1
[Link] injector #2
[Link] injector #3
[Link] injector #4
[Link] injector #1
[Link] injector #2
[Link] injector #3
[Link] injector #4
[Link] funnel servo motor
64. Throttle servo motor
[Link] damper solenoid
[Link] unit assembly (ABS ECU)
[Link] wheel sensor
[Link] wheel sensor

9-12
 FUEL INJECTION SYSTEM

EAS32917

BASIC PROCESS FOR TROUBLESHOOTING

This section describes the basic process about fuel injection system troubleshooting.
But because a work procedure varies depending to symptom and DTC, check and repair it according
to applicable troubleshooting.

When turning the main switch to No Does the MIL (LED) work No
“ON", does the MIL come on? > properly? [$$$ Check the MIL (LED)

ve Yes |

¥ ' /

The MIL goes off after 2 seconds? = dl [B} Perform ihe checking wan the
diagnostic mode.

Still on/flash.
[A] Check the DTC.

|
Do the troubleshooting according
to the DTCs of “malfunction”.

|
Check the DTCs of “malfunction”
are not displayed on the screen.

|
Finished.

9-13
 FUEL INJECTION SYSTEM

EA533147

[A] THE MIL COMES ON/FLASHES AND ENGINE OPERATION IS NOT NORMAL
1. Check the DTC of “malfunction” using the YDT.
2. Delete the DTC using the YDT. (Only for *1)
3. Check and repair the malfunction according to applicable DTC troubleshooting.
4. Turn the main switch from “OFF” to “ON”, and then check the DTC of “malfunction” is not displayed.
TIP
e lf another DTC is displayed, repeat steps (1) to (4) until no DTC is displayed.
¢ Turning the main switch to “OFF” will not erase the malfunction history.

EAS331 48

[B] THE MIL DOES NOT COME ON, BUT THE ENGINE OPERATION IS NOT NORMAL
1. Monitor the operation of these sensors and actuators by using the YDT in the diagnostic mode.
Refer to “DIAGNOSTIC CODE: SENSOR OPERATION TABLE” on page 9-59 and “DIAGNOSTIC
CODE: ACTUATOR OPERATION TABLE” on page 9-62.
DO1: Throttle position sensor signal 1 (throttle angle)
D13: Throttle position sensor signal 2 (throttle angle)
D14: Accelerator position sensor signal 1 (throttle angle)
D15: Accelerator position sensor signal 2 (throttle angle)
D30: Cylinder-#1 ignition coil
D31: Cylinder-#2 ignition coil
D32: Cylinder-#3 ignition coil
D33: Cylinder-#4 ignition coil
D36: Primary injector #1
D37: Primary injector #2
D38: Primary injector #3
D39: Primary injector #4
D40: Secondary injector #1
D41: Secondary injector #2
D42: Secondary injector #3
D43: Secondary injector #4
D48: Air induction system solenoid

lf a malfunction is detected in the sensors or actuators, repair or replace all faulty parts.
lf no malfunction is detected in the sensors and actuators, check and repair the inner parts of the
engine.

9-14
 ABS (Anti-lock Brake System)

ABS (Anti-lock Brake System)

CIRCUIT DIAGRAM
Ti
TUTTE
a
if

9-15
 ABS (Anti-lock Brake System)

Main switch
Rw Main fuse
ABS solenoid fuse
SO

Fuel injection system fuse

9. Backup fuse
12. Ignition fuse
[Link] system fuse
[Link] ECU fuse
[Link] ground
[Link]
[Link] motor fuse
[Link] coupler
[Link] brake light switch
[Link] switch (right)
[Link] (Engine Control Unit)
[Link] unit assembly (ABS ECU)
[Link] wheel sensor
[Link] wheel sensor
[Link] (Inertial Measurement Unit)
[Link] assembly
[Link]-function meter
[Link] warning light
[Link] coupler
[Link] brake light switch
[Link]/brake light
“, Joint coupler for YZF-R1
“*. Joint coupler for YZF-R1M

9-16
 ABS (Anti-lock Brake System)

EAS32691

ABS COMPONENTS CHART

Meter assembly
ONOahtah=

Hydraulic unit assembly (ABS ECU)

Fuse box 1
ABS solenoid fuse
YDT coupler
Starter relay
ABS motor fuse
Rear brake caliper
9. Rear wheel sensor rotor
10. Rear wheel sensor
11. Front brake caliper (left)
12. Front wheel sensor
13. Front wheel sensor rotor
14. Front brake caliper (right)
[Link] box 2
16. Signaling system fuse

9-17
 ABS (Anti-lock Brake System)

EASa2892

ABS COUPLER LOCATION CHART

Meter assembly coupler

akon =

YDT coupler
ABS ECU coupler
Rear wheel sensor coupler
Front wheel sensor coupler

9-18
 ABS (Anti-lock Brake System)

EAS32893

MAINTENANCE OF THE ABS ECU

Checking the ABS ECU

1. Check:
¢ Terminals “1” of the hydraulic unit assembly (ABS ECU)
Cracks/damages — Replace the hydraulic unit assembly, brake hoses, and brake pipes that are
connected to the assembly as a set.
¢ Terminals “2” of the ABS ECU coupler
Connection defective, contaminated, come-off — Correct or clean.
TIP
lf the ABS ECU coupler is clogged with mud or dirt, clean with compressed air.

EAS33284

ABS TROUBLESHOOTING OUTLINE

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 9-24.

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 9-31.

Self-diagnosis with 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 detected, it is possible to check the recorded malfunction data by utilizing the YDT when the ABS
ECU has entered the self-diagnosis mode.

9-19
 ABS (Anti-lock Brake System)

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 under the seat,
and if the brake lever or brake pedal are even slightly applied, a vibration can be felt at the lever and
pedal, but these do not indicate a malfunction.

Special precautions for handling and servicing a vehicle equipped with ABS
ECA17620

NOTICE
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 DTC when the service is
finished. (This is because the past DTC will be displayed again if another malfunction occurs.)
EAS32895

BASIC INSTRUCTIONS FOR TROUBLESHOOTING

1. Check the DTC of “malfunction” using the YDT.
2. Check and repair the malfunction according to applicable DTC troubleshooting.
3. Turn the main switch from “OFF” to “ON”, and then check the DTC of “malfunction” is not displayed.
TIP
¢ lf another DTC is displayed, repeat steps (1) to (3) until no DTC is displayed.
¢ Turning the main switch to “OFF” will not erase the malfunction history.
4. Do the final check.
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.

9-20
 ABS (Anti-lock Brake System)

; una | Fails to
[A] Turn the main switch to “ON", ae [A-1] Does only the ABS Yas * The ABS warning light (LED) is
and check the ABS warning waming light fail to -———_ defective. Return to [A].
light. come on? « The wire harness is grounded
between the ABS ECU and the
Comes on meter assembly.
* The meter assembly is defective.
* The hydraulic unit assembly is
defective.

¥ N Oo
«* The main switch is defective.
[A-2] Do all indicator lights | Yes * The battery voltage is low.
fail to come on? Return to [A].
* The main fuse is blown.
« The meter assembly is defective.

¥
Cannot
[A-3] ue ABS warning light comes [communicate [A-4] Only the ABS ECU Yes « The ABS ECU fuse is blown.
«The ABS ECU coupler is Return to [A]. |
: fails to communicate. ,
Connect the YDT, and then disconnected.
execute functional diagnosis. « The wire harness is defective.
Can the YDT communicate * The hydraulic unit assembly
with the ABS ECU? is defective.

Gan communicate
No

[A-5) ABS ECU and FI ECU | Yes ; « The connection with the YDT is
defective. Return to [A].
fail to communicate.
* The wire harness is defective.

¥
[B-1] Check for ABS DTC in the Yes [B-2] Diagnose by the DTC. [B-3] Delete the DTC.
tt -————_ Return to [A].
screen for the YDT.
Execute diagnosis of
malfunction.
Are DTC displayed on
the screen?
The reaction force generated
No during brake line routing
confirmation is incorrect. Refer to
“[(C-1] FINAL GHECK”.
[C-1] Perform the final checks. No * The brake hoses and brake
Were all of the final checks © —-——————-}| pipes are not connected > Return to [A]. |
completed normally? correctly.
The ABS warning light does
Yes not go off when the light is
(The ABS warning light checked. Refer to “[C-1]
goes off when the light is FINAL CHECK”.
checked.) « The malfunction is not
corrected.
« There is a break in the wire
harness between the ABS ECU
and the meter assembly.
« The meter assembly is defective.
« The ABS warning light circuit in
the hydraulic unit assembly is
defective.

¥
Finished.

9-21
 ABS (Anti-lock Brake System)

EAS32897

[A] CHECKING THE ABS WARNING LIGHT

Turn the main switch to “ON”. (Do not start the engine.)
1. The ABS warning light does not come on.
¢ Only the ABS warning light fails to come on. [A-1]
¢ The ABS warning light and all other indicator lights fail to come on. [A-2]
2. The ABS warning light comes on. [A-3]
EAS32898

[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON

1. Check for a short circuit to the ground between the green/orange terminal of the ABS ECU coupler
and green/orange 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.
EASa2899

[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 8-40.
¢ If there is no continuity, replace the main switch unit.
2. Battery
¢ Check the condition of the battery.
Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-42.
¢ If the battery is defective, clean the battery terminals and recharge it, or replace the battery.
3. Main fuse
¢ Check the fuse for continuity.
Refer to “CHECKING THE FUSES” on page 8-41.
¢ If the main fuse is blown, replace the fuse.
4. Circuit
¢ Check the meter assembly circuit.
Refer to “CIRCUIT DIAGRAM” on page 9-15.
¢ If the meter assembly circuit is open, replace the wire harness.
EAS32900

[A-3] THE ABS WARNING LIGHT COMES ON

Connect the YDT to the YDT coupler and execute functional diagnosis. (For information 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.
e Only the ABS ECU fails to communicate. [A-4]
e ABS ECU and FI ECU fail to communicate. [A-5]
¢ Communication is possible with the ABS ECU. [B-1] (The ABS is displayed on the select unit screen.)
EsASaeon

[A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE

1. ABS ECU fuse
¢ Check the ABS ECU fuse for continuity.
Refer to “CHECKING THE FUSES” on page 8-41.
¢ If the ABS ECU fuse is blown, replace the fuse.

9-22
 ABS (Anti-lock Brake System)

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 4-78.
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/blue terminal of the main switch coupler and red/black terminal
of the ABS ECU coupler.
Check for continuity between black terminal of the ABS ECU coupler and the ground.
lf 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 YDT coupler.
Check for continuity between blue/white terminal of the ABS ECU coupler and blue/white terminal
of the YDT coupler. (CANH)
Check for continuity between blue/black terminal of the ABS ECU coupler and blue/black terminal
of the YDT coupler. (CANL)
4. ABS ECU malfunction
Replace the hydraulic unit assembly.
EASSa2902

[A-5] ABS ECU AND FI ECU FAIL TO COMMUNICATE

1. YDT
Check that the YDT is properly connected.
2. Wire harness
¢ Open circuit in the wire harness between the ABS ECU coupler and the YDT coupler.
Check for continuity between blue/white terminal of the ABS ECU coupler and blue/white terminal
of the YDT coupler. (CANH)
Check for continuity between blue/black terminal of the ABS ECU coupler and blue/black terminal
of the YDT coupler. (CANL)
EASa2903

[B-1] MALFUNCTION ARE CURRENTLY DETECTED

When the YDT is connected to the YDT coupler, the DTC will be displayed on the computer screen.
e A DTC is displayed. [B-2]
¢ A DTC is not displayed. [C-1]
EASa2904

[B-2] DIAGNOSIS USING THE DTC

This model uses the YDT to identify malfunctions.
For information about using the YDT, refer to the operation manual that is included with the tool.

Yamaha diagnostic tool USB (US)

90890-03269
Yamaha diagnostic tool (A/l)
90890-03264

TIP
e Yamaha diagnostic tool (A/l) (90890-03264) includes YDT sub harness (6P) (90890-03266).
¢ If you already have Yamaha diagnostic tool (A/I) (90890-03262), YDT sub harness (6P) (90890-
03266) is separately required.
Details about the displayed DTCs are shown in the following chart. Refer to this chart and check the
vehicle.
Once all the work is complete, delete the DTCs. [B-3]
TIP
Do the final check after terminating the connection with the YDT and turning the main switch off. [C-1]

9-23
 ABS (Anti-lock Brake System)

EAS33339

[B-3] DELETING THE DTC

To delete the DTCs, use the YDT. For information about deleting the DTCs, refer to the operation man-
ual of the YDT.
Check that all the displayed DTCs are deleted.

Yamaha diagnostic tool USB (US)

90890-03269
Yamaha diagnostic tool (A/l)
90890-03264

TIP
e Yamaha diagnostic tool (A/I) (90890-03264) includes YDT sub harness (6P) (90890-03266).
¢ If you already have Yamaha diagnostic tool (A/l) (90890-03262), YDT sub harness (6P) (90890-
03266) is separately required.

EASS2905

[C-1] FINAL CHECK

EWAI6710

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.
Check all the following items to complete the inspection.
lf the process is not completed properly, start again from the beginning.

Checking procedures
1. Check the brake fluid level in the front brake master cylinder reservoir and the rear brake master
cylinder reservoir.
Refer to “CHECKING THE BRAKE FLUID LEVEL’ on page 3-13.
2. Check the wheel sensors for proper installation.
Refer to “INSTALLING THE FRONT WHEEL (DISC BRAKE)” on page 4-40 and “INSTALLING THE
REAR WHEEL (DISC BRAKE)” on page 4-49.
3. Perform brake line routing confirmation.
Refer to “HYDRAULIC UNIT OPERATION TEST” on page 4-79.
lf it does not have reaction-force properly, the brake hose is not properly routed or connected.
4. Delete the DTCs.
Refer to “[B-3] DELETING THE DTC’ on page 9-24.
5. Checking the ABS warning light.
Confirm the ABS warning light go off.
lf the ABS warning light does not come on or does not go off, refer to “[A] CHECKING THE ABS
WARNING LIGHT” on page 9-22.
lf 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 green/orange terminal of the ABS ECU coupler and green/orange ter-
minal of the meter assembly coupler.
¢ Malfunction in the meter assembly circuit.
¢ Malfunction in the ABS warning light circuit in the hydraulic unit assembly.

9-24
 STEERING DAMPER SYSTEM

EAS20445

STEERING DAMPER SYSTEM

EAS32912

CIRCUIT DIAGRAM
TLE ETT ET Th
eee
eres

ittT

FLA
‘ae TL
tile ial

sinc
(Low

9-25
 STEERING DAMPER SYSTEM

Main switch
“NFO Main fuse
Fuel injection system fuse
9. Backup fuse
12. Ignition fuse
[Link] ground
[Link]
[Link] coupler
[Link] (Engine Control Unit)
[Link] damper solenoid
[Link] assembly
[Link]-function meter
[Link] system warning light
[Link] coupler
*, Joint coupler for YZF-R1
“*. Joint coupler for YZF-R1M

9-26
 STEERING DAMPER SYSTEM

EAS32913

BASIC INSTRUCTIONS FOR TROUBLESHOOTING

The auxiliary system warning light comes on.

1. Check the DTC of “malfunction” using the YDT.
2. Check and repair the malfunction according to applicable DTC troubleshooting.
3. Turn the main switch from “OFF” to “ON”, and then check the DTC of “malfunction” is not displayed.
TIP
e lf another DTC is displayed, repeat steps (1) to (3) until no DTC is displayed.
¢ Turning the main switch to “OFF” will not erase the malfunction history.

9-27
 STEERING DAMPER SYSTEM

9-28
 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for
YZF-R1M)
ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for YZF-R1M)
EAsa2914

CIRCUIT DIAGRAM

ads [ex]
FLA
‘ae TL

xp = [Co]
=r
 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for
YZF-R1M)
Main switch
“NFO Main fuse
Fuel injection system fuse
9. Backup fuse
12. Ignition fuse
[Link] ground
[Link]
[Link] coupler
[Link] (Engine Control Unit)
[Link] (Inertial Measurement Unit)
[Link] assembly
[Link]-function meter
[Link] system warning light
[Link] coupler
[Link] fuse
[Link] (Suspension Control Unit)
[Link] fork stepping motor (left)
[Link] fork stepping motor (right)
[Link] shock absorber assembly stepping
motor (compression damping)
[Link] shock absorber assembly stepping
motor (rebound damping)
[Link] damper solenoid (OPTION)
A. Wire harness
G. Sub-wire harness (SCU, steering damper
solenoid, sub-wire harness)
H. Sub-wire harness (front fork stepping motor)
|. Sub-wire harness (Steering damper
solenoid), (OPTION)

9-30
 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for
YZF-R1M)
EAS32915

MAINTENANCE OF THE SCU (suspension control unit)

Checking the SCU (suspension control unit)

1. Check:
¢ Terminals “1” of the SCU
Cracks/damages — Replace the SCU.
¢ Terminals “2” of the SCU couplers
Connection defective, contaminated, come-off — Replace or clean.
TIP
lf the SCU couplers are clogged with mud or dirt, clean with compressed air.

EASa2916

BASIC INSTRUCTIONS FOR TROUBLESHOOTING

1. Check the DTC of “malfunction” using the YDT.
2. Check and repair the malfunction according to applicable DTC troubleshooting.
3. Turn the main switch from “OFF” to “ON”, and then check the DTC of “malfunction” is not displayed.
TIP
e lf another DTC is displayed, repeat steps (1) to (3) until no DTC is displayed.
¢ Turning the main switch to “OFF” will not erase the malfunction history.

9-31
 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EAS20551

SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

E4S33149

DTC TABLE
Fail-safe system
Diagnostic
DTC Symptom Starting the | Driving the code
engine vehicle
c » | Front wheel sensor (intermittent pulses or no | | _
11_ABS pulses)

“12 ABS” Rear wheel sensor (intermittent pulses or no __ __ _

pulses)
“13, ;
26_ABS” Front wheel sensor (abnormal pulse period) — — —
on 4. ;

27_ABS” Rear wheel sensor (abnormal pulse period) — — —

“15_ABS” | Front wheel sensor (open or short circuit) — a —

“16_ABS” | Rear wheel sensor (open or short circuit) — — —
“ » | Hydraulic unit assembly (defective solenoid _ _ __
21_ABS drive circuit)
"30_EVENT” | Latch up detected. Unable Unable D17
a » | Hydraulic unit aoassembly (defective ABS sole- — — —
31_ABS ;
noid power circuit)
i » | Hydraulic unit assembly (abnormal ABS mo- __ __ __
33_ABS tor power supply)
“34 ABS” Hydraulic unit assembly (short circuit in ABS _ _ _
— motor power supply circuit)
a » | Front wheel ABS (intermittent wheel speed
41_ABS . pt — — —
pulses or incorrect depressurization)
a » | Rear wheel ABS (intermittent wheel speed
42 ABS ite — — —
pulses or incorrect depressurization)

a5 ane Front wheel sensor (missing pulses) a a —

46_44,
ABS” Rear wheel sensor (missing
gP pulses) — — —

“S14 ABS” Vehicle system power supply (voltage of | | _

- ABS ECU power supply is high)
“53 ABS” Vehicle system power supply (voltage of __ __ __
— ABS ECU power supply is low)
“55 ABS” Hydraulic unit assembly (defective ABS __ __ __
ECU)
a » | Hydraulic unit assembly (abnormal internal
S6_ABS" | circu it) a _ a
“67 ABS” Vehicle CAN communication line or power __ __ _
source of vehicle system
“62 ABS” a supply voltage failure in pressure sen- | _ _

a » | Defective hydraulic unit assembly (defective

68_ABS" | front pressure sensor) a _ a
“70 EVENT” Engine forcibly stops when the vehicle is left Unable Unable __
idling for a long period.

9-32
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Fail-safe system
Diagnostic
DTC Symptom Starting the | Driving the code
engine vehicle
“89 ABS” CAN communication (between meter as- _ _ _
. sembly and hydraulic unit assembly)
“99 ABS” CAN communication (between ECU and hy- _ _ _
- draulic unit assembly)
“91 ABS” | CAN communication (between IMU and hy- _ _ __
- draulic unit assembly)
“C0044” Abnormal ABS Able Able —
“C0520 (FI)” | Abnormal IMU Able/Unable | Able/Unable a
“C0520
(SCU)” Abnormal IMU Unable Able/Unable —

“C1000” Steering damper solenoid: open or short cir- Able Able D47
cuit detected.
“C1002” Abnormal SCU EEPROM Able Able a
“C4003” Stepping motor: open or short circuit detect- Able Able _

“C1007” Abnormality inside SCU Able Able —

“P0030” Op» sensor 1 heater: defective heater control- Able Able _
ler detected.
“P0050” Op» sensor 2 heater: defective heater control- Able Able _
ler detected.
Intake air pressure sensor or atmospheric
pressure sensor: when the main switch is
“P0069” turned to “ON”, the intake air pressure sen- Able Able DO?2, DOS
sor voltage and atmospheric pressure sen-
sor voltage differ greatly.
(PO00D1] O». sensor 1: heater performance
“POOD1, a
P2195” deterioration a Able Able —
[P2195] Oo sensor 1: open circuit detected.
'POOD3] Os sensor 2: heater performance
“POODS, s
P2197” deterioration oe Able Able —
[P2197] Os sensor 2: open circuit detected.
'P0107] Intake air pressure sensor: ground
“P0107, short circuit detected.
P0108" P0108] Intake air pressure sensor: open or Able Able DO3
power short circuit detected.
[P0112] Intake air temperature sensor:
“P0112, ground short circuit detected.
P0113" [P0113] Intake air temperature sensor: open Able Able DOS
or power short circuit detected.
[P0117] Coolant temperature sensor: ground
“P0117, short circuit detected.
P0118" [P0118] Coolant temperature sensor: open Able Able DOG
or power short circuit detected.

9-33
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Fail-safe system
Diagnostic
DTC Symptom Starting the | Driving the code
engine vehicle
P0122] Throttle position sensor: ground
short circuit detected.
a P0123] Throttle position sensor: open or
P0122, i
P0123 power short circuit detected.
po222,__|
P9203
[P0222] Throttle position sensor: open or
ground short circuit detected.
Able/Unable | Able/Unable | DO1, D13
po4 5° P0223] Throttle position sensor: power
short circuit detected.
P2135] Throttle position sensor: output volt-
age deviation error.
“P0132” Os sensor 1: short circuit detected (power Able Able __
short circuit).
“p9150” Os sensor 2: short circuit detected (power Able Able __
short circuit).
Able Able
el al (dependingon | (depending on
“PQ201" ihtsboa4 ow #1; maifunction in primary the number of | the number of D36
faulty cylin- faulty cylin-
ders) ders)
Able Able
. . Se
~po2o2" _| Primary injector #2: malfunction in primary | the number of | the number of | D37
(dependingon | (depending on

faulty cylin- faulty cylin-

ders) ders)
Able Able
; a a (dependingon | (depending on
“P0203” anay . #3: maitunction In primary the number of | the number of D38
faulty cylin- faulty cylin-
ders) ders)
Able Able
. ee e ay (dependingon | (depending on
“P0204” See oo #4: matiunction in primary the number of | the number of D39
faulty cylin- faulty cylin-
ders) ders)
Crankshaft position sensor: no normal sig-
“P0335” nals are received from the crankshaft posi- Unable Unable —
tion sensor.
Cylinder identification sensor: no normal sig-
“P0340” nals are received from the cylinder identifica- Unable Able —
tion sensor.
Able Able
Cylinder-#1 ignition coil: open or short circuit | (dependingon | (depending on
“P0351” detected in the primary lead of the cylinder- | the number of | the number of D30
#1 ignition coil. faulty cylin- faulty cylin-
ders) ders)
Able Able
Cylinder-#2 ignition coil: open or short circuit | (dependingon | (depending on
“P0352” detected in the primary lead of the cylinder- | the number of | the number of D31
#2 ignition coil. faulty cylin- faulty cylin-
ders) ders)

9-34
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Fail-safe system
Diagnostic
DTC Symptom Starting the | Driving the code
engine vehicle
Able Able
Cylinder-#3 ignition coil: open or short circuit | (dependingon | (depending on
“P0353” detected in the primary lead of the cylinder- | the number of | the number of D32
#3 ignition coil. faulty cylin- faulty cylin-
ders) ders)
Able Able
Cylinder-#4 ignition coil: open or short circuit | (dependingon | (depending on
“P0354” detected in the primary lead of the cylinder- | the number of | the number of D33
#4 ignition coil. faulty cylin- faulty cylin-
ders) ders)
[P0475] EXUP servo motor: performance
“P0475, deterioration
P0476, [P0476] EXUP servo motor: stuck EXUP Able Able D53
P048B” servo motor is detected.
[PO48B] EXUP servo motor: signal stuck
“DQ480” Radiator fan motor relay: open or short cir- Able Able D51
cuit detected.
[PO48D] EXUP servo motor: open or ground
“P048D, short circuit detected.
PO48E” [PO048E] EXUP servo motor: power short cir- Able Able bS3
cuit detected.
[P0500 (Fl)] Rear wheel sensor: no normal
signals are received from the rear wheel
“PQ500 (FI) sensor.
» | [P1500] Neutral switch: open or short circuit Able Able DO7, D21
P1500 .
is detected.
Clutch switch: open or short circuit is detect-
ed.
“P0500
(SCUY’ Abnormal rear wheel sensor Able Able —

“P0560 (FI) [P0560 (Fl)] Charging voltage is abnormal.

P0563” ’ | [P0563] Vehicle system power voltage out of Able Able —
range

scuy Abnormal SCU power supply voltage Able Able DOg

Internal malfunction in ECU. (When this mal-

“P0601” function is detected in the ECU, the DTC Unable Unable —
might not appear on the tool display.)
Internal malfunction in ECU. (When this mal-
“P0606” function is detected in the ECU, the DTC Able/Unable Able/Unable —
might not appear on the tool display.)
, » | EEPROM DTC: an error is detected while
PO62F reading or writing on EEPROM. Able/Unable | Able/Unable D60

“P0638” | YCC-T drive system: malfunction detected. Able/Unable | Able/Unable

“DQG57” Fuel system voltage: incorrect voltage sup- Able Able D09, D50
plied to the fuel injector and fuel pump.
[P0916] Gear position sensor: open or
“P0916, | ground short circuit detected. Able Able __
P0917" [P0917] Gear position sensor: power short
circuit detected.

9-35
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Fail-safe system
Diagnostic
DTC Symptom Starting the | Driving the code
engine vehicle
2 7 Air induction system solenoid: open or short
P1400 circuit detected. Able Able D48
“P1600” Lean angle sensor: open or short circuit de- Unable Unable D17
tected.
‘ Sidestand switch: open or short circuit of the
P1601 blue/yellow lead of the ECU is detected. Unable Unable b20
“P1602” | Malfunction in ECU internal circuit (malfunc- Able/Unable | Able/Unable _
tion of ECU power cut-off function).
[P1806] Shift sensor: open or ground short
“P1806, circuit detected.
P1807” [P1807] Shift sensor: power short circuit de- Able Able D935
tected.
P2122] Accelerator position sensor: open or
ground short circuit detected.
“P2122, P2123] Accelerator position sensor: power
P2123, short circuit detected.
P2127, P2127] Accelerator position sensor: open or | Able/Unable Able/Unable D14, D15
P2128, ground short circuit detected.
P2138" P2128] Accelerator position sensor: power
short circuit detected.
P2138] Deviation error
“P9158 (FI)” Front wheel sensor: no normal signals are Able Able D16
received trom the front wheel sensor.
“P2158 Front wheel sensor: no normal signals are
(SCU)” received from the front wheel sensor. Able Able i
Able Able
_ a ; (dependingon | (depending on
“P21CF” eee eae #1; malfunction in sec the number of | the number of D40
a faulty cylin- faulty cylin-
ders) ders)
Able Able
_ i, ; (dependingon | (depending on
“P21D0” ee aa #2: malfunction in sec the number of | the number of D41
yin faulty cylin- faulty cylin-
ders) ders)
Able Able
= — ; (dependingon | (depending on
“P21D1” eee nt aA, #3: matfunction In sec the number of | the number of D42
yin faulty cylin- faulty cylin-
ders) ders)
Able Able
a fancy - (dependingon | (depending on
“P21D2” sah a ee #4; malfunction In sec the number of | the number of D43
yin faulty cylin- faulty cylin-
ders) ders)
[P2228] Atmospheric pressure sensor:
“P2228, | ground short circuit detected.
P2229” [P2229] Atmospheric pressure sensor: open Able Able b02
or power short circuit detected.
“W0100" Abnormal CAN communication (between Able Able _
ECU and SCU)

9-36
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Fail-safe system
Diagnostic
bre Symptom Starting the | Driving the code
engine vehicle
je ; Abnormal CAN communication (between
U0121 ABS ECU and SCU) Able Able —

7 » | Signals cannot be transmitted between the

U0125 (Fl) ECU and the IMU. Unable Able/Unable

“U0125 Abnormal CAN communication (between

(SCU)” | IMU and SCU) Able Able =
“U0155 or Multi-function meter: signals cannot be
Err (Fl)” transmitted between the ECU and the multi- Able Able —
function meter.
“U0155 or | Abnormal CAN communication (between
Err (SCU)” | meter assembly and SCU) Able Able —

9-37
 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EAS33028

SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM)

TIP
For details of the DTC, refer to “BASIC PROCESS FOR TROUBLESHOOTING?” on page 9-13.

Probable cause of Fail-safe system op-

DTC ltem Vehicle symptom
malfunction eration
30_EVEN Latch up detected. « The vehicle has
7
overturned.
e Installed condition of
IMU.
* Defective IMU.
« Malfunction in ECU.
7O_EVEN
+ Engine forcibly stops * Allow to idle for a
when the vehicle is long period of time.
left idling for a long ¢ Malfunction in ECU.
period.
C0520 Abnormal IMU e Defective IMU cou- Engine cannot be Engine cannot be
pler or ECU coupler. started (depending on started (depending on
¢ Open or short cir- the circumstances). the circumstances).
cuit in wire harness
between IMU and
ECU.
« Improperly installed
IMU.
* Malfunction in IMU.
« Malfunction in ECU.
P0030 Op» sensor 1 heater: ¢ Open or short cir- (When the Os sensor Display only (If the O»
defective heater con- cuit in wire harness. 1 does not operate sensor 1 does not op-
troller detected. « Disconnected cou- because the exhaust erate, Oo feedback is
pler. temperature is low) not carried out.)
¢ Defective O. sensor Increased exhaust
1 heater controller emissions.
(Malfunction in Fuel learning cannot
ECU). be carried out.
e Broken or discon-
nected lead in O»
sensor 1 heater.
P0050 O, sensor 2 heater: ¢ Open or short cir- (When the O, sensor Display only (If the O,
defective heater con- cuit in wire harness. 2 does not operate sensor 2 does not op-
troller detected. « Disconnected cou- because the exhaust erate, Oo feedback is
pler. temperature is low) not carried out.)
¢ Defective O». sensor Increased exhaust
2 heater controller emissions.
(Malfunction in Fuel learning cannot
ECU). be carried out.
e Broken or discon-
nected lead in O,
sensor 2 heater.

9-38
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system op-

DTC ltem malfunction Vehicle symptom ecoNan

PO069 Intake air pressure ¢ Malfunction in ECU. | Engine is difficult to Intake air pressure Is
sensor or atmospher- | ¢« Intake air pressure | start. fixed to 101.3 [kPa].
ic pressure sensor: sensor hose is dis- | Engine idling speedis | Intake air pressure
when the main switch connected, clogged, | unstable. difference Is fixed to 0
is turned to “ON”, the kinked, or pinched. | Increased exhaust [kPa].
intake air pressure « Defective intake air | emissions. Atmospheric pres-
sensor voltage and at-| pressure sensor or |Loss of engine power. | sure is fixed to 101.3
mospheric pressure atmospheric pres- [kPa].
sensor voltage differ sure sensor. aN is fixed.
greatly. Fuel is not cut off due
to the intake air pres-
sure difference.
Atmospheric pres-
sure sensor output
correction value is
fixed to 0.
O» feedback is not
carried out.
ISC feedback is not
carried out.
ISC learning is not
carried out.
QSS is not carried
out.
POOD1 Op» sensor 1: heater ¢« Improperly installed | Increased exhaust Op» feedback is not
performance deterio- Ops sensor 1. emissions. carried out.
ration ¢ Defective coupler QO, learning is not car-
between Op» sensor ried out.
1 and ECU. Air induction system
¢ Open or short cir- solenoid is turned on
cuit in wire harness all the time (air induc-
between Op, sensor tion system air cut
1 and ECU. off).
¢ Incorrect fuel pres- QSS is not carried
sure. out.
* Defective O5 sensor
1.
¢ Malfunction in ECU.
POODS Op» sensor 2: heater ¢ Improperly installed | Increased exhaust Op» feedback is not
performance deterio- Op» sensor 2. emissions. carried out.
ration « Defective coupler Oz learning is not car-
between Op» sensor ried out.
2 and ECU. Air induction system
¢ Open or short cir- solenoid is turned on
cuit in wire harness all the time (air induc-
between Op» sensor tion system air cut
2 and ECU. off).
« Incorrect fuel pres- QSS is not carried
sure. out.
* Defective Oo sensor
2.
e Malfunction in ECU.

9-39
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system op-

DTC ltem malfunction Vehicle symptom ecoNan

P0107 [P0107] Intake air [P0107] Low voltage /| Engine idling speed is | Intake air pressure
P0108 pressure sensor: of the intake air pres- | unstable. difference is fixed to 0
ground short circuit sure sensor circuit Engine response is [kPa].
detected. (0.5 V or less) poor. a—N is fixed.
[P0108] Intake air [P0108] High voltage | Loss of engine power. | Fuel is not cut off due
pressure sensor: of the intake air pres- | Increased exhaust to the intake air pres-
open or power short | Sure sensor circuit emissions. sure difference.
circuit detected. (4.8 V or more) Atmospheric pres-
* Defective coupler sure sensor output
between intake air correction value is
pressure sensor and fixed to 0.
ECU. Intake air pressure Is
¢ Open or short cir- fixed to 101.3 [kPa].
cuit in wire harness O, feedback is not
between intake air carried out.
pressure sensor and ISC feedback is not
ECU. carried out.
¢« Defective intake air ISC learning is not
pressure Sensor. carried out.
¢ Malfunction in ECU. QSS is not carried
out.
P0112 [P0112] Intake air [P0112] Low voltage /| Engine is difficult to The intake air tem-
P0113 temperature sensor: | of the intake airtem- | start. perature is fixed to 20
ground short circuit perature sensor circuit Increased exhaust [°C].
detected. (0.1 V or less) emissions. O, sensor heater driv-
[P0113] Intake air [P0113] High voltage Engine idling speed Is ing is not carried out.
temperature sensor: of the intake air tem- unstable. O» feedback is not
open or power short perature sensor circuit carried out.
circuit detected. (4.8 V or more) ISC feedback is not
« Defective coupler carried out.
between intake air ISC learning is not
temperature sensor carried out.
and ECU. QSS is not carried
¢ Open or short cir- out.
cuit in wire harness
between intake air
temperature sensor
and ECU.
« Improperly installed
intake air tempera-
ture sensor.
« Defective intake air
temperature sensor.
¢ Malfunction in ECU.

9-40
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system op-

DTC ltem malfunction Vehicle symptom ecoNan

P0117 [P0117] Coolant tem- | [P0117] Low voltage | Engine is difficult to The radiator fan motor
P0118 perature sensor: of the coolant tem- start. relay is on only when
ground short circuit perature sensor circuit | Increased exhaust the vehicle is traveling
detected. (0.1 V or less) emissions. at low speeds.
[P0118] Coolant tem- | [P0118] High voltage /| Engine idling speedis | O» feedback is not
perature sensor: open | of the coolant tem- unstable. carried out.
or power short circuit | perature sensor circuit ISC feedback is not
detected. (4.9 V or more) carried out.
* Defective coupler ISC learning is not
between coolant carried out.
temperature sensor The coolant tempera-
and ECU. ture is fixed to 60 [°C].
* Open or short cir- QSS is not carried
cuit in wire harness out.
between coolant Engine brake man-
temperature sensor agement: control val-
and ECU. ue is fixed.
« Improperly installed
coolant temperature
sensor.
¢ Defective coolant
temperature sensor.
¢ Malfunction in ECU.
P0122 [P0122] Throttle posi- | [P0122, P0222] Low _ | Engine idling speed is | Change in the throttle
P0123 tion sensor: ground voltage of the throttle | high. opening is 0 (transient
P0222 short circuit detected. | position sensor circuit | Engine idling speed is | control is not carried
P0223 [P0123] Throttle posi- | (0.25 V or less) unstable. out).
P2135 tion sensor: openor | [P0123, P0223] High | Engine response is D-j is fixed.
power short circuit de- voltage of the throttle poor. Throttle opening is
tected. position sensor circuit Loss of engine power. fixed to 125 [°].
[P0222] Throttle posi- (4.75 V or more) Deceleration is poor. O, feedback is not
tion sensor: open or [P2135] Difference in Increased exhaust carried out.
ground short circuit output voltage 1 and emissions. Fuel is not cut off due
detected. output voltage 2 of the Vehicle cannot be to the throttle open-
[P0223] Throttle posi- throttle position sen- driven. ing.
tion sensor: power sor Output is restricted.
short circuit detected. « Defective coupler Air induction system
[P2135] Throttle posi- between throttle po- solenoid is turned on
tion sensor: output sition sensor and all the time (air induc-
voltage deviation er- ECU. tion system air cut
ror. ¢ Open or short cir- off).
cuit in wire harness ISC feedback is not
between throttle po- carried out.
sition sensor and ISC learning is not
ECU. carried out.
* Improperly installed O» sensor heater driv-
throttle position sen- ing is not carried out.
sor. QSS is not carried
« Defective throttle po- out.
sition sensor. Engine brake man-
¢ Malfunction in ECU. agement: control
mode is fixed.

9-41
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system op-

DTC ltem malfunction Vehicle symptom ecoNan

P0132 O, sensor 1: short cir- | [P0132] High voltage | Increased exhaust O, feedback is not
cuit detected (power | Of the O, sensor 1 cir- | emissions. carried out.
short circuit). cuit (4.8 V or more) O» feedback learning
* Improperly installed is not carried out.
Oz sensor 1. Air induction system
¢« Defective coupler solenoid is turned on
between Op» sensor all the time (air induc-
1 and ECU. tion system air cut
* Open or short cir- off).
cuit in wire harness QSS is not carried
between O. sensor out.
1 and ECU.
¢ Incorrect fuel pres-
sure.
* Defective O. sensor
1.
¢ Malfunction in ECU.
P0152 O, sensor 2: short cir- | [P0152] High voltage | Increased exhaust O, feedback is not
cuit detected (power | Of the O. sensor 2 cir- | emissions. carried out.
short circuit). cuit (4.8 V or more) O» feedback learning
* Improperly installed is not carried out.
Op, sensor 2. Air induction system
¢ Defective coupler solenoid is turned on
between Op, sensor all the time (air induc-
9 and ECU. tion system air cut
* Open or short cir- off).
cuit in wire harness QSS is not carried
between O, sensor out.
2 and ECU.
« Incorrect fuel pres-
sure.
* Defective O5 sensor
2.
¢ Malfunction in ECU.
P0201 [P0201] Primary injec- | * Defective coupler Loss of engine power. | O, feedback is not
P0202 tor #1: malfunction in between primary in- | Engine is difficult to carried out.
P0203 primary injector #1. jector and ECU. start. Air induction system
P0204 [P0202] Primary injec- | * Open or short cir- Engine cannot be solenoid is turned on
tor #2: malfunction in cuit in wire harness started. all the time (air induc-
primary injector #2. between primary in- Engine stops. tion system air cut
[P0203] Primary injec- jector and ECU. Engine idling speed Is off).
tor #3: malfunction in ¢ Defective primary in- unstable. ISC feedback is not
primary injector #3. jector. Increased exhaust carried out.
[P0204] Primary injec- ¢ Malfunction in ECU. emissions. ISC learning is not
tor #4: malfunction in « Improperly installed carried out.
primary injector #4. primary injector. Injection to the appli-
cable cylinder group
(cylinders #1 and #2
or cylinders #3 and
#4) is cut off.
QSS is not carried
out.

9-42
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system op-

DTC ltem Vehicle symptom
malfunction eration
P0335 Crankshaft position « Defective coupler Engine cannot be Does not operate.
sensor: no normal between crankshaft started. ISC feedback is not
signals are received position sensor and carried out.
from the crankshaft ECU. ISC learning is not
position sensor. ¢ Open or short cir- carried out.
cuit in wire harness
between crankshaft
position sensor and
ECU.
¢« Improperly installed
crankshaft position
sensor.
¢ Malfunction in gen-
erator rotor.
¢ Defective crank-
shaft position sen-
sor.
¢ Malfunction in ECU.
P0340 Cylinder identification ¢ Defective coupler Engine cannot be The vehicle is operat-
sensor: no normal between cylinder started. ed using only the cyl-
signals are received identification sensor inder identification
from the cylinder iden- and ECU. information stored
tification sensor. ¢ Open or short cir- during operation.
cuit in wire harness ISC feedback is not
between cylinder carried out.
identification sensor ISC learning is not
and ECU. carried out.
¢ Improperly installed
cylinder identifica-
tion sensor.
« Defective pickup ro-
tor.
« Defective cylinder
identification sensor.
¢ Malfunction in ECU.

9-43
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system op-

DTC ltem malfunction Vehicle symptom ecoNan

P0351 [P0351] Cylinder-#1 « Defective coupler Engine stops. Injection to the appli-
P0352 ignition coil: open or between ignition coil | Loss of engine power. | cable cylinder group
P0353 short circuit detected and ECU. Engine is difficult to (cylinders #1 and #4
P0354 in the primary lead of | * Open or short cir- start. or cylinders #2 and
the cylinder-#1 igni- cuit in wire harness | Engine cannot be #3) is cut off.
tion coil. between ignition coil | started. Air induction system
[P0352] Cylinder-#2 and ECU. Engine idling speed is | solenoid is turned on
ignition coil: open or | * Improperly installed | unstable. all the time (air induc-
short circuit detected ignition coil. Increased exhaust tion system air cut
in the primary lead of | * Defective ignition emissions. off).
the cylinder-#2 igni- coil. O, feedback is not
tion coil. ¢ Malfunction in ECU. carried out.
[P0353] Cylinder-#3 ISC feedback is not
ignition coil: open or carried out.
short circuit detected ISC learning is not
in the primary lead of carried out.
the cylinder-#3 igni- QSS is not carried
tion coil. out.
[P0354] Cylinder-#4
ignition coil: open or
short circuit detected
in the primary lead of
the cylinder-#4 igni-
tion coil.
P0475 EXUP servo motor: * Defective coupler Loss of engine power. | Learning values for
performance deterio- between EXUP ser- fully closed EXUP are
ration vo motor and ECU. fixed.
¢ Open or short cir- Learning values for
cuit in wire harness fully open EXUP are
between EXUP ser- fixed.
vo motor and ECU. O, feedback is not
« Improperly installed carried out.
EXUP servo motor
and cables.
* Defective EXUP ser-
vo motor.
¢ Stuck EXUP servo
motor (mechanism
or motor).
¢ Malfunction in ECU.
P0476 EXUP servo motor: * Defective coupler Loss of engine power. | Learning values for
stuck EXUP servo between EXUP ser- fully closed EXUP are
motor is detected. vo motor and ECU. fixed.
¢ Open or short cir- Learning values for
cuit in wire harness fully open EXUP are
between EXUP ser- fixed.
vo motor and ECU. O, feedback is not
« Improperly installed carried out.
EXUP servo motor
and cables.
e Defective EXUP ser-
vo motor.
« Stuck EXUP servo
motor (mechanism
or motor).
« Malfunction in ECU.

9-44
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system op-

DTC ltem Vehicle symptom
malfunction eration
P0480 Radiator fan motor re- ¢ Open or short cir- Engine is difficult to Radiator fan motor re-
lay: open or short cir- cuit in wire harness. start. lay is off all the time.
cuit detected. *« Disconnected cou- Loss of engine power. Op» feedback is not
pler. Engine overheats. carried out.
¢ Defective radiator Increased exhaust ISC feedback is not
fan motor relay. emissions. carried out.
¢ Defective radiator ISC learning is not
fan motor relay con- carried out.
troller (Malfunction
in ECU).
P048B EXUP servo motor: « Defective coupler Loss of engine power. Learning values for
signal stuck between EXUP ser- fully closed EXUP are
vo motor and ECU. fixed.
¢ Open or short cir- Learning values for
cuit in wire harness fully open EXUP are
between EXUP ser- fixed.
vo motor and ECU. O, feedback is not
« Improperly installed carried out.
EXUP servo motor
and cables.
e Defective EXUP ser-
vo motor.
« Stuck EXUP servo
motor (mechanism
or motor).
« Malfunction in ECU.
P048D [P048D] EXUP servo * Defective coupler Loss of engine power. Learning values for
PO48E motor: open or ground between EXUP po- fully closed EXUP are
short circuit detected. sition sensor and fixed.
[PO48E] EXUP servo ECU. Learning values for
motor: power short ¢ Open or short cir- fully open EXUP are
circuit detected. cuit in wire harness fixed.
between EXUP po- O, feedback is not
sition sensor and carried out.
ECU.
« Defective EXUP po-
sition sensor.
¢ Malfunction in ECU.

9-45
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system op-

DTC ltem malfunction Vehicle symptom ecoNan

PO500 [P0500] Rear wheel ¢ Open or short cir- Vehicle speedis not | Vehicle speed dis-
P1500 sensor: no normal cuit in wire harness | displayed on the me-_ | played on the meter =
signals are received between rear wheel | ter. 0 [km/h]
from the rear wheel sensor and ABS Indication of the neu- | O» feedback is not
sensor. unit. tral indicator light is in- | carried out.
[P1500] Neutral ¢ Open or short cir- correct. Fuel cut-off control
switch: open or short cuit in wire harness | Engine idling speed Is | when the rear wheel
circuit is detected. between ABS unit unstable. sensor or neutral
[P1500] Clutch switch: | and ECU. Traction control does | switch malfunctions is
open or short circuit is | * Open or short cir- not work. carried out.
detected. cuit in wire harness ISC feedback is not
between neutral carried out.
switch and ECU. ISC learning is not
¢ Open or short cir- carried out.
cuit in wire harness Traction control does
between clutch not work.
switch and ECU. QSS is not carried
« Defective rear wheel out.
sensor.
* Defective neutral
switch.
* Defective clutch
switch.
* Improper adjust-
ment of clutch lever.
¢ Malfunction in ECU.
PO560 Charging voltage is ¢ Battery over-dis- Engine is difficult to Op» feedback is not
abnormal. charging (broken or | start. carried out.
disconnected lead in | Increased exhaust
charging system). emissions.
¢ Battery over-dis- Battery performance
charging (defective | has deteriorated or
rectifier/regulator). battery is defective.
P0563 Vehicle system power | * Battery overcharg- | Engine Is difficult to OQ, feedback is not
voltage out of range ing (defective rectifi- | start. carried out.
er/regulator). Increased exhaust
¢ Battery overcharg- | emissions.
ing (broken or dis- Battery performance
connected lead in has deteriorated or
rectifier/regulator battery is defective.
wire harness).
P0601 Internal malfunction in | « Malfunction in ECU. | Engine cannot be Engine cannot be
ECU. (When this mal- started. started.
function is detected in
the ECU, the DTC
might not appear on
the tool display.)

9-46
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system op-

DTC ltem malfunction Vehicle symptom ecoNan

PO606 Internal malfunction in | * Malfunction in ECU. | Engine cannot be Engine cannot be

ECU. (When this mal- started. started.
function is detected in Engine response is Ignition and injection
the ECU, the DTC poor. are not carried out.
might not appear on Loss of engine power. | Judgment for other
the tool display.) DTCs is not carried
out.
Load control is not
carried out. (The relay
unit, radiator fan mo-
tor relay, and other re-
lays are all turned off.)
The CO adjustment
mode and diagnostic
mode cannot be acti-
vated.
Output is restricted.
PO62F EEPROM DTC: an er- | * CO adjustment val- | Increased exhaust CO adjustment value
ror is detected while ue is not properly emissions. for the faulty cylinder
reading or writing on written. Engine cannot be = 0 (default value)
EEPROM. ¢ ISC learning value is | started or is difficult to | ISC learning values =
not properly written. | start. Default values.
* O» feedback learn- | Engine idling speed is | OBD memory value is
ing value is not unstable. initialized.
properly written. OBD memory value is | Initialization of O.
* OBD memory value | not correct. feedback learning val-
is not properly writ- ue.
ten.
¢ Malfunction in ECU.
P0638 YCC-T drive system: | ¢ Defective coupler Engine response is Op» feedback is not
malfunction detected. between throttle ser- | poor. carried out.
vo motor and ECU. | Loss of engine power. | YCC-T evacuation is
¢ Open or short cir- Engine idling speed is | activated.
cuit in wire harness | unstable. Output is restricted.
between throttle ser- ISC feedback is not
vo motor and ECU. carried out.
* Defective throttle ISC learning is not
servo motor. carried out.
* Throttle servo mo- QSS is not carried
tor is stuck (mecha- out.
nism or motor).
¢ Malfunction in ECU.
¢ Blown electric throt-
tle valve fuse.
P0657 Fuel system voltage: | * Open or short cir- Engine is difficult to Monitor voltage = 12
incorrect voltage sup- cuit in wire harness start. [V]
plied to the fuel injec- between relay unit Increased exhaust Op» feedback is not
tor and fuel pump. and ECU. emissions. carried out.
¢ Open circuit in wire
harness between
battery and ECU.
* Defective relay unit.
¢ Malfunction in ECU.

9-47
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system op-

DTC ltem malfunction Vehicle symptom ecoNan

P0916 [P0916] Gear posi- [P0916] Low voltage | Improper display for Maintains the gear
P0917 tion sensor: open or ‘| of the gear position position. position value at the
ground short circuit sensor circuit (0.2 V Engine response is previous value.
detected. or less) poor. QSS is not carried
[P0917] Gear posi- [P0917] High voltage out.
tion sensor: power of the gear position Engine brake man-
short circuit detected. | sensor circuit (4.8 V agement: control
or more) mode is fixed.
* Defective coupler Engine brake man-
between gear posi- agement: control val-
tion sensor and ue is fixed.
ECU.
* Open or power short
circuit in wire har-
ness between gear
position sensor and
ECU.
« Improperly installed
gear position sen-
sor.
* Defective gear posi-
tion sensor.
¢ Malfunction in ECU.
P1400 Air induction system | * Open or short cir- Increased exhaust Electric current in air
solenoid: open or cuit in wire harness. | emissions. induction system so-
short circuit detected. | « Disconnected cou- lenoid is prohibited
pler. (air induction system
* Defective air induc- air in).
tion system sole- O, feedback is not
noid. carried out.
* Defective air induc-
tion system sole-
noid controller.
(malfunction in
ECU)
P1600 Lean angle sensor: ¢ Open or short cir- Engine cannot be Engine cannot be
open or short circuit cuit in wire harness. | started. started.
detected. * Malfunction in IMU.
¢ Malfunction in ECU.
P1601 Sidestand switch: * Defective coupler Engine cannot be Engine is forcefully
open or short circuit of between relay unit started. stopped (the injector
the blue/yellow lead of and ECU. output is stopped).
the ECU is detected. ¢ Open or short cir-
cuit in wire harness
between relay unit
and ECU.
« Defective coupler
between sidestand
switch and relay
unit.
¢ Open or short cir-
cuit in wire harness
between sidestand
switch and relay
unit.
« Defective sidestand
switch.
¢ Malfunction in ECU.

9-48
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system op-

DTC ltem malfunction Vehicle symptom ecoNan

P1602 Malfunction in ECU ¢ Open or short cir- Engine idling speedis | O, feedback learning
internal circuit (mal- cuit in wire harness | unstable. is not carried out.
function of ECU pow- between ECU and Engine idling speed Is O, feedback learning
er cut-off function). battery. high. value is not written.
¢ Open or short cir- Increased exhaust
cuit in wire harness | emissions.
between ECU and Engine is difficult to
main switch. start.
* Blown backup fuse.
¢ Malfunction in ECU.
P1806 [P1806] Shift sensor: | * Defective coupler Unable to carry out QSS is not carried
P1807 open or ground short between shift sensor | QSS. out.
circuit detected. and ECU. (If this abnormality oc-
[P1807] Shift sensor: | * Open or power short | curs during actual
power short circuit de- | circuit in wire har- shifting, the operation
tected. ness between shift | will be carried out until
sensor and ECU. the process is com-
¢ Improperly installed | pleted.)
shift sensor.
¢ Defective shift sen-
sor.
¢ Malfunction in ECU.
P2122 [P2122] Accelerator [P2122, P2127] Low _ | Engine response is No change in acceler-
P2123 position sensor: open | voltage of the acceler- | poor. ator opening (tran-
P2127 or ground short cir- ator position sensor Loss of engine power. | sient control is not
P2128 cuit detected. circuit (0.25 V or less) | Engine idling speed is | carried out).
P2138 [P2123] Accelerator [P2123, P2128] High | unstable. Accelerator opening is
position sensor: pow- voltage of the acceler- fixed to O[°].
er short circuit detect- ator position sensor O, feedback is not
ed. circuit (4.75 V or carried out.
[P2127] Accelerator more) YCC-T evacuation is
position sensor: open [P2138] Difference in activated.
or ground short cir- output voltage 1 and Fuel cut is prohibited
cuit detected. output voltage 2 of the by accelerator open-
[P2128] Accelerator accelerator position ing.
position sensor: pow- sensor Output is restricted.
er short circuit detect- « Defective coupler ISC feedback is not
ed. between accelera- carried out.
[P2138] Deviation er- tor position sensor ISC learning is not
ror and ECU. carried out.
¢ Open or short cir- QSS is not carried
cuit in wire harness out.
between accelera-
tor position sensor
and ECU.
« Improperly installed
accelerator position
sensor.
* Defective accelera-
tor position sensor.
¢ Malfunction in ECU.

9-49
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system op-

DTC ltem malfunction Vehicle symptom ecoNan

P2158 Front wheel sensor: ¢ Open or short cir- Traction control does | Traction control does
no normal signals are | cuitin wire harness | not work. not work.
received from the between front wheel | Traction control sys-
front wheel sensor. sensor and ABS tem indicator on the
ECU. meter comes on.
¢ Open or short cir- Traction control sys-
cuit in wire harness | tem switch is dis-
between ABS ECU | abled. (Traction
and ECU. control system indica-
* Defective front tor on the meter goes
wheel sensor. OFF.)
¢ Malfunction in ABS
ECU.
¢ Malfunction in ECU.
P2195 O», sensor 1: open cir- | * Signal voltage is Increased exhaust O. feedback is not
cuit detected. 0.18—0.49 V. emissions. carried out.
* Improperly installed O, feedback learning
O2 sensor 1. is not carried out.
* Defective coupler Air induction system
between Oz sensor solenoid is turned on
1 and ECU. all the time (air induc-
¢ Open or short cir- tion system air cut
cuit in wire harness off).
between Op» sensor QSS is not carried
1 and ECU. out.
« Incorrect fuel pres-
sure.
* Defective O. sensor
1.
¢ Malfunction in ECU.
P2197 O» sensor 2: open cir- | * Signal voltage is Increased exhaust Op» feedback is not
cuit detected. 0.18—0.49 V. emissions. carried out.
« Improperly installed Op» feedback learning
Op» sensor 2. is not carried out.
* Defective coupler Air induction system
between O, sensor solenoid is turned on
2 and ECU. all the time (air induc-
¢ Open or short cir- tion system air cut
cuit in wire harness off).
between Op» sensor QSS is not carried
2 and ECU. out.
* Incorrect fuel pres-
sure.
* Defective O. sensor
2.
e Malfunction in ECU.

9-50
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system op-

DTC ltem malfunction Vehicle symptom ecoNan

P21CF [P21CF] Secondary | * Defective coupler Loss of engine power. | O, feedback is not
P21D0 injector #1: malfunc- between secondary carried out.
P21D1 tion in secondary in- injector and ECU. Air induction system
P21D2 jector #1. ¢ Open or short cir- solenoid is turned on
[P21D0] Secondary cuit in wire harness all the time (air induc-
injector #2: malfunc- between secondary tion system air cut
tion in secondary in- injector and ECU. off).
jector #2. « Defective second- ISC feedback is not
[P21D1] Secondary ary injector. carried out.
injector #3: malfunc- | « Malfunction in ECU. ISC learning is not
tion in secondary in- | * Improperly installed carried out.
jector #3. secondary injector. Injection to the appli-
[P21D2] Secondary cable cylinder group
injector #4: malfunc- (cylinders #1 and #2
tion In secondary IN- or cylinders #3 and
jector #4. #4) is cut off.
QSS is not carried
out.
P2228 [P2228] Atmospheric | [P2228] Low voltage | Engine is difficult to a—N is fixed.
P2229 pressure sensor: of the atmospheric start. Intake air pressure
ground short circuit pressure sensor cir- Increased exhaust difference is fixed to 0
detected. cuit (0.5 V or less) emissions. [kPa].
[P2229] Atmospheric | [P2229] High voltage | Insufficient power at | Atmospheric pres-
pressure sensor: of the atmospheric high altitudes. sure is fixed to 101.3
open or power short | pressure sensor cir- Engine idling speed Is | [kPa].
circuit detected. cuit (4.8 V or more) unstable. Atmospheric pres-
* Defective coupler Sure sensor output
between atmospher- correction value is
ic pressure sensor fixed to 0.
and ECU. Fuel is not cut off due
¢ Open or short cir- to the intake air pres-
cuit in wire harness sure difference.
between atmospher- OQ, feedback is not
ic Dressure Sensor carried out.
and ECU. ISC feedback is not
* Improperly installed carried out.
atmospheric pres- ISC learning is not
sure sensor. carried out.
* Defective atmo- QSS is not carried
spheric pressure out.
sensor.
¢ Malfunction in ECU.
U0125 Signals cannot be * Defective IMU cou- | Engine cannot be Engine cannot be
transmitted between pler or ECU coupler. started. started.
the ECU and the IMU. ¢ Open or short cir-
cuit in wire harness
between IMU and
ECU.
e Malfunction in IMU.
« Malfunction in ECU.

9-51
 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EAS33286

SELF-DIAGNOSTIC FUNCTION TABLE (FOR ABS (Anti-lock Brake System))

TIP
For details of the DTC, refer to “BASIC INSTRUCTIONS FOR TROUBLESHOOTING?” on page 9-20.

DTC ltem Symptom Check point

11 Front wheel sensor (intermit- Front wheel sensor signal is ¢ Foreign material adhered
tent pulses or no pulses) not received properly. (Puls- around the front wheel sen-
es are not received or are re- sor
ceived intermittently while ¢ Incorrect installation of the
the vehicle is traveling.) front wheel
¢« Defective sensor rotor or
incorrect installation of the
rotor
e Defective front wheel sen-
sor or incorrect installation
of the sensor
12 Rear wheel sensor (intermit- Rear wheel sensor signal is ¢ Foreign material adhered
tent pulses or no pulses) not received properly. (Puls- around the rear wheel sen-
es are not received or are re- sor
ceived intermittently while ¢ Incorrect installation of the
the vehicle is traveling.) rear wheel
¢ Defective sensor rotor or
incorrect installation of the
rotor
« Defective rear wheel sen-
sor or incorrect installation
of the sensor
13° Front wheel sensor (abnor- Front wheel sensor signal is ¢ Foreign material adhered
26° mal pulse period) not received properly. (The around the front wheel sen-
pulse period is abnormal sor
while the vehicle is traveling.) ¢ Incorrect installation of the
front wheel
¢e Defective sensor rotor or
incorrect installation of the
rotor
¢ Defective front wheel sen-
sor or incorrect installation
of the sensor
14* Rear wheel sensor (abnor- Rear wheel sensor signal is ¢ Foreign material adhered
27" mal pulse period) not received properly. (The around the rear wheel sen-
pulse period is abnormal sor
while the vehicle is traveling.) ¢ Incorrect installation of the
rear wheel
¢« Defective sensor rotor or
incorrect installation of the
rotor
¢ Defective rear wheel sen-
sor or incorrect installation
of the sensor

9-52
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

DTC ltem Symptom Check point

15 Front wheel sensor (open or | Open or short circuit is de- ¢ Defective coupler between
short circuit) tected in the front wheel sen- | the front wheel sensor and
sor. the hydraulic unit assembly
¢ 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
16 Rear wheel sensor (open or | Open or short circuit is de- ¢ Defective coupler between
short circuit) tected in the rear wheel sen- | the rear wheel sensor and
sor. the hydraulic unit assembly
¢ Open or short circuit in the
wire harness between the
rear wheel sensor and the
hydraulic unit assembly
¢ Defective rear wheel sen-
sor or hydraulic unit as-
sembly
21 Hydraulic unit assembly (de- | Solenoid drive circuit in the | * Defective hydraulic unit as-
fective solenoid drive circuit) | hydraulic unit assembly is sembly
open or short-circuited.
31 Hydraulic unit assembly (de- | Power is not supplied to the | * Blown ABS solenoid fuse
fective ABS solenoid power | solenoid circuit in the hy- ¢ Defective coupler between
circuit) draulic unit assembly. 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
33 Hydraulic unit assembly (ab- | Power is not supplied to the | * Blown ABS motor fuse
normal ABS motor power motor circuit in the hydraulic | « Defective coupler between
supply) unit assembly. 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 is detected in ¢ Defective hydraulic unit as-
(short circuit in ABS motor the motor power supply cir- sembly
power supply circuit) cuit in the hydraulic unit as-
sembly.
41 Front wheel ABS (intermit- ¢ Pulses from the front wheel | * Incorrect installation of the
tent wheel speed pulses or sensor are received inter- front wheel sensor
incorrect depressurization) mittently while the vehicle ¢ Incorrect rotation of the
is traveling. front wheel
* Front wheel will not recover ¢ Front brake dragging
from the locking tendency ¢ Defective hydraulic unit as-
even though the signal is sembly
transmitted from the ABS
ECU to reduce the hydrau-
lic pressure.

9-53
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

DTC ltem Symptom Check point

42 Rear wheel ABS (intermit- « Pulses from the rear wheel | « Incorrect installation of the
tent wheel speed pulses or sensor are received inter- rear wheel sensor
incorrect depressurization) mittently while the vehicle | * Incorrect rotation of the
is traveling. rear wheel
* Rear wheel will not recover | * Rear brake dragging
from the locking tendency | * Defective hydraulic unit as-
even though the signal is sembly
transmitted from the ABS
ECU to reduce the hydrau-
lic pressure.
43" Front wheel sensor (missing | Front wheel sensor signal is | * Foreign material adhered
45* pulses) not received properly. (Miss- around the front wheel sen-
ing pulses are detected in sor
the signal while the vehicle is | * Incorrect installation of the
traveling.) front wheel
¢ Defective sensor rotor or
incorrect installation of the
rotor
¢ Defective front wheel sen-
sor or incorrect installation
of the sensor
ab” Rear wheel sensor (missing | Rear wheel sensor signal is | * Foreign material adhered
46° pulses) not received properly. (Miss- around the rear wheel sen-
ing pulses are detected in sor
the signal while the vehicle is | * Incorrect installation of the
traveling.) rear wheel
¢ Defective sensor rotor or
incorrect installation of the
rotor
¢ Defective rear wheel sen-
sor or incorrect installation
of the sensor
51 Vehicle system power supply | Power voltage supplied to ¢ Defective battery
(voltage of ABS ECU power | the ABS ECU in the hydrau- | « Disconnected battery ter-
supply is high) lic unit assembly is too high. minal
¢ Defective charging system
53 Vehicle system power supply | Power voltage supplied to ¢ Defective battery
(voltage of ABS ECU power | the ABS ECU in the hydrau- | * Defective coupler between
supply is low) lic unit assembly is too low. 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
55 Hydraulic unit assembly (de- | Abnormal data is detected in | * Defective hydraulic unit as-
fective ABS ECU) the hydraulic unit assembly. sembly
56 Hydraulic unit assembly (ab- | Abnormality detected in of ¢ Defective hydraulic unit as-
normal internal circuit) hydraulic unit assembly. sembly

9-54
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

DTC Item Symptom Check point

57 Vehicle CAN communication | Short-circuit in CAN commu- | © Short-circuit in CAN com-
line or power source of vehi- | nication line or the voltage munication line
cle system that supplies the hydraulic ¢ Defective battery
unit assembly is too low. ¢ Defective coupler between
battery and hydraulic unit
assembly
e Wire harness between bat-
tery and hydraulic unit is in-
terrupted or has short-
circuited
¢ Defective charging system
62 Power supply voltage failure | Abnormality detected in ¢ Defective hydraulic unit as-
in pressure sensor pressure sensor power sup- sembly
ply circuit of hydraulic unit
assembly.
68 Defective hydraulic unitas- | Abnormality detected in In case of electrical interlock-
sembly (defective front pres- | pressure sensor circuit at ing brake
sure sensor) front caliper side of hydrau-_ | * Defective front brake line
lic unit assembly. ¢ Defective hydraulic unit as-
sembly
89 CAN communication (be- Transmitted data from the ¢ Defective coupler between
tween meter assembly and_ | meter cannot be normally re-| meter assembly and hy-
hydraulic unit assembly) ceived. draulic unit assembly
e Harness is broken or short-
circuit between meter as-
sembly and hydraulic unit
assembly
¢ Defective meter assembly
¢ Defective hydraulic unit as-
sembly
90 CAN communication (be- Transmitted data from the FI | * Defective coupler between
tween ECU and hydraulic ECU cannot be normally re- Fl ECU and hydraulic unit
unit assembly) ceived. assembly
e Harness is broken or short-
circuit between FI ECU and
hydraulic unit assembly
¢ Defective Fl ECU
¢ Defective hydraulic unit as-
sembly
91 CAN communication (be- Transmitted data from the ¢ Defective coupler between
tween IMU and hydraulic unit IMU cannot be normally re- IMU and hydraulic unit as-
assembly) ceived. sembly
¢ Harness is broken or short-
circuit between IMU and
hydraulic unit assembly
* Defective IMU
¢ Defective hydraulic unit as-
sembly

* The DTC number varies according to the vehicle conditions.

9-55
 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EAS33287

SELF-DIAGNOSTIC FUNCTION TABLE (FOR STEERING DAMPER SYSTEM)

TIP
For details of the DTC, refer to “BASIC INSTRUCTIONS FOR TROUBLESHOOTING” on page 9-27.

Probable cause of Fail-safe system op-

DTC ltem vealtinean Vehicle symptom ata

C1000 Steering damper sole- | * Defective coupler Steering damper does | Solenoid fixed at OFF.
noid: open or short between steering not work.
circuit detected. damper solenoid
and ECU.
¢ Open or short cir-
cuit in wire harness
between steering
damper solenoid
and ECU.
* Defective steering
damper solenoid.
¢ Malfunction in ECU.

EAS33288

SELF-DIAGNOSTIC FUNCTION TABLE (FOR ELECTRONICALLY ADJUSTABLE SUSPENSION

SYSTEM (for YZF-R1M))
TIP
For details of the DTC, refer to “BASIC INSTRUCTIONS FOR TROUBLESHOOTING?” on page 9-31.

Probable cause of
DTC Item Vehicle symptom Fail-safe system operation
malfunction

¢ ERS adjustments can-

¢ Defective front and rf 7 performed.
rear brake line. » The damping preset
C0044 | Abnormal ABS ; value is fixed at the —
. Defective hydraulic prescribed position
uni eesermly. (automatic setting
modes).
¢ Defective IMU cou-
pler or ECU coupler. | , . :
¢ Open or short circuit ERS adjustments can
in wire harness be- not be performed.
tween IMU and * The damping preset
C0520 | Abnormal IMU ECU value is fixed at the a
rescribed position
° 1 raid installed (automatic Setting
° Malfunction in IMU. | 92S).
¢ Malfunction in ECU.

C1002 Abnormal SCU ° SCU abnormal data | , ERS adjustments can-

writing error. —
EEPROM * Malfunction in SCU. not be performed.

9-56
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of
DTC Item eaninedon Vehicle symptom Fail-safe system operation

e Defective connec-
tion of stepping mo-
cae ¢ ERS adjustments can-
e Defective connec- . slike a eAlcolunigen
Stepping motor: tion of sub-wire har- voluesic hie “a the de-

(1008 oe | eee UP wire | f2etve side (ront fork |—

hotness or wire her.| o RCU) at the current
ness continuity value (automatic set-
* Defective stepping ting modes).
motor.
¢ Malfunction in SCU.
Abnormality in- Lo ¢ ERS adjustments can- |
C1007 side SCU Malfunction in SCU. not be performed.

¢ Open or short circuit

in wire harness be-

et ane | ¢ ERS adjustments can-

unit not be performed.
P9500 Abnormal rear ¢ Open or short circuit ° see tea a __
wheel sensor In wire harness be- ; i
tween ABS unit and prescribed position
ECU (automatic setting

« Defective rear modes).

wheel sensor.
¢ Malfunction in ECU.
¢ Battery overcharg-
ing (defective rectifi-
er/regulator).
¢ Battery overcharg-
ing (broken or dis-
connected lead in
Abnormal SCU rectifier/regulator ; _
PO560 | power supply volt- | wire harness). Se tetemnad Gane |
age ¢ Battery over-dis- P )
charging (broken or
disconnected lead
in charging system).
e Battery over-dis-
charging (defective
rectifier/regulator).
Front wheel sen- |° Open or shortcircuit | * ERS adjustments can-
sare papel in wire harness be- not be performed.
Sj nals arenes tween front wheel *« The damping preset
P2158 nalvod from the sensor and ECU. value is fixed at the —
front wheel sen- « Defective front prescribed position
aor wheel sensor. (automatic setting
e Malfunction in ECU. modes).
« Defective connec- '
tion of wire harness, |~ ah gisebloedn aes
not be performed.

YOT09 (between ECU * Wire harness conti- | Value !s fixed at the a

and SCU) nuity. prescribed position
(automatic setting
¢ Malfunction in SCU.
modes).
e Malfunction in ECU.

9-57
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of
DTC ltem malfunction Vehicle symptom Fail-safe system operation

¢« Defective connec-
tion of wire harness, | * ERS adjustments can-
ABS ECU, andSCU | not be performed.
devil nbn couplers. ¢ The damping preset
U0121 (between ABS ¢« Wire harness conti- value is fixed at the —
ECU and SCU) nuity. prescribed position
¢ Malfunction in SCU. | (automatic setting
¢ Malfunction in ABS modes).
ECU.

° pene ERS adjustments can-

not be performed.
crrniccton ses and SCU cou- |, The damping preset
U0125 (between IMU
Be
¢ Wire harness conti-
_ | value is fixed at the
prescribed position
—
and SCU) nuity.
¢ Malfunction in SCU. odes). setting
* Malfunction in IMU. | ™O9°S?:
¢ Defective connec-
tion of wire harness, ERS adjustments can-
Abnormal CAN meter assembly, not be performed.
communication and SCU couplers. The damping preset
U0155 | (between meter « Wire harness conti- value is fixed at the —
assembly and nuity. prescribed position
SCU) ¢e Malfunction in SCU. (automatic setting
e Malfunction in meter modes).
assembly.
ERS adjustments can-
not be performed.
Abnormality in-
e Malfunction in SCU. The “Err” and ERS
side SCU
icons are displayed on
the meter display.
¢ Defective connec-
tion of stepping mo- ERS adjustments can-
tor and SCU not be performed.
Steering damper couplers. The damping preset
stepping motor « Defective connec- value is fixed at the cur-
(manufactured by tion of sub-wire har- rent value.
Ohlins: optional): ness coupler. The auxiliary system
open circuit or e Short circuit in wire warning light comes on
short-circuit de- harness or wire har- on the meter and the
tected. ness continuity. steering damper warn-
¢ Defective stepping ing icon is displayed on
motor. the meter display.
¢ Malfunction in SCU.

9-58
 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EAS33030

COMMUNICATION ERROR WITH THE METER

Probable cause of . Fail-safe system op-
DTC ltem malfunction Vehicle symptom eration

U0155 [U0155 (FI)] Multi- Communication be- Defective meter dis- MAP changeover:
(YDT) function meter: sig- tween the ECU and play. State is fixed.
Err (multi- | nals cannot be trans- | the meter is not possi- | Traction control does _ | Traction control does
function mitted between the ble not work. not work.
meter dis- | ECU and the multi- ¢ Defective meter cou- Meter switch input:
play) function meter. pler and ECU cou- OFF is fixed.
[U0155 (SCU)] Abnor- | plier QSS is not carried
mal CAN communica- | * Open or short cir- out.
tion (between meter cuit in the wire har- Engine brake man-
assembly and SCU) ness between the agement: control
meter and the ECU mode is fixed.
« Defective meter
¢ Defective ECU

EASS3051

DIAGNOSTIC CODE: SENSOR OPERATION TABLE

eet tem Tool display Procedure

DO1 Throttle position sensor sig-
nal 1
« Fully closed position 11-21 Check with throttle valves ful-
ly closed.
¢ Fully open position 96-107 Check with throttle valves ful-
ly open.
DOQ2 Atmospheric pressure Displays the atmospheric Compare the actually mea-
pressure. sured atmospheric pressure
with the tool display value.
DOS Intake air pressure Displays the intake air pres- | Operate the throttle while
sure. pushing the “~”" side of the
start/engine stop switch. (If
the display value changes,
the performance is OK.)
DO5 Intake air temperature Displays the intake airtem- | Compare the actually mea-
perature. sured air temperature with
the tool display value.
DO6 Coolant temperature When engine is cold: Dis- Compare the actually mea-
plays temperature closer to | sured coolant temperature
air temperature. with the tool display value.
When engine is hot: Displays
current coolant temperature.
DO7 Rear wheel vehicle speed Rear wheel speed pulse Check that the number in-
pulses 0-999 creases when the rear wheel
is rotated. The number is cu-
mulative and does not reset
each time the wheel is
stopped.
DO9 Fuel system voltage Fuel system voltage Set the start/engine stop
(battery voltage) Approximately 12.0 switch to “(4", and then com-
pare the actually measured
battery voltage with the tool
display value. (If the actually
measured battery voltage is
low, recharge the battery.)

9-59
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Diagnostic ;
code No. ltem Tool display Procedure

D13 Throttle position sensor sig-

nal 2
¢ Fully closed position 9-23 Check with throttle valves ful-
ly closed.
* Fully open position 93-109 Check with throttle valves ful-
ly open.
D14 Accelerator position sensor
signal 1
¢ Fully closed position 9-23 Check with throttle grip fully
closed position.
* Fully open position 41-87 Check with throttle grip fully
open position.
D15 Accelerator position sensor
signal 2
* Fully closed position 7-25 Check with throttle grip fully
closed position.
« Fully open position 69-89 Check with throttle grip fully
open position.
D16 Front wheel vehicle speed Front wheel speed pulse Check that the number in-
pulses 0-999 creases when the front wheel
is rotated. The number is cu-
mulative and does not reset
each time the wheel is
stopped.
D17 Bank angle display Displays the bank angle in in- | Check that 0—5° is displayed
crements of 5° when the vehicle is vertical
¢ Q—5° (vehicle is vertical) and that the displayed value
¢« Less than 30° (when the increases as the vehicle con-
sidestand is used) tinues to incline.
D20 Sidestand switch Extend and retract the side-
* Sidestand retracted ON psi the transmission

¢ Sidestand extended OFF

D21 Neutral switch and clutch Operate the transmission,
switch clutch lever, and sidestand.
« Transmission is in neutral ON
¢ Transmission is in gearor | OFF
the clutch lever released
¢ Clutch lever is squeezed ON
with the transmission in
gear and when the side-
stand is retracted
¢ Clutch lever is squeezed OFF
with the transmission in
gear and when the side-
stand is extended

9-60
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Diagnostic ltem Tool display Procedure

code No.
D60 EEPROM DTC display
* No history 00
« No malfunctions detected
(lf the DTC PO62F is indi-
cated, the ECU is defec-
tive.)
* History exists 01-04 (CO adjustment val-
ue)
e (If more than one cylinder is
defective, the display alter-
nates every two seconds to
show all the detected cylin-
der numbers.
When all cylinder numbers
are shown, the display re-
peats the same process.)
Except 00-04 (EEPROM
data error for corresponding
learning/memory values)
D67 ISC (Idle Speed Control) 00 To erase the ISC (Idle Speed
learning condition display ISC (Idle Speed Control) Control) learning data, push
ISC (Idle Speed Control) learning data has been the “Operation” button 3
learning data erasure erased. times in 5 seconds.
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.
D70 Control number 0-254 [-]
D87 O» feedback learning data 00 To erase the O» feedback
erasure Op» feedback learning data learning data, push the “Op-
has been erased. eration” button 3 times in 5
01 seconds.
Op» feedback learning data
has not been erased.

D95 Shift sensor Check the sensor condition

by operating the shift pedal.
¢ Shift sensor output voltage 0.2—4.8 [V]
display
¢ With no shift weighting in- Approx. 2.5 [V]
put
¢ Shift up weighting Changes to the low side
¢ Shift down weighting Changes to the high side

9-61
 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EAS330a2

DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE

Diagnostic
code No. ltem Actuation Procedure

D30 Cylinder-#1 ignition coil Actuates the cylinder-#1 igni- | Check that a spark is gener-
tion coil five times at one- ated five times.
second intervals. * Connect an ignition check-
The “check” indicator on the er.
YDT screen come on each
time the ignition coil is actu-
ated.
D31 Cylinder-#2 ignition coil Actuates the cylinder-#2 igni- | Check that a spark is gener-
tion coil five times at one- ated five times.
second intervals. * Connect an ignition check-
The “check” indicator on the er.
YDT screen come on each
time the ignition coil is actu-
ated.
D32 Cylinder-#3 ignition coil Actuates the cylinder-#3 igni- | Check that a spark is gener-
tion coil five times at one- ated five times.
second intervals. * Connect an ignition check-
The “check” indicator on the er.
YDT screen come on each
time the ignition coil is actu-
ated.
D33 Cylinder-#4 ignition coil Actuates the cylinder-#4 igni- | Check that a spark is gener-
tion coil five times at one- ated five times.
second intervals. * Connect an ignition check-
The “check” indicator on the er.
YDT screen come on each
time the ignition coil is actu-
ated.
D34 Intake funnel servo motor Actuates the intake funnels | Check the operating of the
(up position down, position intake funnel servo motor.
for each six seconds).
llluminates the “check” indi-
cator
D36 Primary injector #1 Actuates the primary injec- | Disconnect the fuel pump
tor #1 five times at one-sec- | coupler before doing this
ond intervals. procedure.
The “check” indicator on the | Check that primary injector
YDT screen come on each #1 is actuated five times by
time the fuel injector is actu- | listening for the operating
ated. sound.
D37 Primary injector #2 Actuates the primary injec- | Disconnect the fuel pump
tor #2 five times at one-sec- | coupler before doing this
ond intervals. procedure.
The “check” indicator on the | Check that primary injector
YDT screen come on each #2 is actuated five times by
time the fuel injector is actu- | listening for the operating
ated. sound.
D38 Primary injector #3 Actuates the primary injec- | Disconnect the fuel pump
tor #3 five times at one-sec- coupler before doing this
ond intervals. procedure.
The “check” indicator on the Check that primary injector
YDT screen come on each #3 is actuated five times by
time the fuel injector is actu- listening for the operating
ated. sound.

9-62
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

gin Hately Item Actuation Procedure

D39 Primary injector #4 Actuates the primary injec- | Disconnect the fuel pump
tor #4 five times at one-sec- | coupler before doing this
ond intervals. procedure.
The “check” indicator on the | Check that primary injector
YDT screen come on each #4 is actuated five times by
time the fuel injector is actu- | listening for the operating
ated. sound.
D40 Secondary injector #1 Actuates the secondary in- | Disconnect the fuel pump
jector #1 five times at one- coupler before doing this
second intervals. procedure.
The “check” indicator on the | Check that secondary injec-
YDT screen come on each _i| tor #1 is actuated five times
time the fuel injector is actu- | by listening for the operating
ated. sound.
D41 Secondary injector #2 Actuates the secondary in- | Disconnect the fuel pump
jector #2 five times at one- coupler before doing this
second intervals. procedure.
The “check” indicator on the | Check that secondary injec-
YDT screen come on each _|tor #2 is actuated five times
time the fuel injector is actu- | by listening for the operating
ated. sound.
D42 Secondary injector #3 Actuates the secondary in- | Disconnect the fuel pump
jector #3 five times at one- coupler before doing this
second intervals. procedure.
The “check” indicator on the | Check that secondary injec-
YDT screen come on each _i| tor #3 is actuated five times
time the fuel injector is actu- | by listening for the operating
ated. sound.
D43 Secondary injector #4 Actuates the secondary in-_ | Disconnect the fuel pump
jector #4 five times at one- coupler before doing this
second intervals. procedure.
The “check” indicator on the | Check that secondary injec-
YDT screen come on each _| tor #4 is actuated five times
time the fuel injector is actu- | by listening for the operating
ated. sound.
D47 Steering damper solenoid When the start/engine stop | Check the operating of the
switch is “ON”, the steering | steering damper.
damper solenoid is on.
When the start/engine stop
switch is “OFF”, the steering
damper solenoid is off.
The “check” indicator on the
YDT screen come on each
time the steering damper so-
lenoid is actuated.
D48 Air induction system sole- Actuates the air induction Check that the air induction
noid system solenoid five times at system solenoid is actuated
one-second intervals. five times by listening for the
The “check” indicator on the operating sound.
YDT screen come on each
time the air induction system
solenoid is actuated.

9-63
 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Diagnostic
code No. ltem Actuation Procedure

D49 Intake solenoid Actuates the intake solenoid | Check that the intake sole-
five times at one-second in- | noid is actuated five times by
tervals. listening for the operating
The “check” indicator on the | sound.
YDT screen come on each
time the intake solenoid is
actuated.
D50 Relay unit Actuates the relay unit five Check that the relay unit is
times at one-second inter- actuated five times by listen-
vals. ing for the operating sound.
The “check” indicator on the
YDT screen come on each
time the relay is actuated.
D51 Radiator fan motor relay Actuates the radiator fan mo- | Check that the radiator fan
tor relay five times at five- motor relay is actuated five
seconds intervals. times by listening for the op-
The “check” indicator on the | erating sound.
YDT screen come on each
time the relay is actuated.
D52 Headlight relay Actuates the headlight five Check that the headlight
times at five-seconds inter- comes on five times.
vals.
The “check” indicator on the
YDT screen come on each
time the headlight is actuat-
ed.
D53 EXUP servo motor After the EXUP is fully Check the operating sound.
closed, it stops at the open-
ing base position (intermedi-
ate position).
This operation takes approxi-
mately 3 seconds during
which the “check” indicator is
displayed on the YDT.

EASa3a289

DIAGNOSTIC CODE TABLE (SCU) (for YZF-R1M)

Diagnostic
ltem Tool display Procedure
code No.

DO9 Monitor voltage Displays the SCU power Check the displayed SCU
supply voltage. power supply voltage.
Approximately 12.0 V

9-64
 EVENT CODE TABLE

EAS2o707

EVENT CODE TABLE

TIP
The event code numbers listed below cannot be displayed on the meter. To display the event code
numbers, use the YDT.

No. Item Symptom Possible causes Note

192 Intake air pres- Brief abnormality de- | Same as forDTC num- | Perform the inspection
sure sensor tected in the intake air | ber PO107 and P0108 items listed for DTC num-
pressure sensor ber P0107 and P0108.
193 Throttle position | Brief abnormality de- | Same as forDTC num-_| Perform the inspection
sensor tected in the throttle ber P0122, P0123, items listed for DTC num-
position sensor POQ222 and P0223 ber P0122, P0123, P0222
and P0223.
194 EXUP servo mo- | Brief abnormality de- | Same as forDTC num-_| Perform the inspection
tor circuit tected in EXUP servo | ber PO48D and PO48E items listed for DTC num-
motor circuit ber P048D and PO48E.
195 Sidestand switch | Brief abnormality de- | Same as for DTC num-_| Perform the inspection
tected in the ECU ber P1601 items listed for DTC num-
(blue/yellow) input ber P1601.
line
196 Coolant tempera- | Brief abnormality de- | Same as for DTC num-_| Perform the inspection
ture sensor tected a inthe coolant | ber PO117 and P0118 items listed for DTC num-
temperature sensor ber P0117 and P0118.
197 Intake air tem- Brief abnormality de- | Same as forDTC num-_| Perform the inspection
perature sensor | tected inthe intake air | ber PO112 and P0113 items listed for DTC num-
temperature sensor ber P0112 and P0113.
198 Atmospheric Brief abnormality de- | Same as for DTC num-_| Perform the inspection
pressure sensor | tected in atmospher- | ber P2228 and P2229 items listed for DTC num-
ic pressure sensor ber P2228 and P2229.
207 Accelerator posi- | Brief abnormality de- | Same as for DTC num- _| Perform the inspection
tion sensor tected in the acceler- | ber P2122, P2123, items listed for DTC num-
ator position sensor P2127 and P2128 ber P2122, P2123, P2127
and P2128.
220 Gear position Brief abnormality de- | Same as forDTC num- | Perform the inspection
sensor tected in the gear po- | ber P0916 and P0917 items listed for DTC num-
sition sensor ber P0916 and P0917.
240 0 During O5 feedback, | * Open or short circuit in | « Ifa DTC is occurring, re-
9 sensor .
the adjustment is the wire harness be- spond to that first.
(Stuck at the up- maintained at the up- tween the sensor and _ | * Rarely, Code 240 occurs
pet limit for ad- per limit ECU even when the system is
justment) ¢ Drop in fuel pressure functioning properly.
¢ Clogged fuel injector
« Fault in sensor
¢ Malfunction in ECU
¢ Malfunction in the fuel
injection system

9-65
 EVENT CODE TABLE

No. ltem Symptom Possible causes Note

241 O During O, feedback, | * Open or short circuit in | * If a DTC is occurring, re-
» sensor : " .
the adjustment is the wire harness be- spond to that first.
(Stuck at the low- maintained atthe low-| tweenthe sensor and | * Rarely, Code 241 occurs
er limit for adjust- | i ais ECU even when the system is
ment) ¢ Drop in fuel pressure functioning properly.
¢ Clogged fuel injector
¢ Fault in sensor
¢ Malfunction in ECU
¢ Malfunction in the fuel
injection system
242 ISC During idling, the ad- | Idling engine speed is * Implement diagnosis
(Stuck at the up- | justment is main- slow mode D6/7, and check the
per limit for ad- tained at the upper ¢ Clogged throttle body ISC maintenance request.
justment) limit ¢ Poorly adjusted clutch | Ifa DTC is occurring, re-
cable spond to that first.
¢ Malfunction in the fuel | * Rarely, Code 242 occurs
injection system even when the system is
¢ Dirty or worn spark functioning properly.
plug
¢ Malfunction in the bat-
tery
¢ Malfunction in ECU
243 ISC During idling, the ad- | Idling engine speed is * Ifa DTC is occurring, re-
(Stuck at the low- | justment is main- fast spond to that first.
er limit for adjust- | tained at the lower ¢ Poorly adjusted clutch | * Rarely, Code 243 occurs
ment) limit cable even when the system is
¢ Malfunction in the fuel | functioning properly.
injection system
« Dirty or worn spark
plug
¢ Malfunction in the bat-
tery
¢ Malfunction in ECU
244 Poor starting/in- | Poor starting/inability | * No gasoline ¢ If a DTC is occurring, re-
ability to start to start detected ¢ Malfunction in the fuel spond to that first.
injection system * Rarely, Code 244 occurs
¢ Dirty or worn spark even when the system is
plug functioning properly.
¢ Malfunction in the bat-
tery
¢ Malfunction in ECU
245 Engine stop Engine stop detected | * No gasoline * Ifa DTC is occurring, re-
¢ Poorly adjusted clutch spond to that first.
cable * Rarely, Code 245 occurs
¢ Malfunction in the fuel | even when the system is
injection system functioning properly.
¢ Dirty or worn spark
plug
¢ Malfunction in the bat-
tery
¢ Malfunction in ECU
251 Shift sensor Brief abnormality de- | Same as for DTC num-_| Perform the inspection
tected in the shift sen- ber P1806 and P1807 items listed for DTC num-
SOP ber P1806 and P1807.

9-66
 30_EVENT

EAS20552

30_EVENT
EASa30a3

TROUBLESHOOTING
ltem
Latch up detected.
Fail-safe system
e Unable to start engine
e Unable to drive vehicle

Procedure
1. The vehicle has overturned.
¢ Raise the overturned vehicle vertically and check again.
e Turn the main switch to “ON”, then to “OFF”, and then back to “ON”.

Is the MIL on?

YES
— Go to step 2.
NO
— Service is completed.

2. Installed condition of IMU.

¢ Check the installed direction and condition of the sensor.
¢ Check the grommet for cracks.

Is check result OK?

YES
— Go to step 3.
NO
a. Fix the IMU installation condition.
b. Turn the main switch to “ON”, then to “OFF”, and then back to “ON”.

Is the MIL on?

YES
— Go to step 3.
NO
— Service is completed.

3. Defective IMU.
* Execute the diagnostic mode. (Code D17)
¢ Check that 0°—5° is displayed when the vehicle is vertical and that the displayed value increases as
the vehicle continues to incline.

Is check result OK?

YES
— Go to step 4.
NO
a. Replace the IMU.
Refer to “GENERAL CHASSIS (1)” on page 4-1.
b. Turn the main switch to “ON”, then to “OFF”, and then back to “ON”.

Is the MIL on?

YES
— Go to step 4.

9-67
 30_EVENT

NO
— Service is completed.
4. Malfunction in ECU.
¢« Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.

9-68
 70_EVENT

EAS20554

70_EVENT
Es«sa30a4

TROUBLESHOOTING
ltem
Engine forcibly stops when the vehicle is left idling for a long period.

Procedure
TIP
lf another error code is displayed at the same time, check the other error code first and repair it.
1. Allow to idle for a long period.
¢ Turn the main switch to “OFF”.
* Check whether it is possible to start the engine.

Can the engine starting?

YES
— Service is completed.
NO
— Go to step 2.

2. Malfunction in ECU.
¢ Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.

9-69
 C0044

EAS20559

C0044
EASa30a9

TROUBLESHOOTING
ltem
Abnormal ABS
Fail-safe system
e Able to start engine
e Able to drive vehicle

Procedure
1. Abnormal ABS
« Check the items of DTCs 62 and 68 for the ABS.
Refer to “[B-2] DIAGNOSIS USING THE DTC” on page 9-23.
¢ Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the
malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Service is completed.
NO
— Refer to the item corresponding to the DTC.

9-70
 C0520 (Fl)

C0520 (Fl)
EAS20689

EAS3a3319

TROUBLESHOOTING
ltem
Abnormal IMU
Fail-safe system
e Able/Unable to start engine
e Able/Unable to drive vehicle

Procedure
1. Connection of IMU coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 2.

2. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 3.

3. Wire harness continuity.

¢ Disconnect the ECU coupler “1”, joint coupler “2”, IMU coupler “S” and ignition fuse “4”.
* Open circuit check
blue/white—blue/white
Between ECU coupler and joint coupler blue/black—blue/black

9-71
 C0520 (Fl)
blue/white—blue/white
Between joint coupler and IMU coupler blue/black—blue/black

Between IMU coupler and ignition fuse holder red/white—red/white

Between IMU coupler and ECU coupler black/white—black/white

4
ono
Q) BIW] LW] LB | RW

= ee ee

“, Joint coupler for YZF-R1

“*. Joint coupler for YZF-R1M

Is resistance 0 (2?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to “Short circuit check”.

e Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
qn blue/white—ground
Between ECU coupler “1” and ground blue/black-ground

blue/white—ground
Between IMU coupler “3” and ground blue/black—ground
red/white—ground

Lines short circuit check “B”

blue/white—any other coupler terminal
ECU coupler blue/black—any other coupler terminal

9-72
 C0520 (Fl)
blue/white—any other coupler terminal
Joint coupler “2”
blue/black—any other coupler terminal
blue/white—any other coupler terminal
IMU coupler blue/black—any other coupler terminal
red/white—any other coupler terminal

A
1

C — | Fa ee
LIB pw) P<] v | Lun Gy
BY BL| W 1B
" Liv [LW ay >< fav!G [>< Jawa >< iw

“, Joint coupler for YZF-R1

“*. Joint coupler for YZF-R1M

Is resistance o 0?
YES
— Go to step 4.
NO
a . Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 4.

4. Installed condition of IMU.

* Check the installed direction and condition of the sensor.
¢ Check the grommet for cracks.

Is check result OK?

YES
— Go to step 5.
NO

9-73
 C0520 (Fl)
a. Fix the IMU installation condition.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 5.
5. Defective IMU.
¢ Replace the IMU.
Refer to “GENERAL CHASSIS (1)” on page 4-1.
¢ Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 6.

6. Malfunction in ECU.
* Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
7. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-74
 C0520 (SCU)

EAS20664

C0520 (SCU)
EASa3290

TROUBLESHOOTING
ltem
Abnormal IMU
Fail-safe system
e Unable to start engine
e Able/Unable to drive vehicle

Procedure
1. Abnormal front wheel sensor
« Check the item of DTC C0520 for the ECU.
Refer to “SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM)” on page
9-38.
¢ Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the
malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Service is completed.
NO
— Refer to the item corresponding to DTC.

9-75
 C1000

EAS20561

C1000
Es«Saa0oiH1

TROUBLESHOOTING
ltem
Steering damper solenoid: open or short circuit detected.
Fail-safe system
e Able to start engine
e Able to drive vehicle

Procedure
1. Connection of steering damper solenoid coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 2.

2. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 3.

3. Wire harness continuity.

¢ Disconnect the ECU coupler “1 ” and steering damper solenoid coupler “2”.
* Open circuit check
Between steering damper solenoid coupler and
yellow/black—yellow/black
ECU coupler

9-76
 C1000

Between steering damper solenoid coupler and en-

black—black
gine ground

Is resistance 0)?
YES
— Go to “Short circuit check”.
NO
a . Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to “Short circuit check”.

© Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
Between ECU coupler “1” and ground yellow/black—ground

Lines short circuit check “B”

ECU coupler yellow/black—any other coupler terminal
Steering damper solenoid coupler “2” yellow/black—any other coupler terminal

A B

IVD] L >< fye Bal

wilwh<Jud<Jer
BIG B BIG
[pr ><] Ber B < ry

Is resistance oo Q?
YES
— Go to step 4.
 C1000

NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 4.
4. Defective steering damper solenoid.
¢ Check the steering damper solenoid.
Refer to “CHECKING THE STEERING DAMPER SOLENOID” on page 8-51.

Is check result OK?

YES
— Go to step 5.
NO
a. Replace the steering damper solenoid.
Refer to “STEERING HEAD” on page 4-108.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 5.

5. Malfunction in ECU.
* Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
6. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-78
 C1002

EAS20562

C1002
EASaSa042

TROUBLESHOOTING
ltem
Abnormal SCU EEPROM
Fail-safe system
e Able to start engine
e Able to drive vehicle

Procedure
1. Confirmation after correction of abnormality.
¢ Turn the main switch to “OFF” and back to “ON”.
¢ Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Service is completed.
NO
— Go to step 2.

2. Malfunction in SCU.
¢ Replace the SCU.
Refer to “GENERAL CHASSIS (6)” on page 4-23.
¢ Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the
malfunction mode of the YDT.
¢ Make sure confirm the “Recovered” condition, and complete the service.

9-79
 C1003

EAS20563

C1003
EASSaS043

TROUBLESHOOTING
ltem
Stepping motor: open or short circuit detected.
Fail-safe system
e Able to start engine
e Able to drive vehicle

Procedure
1. Connection of stepping motor coupler.
¢ Check the locking condition of the coupler.
—Front fork stepping motor (left)
—Front fork stepping motor (right)
—Rear shock absorber assembly stepping motor (x2)
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness and/or sub-wire harness.
b. Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the
malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Service is completed.
NO
— Go to step 2.

2. Connection of SCU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness and/or sub-wire harness.
b. Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the
malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Service is completed.
NO
— Go to step 3.

3. Connection of stepping motor sub-wire harness coupler.

¢ Check the locking condition of the coupler.

9-80
 C1003

¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 4.
NO
a . Connect the coupler securely or replace the wire harness and/or sub-wire harness.
b. Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the
malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Service is completed.
NO
— Go to step 4.

4. Wire harness continuity.

* Open circuit check
green—green
Between SCU coupler “1” and front fork stepping green/black—green/black
motor (left) “2” green/red—green/red
green/blue—green/blue

m=
2)
, W.
po
PIWiciR| ¥ evi)
2
Ais ic yirlsid Gy] a

a
Mah agi aly ichoyahh
SAGE * WB] W [WRENN
(CW
p82)
Se

pink—pink
Between SCU coupler “1” and front fork stepping pink/black—pink/black
motor (right) “2” pink/white—pink/white
pink/blue—pink/blue

ee P| G [vir lGyG Gy} B

$a rics] vicianelaye
Lnp< | Pie |GiL|Yie] WW [WIRIWIBIWIG
t__@q—_—
6)
82)
white—white
Between SCU coupler “1” and rear shock absorber
white/black—white/black
assembly stepping motor (compression damping)
aa white/red—white/red
white/green—white/green

9-81
 C1003

PT G [vAlanG| Gy
Lie
LW,
PYL GIB) ¥ came
|PIBIGILIVI/B) W bia
paar A

yellow—yellow
Between SCU coupler “1” and rear shock absorber yellow/black—yellow/black
assembly stepping motor (rebound damping) “2” yellow/red—yellow/red
yellow/green—yellow/green

hr ll
|
— ist
Ken kAn e315) CVA

=
Li<]pslaL| we] w WwalWelwiG =

Is resistance 0 02?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness and/or sub-wire harness.
b. Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the
malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Service is completed.
NO
— Go to “Short circuit check”.

e Short circuit check

TIP
Disconnect the SCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SCU (for YZF-R1M)” on page 9-3.

green—black
Between front fork stepping motor (left) “1” and pow- green/black—black
er ground “2” green/red—black
green/blue—black
pink—black
Between front fork stepping motor (right) “3” and pink/black—black
power ground “2” pink/white—black
pink/blue—black

9-82
 C1003

white—black
Between rear shock absorber assembly stepping
white/black—black
motor (compression damping) “4” and power ground
“oe white/red—black
white/green—black
yellow—black
Between rear shock absorber assembly stepping yellow/black—black
motor (rebound damping) “5” and power ground “2” yellow/red—black
yellow/green—black
green—brown/white
Between front fork stepping motor (left) “1” and pow- green/black—brown/white
er battery “6” green/red—brown/white
green/blue—brown/white
pink—brown/white
Between front fork stepping motor (right) “3” and pink/black—brown/white
power battery “6” pink/white—brown/white
pink/blue—brown/white
white—brown/white
Between rear shock absorber assembly stepping
white/black—brown/white
motor (compression damping) “4” and power battery
“6” white/red—brown/white
white/green—brown/white
yellow—brown/white
Between rear shock absorber assembly stepping yellow/black—brown/white
motor (rebound damping) “5" and power battery “6” yellow/red—brown/white
yellow/green—brown/white

391 5
\_ca |
PIWIG/
P mal GyiG
UB) <IPIL |GiBIY/GIGyB
P/BIGILIY/B] W WWI

Is resistance - 0)?
YES
— Go to step 5.
NO
a. Replace the wire harness and/or sub-wire harness.
b. Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the
malfunction mode of the YDT.

Is itin the “Recovered” condition?

YES
— Service is completed.
NO
— Go to step 5.

5. Malfunction in stepping motor.

a. Connect the digital circuit tester (Q) to the stepping motor.
e Positive tester probe “1”
¢ Negative tester probe “2”

9-83
 C1003

208
A. Stepping motor coupler
B. Connection wiring diagram
b. Measure the resistance of the stepping motor between “1” and “2”.

14.8-18.2 © (When the motor is cold at 20 °C (68 °F))?

YES
— Go to step c.
NO
a. Replace the front fork cap bolt and rear shock absorber assembly.
Refer to “FRONT FORK (for YZF-R1M)” on page 4-100 and “REAR SHOCK ABSORBER ASSEM-
BLY” on page 4-112.
b. Turn the main switch to “ON”. Check the condition of the DTC using the malfunction mode of the
YDT.

Is it in the “Recovered” condition?

YES
— Service is completed.
NO
— Go to step c.

c. Connect the digital circuit tester (Q) to the stepping motor.

e Positive tester probe “3”
¢ Negative tester probe “4”
d. Measure the resistance of the stepping motor between “3” and “4”.

14.8-18.2 © (When the motor is cold at 20 °C (68 °F))?

YES
— Go to step 6.
NO
a. Replace the front fork cap bolt and rear shock absorber assembly.
Refer to “FRONT FORK (for YZF-R1M)” on page 4-100 and “REAR SHOCK ABSORBER ASSEM-
BLY” on page 4-112.
b. Turn the main switch to “ON”. Check the condition of the DTC using the malfunction mode of the
YDT.

Is it in the “Recovered” condition?

YES
— Service is completed.
NO
— Go to step 6.

6. Malfunction in SCU.
¢ Replace the SCU.
Refer to “GENERAL CHASSIS (6)” on page 4-23.

9-84
 C1003

¢ Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the
malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Service is completed.
NO
— Refer to the item corresponding to DTC.

9-85
 C1007

EAS20566

C1007
EASSaS046

TROUBLESHOOTING
ltem
Abnormality inside SCU
Fail-safe system
e Able to start engine
e Able to drive vehicle

Procedure
1. Malfunction in SCU.
¢ Replace the SCU.
Refer to “GENERAL CHASSIS (6)” on page 4-23.
¢ Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the
malfunction mode of the YDT.
¢ Make sure confirm the“Recovered”condition, and complete the service.

9-86
 P0030

EAS20397

P0030
E4S33134

TROUBLESHOOTING
ltem
Os sensor 1 heater: defective heater controller detected.
Fail-safe system
¢ Able to start engine
¢ Able to drive vehicle

Procedure
TIP
lf more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first.
e P0112, P0113, P0122, P0123, P0222, P0223, P2135
1. Connection of Os sensor 1 coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Start the engine, and then check the condition of the DTC.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 2.

TIP
For this check, also set the start/engine stop switch to “ON”.
2. Connection of ECU coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO

9-87
 P0030

. Connect the coupler securely or replace the wire harness.

om
Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Start the engine, and then check the condition of the DTC.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 3.

TIP
For this check, also set the start/engine stop switch to “ON”.
3. Wire harness continuity.
¢ Disconnect the O, sensor 1 coupler “1”, ECU coupler “2”, ignition fuse “3” and main switch coupler
“4”,
* Open circuit check
Between O, sensor 1 coupler and ECU coupler pink/black—pink/black
Between O, sensor 1 coupler and ignition fuse hold-
red/white—red/white
er
Between main switch coupler and ignition fuse hola-
ay brown/blue—brown/blue

Is resistance 0 9?
YES
— Go to “Short circuit check”.
NO
a . Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Start the engine, and then check the condition of the DTC.

9-88
 P0030

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to “Short circuit check”.

TIP
For this check, also set the start/engine stop switch to “ON”.
¢ Short circuit check
TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”

Between Oz sensor 1 coupler red/white—ground

“1” and ground pink/black-ground

Between main switch coupler “4° and ground brown/blue—ground

Lines short circuit check “B”

red/white—any other coupler terminal
Oz sensor 1 coupler pink/black—any other coupler terminal
ECU coupler “2” pink/black—any other coupler terminal
Main switch coupler brown/blue—any other coupler terminal

° ° Q)
fa C v1 :
RW] PIB! Q) Bri () i fal<D<Pmlpsloceys[oleyn)
Gwi| BIL PRIA <|Ue OB) Ge| Bd
I PL |GivenAleny eve WL BOW B I

=— — | jel lweluw[ vit [sb |AaAvEy |

Is resistance oo (2?
YES
— Go to step 4.
NO
a . Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Start the engine, and then check the condition of the DTC.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO

9-89
 P0030

— Go to step 4.

TIP
For this check, also set the start/engine stop switch to “ON”.
4. Defective O. sensor 1.
¢ Replace the Oz», sensor 1.
Refer to “ENGINE REMOVAL” on page 5-11.
¢ Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Start the engine, and then check the condition of the DTC.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 5.

TIP
For this check, also set the start/engine stop switch to “ON”.
5. Malfunction in ECU.
¢ Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
6. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-90
 P0050

EAS20398

P0050
E4S33135

TROUBLESHOOTING
ltem
Os sensor 2 heater: defective heater controller detected.
Fail-safe system
¢ Able to start engine
¢ Able to drive vehicle

Procedure
TIP
lf more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first.
e P0112, P0113, P0122, P0123, P0222, P0223, P2135
1. Connection of Os sensor 2 coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Start the engine, and then check the condition of the DTC.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 2.

TIP
For this check, also set the start/engine stop switch to “ON”.
2. Connection of ECU coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO

9-91
 P0050

. Connect the coupler securely or replace the wire harness.

om
Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Start the engine, and then check the condition of the DTC.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 3.

TIP
For this check, also set the start/engine stop switch to “ON”.
3. Wire harness continuity.
¢ Disconnect the O, sensor 2 coupler “1”, ECU coupler “2”, ignition fuse “3” and main switch coupler
“4”,
* Open circuit check
Between O, sensor 2 coupler and ECU coupler pink/white—pink/white
Between O, sensor 2 coupler and ignition fuse hold-
red/white—red/white
er
Between main switch coupler and ignition fuse hola-
ay brown/blue—brown/blue

Is resistance 0 9?
YES
— Go to “Short circuit check”.
NO
a . Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Start the engine, and then check the condition of the DTC.

9-92
 P0050

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to “Short circuit check”.

TIP
For this check, also set the start/engine stop switch to “ON”.
© Short circuit check
TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”

Between Op sensor 2 coupler

qn
“1” and ground
red/white—ground
pink/white—ground

Between main switch coupler “4° and ground brown/blue—ground

Lines short circuit check “B”

red/white—any other coupler terminal
Oz sensor 2 coupler pink/white—any other coupler terminal
ECU coupler “2” pink/white—any other coupler terminal
Main switch coupler brown/blue—any other coupler terminal

A B
; OF
1 4 th ! 3 a | ov.
PAW Q) "ert —@ ! : ! ' fir pwlPmlocenlo [arn :
4] BIL ‘ | borlual<]ue jovelrve lave] B |X]
ee ! | RRL |Gry/evrlerry
Bi WL Bb) Bf] |
= — | (pic vip|uw|
yi [sb [AALS |

Is resistance oo (2?
YES
— Go to step 4.
NO
a . Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Start the engine, and then check the condition of the DTC.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO

9-93
 P0050

— Go to step 4.

TIP
For this check, also set the start/engine stop switch to “ON”.
4. Defective O. sensor 2.
¢ Replace the Ox. sensor 2.
Refer to “ENGINE REMOVAL” on page 5-11.
¢ Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Start the engine, and then check the condition of the DTC.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 5.

TIP
For this check, also set the start/engine stop switch to “ON”.
5. Malfunction in ECU.
¢ Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
6. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-94
 P0069

EAS20390

P0069
E4S33136

TROUBLESHOOTING
ltem
Intake air pressure sensor or atmospheric pressure sensor: when the main switch is turned to “ON”, the
intake air pressure sensor voltage and atmospheric pressure sensor voltage differ greatly.
Fail-safe system
e Able to start engine
e Able to drive vehicle

Procedure
TIP
lf more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first.
¢ P0107, P0108, P0335, P2228, P2229
1. Defective intake air pressure sensor.
* Execute the diagnostic mode. (Code DO3)
¢« When engine is stopped: Atmospheric pressure at the current altitude and weather conditions is in-
dicated.
0 m above sea level Approx. 101 kPa (757.6 mmHg, 29.8 inHg)
3000 m (9800 ft) above sea level Approx. 70 kPa (525.0 mmHg, 20.7 inHg)

Is check result OK?

YES
— Go to step 2.
NO
a. Replace the intake air pressure sensor.
Refer to “THROTTLE BODIES” on page 7-11.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 4, and complete the service.
NO
— Go to step 2.

2. Defective atmospheric pressure sensor.

¢ Execute the diagnostic mode. (Code DQO2)
¢ When engine is stopped: Atmospheric pressure at the current altitude and weather conditions is in-
dicated.
0 m above sea level Approx. 101 kPa (757.6 mmHg, 29.8 inHg)
3000 m (9800 ft) above sea level Approx. 70 kPa (525.0 mmHg, 20.7 inHg)

Is check result OK?

YES
— Go to step 3.
NO

9-95
 P0069

a. Replace the atmospheric pressure sensor.

Refer to “AIR INDUCTION SYSTEM” on page 7-20.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 4, and complete the service.
NO
— Go to step 3.
3. Malfunction in ECU.
¢« Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
4. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-96
 POOD1, P2195

EAS20660

P00D1, P2195
EAS33115

TROUBLESHOOTING
ltem
¢ [POOD1] Os. sensor 1: heater performance deterioration
* [P2195] O. sensor 1: open circuit detected.
Fail-safe system
e Able to start engine
e Able to drive vehicle

Procedure
TIP
lf more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first.
¢« POQO3O
1. Installed condition of Oz sensor 1.
¢ Check for looseness or pinching.

Is check result OK?

YES
— Go to step 2.
NO
a. Reinstall or replace the Os sensor 1.
Refer to “ENGINE REMOVAL’ on page 5-11.
b. Start the engine and let it idle for approximately 1 minute.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 2.

2. Connection of Os sensor 1 coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and let it idle for approximately 1 minute.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 3.

9-97
 POOD1, P2195

3. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and let it idle for approximately 1 minute.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 4.

4. Wire harness continuity.

e Disconnect the O, sensor 1 coupler “1”, ECU coupler “2” and ignition fuse “3”.
* Open circuit check
gray/green—gray/green
Between Op sensor 1 coupler and ECU coupler pink/black—pink/black
black/blue—black/blue
Between QO, sensor 1 coupler and ignition fuse hold- Jadiwiniavecluaaiie
er

3
-—O*_.O —i (Q)
Q)
2 *) = Cc —]| | , jc
—
L FAD D<Pfpelaceyclo la ———
LAUR >< UB (8)RB GiB) B UB pw P LX] vb [um Gy|
PIL |Giv/earlaay
ade WL BoM) B Liwi BIY awe <eow) en] Ww WIE
nig><weluw|vi [sb [an BAB uy| Avi<Jow] o Be Jayel <u

(Q) {Cy\
82)

Is resistance 0 (2?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Start the engine and let it idle for approximately 1 minute.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to “Short circuit check”.

e Short circuit check

9-98
 POOD1, P2195

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
gray/green—ground
Between Op sensor1 coupler
qn
“1” and ground
pink/black—ground
black/blue-ground
red/white—ground

Lines short circuit check “B”

gray/green—any other coupler terminal
pink/black—any other coupler terminal
Op sensor 1 coupler black/blue—any other coupler terminal
red/white—any other coupler terminal
gray/green—any other coupler terminal
ECU coupler “2” pink/black—any other coupler terminal
black/blue—any other coupler terminal

H~e eke mek en eee een me eee ec em ee em em ee ere eee Vem eM eM eM HS

Is resistance oo 0)?
YES
— Go to step 5.
NO
a. Replace the wire harness.
b. Start the engine and let it idle for approximately 1 minute.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 5.

5. Check fuel pressure.

¢ Check the fuel pressure.
Refer to “CHECKING THE FUEL PRESSURE” on page 7-18.

is check result OK?

YES
— Go to step 6.

9-99
 POOD1, P2195

NO
a. Replace the fuel pump.
Refer to “REMOVING THE FUEL PUMP” on page 7-3.
b. Start the engine and let it idle for approximately 1 minute.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 6.
6. Defective O2 sensor 1.
a. Replace the Os, sensor 1.
Refer to “ENGINE REMOVAL” on page 5-11.
b. Start the engine and let it idle for approximately1 minute.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 7.

7. Malfunction in ECU.
¢ Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
8. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-100
 POODS3, P2197

EAS20661

POOD3, P2197
EASa3g3398

TROUBLESHOOTING
ltem
¢ [POOD3] Os sensor 2: heater performance deterioration
* [P2197] O. sensor 2: open circuit detected.
Fail-safe system
e Able to start engine
e Able to drive vehicle

Procedure
TIP
lf more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first.
e« PQO50
1. Installed condition of Oz sensor 2.
¢ Check for looseness or pinching.

Is check result OK?

YES
— Go to step 2.
NO
a. Reinstall or replace the Os sensor 2.
Refer to “ENGINE REMOVAL’ on page 5-11.
b. Start the engine and let it idle for approximately 1 minute.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 2.

2. Connection of Os sensor 2 coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and let it idle for approximately 1 minute.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 3.

9-101
 POODS3, P2197

3. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and let it idle for approximately 1 minute.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 4.

4. Wire harness continuity.

e Disconnect the O, sensor 2 coupler “1”, ECU coupler “2” and ignition fuse “3”.
* Open circuit check
gray/yellow—gray/yellow
Between Op» sensor 2 coupler and ECU coupler pink/white—pink/white
black/blue—black/blue
Between Os, sensor 2 coupler and ignition fuse hold-
- red/white—red/white

3 (Cy \
Q)——
2
,
pon. —n So cc —J _—
2) TS DCEMT ESE ! :
LAUR >< UB (8)RB |GiB) B UB pwiP LX] Vv |b [ue Gy|
1 RiLlcrviecrlacy
Bas wi bow) B Li BY Gy >< Bow) <a [Ww Wi
nia] ><]veluw|vin [sb [an Bw BM uy] i G aye

(Q)
(Q)
\ee/

Is resistance 0 (2?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Start the engine and let it idle for approximately 1 minute.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to “Short circuit check”.

e Short circuit check

9-102
 POODS3, P2197

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
gray/yellow—ground
Between Op sensor 2 coupler
qn
“1” and ground
pink/white—ground
black/blue-ground
red/white—ground

Lines short circuit check “B”

gray/yellow—any other coupler terminal
pink/white—any other coupler terminal
Op sensor 2 coupler black/blue—any other coupler terminal
red/white—any other coupler terminal
gray/yellow—any other coupler terminal
ECU coupler “2” pink/white—any other coupler terminal
black/blue—any other coupler terminal

oes

Is resistance oo 0)?
YES
— Go to step 5.
NO
a. Replace the wire harness.
b. Start the engine and let it idle for approximately 1 minute.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 5.

5. Check fuel pressure.

¢ Check the fuel pressure.
Refer to “CHECKING THE FUEL PRESSURE” on page 7-18.

is check result OK?

YES
— Go to step 6.

9-103
 POODS3, P2197

NO
a. Replace the fuel pump.
Refer to “REMOVING THE FUEL PUMP” on page 7-3.
b. Start the engine and let it idle for approximately 1 minute.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 6.
6. Defective O. sensor 2.
a. Replace the Os, sensor 2.
Refer to “ENGINE REMOVAL” on page 5-11.
b. Start the engine and let it idle for approximately1 minute.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 7.

7. Malfunction in ECU.
¢ Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
8. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-104
 P0107, P0108

EAS20567

P0107, P0108
EASaS047

TROUBLESHOOTING
ltem
¢ [P0107] Intake air pressure sensor: ground short circuit detected.
¢ [P0108] Intake air pressure sensor: open or power short circuit detected.
Fail-safe system
e Able to start engine
e Able to drive vehicle

Procedure
1. Connection of intake air pressure 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).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 2.

2. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 3.

3. Wire harness continuity.

¢ Disconnect the intake air pressure sensor coupler “1” and ECU coupler “2”.
* Open circuit check

9-105
 P0107, P0108

blue—blue
Between intake air pressure sensor coupler and
pink/white—pink/white
ECU coupler
black/blue—black/blue

Is resistance 0 0?
YES
— Go to “Short circuit check”.
NO
a . Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to “Short circuit check”.

© Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
Between intake air pressure sensor coupler “1” and blue—ground
ground pink/white—ground

Lines short circuit check “B”

blue—any other coupler terminal
Intake air pressure sensor coupler pink/white—any other coupler terminal
black/blue—any other coupler terminal
blue—any other coupler terminal
ECU coupler “2” pink/white—any other coupler terminal
black/blue—any other coupler terminal

A B

1
(en Prw[L

9-106
 P0107, P0108

Is resistance - ()?
YES
— Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 4.

4. Installed condition of intake air pressure sensor.

¢ Check for looseness or pinching.

Is check result OK?

YES
— Go to step 5.
NO
a. Reinstall or replace the sensor.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 5.

5. Defective intake air pressure sensor.

« Execute the diagnostic mode. (Code D003)
¢ When engine is stopped: Atmospheric pressure at the current altitude and weather conditions is in-
dicated.
Approx. 101 kPa (757.6 mmHg, 29.8 inHg), approx.
At sea level 264 V

Approx. 90 kPa (675.1 mmHg, 26.6 inHg), approx.

1000 m (3300 ft) above sea level
3.30 V
2000 m (6700 ft) above sea level ae 80 kPa (600.0 mmHg, 23.6 inHg), approx.

3000 m (9800 ft) above sea level oa 70 kPa (525.0 mmHg, 20.7 inHg), approx.

¢ When engine is cranking: Make sure that the indication value changes.

is check result OK?

YES
— Go to step 6.
NO
a. Replace the intake air pressure sensor.
Refer to “THROTTLE BODIES” on page 7-11.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

9-107
 P0107, P0108

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 6.
6. Malfunction in ECU.
¢« Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
7. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-108
 P0112, P0113
EAS20568

P0112, P0113
EASSaS048

TROUBLESHOOTING
ltem
¢ [P0112] Intake air temperature sensor: ground short circuit detected.
¢ [P0113] Intake air temperature sensor: open or power short circuit detected.
Fail-safe system
e Able to start engine
e Able to drive vehicle

Procedure
TIP
Perform this procedure when the engine is cold.
1. Connection of intake air temperature 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).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a . Connect the coupler securely or replace the wire harness and/or sub-wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 2.

2. Connection of wire harness coupler and sub-wire harness coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO
a . Connect the coupler securely or replace the wire harness and/or sub-wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 3.

3. Connection of ECU coupler.

¢ Check the locking condition of the coupler.

9-109
 P0112, P0113
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 4.

4. Wire harness continuity.

¢ Disconnect the intake air temperature sensor coupler “1”, sub-wire harness coupler (wire harness
side) “2”, wire harness coupler (sub-wire harness side) “3” and ECU coupler “4”.
* Open circuit check
Between intake air temperature sensor coupler and | brown/white—brown/white
sub-wire harness coupler (wire harness side) black/blue—black/blue
Between wire harness coupler (sub-wire harness brown/white—brown/white
side) and ECU coupler black/blue—black/blue

(Cy)
22)
4
— Ayn eS
‘ | pi P LV | L [UR Gy
BIY yo) Bow < JBL [wv 3
LY oy Xen]
G Ak Jaye) <i. J

(-—)
2)

Is resistance 0 2?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness and/or sub-wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to “Short circuit check”.

¢ Short circuit check

TIP
Disconnect the ECU related connectors before checking.

9-110
 P0112, P0113
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
Between intake air temperature sensor coupler “1”
brown/white—ground
and ground
Between wire harness coupler (sub-wire harness
brown/white—ground
side) “3” and ground

Lines short circuit check “B”

brown/white—any other coupler terminal
Intake air temperature sensor coupler
black/blue—any other coupler terminal
brown/white—any other coupler terminal
Wire harness coupler (sub-wire harness side)
black/blue—any other coupler terminal
brown/white—any other coupler terminal
ECU coupler “4”
black/blue—any other coupler terminal

A B
1 3 1 3

° 5
oe,

Is resistance - (?
YES
— Go to step 5.
NO
a. Replace the wire harness and/or sub-wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 5.

5. Installed condition of intake air temperature sensor.

¢ Check for looseness or pinching.
Refer to “AIR INDUCTION SYSTEM” on page 7-20.

Is check result OK?

YES
— Go to step 6.
NO

9-111
 P0112, P0113

Reinstall the sensor.

of
Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 6.
6. Defective intake air temperature sensor.
* Execute the diagnostic mode. (Code DO5)
¢ When engine is cold: Displayed temperature is close to the ambient temperature.
¢ The displayed temperature is not close to the ambient temperature — Check the intake air tempera-
ture sensor.
Refer to “CHECKING THE INTAKE AIR TEMPERATURE SENSOR?” on page 8-50.

Is check result OK?

YES
— Go to step 7.
NO
a. Replace the intake air temperature sensor.
Refer to “AIR INDUCTION SYSTEM” on page 7-20.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 7.

7. Malfunction in ECU.
* Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
8. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-112
 P0117, P0118

EAS20569

P0117, P0118
EASaS049

TROUBLESHOOTING
ltem
¢ [P0117] Coolant temperature sensor: ground short circuit detected.
¢ [P0118] Coolant temperature sensor: open or power short circuit detected.
Fail-safe system
e Able to start engine
e Able to drive vehicle

Procedure
TIP
Perform this procedure when the engine is cold.
1. Connection of coolant temperature 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).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a . Connect the coupler securely or replace the wire harness and/or sub-wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 2.

2. Connection of wire harness coupler and sub-wire harness coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO
a . Connect the coupler securely or replace the wire harness and/or sub-wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 9, and complete the service.
NO
— Go to step 3.

3. Connection of ECU coupler.

¢ Check the locking condition of the coupler.

9-113
 P0117, P0118

¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 4.
NO
a . Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 4.

4. Wire harness continuity.

¢ Disconnect the coolant temperature sensor coupler “1”, sub-wire harness coupler (wire harness
side) “2”, wire harness coupler (sub-wire harness side) “3” and ECU coupler “4”.
* Open circuit check
Between coolant temperature sensor coupler and green/white—green/white
sub-wire harness coupler (wire harness side) black/blue—black/blue
Between wire harness coupler (sub-wire harness green/white—green/white
side) and ECU coupler black/blue—black/blue

Q)
4
ee ee
Gy

Gel >< WL
mS

Is resistance 0 2?
YES
— Go to step “Short circuit check”.
NO
a . Replace the wire harness and/or sub-wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step “Short circuit check”.

¢ Short circuit check

TIP
Disconnect the ECU related connectors before checking.

9-114
 P0117, P0118

Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.

Ground short circuit check “A”
Between coolant temperature sensor coupler “1”
green/white—ground
and ground
Between wire harness coupler (sub-wire harness
side) “3” and ground green/white—ground

Lines short circuit check “B”

green/white—any other coupler terminal
Coolant temperature sensor coupler
p P black/blue—any other coupler terminal
green/white—any other coupler terminal
Wire harness coupler (sub-wire harness side) black/blue—any other coupler terminal

aan green/white—any other coupler terminal

ECU coupler “4 black/blue—any other coupler terminal

A B

oe,

Is resistance oo (2?
YES
— Go to step 5.
NO
a. Replace the wire harness and/or sub-wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 5.

5. Installed condition of coolant temperature sensor.

¢ Check for looseness or pinching.
Refer to “CYLINDER HEAD” on page 5-33.

Is check result OK?

YES
— Go to step 6.
NO

9-115
 P0117, P0118

Reinstall the sensor.

of
Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 6.
6. Defective coolant temperature sensor.
* Execute the diagnostic mode. (Code D06)
¢ When engine is cold: Displayed temperature is close to the ambient temperature.
¢ The displayed temperature is not close to the ambient temperature — Check the coolant tempera-
ture sensor.
Refer to “CHECKING THE COOLANT TEMPERATURE SENSOR’ on page 8-48.

Is check result OK?

YES
— Go to step 7.
NO
a. Replace the coolant temperature sensor.
Refer to “CYLINDER HEAD” on page 5-33.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 7.

7. Malfunction in ECU.
* Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
8. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-116
 P0122, P0123, P0222, P0223, P2135
EAS20570

P0122, P0123, P0222, P0223, P2135

EAS33050

TROUBLESHOOTING
ltem
e [P0122] Throttle position sensor: ground short circuit detected.
e [P0123] Throttle position sensor: open or power short circuit detected.
e [P0222] Throttle position sensor: open or ground short circuit detected.
e [P0223] Throttle position sensor: power short circuit detected.
¢ [P2135] Throttle position sensor: output voltage deviation error.
Fail-safe system
e Able/Unable to start engine
e Able/Unable to drive vehicle

Procedure
TIP
lfa DTC other than P2135 (P0122, P0123, P0222, P0223) is detected, perform troubleshooting first.
1. Connection of throttle position 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).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 2.

2. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO

9-117
 P0122, P0123, P0222, P0223, P2135
— Go to step 3.
3. Wire harness continuity.
¢ Disconnect the throttle position sensor coupler “1” and ECU coupler “2”.
¢ Open circuit check
white—white
Between throttle position sensor coupler and ECU | black/green—black/green
coupler blue—blue
black—black

(—)\
02)
fey)
2)
(Q) 2
1 tt ad LYS) Sor RI
— Ni

[w jac] LB aot aa
BL B |BIfY WY
a

Is resistance 0 0?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to “Short circuit check”.

© Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
white—ground
Between throttle position sensor coupler “1” and
blue—ground
ground
black—ground

Lines short circuit check “B”

white—any other coupler terminal
black/green—any other coupler terminal
Throttle position sensor coupler
blue—any other coupler terminal
black—any other coupler terminal
white—any other coupler terminal
black/green—any other coupler terminal
ECU coupler “2”
blue—any other coupler terminal
black—any other coupler terminal

9-118
 P0122, P0123, P0222, P0223, P2135

Is resistance - (?
YES
— Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 4.

4. Installed condition of throttle position sensor.

¢ Check for looseness or pinching.
Refer to “ADJUSTING THE THROTTLE POSITION SENSOR?’ on page 7-19.

Is check result OK?

YES
— Go to step 5.
NO
a. Reinstall or adjust the sensor.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 5.

5. Defective throttle position sensor.

¢ Check throttle position sensor signal 1.
* Execute the diagnostic mode. (Code D01)
When the throttle valves are fully closed 11-21
When throttle valves are fully open 96-107

Is check result OK?

YES
— Go to step 6.
NO

9-119
 P0122, P0123, P0222, P0223, P2135
a. Replace the throttle position sensor.
Refer to “ADJUSTING THE THROTTLE POSITION SENSOR’ on page 7-19.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 6.
6. Defective throttle position sensor.
¢ Check throttle position sensor signal 2.
¢ Execute the diagnostic mode. (Code D13)
When the throttle valves are fully closed 9-23
When throttle valves are fully open 93-109

Is check result OK?

YES
— Go to step 7.
NO
a. Replace the throttle position sensor.
Refer to “ADJUSTING THE THROTTLE POSITION SENSOR?” on page 7-19.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 7.

7. Malfunction in ECU.
« Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
8. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-120
 P0132

EAS2O571

P0132
Es4S3a3051

TROUBLESHOOTING
ltem
Os sensor 1: short circuit detected (power short circuit).
Fail-safe system
¢ Able to start engine
¢ Able to drive vehicle

Procedure
1. Installed condition of OQ, sensor 1.
¢ Check for looseness or pinching.
Refer to “ENGINE REMOVAL” on page 5-11.

Is check result OK?

YES
— Go to step 2.
NO
a . Reinstall or replace the sensor.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 2.

2. Connection of O. sensor 1 coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO
a . Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 3.

3. Connection of ECU coupler.

* Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

9-121
 P0132

YES
— Go to step 4.
NO
a . Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 4.
4. Wire harness continuity.
¢ Disconnect the O, sensor 1 coupler “1” and ECU coupler “2”.
¢ Open circuit check
black/blue—black/blue
Between O>, sensor 1 coupler and ECU coupler
gray/green—gray/green

Is resistance 0 Q?
YES
— Go to “Short circuit check”.
NO
a . Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to “Short circuit check”.

© Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
Between Op sensor 1 coupler “1” and ground gray/green—ground

Lines short circuit check “B”

black/blue—any other coupler terminal
Oz sensor 1 coupler gray/green—any other coupler terminal

9-122
 P0132

ECU coupler “2” black/blue—any other coupler terminal

gray/green—any other coupler terminal

A B
1

Is resistance ~ 0?
YES
— Go to step 5.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 5.

5. Defective O. sensor 1.
a. Replace the Os, sensor 1.
Refer to “ENGINE REMOVAL’ on page 5-11.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 6.

6. Malfunction in ECU.
¢« Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
7. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-123
 P0152

EAS@05T2

P0152
EASaS052

TROUBLESHOOTING
ltem
Os sensor 2: short circuit detected (power short circuit).
Fail-safe system
¢ Able to start engine
¢ Able to drive vehicle

Procedure
1. Installed condition of O, sensor 2.
¢ Check for looseness or pinching.
Refer to “ENGINE REMOVAL” on page 5-11.

Is check result OK?

YES
— Go to step 2.
NO
a . Reinstall or replace the sensor.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 2.

2. Connection of O. sensor 2 coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO
a . Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 3.

3. Connection of ECU coupler.

* Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

9-124
 P0152

YES
— Go to step 4.
NO
a . Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 4.
4. Wire harness continuity.
¢ Disconnect the O, sensor 2 coupler “1” and ECU coupler “2”.
¢ Open circuit check
black/blue—black/blue
Between O, sensor 2 coupler and ECU coupler
gray/yellow—gray/yellow

Is resistance 0 Q?
YES
— Go to “Short circuit check”.
NO
a . Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to “Short circuit check”.

© Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
Between Op sensor 2 coupler “1” and ground gray/yellow—ground

Lines short circuit check “B”

black/blue—any other coupler terminal
Oz sensor 2 coupler gray/yellow—any other coupler terminal

9-125
 P0152

ECU coupler “2” black/blue—any other coupler terminal

gray/yellow—any other coupler terminal

A B
1

Is resistance ~ 0?
YES
— Go to step 5.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 5.

5. Defective O. sensor 2.
a. Replace the Os, sensor 2.
Refer to “ENGINE REMOVAL’ on page 5-11.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 6.

6. Malfunction in ECU.
¢« Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
7. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-126
 P0201

EAS2o574

P0201
EsASaS054

TROUBLESHOOTING
ltem
Primary injector #1: malfunction in primary injector #1.
Fail-safe system
e Able to start engine (depending on the number of faulty cylinders)
e Able to drive vehicle (depending on the number of faulty cylinders)

Procedure
1. Connection of primary injector#1 coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code D36)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 2.

2. Defective primary injector #1.

¢ Measure the primary injector resistance.
Refer to “CHECKING THE FUEL INJECTORS’ on page 8-51.

Is check result OK?

YES
— Go to step 3.
NO
a. Replace the primary injector #1.
Refer to “THROTTLE BODIES” on page 7-11.
b. Execute the diagnostic mode. (Code D36)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 3.

3. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES

9-127
 P0201

— Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code D36)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 4.
4. Wire harness continuity.
¢ Disconnect the primary injector #1 coupler “1”, ECU coupler “2” and relay unit coupler “3”
¢ Open circuit check
Between primary injector #1 coupler and ECU cou-
red/black—red/black
pler
Between primary injector #1 coupler and relay unit
coupler red/blue—red/blue

©)

Is resistance 0 (2?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code D36)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to “Short circuit check”.

e Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
red/black—ground
Between primary injector #1 coupler “1” and ground red/blue—ground

Lines short circuit check “B”

red/black—any other coupler terminal
Primary injector #1 coupler red/blue—any other coupler terminal

9-128
 P0201

ECU coupler “2” red/black—any other coupler terminal

Relay unit coupler “3” red/blue—any other coupler terminal

A B
i
TELE
A B
LC

Is resistance o> 0?
YES
— Go to step 5.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code D36)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 5.

5. Malfunction in ECU.
¢« Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
6. Delete the DTC and check that the MIL goes off.
¢ Start the engine and let it idle for approximately 5 seconds.
¢ Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT, and
then delete the DTC.

9-129
 P0202

EAS20575

P0202
EASSaS055

TROUBLESHOOTING
ltem
Primary injector #2: malfunction in primary injector #2.
Fail-safe system
e Able to start engine (depending on the number of faulty cylinders)
e Able to drive vehicle (depending on the number of faulty cylinders)

Procedure
1. Connection of primary injector #2 coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code D37)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 2.

2. Defective primary injector #2.

¢ Measure the primary injector resistance.
Refer to “CHECKING THE FUEL INJECTORS’ on page 8-51.

Is check result OK?

YES
— Go to step 3.
NO
a. Replace the primary injector #2.
Refer to “THROTTLE BODIES” on page 7-11.
b. Execute the diagnostic mode. (Code D37)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 3.

3. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES

9-130
 P0202

— Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code D37)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 4.
4. Wire harness continuity.
¢ Disconnect the primary injector #2 coupler “1”, ECU coupler “2” and relay unit coupler “3”
¢ Open circuit check
i primary injector #2 coupler and ECU cou- green/black—green/black

Between primary injector #2 coupler and relay unit

coupler red/blue—red/blue

1
(Q)

2 _ (Q)
Le 3
VIAL >< >< PIM PIB [Or Gyiagd [ Gy BaWILIW =| fan LR
NILoR|
UR |< | We oe] VE GB}B UR UWIAA UB [LY | Sb [By Baw
FL [Gry [Buh Bey BoB] Bea] B
is ><] we)uw] vi [so |FuL Ban

Is resistance 0 (2?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code D37)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to “Short circuit check”.

e Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
green/black—ground
Between primary injector #2 coupler “1” and ground red/blue—ground

Lines short circuit check “B”

green/black—any other coupler terminal
Primary injector #2 coupler red/blue—any other coupler terminal

9-131
 P0202

ECU coupler “2” green/black—any other coupler terminal

Relay unit coupler “3” red/blue—any other coupler terminal

A B
i
TEE
A B
LC

Is resistance o> 0?
YES
— Go to step 5.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code D37)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 5.

5. Malfunction in ECU.
¢« Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
6. Delete the DTC and check that the MIL goes off.
¢ Start the engine and let it idle for approximately 5 seconds.
¢ Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT, and
then delete the DTC.

9-132
 P0203

EAS20576

P0203
EASSS056

TROUBLESHOOTING
ltem
Primary injector #3: malfunction in primary injector #3.
Fail-safe system
e Able to start engine (depending on the number of faulty cylinders)
e Able to drive vehicle (depending on the number of faulty cylinders)

Procedure
1. Connection of primary injector #3 coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code D38)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 2.

2. Defective primary injector #3.

¢ Measure the primary injector resistance.
Refer to “CHECKING THE FUEL INJECTORS’ on page 8-51.

Is check result OK?

YES
— Go to step 3.
NO
a. Replace the primary injector #3.
Refer to “THROTTLE BODIES” on page 7-11.
b. Execute the diagnostic mode. (Code D38)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 3.

3. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES

9-133
 P0203

— Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code D38)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 4.
4. Wire harness continuity.
¢ Disconnect the primary injector #3 coupler “1”, ECU coupler “2” and relay unit coupler “3”
¢ Open circuit check
Between primary injector #3 coupler and ECU cou-
blue/black—blue/black
pler
Between primary injector #3 coupler and relay unit
coupler red/blue—red/blue

vie ><D< Pris orcleyelo faye

©) Bo]

eh
|=
=
a
5
RAL |evy [Berl Bay BoB) WL Bb B
is ><] we)uw] vi [so |FuL Ban

Is resistance 0 (2?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code D38)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to “Short circuit check”.

e Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
blue/black—ground
Between primary injector #3 coupler “1” and ground red/blue—ground

Lines short circuit check “B”

blue/black—any other coupler terminal
Primary injector #3 coupler red/blue—any other coupler terminal

9-134
 P0203

ECU coupler “2” blue/black—any other coupler terminal

Relay unit coupler “3” red/blue—any other coupler terminal

A B
EEE

ay
oe a

Is resistance o> 0?
YES
— Go to step 5.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code D38)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 5.

5. Malfunction in ECU.
¢« Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
6. Delete the DTC and check that the MIL goes off.
¢ Start the engine and let it idle for approximately 5 seconds.
¢ Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT, and
then delete the DTC.

9-135
 P0204

EAS20577

P0204
EASSaS057

TROUBLESHOOTING
ltem
Primary injector #4: malfunction in primary injector #4.
Fail-safe system
e Able to start engine (depending on the number of faulty cylinders)
e Able to drive vehicle (depending on the number of faulty cylinders)

Procedure
1. Connection of primary injector #4 coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code D39)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 2.

2. Defective primary injector #4.

¢ Measure the primary injector resistance.
Refer to “CHECKING THE FUEL INJECTORS’ on page 8-51.

Is check result OK?

YES
— Go to step 3.
NO
a. Replace the primary injector #4.
Refer to “THROTTLE BODIES” on page 7-11.
b. Execute the diagnostic mode. (Code D39)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 3.

3. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES

9-136
 P0204

— Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code D39)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 4.
4. Wire harness continuity.
¢ Disconnect the primary injector #4 coupler “1”, ECU coupler “2” and relay unit coupler “3”
¢ Open circuit check
i primary injector #4 coupler and ECU cou- orange/black—orange/black

Between primary injector #4 coupler and relay unit

coupler red/blue—red/blue

a
02)
1

2 : 3
VIR >< PI PiguIG)SyIG] O [Gy Bo |LW >= | wie lA
NILoR| UR |< | We Oe]
VE GB} B UR UWIAA UB [LY | Sb [By Baw
FL [Gry [Boh Boy Bow Boa] B
is ><] we)uw] vi [So |FuL Ban

Is resistance 0 (2?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code D39)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to “Short circuit check”.

e Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
orange/black—ground
Between primary injector #4 coupler “1” and ground | 4/olue—ground

Lines short circuit check “B”

orange/black—any other coupler terminal
Primary injector #4 coupler red/blue—any other coupler terminal

9-137
 P0204

ECU coupler “2” orange/black—any other coupler terminal

Relay unit coupler “3” red/blue—any other coupler terminal

A B

Ze,

SS
EB

Is resistance o> 0?
YES
— Go to step 5.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code D39)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 5.

5. Malfunction in ECU.
¢« Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
6. Delete the DTC and check that the MIL goes off.
¢ Start the engine and let it idle for approximately 5 seconds.
¢ Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT, and
then delete the DTC.

9-138
 P0335

EAS20576

P0335
EASSaS058

TROUBLESHOOTING
ltem
Crankshaft position sensor: no normal signals are received from the crankshaft position sensor.
Fail-safe system
e Unable to start engine
e Unable to drive vehicle

Procedure
1. Connection of crankshaft position 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).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Crank the engine, and then check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 2.

2. Connection of wire harness ECU coupler.

* Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Crank the engine, and then check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 3.

3. Wire harness continuity.

¢ Disconnect the crankshaft position sensor coupler “1” and ECU coupler “2”.
¢ Open circuit check
Between crankshaft position sensor coupler and black/blue—black/blue
ECU coupler gray—gray

9-139
 P0335

Is resistance 0 (2?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Crank the engine, and then check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to “Short circuit check”.

© Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
Between crankshaft position sensor coupler “1” and
gray—ground
ground

Lines short circuit check “B”

black/blue—any other coupler terminal
Crankshaft position sensor coupler
gray—any other coupler terminal
ann black/blue—any other coupler terminal
ECU coupler "2 gray—any other coupler terminal

A B

1 —~ eK Ke Ke Km ee em Ke ee em em em er eer rer rr errr errr errr errr er HG

Is resistance « 0?
YES
— Go to step 4.
NO

9-140
 P0335

a. Replace the wire harness.

b. Crank the engine, and then check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 4.
4. Installed condition of crankshaft position sensor.
¢ Check for looseness or pinching.
¢ Check the gap (0.75 mm (0.03 in)) between the crankshaft position sensor and the generator rotor.

is check result OK?

YES
— Go to step 5.
NO
a. Reinstall or replace the sensor.
b. Crank the engine, and then check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 5.

5. Defective crankshaft position sensor.

¢ Check the crankshaft position sensor.
Refer to “CHECKING THE CRANKSHAFT POSITION SENSOR’ on page 8-45.

Is check result OK?

YES
— Go to step 6.
NO
a. Replace the crankshaft position sensor.
b. Crank the engine, and then check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 6.

6. Malfunction in ECU.
¢« Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
7. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-141
 P0340

EAS20579

P0340
EASa2849

TROUBLESHOOTING
ltem
¢ Cylinder identification sensor: no normal signals are received from the cylinder identification sensor.
Fail-safe system
e Unable to start engine
e Able to drive vehicle

Procedure
TIP
lf more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first.
« PO335
1. Connection of cylinder identification 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).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Crank the engine, and then check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 2.

2. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Crank the engine, and then check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 3.

3. Wire harness continuity.

¢ Disconnect the cylinder identification sensor coupler “1” and ECU coupler “2”.
¢ Open circuit check

9-142
 P0340

white/black—white/black
Between cylinder identification sensor coupler and
blue—blue
ECU coupler
black/blue—black/blue

Q)
\ee/
(Q)
2
1 c —_Rex
L We ‘ a ae Vv LV |
Ly IL! ayy >< fany]
G aie eye WL

{ry\
02)

Is resistance 0 (2?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Crank the engine, and then check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to “Short circuit check”.

© Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
Between cylinder identification sensor coupler “1” white/black—ground
and ground blue—ground

Lines short circuit check “B”

white/black—any other coupler terminal
Cylinder identification sensor coupler blue—any other coupler terminal
black/blue—any other coupler terminal
white/black—any other coupler terminal
ECU coupler “2” blue—any other coupler terminal
black/blue—any other coupler terminal

Al B
1 2

¥.
UB paw] P<] v | o [uA
Biv Gwe, <6 ByL| W
Lv an] G AC Jaye[
>< wn
oo sf

Q)
9-143
 P0340

Is resistance - ()?
YES
— Go to step 4.
NO
a. Replace the wire harness.
b. Crank the engine, and then check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 4.

4. Installed condition of cylinder identification sensor.

* Check for looseness or pinching.

Is check result OK?

YES
— Go to step 5.
NO
a. Replace the cylinder identification sensor.
b. Crank the engine, and then check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 5.

5. Defective cylinder identification sensor.

¢ Replace the cylinder identification sensor.
¢ Crank the engine, and then check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 6.

6. Malfunction in ECU.
¢« Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
7. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-144
 P0351

EAS20580

P0351
EASa3060

TROUBLESHOOTING
ltem
Cylinder-#1 ignition coil: open or short circuit detected in the primary lead of the cylinder-#1 ignition coil.
Fail-safe system
e Able to start engine (depending on the number of faulty cylinders)
e Able to drive vehicle (depending on the number of faulty cylinders)

Procedure
1. Connection of cylinder-#1 ignition coil coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 2.

2. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 3.

3. Wire harness continuity.

¢ Disconnect the cylinder-#1 ignition coil coupler “1”, ECU coupler “2” and handlebar switch (right)
coupler “3”.
* Open circuit check

9-145
 P0351

Between cylinder-#1 ignition coil coupler and ECU

orange—orange
coupler
Between cylinder-#1 ignition coil coupler and han-
dlebar switch (right) coupler “3” red/white—red/white

Is resistance 0 0?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to “Short circuit check”.

© Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
Between cylinder-#1 ignition coil coupler “1” and orange—ground
ground red/white—ground

Lines short circuit check “B”

orange—any other coupler terminal
Cylinder-#1 ignition coil coupler red/white—any other coupler terminal
ECU coupler “2” orange—any other coupler terminal
Handlebar switch (right) coupler “3” red/white—any other coupler terminal

A B

— oe eee ¥i ee ;
eee !

i PM PIS|OraGWa|OlGyR]
' Xbge|UR |<] ove) eve |6ie)&
FL Gryleurleey lve] WLBbiW B i

| fe |yeluw] vit [so lan eave) |

9-146
 P0351

Is resistance oo (2?
YES
— Go to step 4.
NO
a. Replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 4.

4. Installed condition of cylinder-#1 ignition coil.

¢ Check for looseness or pinching.

Is check result OK?

YES
— Go to step 5.
NO
a. Reinstall or replace the ignition coil.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 5.

5. Defective cylinder-#1 ignition coil.

¢ Measure the primary coil resistance of the cylinder-#1 ignition coil.
Refer to “CHECKING THE IGNITION COILS” on page 8-44.

Is check result OK?

YES
— Go to step 6.
NO
a. Replace the cylinder-#1 ignition coil.
Refer to “CAMSHAFTS’ on page 5-18.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 6.

6. Malfunction in ECU.
* Execute the diagnostic mode. (Code D30)
¢ Confirm that spark plug does not sparking.

9-147
 P0351

¢ Replace the ECU, and complete the service.

Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
7. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-148
 P0352

EAS20581

P0352
Es«Saa0i1

TROUBLESHOOTING
ltem
Cylinder-#2 ignition coil: open or short circuit detected in the primary lead of the cylinder-#2 ignition coil.
Fail-safe system
e Able to start engine (depending on the number of faulty cylinders)
e Able to drive vehicle (depending on the number of faulty cylinders)

Procedure
1. Connection of cylinder-#2 ignition coil coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 2.

2. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 3.

3. Wire harness continuity.

¢ Disconnect the cylinder-#2 ignition coil coupler “1”, ECU coupler “2” and handlebar switch (right)
coupler “3”.
* Open circuit check

9-149
 P0352

Between cylinder-#2 ignition coil coupler and ECU

coupler gray/red—gray/red

Between cylinder-#2 ignition coil coupler and han-

dlebar switch (right) coupler red/white—red/white

2
TADLoAlUn Prders eyo ov

s
UB Ove] Ave }Gve]B
PUL vy [BoR| Bey BB
WIL Bay Bi
lave) ><] ys |Lw]wit [Sb | YL BWBiM

Is resistance 0 0?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to “Short circuit check”.

© Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
Between cylinder-#2 ignition coil coupler “1” and gray/red—ground
ground red/white—ground

Lines short circuit check “B”

gray/red—any other coupler terminal
Cylinder-#2 ignition coil coupler red/white—any other coupler terminal
ECU coupler “2” gray/red—any other coupler terminal
Handlebar switch (right) coupler “3” red/white—any other coupler terminal

A B

Gy | 2
ee Nee ° e
! YA PAVPIS|CIgGWa)O)GR]
Xbgriue |<] ove) eve |6i8)&
FL Gry leurleey lave] WEEN B i

| |yeluw]yit
ve [so lan aAveny |

9-150
 P0352

Is resistance oo (2?
YES
— Go to step 4.
NO
a. Replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 4.

4. Installed condition of cylinder-#2 ignition coil.

¢ Check for looseness or pinching.

Is check result OK?

YES
— Go to step 5.
NO
a. Reinstall or replace the ignition coil.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 5.

5. Defective cylinder-#2 ignition coil.

¢« Measure the primary coil resistance of the cylinder-#2 ignition coil.
Refer to “CHECKING THE IGNITION COILS” on page 8-44.

Is check result OK?

YES
— Go to step 6.
NO
a. Replace the cylinder-#2 ignition coil.
Refer to “CAMSHAFTS’ on page 5-18.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 6.

6. Malfunction in ECU.
*« Execute the diagnostic mode. (Code D381)
¢ Confirm that spark plug does not sparking.

9-151
 P0352

¢ Replace the ECU, and complete the service.

Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
7. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-152
 P0353

EAS20582

P0353
EASSaS062

TROUBLESHOOTING
ltem
Cylinder-#3 ignition coil: open or short circuit detected in the primary lead of the cylinder-#3 ignition coil.
Fail-safe system
e Able to start engine (depending on the number of faulty cylinders)
e Able to drive vehicle (depending on the number of faulty cylinders)

Procedure
1. Connection of cylinder-#3 ignition coil coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 2.

2. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 3.

3. Wire harness continuity.

¢ Disconnect the cylinder-#3 ignition coil coupler “1”, ECU coupler “2” and handlebar switch (right)
coupler “3”.
* Open circuit check

9-153
 P0353

Between cylinder-#3 ignition coil coupler and ECU

orange/qreen—orange/areen
coupler ge'g ge'g
Between cylinder-#3 ignition coil coupler and han-
dlebar switch (right) coupler red/white—red/white

Is resistance 0 0?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to “Short circuit check”.

© Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
Between cylinder-#3 ignition coil coupler “1” and orange/green—ground
ground red/white—ground

Lines short circuit check “B”

orange/green—any other coupler terminal
Cylinder-#3 ignition coil coupler red/white—any other coupler terminal
ECU coupler “2” orange/green—any other coupler terminal
Handlebar switch (right) coupler “3” red/white—any other coupler terminal

A B

1 1

I
I FL Gry leurleey lave] WEEN B I
I

| ale
|welua[vit [so [eva |

9-154
 P0353

Is resistance oo (2?
YES
— Go to step 4.
NO
a. Replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 4.

4. Installed condition of cylinder-#3 ignition coil.

¢ Check for looseness or pinching.

Is check result OK?

YES
— Go to step 5.
NO
a. Reinstall or replace the ignition coil.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 5.

5. Defective cylinder-#3 ignition coil.

¢ Measure the primary coil resistance of the cylinder-#3 ignition coil.
Refer to “CHECKING THE IGNITION COILS” on page 8-44.

Is check result OK?

YES
— Go to step 6.
NO
a. Replace the cylinder-#3 ignition coil.
Refer to “CAMSHAFTS’ on page 5-18.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 6.

6. Malfunction in ECU.
*« Execute the diagnostic mode. (Code D32)
¢ Confirm that spark plug does not sparking.

9-155
 P0353

¢ Replace the ECU, and complete the service.

Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
7. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-156
 P0354

EAS20583

P0354
EASSaS083

TROUBLESHOOTING
ltem
Cylinder-#4 ignition coil: open or short circuit detected in the primary lead of the cylinder-#4 ignition coil.
Fail-safe system
e Able to start engine (depending on the number of faulty cylinders)
e Able to drive vehicle (depending on the number of faulty cylinders)

Procedure
1. Connection of cylinder-#4 ignition coil coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 2.

2. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 3.

3. Wire harness continuity.

¢ Disconnect the cylinder-#4 ignition coil coupler “1”, ECU coupler “2” and handlebar switch (right)
coupler “3”.
* Open circuit check

9-157
 P0354

Between cylinder-#4 ignition coil coupler and ECU

coupler gray/green—gray/green

Between cylinder-#4 ignition coil coupler and han-

dlebar switch (right) coupler red/white—red/white

Is resistance 0 0?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to “Short circuit check”.

© Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
Between cylinder-#4 ignition coil coupler “1” and gray/green—ground
ground red/white—ground

Lines short circuit check “B”

gray/green—any other coupler terminal
Cylinder-#4 ignition coil coupler red/white—any other coupler terminal
ECU coupler “2” gray/green—any other coupler terminal
Handlebar switch (right) coupler “3” red/white—any other coupler terminal

A B

1 1
! mn ee : — |
! YA PAVPIB|CIgGWa]O)GuR)
Aigrlue |<] velo] AB|cm) &
FL cryleurleey lve] WEB B i

| fie |< |ye|uw]yit [so lan |aavienny |

9-158
 P0354

Is resistance oo (2?
YES
— Go to step 4.
NO
a. Replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 4.

4. Installed condition of cylinder-#4 ignition coil.

¢ Check for looseness or pinching.

Is check result OK?

YES
— Go to step 5.
NO
a. Reinstall or replace the ignition coil.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 5.

5. Defective cylinder-#4 ignition coil.

¢« Measure the primary coil resistance of the cylinder-#4 ignition coil.
Refer to “CHECKING THE IGNITION COILS” on page 8-44.

Is check result OK?

YES
— Go to step 6.
NO
a. Replace the cylinder-#4 ignition coil.
Refer to “CAMSHAFTS’ on page 5-18.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 6.

6. Malfunction in ECU.
* Execute the diagnostic mode. (Code D33)
¢ Confirm that spark plug does not sparking.

9-159
 P0354

¢ Replace the ECU, and complete the service.

Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
7. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-160
 P0475, P0476, P048B

EAS206T2

P0475, P0476, P048B

EsASa2841

TROUBLESHOOTING
ltem
e [P0475] EXUP servo motor: performance deterioration
e [P0476] EXUP servo motor: stuck EXUP servo motor is detected.
¢ [PO048B] EXUP servo motor: signal stuck
Fail-safe system
e Able to start engine
e Able to drive vehicle

Procedure
TIP
lf more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first.
¢« PO048D, P048E
1. Connection of EXUP servo motor coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 2.

2. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO
a . Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 3.

9-161
 P0475, P0476, P048B

3. Wire harness continuity.

¢ Disconnect the EXUP servo motor coupler “1” and ECU coupler “2”.
* Open circuit check
Between EXUP servo motor coupler and ECU cou- | black/green—black/green
pler black/red—black/red

Is resistance 0 0?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to “Short circuit check”.

© Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
black/green—ground
Between EXUP servo motor coupler “1” and ground black/red—ground

Lines short circuit check “B”

black/green—any other coupler terminal
EXUP servo motor coupler black/red—any other coupler terminal
black/green—any other coupler terminal
ECU coupler “2 black/red—any other coupler terminal

9-162
 P0475, P0476, P048B

Al B)
; 2 weennen-- a i
L IW} BIL
G |aclam a
Tw wi aS *
~ RIG B rN

QO ses fees BL ><]T B Jan

faulp BY da

_.@
Is resistance oo 0)?
YES
— Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 4.

4. Defective EXUP servo motor.

¢ Disconnect the cables and execute the diagnostic code. (Code D53)
¢ Check the operating sound of the motor.

Is check result OK?

YES
— Go to step 5.
NO
a. Replace the EXUP servo motor.
Refer to “ENGINE REMOVAL’ on page 5-11.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 5.

5. Defective EXUP valve, pulley, and EXUP cables.

¢ Turn the EXUP valve manually with the EXUP cables disconnected.

Is check result OK?

YES
« Check the EXUP cables. (bends/damage/excessive wear)
Is check result OK?
YES
— Go to step 6.
NO

9-163
 P0475, P0476, P048B

a. Replace the cables.

b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction
mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 6.
NO
a. Replace the exhaust chamber.
Refer to “ENGINE REMOVAL’ on page 5-11.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 6.
6. Malfunction in ECU.
* Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
7. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-164
 P0480

EAS20585

P0480
EASSaS0605

TROUBLESHOOTING
ltem
Radiator fan motor relay: open or short circuit detected.
Fail-safe system
e Able to start engine
e Able to drive vehicle

Procedure
1. Connection of radiator fan motor relay coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 2.

2. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 3.

3. Wire harness continuity.

¢ Disconnect the radiator fan motor relay “1”, ECU coupler “2” and ignition fuse “3”.
* Open circuit check
ee radiator fan motor relay and ignition fuse reclhwhe—reclhanlie

9-165
 P0480

Between radiator fan motor relay and ECU coupler | green/yellow—green/yellow

Is resistance 0 (2?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to “Short circuit check”.

© Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
green/yellow—ground
Between radiator fan motor relay “1” and ground red/white—ground

Lines short circuit check “B”

green/yellow—any other coupler terminal
Radiator fan motor relay red/white—any other coupler terminal
ECU coupler “2” green/yellow—any other coupler terminal

A B

i I [ol
+ fueD><]><Paefprefarcfayfo
fey)
La/A L/B (0/8/ AVE |GiB|B
“<a

+ Pane BR| Ea aE] WIL Bbw] B

PusL><lyre|uw
yi [se [ruLlenvianNy |
LL

Is resistance co Q?
YES
— Go to step 4.

9-166
 P0480

NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 4.
4. Defective radiator fan motor relay.
* Replace the radiator fan motor relay.
¢ Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 5.

5. Malfunction in ECU.
* Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
6. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-167
 P048D, P048E
EAS20586

P048D, PO48E
EASSS086

TROUBLESHOOTING
ltem
e [PO048D] EXUP servo motor: open or ground short circuit detected.
e [PO48E] EXUP servo motor: power short circuit detected.
Fail-safe system
e Able to start engine
e Able to drive vehicle

Procedure
TIP
lf “PO48D/P048E” and “P0476” are both indicated, take the actions specified for “PO48D/P048E” first.
1. Connection of EXUP servo motor coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 2.

2. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 3.

3. Wire harness continuity.

¢ Disconnect the EXUP servo motor coupler “1” and ECU coupler “2”.

9-168
 P048D, P048E
* Open circuit check
blue—blue
Between EXUP servo motor coupler and ECU cou-
white/yellow—white/yellow
pler
black/blue—black/blue

Q)
2

Is resistance 0 0)?
YES
— Go to “Short circuit check”.
NO
a . Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to “Short circuit check”.

© Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
white/yellow—ground
Between EXUP servo motor coupler “1” and ground
blue—ground

Lines short circuit check “B”

white/yellow—any other coupler terminal
EXUP servo motor coupler blue—any other coupler terminal
black/blue—any other coupler terminal
white/yellow—any other coupler terminal
ECU coupler “2” blue—any other coupler terminal
black/blue—any other coupler terminal

9-169
 P048D, P048E

1 1 ee |

WI
ryED I

Beam TE wl! |]
>»

¥
! eta |

L
Is resistance - (?
YES
— Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 4.

4. Defective EXUP servo motor.

¢ Replace the EXUP servo motor.
Refer to “ENGINE REMOVAL” on page 5-11.
¢ Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 5.

5. Malfunction in ECU.
¢« Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
6. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-170
 P0500 (FI), P1500

P0500 (FI), P1500

EAS206T4

EASa3203

TROUBLESHOOTING
ltem
¢ Rear wheel sensor: no normal signals are received from the rear wheel sensor.
¢ Neutral switch: open or short circuit is detected.
e Clutch switch: open or short circuit is detected.
Fail-safe system
e Able to start engine
e Able to drive vehicle

Procedure
TIP
¢ In case P0500 is detected, or both P0500 and P1500 are detected, proceed from step 1.
¢ lf more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first.
e P0335
1. Locate the malfunction.
¢ DTCs P0500 or P0500 and P1500 detected.
a. Execute the diagnostic mode. (Code D07)
b. Rotate the rear wheel by hand and check that the indicated value increases.

Is that value increased?

YES
— Go to step 21.
NO
— Go to step 2.

TIP
Perform the procedure from step 2 to step 7 and step 21.
¢ DTC P1500 detected.
a. Execute the diagnostic mode. (Code D21)

When the transmission is in neutral ON

When the transmission is in gear with the clutch lever released OFF

Is check result OK?

YES
— Go to step b.
NO
— Go to step 8.

TIP
Perform the procedure from step 8 to step 14 and step 21.
b. Execute the diagnostic mode. (Code D21)

When the transmission Is in gear with the clutch lever squeezed and the side-
stand retracted ON

9-171
 P0500 (FI), P1500
Is check result OK?
YES
— Go to step 21.
NO
— Go to step 15.

TIP
Perform the procedure from step 15 to step 21.
2. Connection of rear wheel 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).

Is the coupler condition normal?

YES
— Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code D07)
c. Rotate the rear wheel by hand and check that the indicated value increases.

Is that value increased?

YES
— Go to step 21.
NO
— Go to step 3.

3. Connection of ABS ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code D07)
c. Rotate the rear wheel by hand and check that the indicated value increases.

Is that value increased?

YES
— Go to step 21.
NO
— Go to step 4.

4. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 5.

9-172
 P0500 (FI), P1500
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code D07)
c. Rotate the rear wheel by hand and check that the indicated value increases.

Is that value increased?

YES
— Go to step 21.
NO
— Go to step 5.
5. Wire harness continuity.
* Disconnect the rear wheel sensor coupler “1”, ABS ECU coupler “2” and ECU coupler “3”.
¢ Open circuit check
Between rear wheel sensor coupler and ABS ECU | black—black
coupler white—white
Between ABS ECU coupler and ECU coupler white/blue—white/blue

‘Cy’
22)
1 : .
uw} bye L | ¥ [6 [AB B lu a) IuB paw] P<] v | [ue Gy |

Q)
Is resistance 0 (2?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code D07)
c. Rotate the rear wheel by hand and check that the indicated value increases.

Is that value increased?

YES
— Go to step 21.
NO
— Go to “Short circuit check”.

© Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
black—ground
Between ABS ECU coupler “2” and ground white—ground
white/blue—ground

9-173
 P0500 (FI), P1500
Lines short circuit check “B”
black—any other coupler terminal
Rear wheel sensor coupler “1” ,
white—any other coupler terminal
black—any other coupler terminal
ABS ECU coupler white—any other coupler terminal
white/blue—any other coupler terminal
ECU coupler “3” white/blue—any other coupler terminal

A B

prtrr treme e em eke em em ee er eee eee ee

i ees aes tes heme cee pees eee nn cee Pi ce ees ce ce ce ee cee ee cae ce cae ce ce ce ee es ee ed eee |

Is resistance oo 0)?
YES
— Go to step 6.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code D07)
c. Rotate the rear wheel by hand and check that the indicated value increases.

Is that value increased?

YES
— Go to step 21.
NO
— Go to step 6.

6. Malfunction in ECU.
¢ Replace the ECU.
Refer to “REPLACING THE ECU (Engine Control! Unit)” on page 8-41.
¢ Execute the diagnostic mode. (Code DO7)
¢ Rotate the rear wheel by hand and check that the indicated value increases.

Is that value increased?

YES

9-174
 P0500 (FI), P1500
— Go to step 21.
NO
— Go to step 7.
7. Malfunction in ABS ECU.
*« Replace the ABS ECU and go to step 21.
8. Connection of neutral switch coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 9.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code D21)

When the transmission is in neutral ON

When the transmission is in gear with the clutch lever released OFF

Is it correct indication?
YES
— Go to step 21.
NO
— Go to step 9.

9. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 10.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code D21)

When the transmission is in neutral ON

When the transmission is in gear with the clutch lever released OFF

Is it correct indication?
YES
— Go to step 21.
NO
— Go to step 10.

[Link] harness continuity.

¢ Disconnect the relay unit coupler “1”, ECU coupler “2” and neutral switch coupler “3”.
¢ Open circuit check
Between relay unit coupler and ECU coupler black/yellow—black/yellow

9-175
 P0500 (FI), P1500
Between relay unit coupler and neutral switch cou-
sky blue-sky blue
pler

Is resistance 0 0)?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code D21)

When the transmission is in neutral ON

When the transmission is in gear with the clutch lever released OFF

Is it correct indication?
YES
— Go to step 21.
NO
— Go to “Short circuit check”.

© Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
black/yellow—ground
Between relay unit coupler “1” and ground
sky blue—ground

Lines short circuit check “B”

black/yellow—any other coupler terminal
Relay unit coupler
sky blue—any other coupler terminal
ECU coupler “2” black/yellow—any other coupler terminal
Neutral switch coupler “3S” sky blue—any other coupler terminal

9-176
 P0500 (FI), P1500

A B
1 Ay See
ee ee
Bal (LW | Faw A Bri =| rw [RIL
UR|LAVIANY WB |Liy| Sb [ey sr Ua (LWIA)
LB | Ly | Sb levy Bod
oe ‘ —__ eT

QO —

Is resistance oo 0)?
YES
— Go to step 11.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code D21)

When the transmission is in neutral ON

When the transmission is in gear with the clutch lever released OFF

Is it correct indication?
YES
— Go to step 21.
NO
— Goto step 11.

[Link] relay unit.

¢ Check the relay unit.
Refer to “CHECKING THE RELAY UNIT (DIODE)”’ on page 8-43.

Is check result OK?

YES
— Go to step 12.
NO
a. Replace the relay unit.
b. Execute the diagnostic mode. (Code D21)

When the transmission is in neutral ON

When the transmission is in gear with the clutch lever released OFF

Is it correct indication?
YES
— Go to step 21.
NO
— Go to step 12.

[Link] neutral switch.

¢ Check the neutral switch.

9-177
 P0500 (FI), P1500
¢ Refer to “CHECKING THE SWITCHES’ on page 8-40.

Is check result OK?

YES
— Go to step 13.
NO
a. Replace the neutral switch.
Refer to “CRANKCASE” on page 5-71.
b. Execute the diagnostic mode. (Code D21)

When the transmission is in neutral ON

When the transmission is in gear with the clutch lever released OFF

Is it correct indication?
YES
— Go to step 21.
NO
— Go to step 13.

[Link] shift drum (neutral detection area).

¢ Check the shift drum.
Refer to “CHECKING THE SHIFT DRUM ASSEMBLY” on page 5-102.

Is check result OK?

YES
— Go to step 14.
NO
— Replace the shift drum and go to step 21.
Refer to “TRANSMISSION” on page 5-98.
[Link] in ECU.
« Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
[Link] lever adjustment.
¢ Refer to “ADJUSTING THE CLUTCH LEVER FREE PLAY” on page 3-12.
¢« Execute the diagnostic mode. (Code D21)

When the clutch lever is released with the transmission in gear and when the
sidestand is retracted
OFF
When the clutch lever is squeezed with the transmission in gear and when the
ON
sidestand is retracted

Is it correct indication?
YES
— Go to step 21.
NO
— Go to step 16.

[Link] of clutch switch 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).

9-178
 P0500 (FI), P1500
Is the coupler condition normal?
YES
— Go to step 17.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code D21)

When the clutch lever is released with the transmission in gear and when the
OFF
sidestand is retracted
When the clutch lever is squeezed with the transmission in gear and when the ON
sidestand is retracted

Is it correct indication?
YES
— Go to step 21.
NO
— Go to step 17.

[Link] of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 18.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code D21)

When the clutch lever is released with the transmission in gear and when the OFF
sidestand is retracted
When the clutch lever is squeezed with the transmission in gear and when the ON
sidestand is retracted

Is it correct indication?
YES
— Go to step 21.
NO
— Go to step 18.

[Link] harness continuity.

¢ Disconnect the ECU coupler “2”, relay unit coupler “1” and clutch switch coupler “3”.
* Open circuit check
Between ECU coupler and relay unit coupler black/yellow—black/yellow
black/yellow—black/yellow
Between clutch switch coupler and relay unit coupler blue/yellow—blue/yellow

9-179
 P0500 (FI), P1500

E|&

5
Is resistance 0 0?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code D21)

When the clutch lever is released with the transmission in gear and when the OFF
sidestand is retracted
When the clutch lever is squeezed with the transmission in gear and when the ON
sidestand is retracted

Is it correct indication?
YES
— Go to step 21.
NO
— Go to “Short circuit check”.

© Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
black/yellow—ground
Between relay unit coupler “1” and ground blue/yellow—ground

Lines short circuit check “B”

black/yellow—any other coupler terminal
Relay unit coupler
blue/yellow—any other coupler terminal
ECU coupler “2” black/yellow—any other coupler terminal
black/yellow—any other coupler terminal
Clutch switch coupler “3”
blue/yellow—any other coupler terminal

9-180
 P0500 (FI), P1500

Is resistance oo 0)?
YES
— Go to step 19.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code D21)

When the clutch lever is released with the transmission in gear and when the
OFF
sidestand is retracted
When the clutch lever is squeezed with the transmission in gear and when the ON
sidestand is retracted

Is it correct indication?
YES
— Go to step 21.
NO
— Go to step 19.

[Link] clutch switch.

¢ Check the clutch switch.
Refer to “CHECKING THE SWITCHES’ on page 8-40.

Is check result OK?

YES
— Go to step 20.
NO
a. Replace the clutch switch.
Refer to “HANDLEBARS?’ on page 4-83.
b. Execute the diagnostic mode. (Code D21)

When the clutch lever is released with the transmission in gear and when the OFF
sidestand is retracted
When the clutch lever is squeezed with the transmission in gear and when the ON
sidestand is retracted

Is it correct indication?
YES
— Go to step 21.

9-181
 P0500 (FI), P1500
NO
— Go to step 20.
[Link] in ECU.
¢« Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
[Link] the DTC and check that the MIL goes off.
¢ Turn the main switch to “ON”, and then rotate the rear wheel by hand.
¢ Start the engine, and input the vehicle speed signals by operating the vehicle at 20 to 30 km/h (12
to 19 mph).
¢ Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT, and
then delete the DTC. Delete this DTC even if it has a condition of “Detected”.

9-182
 P0500 (SCU)

P0500 (SCU)
EAS20588

EASSaS068

TROUBLESHOOTING
ltem
Abnormal rear wheel sensor
Fail-safe system
e Able to start engine
e Able to drive vehicle

Procedure
1. Abnormal rear wheel sensor
« Check the item of DTC P0500 for the ECU.
Refer to “SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM)” on page
9-38.
¢ Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the
malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Service is completed.
NO
— Refer to the item corresponding to DTC.

9-183
 P0560 (FI), PO563

P0560 (Fl), P0563

EAS20675

EASa3a204

TROUBLESHOOTING
ltem
e [P0560 (FI)] Charging voltage is abnormal.
e [P0563] Vehicle system power voltage out of range
Fail-safe system
e Able to start engine
e Able to drive vehicle

Procedure
TIP
lf more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first.
« PQ335
1. Malfunction in charging system.
¢ Check the charging system.
Refer to “CHARGING SYSTEM?” on page 8-12.

Is check result OK?

YES
— Repeat step 1.
NO
a. Defective rectifier/regulator or AC magneto — Replace.
b. Defective connection in the charging system circuit — Properly connect or replace the wire har-
ness.
c. Start the engine and let it idle for approximately 5 seconds.
d. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 2, and complete the service.
NO
— Repeat step 1.

2. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-184
 P0560 (SCU)

P0560 (SCU)
EAS20593

EASaS073

TROUBLESHOOTING
ltem
Abnormal SCU power supply voltage
Fail-safe system
e Able to start engine
e Able to drive vehicle

Procedure
1. Malfunction in charging system.
¢ Check the charging system.
Refer to “CHARGING SYSTEM” on page 8-12.

Is check result OK?

YES
— Repeat step 1.
NO
a. Defective rectifier/regulator or AC magneto — Replace.
b. Defective connection in the charging system circuit — Properly connect or replace the wire har-
ness.
c. Start the engine and let it idle for approximately 5 seconds.
d. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Service is completed.
NO
— Repeat the maintenance job.

9-185
 P0601

EAS20676

P0601
EASaa2305

TROUBLESHOOTING
ltem
Internal malfunction in ECU. (When this malfunction is detected in the ECU, the DTC might not appear
on the tool display.)
Fail-safe system
e Unable to start engine
e Unable to drive vehicle

Procedure
1. Malfunction in ECU.
¢ Replace the ECU.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
¢ Turn the main switch to “ON”.
¢ Check that the MIL does not come on.

9-186
 P0606

EAS20677

P0606
EASSaS206

TROUBLESHOOTING
ltem
Internal malfunction in ECU. (When this malfunction is detected in the ECU, the DTC might not appear
on the tool display.)
Fail-safe system
e Able/Unable to start engine
e Able/Unable to drive vehicle

Procedure
1. Check and repair for simultaneous malfunction.
¢ Check the items of DTCs P0122, P0123, P0222, P0223 and P2135, if they are detected at the same
time, correct the P0122, P0123, P0222, P0223 and P2135 first.
¢ Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 3, and complete the service.
NO
— Go to step 2.

2. Malfunction in ECU.
¢ Replace the ECU.
Refer to “REPLACING THE ECU (Engine Control! Unit)” on page 8-41.
¢ Turn the main switch to “ON”.
¢ Check that the MIL does not come on.
3. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-187
 PO62F

EAS20598

P0O62F
EASSaS078

TROUBLESHOOTING
ltem
EEPROM DTC: an error is detected while reading or writing on EEPROM.
Fail-safe system
e Able/Unable to start engine
e Able/Unable to drive vehicle

Procedure
1. Locate the malfunction.
¢« Execute the diagnostic mode (Code D60)
2. Malfunction in ECU.
¢« Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
3. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-188
 P0638

EAS20599

P0638
EASas079

TROUBLESHOOTING
ltem
YCC-T drive system: malfunction detected.
Fail-safe system
e Able/Unable to start engine
e Able/Unable to drive vehicle

Procedure
1. Connection of throttle servo motor coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 2.

2. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 3.

3. Check the electronic throttle valve fuse.

Is check result OK?

YES
— Go to step 4.

9-189
 P0638

NO
Replace the electronic throttle valve fuse.

of
Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 4.
4. Wire harness continuity.
* Disconnect the throttle servo motor coupler “1”, ECU coupler “2” and electronic throttle valve fuse
at ia

* Open circuit check

Between throttle servo motor coupler and ECU cou- | yellow/red—yellow/red
pler light green/red—light green/red
Between ECU coupler and electronic throttle valve
fuse holder red/blue—red/blue

PIB o
LIB RIB B
B
YL | Sb [AVL

Is resistance 0 0?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to “Short circuit check’.

© Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
yellow/red—ground
Between ECU coupler “2” and ground light green/red—ground
red/blue—ground

9-190
 P0638

Lines short circuit check “B”

yellow/red—any other coupler terminal
Throttle servo motor coupler “1”
light green/red—any other coupler terminal
yellow/red—any other coupler terminal
ECU coupler light green/red—any other coupler terminal
red/blue—any other coupler terminal

A B
2 1
eS
WIR >< [>< JPN PIB [ONG ayhG| © [ay
LA|UIR| >< [LB joe)
YB |ve| B |
: AUL|GiY Bo Boy Bo] WIL Bb] BLY
ve [>< [ye [uw] yi [sb [AL JBaieiin

Is resistance oo (2?
YES
— Go to step 5.
NO
a . Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 5.

5. Defective throttle bodies.

¢ Check the throttle bodies.
Refer to “CHECKING THE THROTTLE SERVO MOTOR’ on page 8-49.

Is check result OK?

YES
— Go to step 6.
NO
a. Replace the throttle bodies.
Refer to “REPLACING THE THROTTLE BODIES” on page 7-17.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 6.

6. Malfunction in ECU.
¢ Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.

9-191
 P0638

7. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-192
 P0657

EAS20601

P0657
Es«S3a3081

TROUBLESHOOTING
ltem
Fuel system voltage: incorrect voltage supplied to the fuel injector and fuel pump.
Fail-safe system
e Able to start engine
e Able to drive vehicle

Procedure
TIP
lf more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first.
« PO335
1. Connection of relay 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).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 2.

2. Connection of handlebar switch coupler (right).

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).
Refer to “HANDLEBARS’ on page 4-83.

Is the coupler condition normal?

YES
— Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 3.

9-193
 P0657

3. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 4.

4. Wire harness continuity.

¢ Disconnect the fuel injection system fuse “1”, relay unit coupler “2”, ignition fuse “3”, handlebar
switch (right) coupler “4” and ECU coupler “5”.
¢ Open circuit check
Between fuel injection system fuse holder and relay
brown/white—brown/white
unit coupler
Between ignition fuse holder and handlebar switch
red/white—red/white
(right) coupler
Between handlebar switch (right) coupler and relay
red/white—red/white
unit coupler
red/blue—red/blue
Between relay unit coupler and ECU coupler
blue/white—blue/white

| 2
@Q)
(TY

onLo—|<¢ (C\ rhWILIW RW] L | PUL (Cy

22) Ua |LwiAnw|
UB | Ly | 4 levy Bon (2)

Q 5 —
3 4 WIR. AV PIB )ONS}G]G] O |e
x Fe ST NILoAILIR isosna a 8
L—_7_LO-—_| PUL Giy'Baiegea’y
Bol ier B IX
(2) AW ASL AG vol elvn [ele bien

Is resistance 0 (2?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.

9-194
 P0657

NO
— Go to “Short circuit check”.

© Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
brown/white—ground
blue/white—ground
Between relay unit coupler “2” and ground
red/white—ground
red/blue—ground
Between handlebar switch (right) coupler “4” and
ground red/white—ground

Lines short circuit check “B”

brown/white—any other coupler terminal
blue/white—any other coupler terminal
Relay unit coupler
red/white—any other coupler terminal
red/blue—any other coupler terminal
Handlebar switch (right) coupler red/white—any other coupler terminal

ECU coupler “5” red/blue—any other coupler terminal

P blue/white—any other coupler terminal

Bel ILW =|
Jaw AL
STS <u UWI UB [Ly | a ery ee

Ler
I
PyWIPIB|OG|G"G)0|GyA]
[5] i

up joe ielevel B [x]

rBlBrY
Bre] WILE] B i

uw] vit |Sb [An BrwiBany |

Is resistance 0?
YES
— Go to step 5.
NO
a. Replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 5.

5. Defective relay unit.

¢ Execute the diagnostic mode. (Code D50)

9-195
 P0657

* Check the operating sound of the relay.

Is check result OK?

YES
— Go to step 6.
NO
a. Replace the relay unit.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 6.

6. Defective relay unit.

¢« Execute the diagnostic mode. (Code DOQ)

Is the Fuel system voltage less than 3V?

YES
a. Replace the relay unit.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 8, and complete the service.
NO
— Go to step 7.
NO
— Go to step 7.

7. Malfunction in ECU.
¢ Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
8. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-196
 P0916, P0917

EAS20611

P0916, P0917
EsSs3a3091

TROUBLESHOOTING
ltem
¢ [P0916] Gear position sensor: open or ground short circuit detected.
¢ [P0917] Gear position sensor: power short circuit detected.
Fail-safe system
e Able to start engine
e Able to drive vehicle

Procedure
1. Connection of gear position 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).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 2.

2. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 3.

3. Wire harness continuity.

¢ Disconnect the gear position sensor coupler “1” and ECU coupler “2”.
¢ Open circuit check

9-197
 P0916, P0917

Between gear position sensor coupler and ECU white—white

coupler green—green
blue/red—blue/red

(Q)
1 = S11|
LIB PM) PL] VL UR Gy
Lela |w) BIY Gy BiL| W iB|
7 uv |uw! Gyn any] G [<<
‘

(CY\
22)
Q)
Is resistance 0 02?
YES
— Go to “Short circuit check”.
NO
a . Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to “Short circuit check”.

¢ Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
Between gear position sensor coupler “1” and green—ground
ground blue/red—ground

Lines short circuit check “B”

white—any other coupler terminal
Gear position sensor coupler green—any other coupler terminal
blue/red—any other coupler terminal
white—any other coupler terminal
ECU coupler “2” green—any other coupler terminal
blue/red—any other coupler terminal

9-198
 P0916, P0917

Is resistance - ()?
YES
— Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 4.

4. Installed condition of gear position sensor.

¢ Check for looseness or pinching.

Is check result OK?

YES
— Go to step 5.
NO
a. Reinstall or replace the sensor.
Refer to “CRANKCASE” on page 5-71.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 5.

5. Defective gear position sensor.

¢ Make sure that the position of each gear is correctly displayed on the meter.

Is check result OK?

YES
— Go to step 6.
NO
a. Replace the gear position sensor.
Refer to “CRANKCASE” on page 5-71.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 6.

6. Malfunction in ECU.
¢ Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.

9-199
 P0916, P0917

7. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-200
 P1400

EAS20612

P1400
EASasa092

TROUBLESHOOTING
ltem
Air induction system solenoid: open or short circuit detected.
Fail-safe system
e Able to start engine
e Able to drive vehicle

Procedure
1. Connection of air induction system solenoid coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Start the engine and check the status of the DTC.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 2.

TIP
Check that the start/engine stop switch is turned to “ON” then.
2. Connection of ECU coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES

9-201
 P1400

— Go to step 6, and complete the service.

NO
— Start the engine and check the status of the DTC.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 3.

TIP
Check that the start/engine stop switch is turned to “ON” then.
3. Wire harness continuity.
¢ Disconnect the air induction system solenoid coupler “1”, ECU coupler “2” and ignition fuse “3”.
* Open circuit check
Between air induction system solenoid coupler and
brown/red—brown/red
ECU coupler
Between air induction system solenoid coupler and
ignition fuse holder red/white-red/white

3
eal, ©)
Q)
2 = 1
a BRIA
PUL Gy eriAleny eve]
WL BOW B
Rie)
><) yew]vit [sb |r[aA

Is resistance 0 0?
YES
— Go to “Short circuit check”.
NO
a . Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Start the engine and check the status of the DTC.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to “Short circuit check’.

TIP
Check that the start/engine stop switch is turned to “ON” then.

9-202
 P1400

¢ Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
Between air induction system solenoid coupler “1” —_| brown/red—ground
and ground red/white—ground

Lines short circuit check “B”

brown/red—any other coupler terminal
Air induction system solenoid coupler red/white—-any other coupler terminal

ECU coupler “2” brown/red—any other coupler terminal

» |.
_o- v
A B

a ra |
1 fiaL><D<Prv[Prelorecyic]O|eyr]
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level a i]
i i
I RAUL |G/BefA) Bel En WL Bbw) B I

' del >< tweluwl

yi [so FuLiewey |

Is resistance oo ()?
YES
— Go to step 4.
NO
a . Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Start the engine and check the status of the DTC.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 4.

TIP
Check that the start/engine stop switch is turned to “ON” then.
4. Defective air induction system solenoid.
¢ Check the air induction system solenoid.
Refer to “CHECKING THE AIR INDUCTION SYSTEM SOLENOID” on page 8-49.
¢ Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

9-203
 P1400

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Start the engine and check the status of the DTC.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 5.

TIP
Check that the start/engine stop switch is turned to “ON” then.
5. Malfunction in ECU.
¢ Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
6. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-204
 P1600

EAS20613

P1600
EASa3S093

TROUBLESHOOTING
ltem
Lean angle sensor: open or short circuit detected.
Fail-safe system
e Unable to start engine
e Unable to drive vehicle

Procedure
TIP
lf more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first.
e U0125
1. Connection of IMU coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, then to “OFF”, and back to “ON”.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 2.

2. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, then to “OFF”, and back to “ON”.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 3.

3. Wire harness continuity.

¢ Disconnect the ECU coupler “1”, joint coupler “2”, IMU coupler “S” and ignition fuse “4”.

9-205
 P1600

¢ Open circuit check

blue/white—blue/white
Between ECU coupler and joint coupler
blue/black—blue/black
blue/white—blue/white
Between joint coupler and IMU coupler
blue/black—blue/black
Between ECU coupler and IMU coupler black/white—black/white
Between ignition fuse holder and IMU coupler red/white—red/white

(2
4 (Q) 1
Lang |g 4 MIR[ << PAV Pra jancsfayic | [ea 3
MugA|UR ><] Us jore|rve
[Gre] B
PUL |GiPy' BoA) Bal) WL B
an (Q) ANG Lae ‘iL ! =]

2 yyy ~ V cc
—b— joo
[UWL LAWiLW LANL) Le | La) Le | La] v8 Q) Pe pw)P<] v | LUA Gy
err pe = bond (Q)———p i BY wD Jen] w ww
4 pve a a =~ ( Ley Livi aly an G oe ML

1) U8 |WB |v |e |U8 |e] ve

Seen ee
E ae 7 =

“, Joint coupler for YZF-R1

“*. Joint coupler for YZF-R1M

Is resistance 0 0?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, then to “OFF”, and back to “ON”.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to “Short circuit check’.

© Short circuit check

TIP
Disconnect the ECU and IMU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
a4 blue/white—ground
Between ECU coupler “1” and ground blue/black—ground

blue/white—ground
Between IMU coupler “3” and ground blue/black—ground
red/white—ground

9-206
 P1600

Lines short circuit check “B”

blue/white—any other coupler terminal
ECU coupler black/black—any other coupler terminal
blue/white—any other coupler terminal
Joint coupler “2 black/black—any other coupler terminal
blue/white—any other coupler terminal
IMU coupler blue/black—any other coupler terminal
red/white—any other coupler terminal

“, Joint coupler for YZF-R1

“*. Joint coupler for YZF-R1M

Is resistance - 0?
YES
— Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, then to “OFF”, and back to “ON”.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 4.

4. Installed condition of IMU.

¢ Check the installed direction and condition of the sensor.
¢ Check the grommet for cracks.

Is check result OK?

9-207
 P1600

YES
— Go to step 5.
NO
a. Fix the IMU installation condition.
b. Turn the main switch to “ON”, then to “OFF”, and back to “ON”.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 5.
5. Defective IMU.
* Replace the IMU.
Refer to “GENERAL CHASSIS (1)” on page 4-1.
e Turn the main switch to “ON”, then to “OFF”, and back to “ON”.
¢ Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 6.

6. Malfunction in ECU.
¢ Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
7. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-208
 P1601

EAS20614

P1601
EASsa3094

TROUBLESHOOTING
ltem
Sidestand switch: open or short circuit of the blue/yellow lead of the ECU is detected.
Fail-safe system
e Unable to start engine
e Unable to drive vehicle

Procedure
1. Connection of sidestand switch coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then extend and retract the sidestand.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 2.

2. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then extend and retract the sidestand.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 3.

3. Connection of relay 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).

9-209
 P1601

Is the coupler condition normal?

YES
— Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then extend and retract the sidestand.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 4.
4. Wire harness continuity.
¢ Disconnect the main switch coupler “1”, ECU coupler “2”, relay unit coupler “3” and sidestand switch
coupler “4”.
* Open circuit check
Between main switch coupler and ECU coupler blue/yellow—blue/yellow
Between main switch coupler and relay unit coupler | blue/black—blue/yellow
Between relay unit coupler and sidestand switch
blue/black—blue/black
coupler

Cc Le [I
LIB pw)P ><] v | [UR Gy|
BIY cL XBL] W WiB|
Urb ayy >< fan)G [>< loyal XW

Is resistance 0 (2?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then extend and retract the sidestand.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to “Short circuit check”.

© Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.

9-210
 P1601

Ground short circuit check “A”

blue/yellow—ground
Between main switch coupler “1” and ground blue/black—ground

blue/yellow—ground
Between relay unit coupler “3” and ground blue/black—ground

Lines short circuit check “B”

blue/yellow—any other coupler terminal
Main switch coupler "1 blue/black—any other coupler terminal
ECU coupler “2” blue/yellow—any other coupler terminal
blue/yellow—any other coupler terminal
Relay unit coupler “3”
blue/black—any other coupler terminal
Sidestand switch coupler “4” blue/black—any other coupler terminal

A B

pw) PL vo un

Is resistance oo 0)?
YES
— Go to step 5.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then extend and retract the sidestand.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 5.

5. Defective sidestand switch.

¢ Execute the diagnostic mode. (Code D20)
¢ Shift the transmission into gear.
Sidestand retracted ON
Sidestand extended OFF

is check result OK?

YES
— Go to step 6.
NO

9-211
 P1601

a. Replace the sidestand switch.

b. Turn the main switch to “ON”, and then extend and retract the sidestand.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 6.
6. Malfunction in ECU.
¢ Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
7. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-212
 P1602

EAS20615

P1602
EsASa3S095

TROUBLESHOOTING
ltem
Malfunction in ECU internal circuit (malfunction of ECU power cut-off function).
Fail-safe system
e Able/Unable to start engine
e Able/Unable to drive vehicle

Procedure
1. Installed condition of battery leads.
¢ Check the installed condition of the battery and battery leads (loose bolts).

Is check result OK?

YES
— Go to step 2.
NO
a . Reinstall or replace the battery leads.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 2.

2. Connection of starter relay coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO
a . Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 3.

3. Connection of main switch coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES

9-213
 P1602

— Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 4.
4. Check the backup fuse.

Is check result OK?

YES
— Go to step 5.
NO
a . Replace the fuse.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 5.

5. Wire harness continuity.

¢ Disconnect the battery “1”, backup fuse “2”, ECU coupler “3”, main switch coupler “4” and ignition
fuse “5”.
* Open circuit check
Between battery and backup fuse holder red-red
Between backup fuse holder and ECU coupler red/green-red/green
dill main switch coupler and ignition fuse hola- Soe bllie—brown/blue

Between ignition fuse holder and ECU coupler red/white—red/white

é L
3 WIA Pa] P8 c1gay6]O [en
a ? MjLgAl UR Lees

Q) > Ln +)
PIL|G/Y |ah)ee¥ ewe) WL Bbw B

4
einai
# oO 5
Tan # (Q) o_o <4 (Q)

3 =
luv ><] L <li
wi wi Jue>>< er
leva ><| iB [>< [ere
la] B len Ni

Is resistance 0 0?

9-214
 P1602

YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to “Short circuit check”.

© Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
Between battery “1” and ground red—ground
— red/green—ground
Between ECU coupler “3” and ground red/white—ground

Between main switch coupler “4" and ground brown/blue—ground

Lines short circuit check “B”

red/green—any other coupler terminal
ECU coupler ;
red/white—any other coupler terminal
Main switch coupler brown/blue—any other coupler terminal

A B
3 =
Oe cere eI
|
VIF Mw) PrB Jareiaye] © Jey | fale <Pwleeloceyaoayal
MuyAlUR|><|uelove| elev] BX | Noaual< us belvsles)BM |
Ful |Giy'|/BeR| Boy |BoB)
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Is resistance o> (?
YES
— Go to step 6.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.

9-215
 P1602

NO
— Go to step 6.
6. Malfunction in ECU.
¢« Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
7. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-216
 P1806, P1807
EAS20623

P1806, P1807
EAS33103

TROUBLESHOOTING
ltem
¢ [P1806] Shift sensor: open or ground short circuit detected.
¢ [P1807] Shift sensor: power short circuit detected.
Fail-safe system
e Able to start engine
e Able to drive vehicle

Procedure
1. Connection of shift 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).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 2.

2. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 3.

3. Wire harness continuity

¢ Disconnect the shift sensor coupler “1” and ECU coupler “2”.
* Open circuit check

9-217
 P1806, P1807

black/blue—black/blue
Between shift sensor coupler and ECU coupler violet—violet
blue—blue

Is resistance 0 (2)?
YES
— Go to “Short circuit check”.
NO
a . Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to “Short circuit check”.

© Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
violet—ground
Between shift sensor coupler “1” and ground blue—ground

Lines short circuit check “B”

black/blue—any other coupler terminal
Shift sensor coupler violet—any other coupler terminal
blue—any other coupler terminal
black/blue—any other coupler terminal
ECU coupler “2” violet—any other coupler terminal
blue—any other coupler terminal

9-218
 P1806, P1807

Is resistance - ()?
YES
— Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 4.

4. Installed condition of shift sensor.

¢ Check for looseness or pinching.

Is check result OK?

YES
— Go to step 5.
NO
a. Reinstall or replace the sensor.
Refer to “CHAIN DRIVE” on page 4-125.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 5.

5. Defective shift sensor.

*« Execute the diagnostic mode. (Code D95)
Shift sensor output voltage display 0.2—4.8 [V]
With no shift weighting input Approx. 2.5 [V]
Shift up weighting Changes to the low side
Shift down weighting Changes to the high side

Is check result OK?

YES
— Go to step 6.
NO
a. Replace the shift sensor.
Refer to “CHAIN DRIVE” on page 4-125.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO

9-219
 P1806, P1807

— Go to step 6.
6. Malfunction in ECU.
¢ Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
7. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-220
 P2122, P2123, P2127, P2128, P2138

EAS20632

P2122, P2123, P2127, P2128, P2138

EAS331 12

TROUBLESHOOTING
ltem
e [P2122] Accelerator position sensor: open or ground short circuit detected.
e [P2123] Accelerator position sensor: power short circuit detected.
e [P2127] Accelerator position sensor: open or ground short circuit detected.
e [P2128] Accelerator position sensor: power short circuit detected.
e [P2138] Deviation error
Fail-safe system
e Able/unable to start engine
e Able/unable to drive vehicle

Procedure
TIP
lfa DTC other than P2138 (P2122, P2123, P2127, or P2128) is indicated, perform troubleshooting first.
1. Connection of accelerator position 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).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 2.

2. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO

9-221
 P2122, P2123, P2127, P2128, P2138

— Go to step 3.
3. Wire harness continuity.
¢ Disconnect the accelerator position sensor coupler “1” and ECU coupler “2”.
¢ Open circuit check
blue/yellow—blue/yellow
white—white
Between accelerator position sensor coupler and black/blue—black/blue
ECU coupler blue/green—blue/green
black—black
black/yellow—black/yellow

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Is resistance 0 0?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to “Short circuit check”.

© Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
blue/yellow—blue/yellow
Between accelerator position sensor coupler “1” and | white—white
ground blue/green—blue/green
black—black

9-222
 P2122, P2123, P2127, P2128, P2138

Lines short circuit check “B”

blue/yellow—any other coupler terminal
white—any other coupler terminal
black/blue—any other coupler terminal
Accelerator position sensor coupler
blue/green—any other coupler terminal
black—any other coupler terminal
black/yellow—any other coupler terminal
blue/yellow—any other coupler terminal
white—any other coupler terminal
ECU coupler “2” black/blue—any other coupler terminal
blue/green—any other coupler terminal
black—any other coupler terminal
black/yellow—any other coupler terminal

A B
je egg ee ee Mee eee eM HK HS

Is resistance oo 0)?
YES
— Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 4.

4. Defective accelerator position sensor.

¢ Execute the diagnostic mode. (Code D14) (Accelerator position sensor signal 1.)
When the throttle valves are fully closed 9-23
When the throttle valves are fully open 41-87

¢ Execute the diagnostic mode. (Code D15) (Accelerator position sensor signal 2.)
When the throttle valves are fully closed 7-25
When the throttle valves are fully open 69-89

Is check result OK?

YES
— Go to step 5.
NO
— Replace the handlebar switch (right).
Refer to “HANDLEBARS’ on page 4-83.

9-223
 P2122, P2123, P2127, P2128, P2138

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 5.
5. Malfunction in ECU.
¢« Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
6. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-224
 P2158 (Fl)

P2158 (Fl)
EAS20633

E4533113

TROUBLESHOOTING
ltem
Front wheel sensor: no normal signals are received from the front wheel sensor.
Fail-safe system
e Able to start engine
e Able to drive vehicle

Procedure
1. Locate the malfunction.
¢ Check the ABS warning light.

Is the ABS warning light on?

YES
— Refer to “BASIC INSTRUCTIONS FOR TROUBLESHOOTING?” on page 9-20.
NO
— Go to step 2.

2. Execute the diagnostic mode.

* Execute the diagnostic mode. (Code D16)
¢ Rotate the front wheel by hand and check that the indicated value increases.

Is that value increased?

YES
— Go to step 10, and complete the service.
NO
— Go to step 3.

3. Connection of front wheel 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).

Is the coupler condition normal?

YES
— Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code D16)
c. Rotate the front wheel by hand and check that the indicated value increases.

Is that value increased?

YES
— Go to step 10, and complete the service.
NO
— Go to step 4.

4. Connection of ABS ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

9-225
 P2158 (Fl)
Is the coupler condition normal?
YES
— Go to step 5.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code D16)
c. Rotate the front wheel by hand and check that the indicated value increases.

Is that value increased?

YES
— Go to step 10, and complete the service.
NO
— Go to step 5.
5. Connection of ECU coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 6.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code D16)
c. Rotate the front wheel by hand and check that the indicated value increases.

Is that value increased?

YES
— Go to step 10, and complete the service.
NO
— Go to step 6.

6. Wire harness continuity.

* Disconnect the front wheel sensor coupler “1”, ABS ECU coupler “2” and ECU coupler “3”.
¢ Open circuit check
Between front wheel sensor coupler and ABS ECU | black—black
coupler white—white
Between ABS ECU coupler and ECU coupler gray/black—gray/black

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Is resistance 0 (2?
YES
— Go to “Short circuit check”.
NO

9-226
 P2158 (Fl)
Replace the wire harness.

oof
Execute the diagnostic mode. (Code D16)
Rotate the front wheel by hand and check that the indicated value increases.

Is that value increased?

YES
— Go to step 10, and complete the service.
NO
— Go to “Short circuit check”.
© Short circuit check
TIP
Disconnect the ECU and ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3 and “PARTS CONNECTED TO THE ABS
ECU” on page 9-4.
Ground short circuit check “A”
black—ground
Between ABS ECU coupler “2” and ground white—ground
gray/black—ground

Lines short circuit check “B”

black—any other coupler terminal
Front wheel sensor coupler “1 white—any other coupler terminal
black—any other coupler terminal
ABS ECU coupler white—any other coupler terminal
gray/black—any other coupler terminal
ECU coupler “3” gray/black—any other coupler terminal

A B

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Is resistance « 0?
YES

9-227
 P2158 (Fl)
— Go to step 7.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code D16)
c. Rotate the front wheel by hand and check that the indicated value increases.

Is that value increased?

YES
— Go to step 10, and complete the service.
NO
— Go to step 7.
7. Defective front wheel sensor.
¢ Check the front wheel sensor.
Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR’ on page
4-40.
Is check result OK?
YES
— Go to step 8.
NO
a. Reinstall or replace the front wheel sensor.
Refer to “FRONT WHEEL’ on page 4-35.
b. Execute the diagnostic mode. (Code D16)
c. Rotate the front wheel by hand and check that the indicated value increases.

Is that value increased?

YES
— Go to step 10, and complete the service.
NO
— Go to step 8.

8. Malfunction in ECU.
* Replace the ECU.
Refer to “REPLACING THE ECU (Engine Control! Unit)” on page 8-41.
* Execute the diagnostic mode. (Code D16)
¢ Rotate the front wheel by hand and check that the indicated value increases.

Is that value increased?

YES
— Go to step 10, and complete the service.
NO
— Go to step 9.

9. Malfunction in ABS ECU.

¢ Replace the ABS ECU.
Refer to “REMOVING THE HYDRAULIC UNIT ASSEMBLY” on page 4-77.
* Go to step 10, and complete the service.
[Link] the DTC and check that the MIL goes off.
¢ Turn the main switch to “ON”, and then rotate the front wheel by hand.
¢ Start the engine, and input the vehicle speed signals by operating the vehicle at 20 to 30 km/h (12
to 19 mph).
¢ Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT, and
then delete the DTC.
* Delete this DTC even if it has a condition of “Detected”.

9-228
 P2158 (SCU)

P2158 (SCU)
EAS20634

EAS33114

TROUBLESHOOTING
ltem
Front wheel sensor: no normal signals are received from the front wheel sensor.
Fail-safe system
e Able to start engine
e Able to drive vehicle

Procedure
1. Abnormal front wheel sensor
¢ Check the item of DTC P2158 for the ECU.
Refer to “SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM)” on page
9-38.
¢ Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the
malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Service is completed.
NO
— Refer to the item corresponding to DTC.

9-229
 P21CF

EAS20637

P21CF
EAS33117

TROUBLESHOOTING
ltem
Secondary injector #1: malfunction in secondary injector #1.
Fail-safe system
e Able to start engine (depending on the number of faulty cylinders)
e Able to drive vehicle (depending on the number of faulty cylinders)

Procedure
1. Connection of secondary injector #1 coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code D40)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 2.

2. Defective secondary injector #1.

¢ Measure the secondary injector resistance.
Refer to “CHECKING THE FUEL INJECTORS’ on page 8-51.

Is check result OK?

YES
— Go to step 3.
NO
a. Replace the secondary injector #1.
Refer to “AIR FILTER CASE” on page 7-5.
b. Execute the diagnostic mode. (Code D40)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 3.

3. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES

9-230
 P21CF

— Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code D40)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 4.
4. Wire harness continuity.
¢ Disconnect the secondary injector #1 coupler “1”, ECU coupler “2” and relay unit coupler “3”.
¢ Open circuit check
Between secondary injector #1 coupler and ECU
white/blue—white/blue
coupler
Between secondary injector #1 coupler and relay
unit coupler red/blue—red/blue

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Is resistance 0 (2?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code D40)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to “Short circuit check”.

e Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
Between secondary injector #1 coupler “1” and white/blue—ground
ground red/blue—ground

Lines short circuit check “B”

white/blue—any other coupler terminal
Secondary injector #1 coupler red/blue—any other coupler terminal

9-231
 P21CF

ECU coupler “2” white/blue—any other coupler terminal

Relay unit coupler “3” red/blue—any other coupler terminal

A B

Is resistance « 0?
YES
— Go to step 5.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code D40)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 5.

5. Malfunction in ECU.
¢« Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
6. Delete the DTC and check that the MIL goes off.
¢ Start the engine and let it idle for approximately 5 seconds.
¢ Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT, and
then delete the DTC.

9-232
 P21D0

EAS20638

P21D0
E4S33118

TROUBLESHOOTING
ltem
Secondary injector #2: malfunction in secondary injector #2.
Fail-safe system
e Able to start engine (depending on the number of faulty cylinders)
e Able to drive vehicle (depending on the number of faulty cylinders)

Procedure
1. Connection of secondary injector #2 coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code D41)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 2.

2. Defective secondary injector #2.

¢ Measure the secondary injector resistance.
Refer to “CHECKING THE FUEL INJECTORS’ on page 8-51.

Is check result OK?

YES
— Go to step 3.
NO
a. Replace the secondary injector #2.
Refer to “AIR FILTER CASE” on page 7-5.
b. Execute the diagnostic mode. (Code D41)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 3.

3. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES

9-233
 P21D0

— Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code D41)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 4.
4. Wire harness continuity.
¢ Disconnect the secondary injector #2 coupler “1”, ECU coupler “2” and relay unit coupler “3”.
¢ Open circuit check
moines secondary injector #2 coupler and ECU sky blue/white-sky blue/white

Between secondary injector #2 coupler and relay

unit coupler red/blue—red/blue

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Is resistance 0 (2?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code D41)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to “Short circuit check”.

e Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
Between secondary injector #2 coupler “1” and sky blue/white—ground
ground red/blue—ground

Lines short circuit check “B”

sky blue/white—any other coupler terminal
Secondary injector #2 coupler red/blue—any other coupler terminal

9-234
 P21D0

ECU coupler “2” sky blue/white—any other coupler terminal

¢
Relay unit coupler “3” red/blue—any other coupler terminal

A B

Is resistance « 0?
YES
— Go to step 5.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code D41)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 5.

5. Malfunction in ECU.
¢« Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
6. Delete the DTC and check that the MIL goes off.
¢ Start the engine and let it idle for approximately 5 seconds.
¢ Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT, and
then delete the DTC.

9-235
 P21D1

EAS20639

P21D1
E4S33119

TROUBLESHOOTING
ltem
Secondary injector #3: malfunction in secondary injector #3.
Fail-safe system
e Able to start engine (depending on the number of faulty cylinders)
e Able to drive vehicle (depending on the number of faulty cylinders)

Procedure
1. Connection of secondary injector #3 coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code D42)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 2.

2. Defective secondary injector #3.

¢ Measure the secondary injector resistance.
Refer to “CHECKING THE FUEL INJECTORS’ on page 8-51.

Is check result OK?

YES
— Go to step 3.
NO
a. Replace the secondary injector #3.
Refer to “AIR FILTER CASE” on page 7-5.
b. Execute the diagnostic mode. (Code D42)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 3.

3. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES

9-236
 P21D1

— Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code D42)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 4.
4. Wire harness continuity.
¢ Disconnect the secondary injector #3 coupler “1”, ECU coupler “2” and relay unit coupler “3”.
¢ Open circuit check
Between secondary injector #3 coupler and ECU
brown/yellow—brown/yellow
coupler
Between secondary injector #3 coupler and relay red/blue—red/blue
unit coupler

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(Q) (22)
2 =
MIA >< [>< JPN IPI Javerayts] [ay 1 a= 3
VILLA >< FONE | Fv |v] B WY. Bal (LW AW] L | RL
PIL [Gry /sun)eery eu] Ww BM) B ana UAL AAW Lie |LY] Sb [By Bian
evel BL!
YL [Sb |FYLIANIaANd

Is resistance 0 Q?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code D42)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to “Short circuit check”.

e Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
Between secondary injector #3 coupler “1” and brown/yellow—ground
ground red/blue—ground

Lines short circuit check “B”

brown/yellow—any other coupler terminal
Secondary injector #3 coupler red/blue—any other coupler terminal

9-237
 P21D1

ECU coupler “2” brown/yellow—any other coupler terminal

Relay unit coupler “3” red/blue—any other coupler terminal

A B

Is resistance « 0?
YES
— Go to step 5.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code D42)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 5.

5. Malfunction in ECU.
¢« Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
6. Delete the DTC and check that the MIL goes off.
¢ Start the engine and let it idle for approximately 5 seconds.
¢ Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT, and
then delete the DTC.

9-238
 P21D2

EAS20640

P21D2
E4533120

TROUBLESHOOTING
ltem
Secondary injector #4: malfunction in secondary injector #4.
Fail-safe system
e Able to start engine (depending on the number of faulty cylinders)
e Able to drive vehicle (depending on the number of faulty cylinders)

Procedure
1. Connection of secondary injector #4 coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code D43)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 2.

2. Defective secondary injector #4.

¢ Measure the secondary injector resistance.
Refer to “CHECKING THE FUEL INJECTORS’ on page 8-51.

Is check result OK?

YES
— Go to step 3.
NO
a. Replace the secondary injector #4.
Refer to “AIR FILTER CASE” on page 7-5.
b. Execute the diagnostic mode. (Code D43)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 3.

3. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES

9-239
 P21D2

— Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code D43)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 4.
4. Wire harness continuity.
¢ Disconnect the secondary injector #4 coupler “1”, ECU coupler “2” and relay unit coupler “3”.
¢ Open circuit check
Between secondary injector #4 coupler and ECU
brown/black—brown/black
coupler
Between secondary injector #4 coupler and relay red/blue—red/blue
unit coupler

(Cy (Cy\
(22) (22)
rappel ogaelolar 1 4h = Bal (LW
2 =

VILLA >< |W RAVE || B WY. AW] L | RL

PiL [Gry /aunleey eu] Ww BoM) B ere [ra} UAL AAW Lie |LY] Sb [By Bian
evel BL!
YL [Sb |FYLIANIaANd

Is resistance 0 (2?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code D43)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to “Short circuit check”.

e Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
Between secondary injector #4 coupler “1” and brown/black—ground
ground red/blue—ground

Lines short circuit check “B”

brown/black—any other coupler terminal
Secondary injector #4 coupler red/blue—any other coupler terminal

9-240
 P21D2

ECU coupler “2” brown/black—any other coupler terminal

Relay unit coupler “3” red/blue—any other coupler terminal

A B

Is resistance « 0?
YES
— Go to step 5.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code D43)

Is it hear operating sound?

YES
— Go to step 6.
NO
— Go to step 5.

5. Malfunction in ECU.
¢« Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
6. Delete the DTC and check that the MIL goes off.
¢ Start the engine and let it idle for approximately 5 seconds.
¢ Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT, and
then delete the DTC.

9-241
 P2228, P2229

EASZ0641

P2228, P2229
EsS3a3121

TROUBLESHOOTING
Item
¢ [P2228] Atmospheric pressure sensor: ground short circuit detected.
¢ [P2229] Atmospheric pressure sensor: open or power short circuit detected.
Fail-safe system
e Able to start engine
e Able to drive vehicle

Procedure
1. Connection of atmospheric pressure 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).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 2.

2. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 3.

3. Wire harness continuity.

¢ Disconnect the atmospheric pressure sensor coupler “1” and ECU coupler “2”.
* Open circuit check

9-242
 P2228, P2229

blue—blue
Between atmospheric pressure sensor coupler and
pink—pink
ECU coupler
black/blue—black/blue

Is resistance 0 0?
YES
— Go to “Short circuit check”.
NO
a . Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to “Short circuit check”.

© Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
Between atmospheric pressure sensor coupler “1” blue—ground
and ground pink—ground

Lines short circuit check “B”

blue—any other coupler terminal
Atmospheric pressure sensor coupler pink—any other coupler terminal
black/blue—any other coupler terminal
blue—any other coupler terminal
ECU coupler “2” pink—any other coupler terminal
black/blue—any other coupler terminal

A B

9-243
 P2228, P2229

Is resistance - ()?
YES
— Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 4.

4. Installed condition of atmospheric pressure sensor.

¢ Check for looseness or pinching.

Is check result OK?

YES
— Go to step 5.
NO
a. Reinstall the sensor.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 5.

5. Defective atmospheric pressure sensor.

¢« Execute the diagnostic mode. (Code D0O2)
¢ When engine is stopped: Atmospheric pressure at the current altitude and weather conditions is in-
dicated.
At sea level Approx. 101 kPa (757.6 mmHg, 29.8 inHg), approx.
3.64 V
1000 m (3300 ft) above sea level one 90 kPa (675.1 mmHg, 26.6 inHg), approx.

2000 m (6700 ft) above sea level ae 80 kPa (600.0 mmHg, 23.6 inHg), approx.

3000 m (9800 ft) above sea level aailbee 70 kPa (525.0 mmHg, 20.7 inHg), approx.

Is check result OK?

YES
— Go to step 6.
NO
a. Replace the atmospheric pressure sensor.
Refer to “AIR INDUCTION SYSTEM” on page 7-20.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

9-244
 P2228, P2229

Is it in the “Recovered” condition?

YES
— Go to step 7, and complete the service.
NO
— Go to step 6.
6. Malfunction in ECU.
¢ Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
7. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-245
 U0100

EASZ0644

U0100
EsAS33124

TROUBLESHOOTING
ltem
Abnormal CAN communication (between ECU and SCU)
Fail-safe system
e Able to start engine
e Able to drive vehicle

Procedure
1. Connection of ECU coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a . Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the
malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Service is completed.
NO
— Go to step 2.

2. Wire harness continuity.

¢ Disconnect the SCU coupler “1”, joint coupler “2” and ECU coupler “3”.
¢ Open circuit check
blue/white—blue/white
Between SCU coupler and joint coupler
blue/black—blue/black
blue/white—blue/white
Between the joint coupler and ECU coupler
blue/black—blue/black

9-246
 U0100

aula]Y D<D< Bm
P| G AGG Gy) 8
LIB | >< | PAL | GiB] iG jayaiGyAl
PHB Gail | YB |W [WMI WE FNS

—-—~
Cc joe
PW) P v]L|uA Gy|
BIY yi Bow BIL] W Wt
GM] G

“, Joint coupler for YZF-R1

“*. Joint coupler for YZF-R1M

Is resistance 0 2?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the
malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Service is completed.
NO
— Go to “Short circuit check”.

e Short circuit check

TIP
Disconnect the ECU and SCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3 and “PARTS CONNECTED TO THE SCU
(for YZF-R1M)” on page 9-3.
Ground short circuit check “A”

Between SCU coupler “1” qn and ground blue/white—ground

piisilacle_around

Between ECU coupler

inn
“3” and ground
blue/white—ground
Bbiatlacie_creund

Lines short circuit check “B”

blue/white—any other coupler terminal
SCU coupler
blue/black—any other coupler terminal
blue/white—any other coupler terminal
Joint coupler “2”
blue/black—any other coupler terminal
blue/white—any other coupler terminal
ECU coupler
blue/black—any other coupler terminal

9-247
 U0100

A B
1 1
PwiGin| ¥ i 1
P| G PR GyalGy| B IX eee PAW |GFI} ¥ rh)
OQ UB] >< | PIL |e] vic ebay] <1 ; ! P |G |wAleyieGy| BX
Fe |GvLlyie |w [wrlwe Oo PIL) Gi} YG |eyBhaytF] >< !
Pr Ga | vi [WW [WORE]
en

“, Joint coupler for YZF-R1

“*, Joint coupler for YZF-R1M

Is resistance -o 0)?
YES
— Go to step 3.
NO
a . Replace the wire harness.
b. Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the
malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Service is completed.
NO
— Go to step 3.

3. Malfunction in ECU.
¢ Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.

9-248
 U0121

EASZOG46

U0121
EAS33126

TROUBLESHOOTING
ltem
Abnormal CAN communication (between ABS ECU and SCU)
Fail-safe system
e Able to start engine
e Able to drive vehicle

Procedure
1. Connection of ABS ECU coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the
malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Service is completed.
NO
— Go to step 2.

2. Wire harness continuity.

¢ Disconnect the SCU coupler “1”, joint coupler “2” and ABS ECU coupler “3”.
¢ Open circuit check
blue/white—blue/white
Between SCU coupler and joint coupler
blue/black—blue/black
blue/white—blue/white
Between the joint coupler and ABS ECU coupler
blue/black—blue/black

9-249
 U0121

cl

PaaGir]¥ [>< [>< pote

P | G |YAlGyG Gy| B
LB) >< | PL |r| Yi ayiajowih
YF) << | PB GAL | Ys |v [Mi at iy

“, Joint coupler for YZF-R1

“*. Joint coupler for YZF-R1M

Is resistance 0 2?
YES
— Go to “Short circuit check”
NO
a. Replace the wire harness.
b. Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the
malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Service is completed.
NO
— Go to “Short circuit check”

© Short circuit check

TIP
Disconnect the SCU and ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SCU (for YZF-R1M)” on page 9-3 and “PARTS CONNECTED
TO THE ABS ECU” on page 9-4.
Ground short circuit check “A”

Between SCU coupler “1” qn and ground blue/white—ground

piisilacle_around

Between ABS ECU coupler un“3” and ground blue/white—ground

hi a/black_arsund

Lines short circuit check “B”

blue/white—any other coupler terminal
SCU coupler blue/black—any other coupler terminal
blue/white—any other coupler terminal
Joint coupler “2 blue/black—any other coupler terminal
blue/white—any other coupler terminal
ABS ECU coupler blue/black—any other coupler terminal

9-250
 U0121

PwIGA] '¥ I 1
P| G lyrleyclGy| B -- > Piw|Grl ¥ cn)

lk
HB [>< | PIL jer) vic GyBlay i P |G /ymewacy| B Ix !
ere} GL lye | Ww [wale UB ><] Pr ais) vic |eyBayel <1 !
PYB| GL] WS |W |WAIWIBIWIG]
en

a
wn] feyele [y | Fave! [Li]

ey
AM} feolwal L |e [Ww] w [ue]

“, Joint coupler for YZF-R1

“*, Joint coupler for YZF-R1M

Is resistance -o 0)?
YES
— Go to step 3.
NO
a . Replace the wire harness.
b. Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the
malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Service is completed.
NO
— Go to step 3.

3. Malfunction in ABS ECU.

¢ Replace the ABS ECU, and complete the service.
Refer to “REMOVING THE HYDRAULIC UNIT ASSEMBLY’ on page 4-77.

9-251
 U0125 (Fl)

U0125 (Fl)
EASZO647

EASsa3127

TROUBLESHOOTING
ltem
Signals cannot be transmitted between the ECU and the IMU.
Fail-safe system
¢ Unable to start engine
e Able/Unable to drive vehicle

Procedure
TIP
lf more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first.
¢ P1600
1. Connection of IMU coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a . Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the
malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 2.

2. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO
a . Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the
malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 3.

3. Wire harness continuity.

¢ Disconnect the ECU coupler “1”, joint coupler “2”, IMU coupler “S” and ignition fuse “4”.

9-252
 U0125 (Fl)
¢ Open circuit check
blue/white—blue/white
Between ECU coupler and joint coupler
blue/black—blue/black
blue/white—blue/white
Between joint coupler and IMU coupler
blue/black—blue/black
Between IMU coupler and ignition fuse holder red/white—red/white
Between IMU coupler and ECU coupler black/white—black/white

(2
4 (Q) 1 MA Dav
Pra jancsfayr]c| Tea 3
ve Gye) Bs
Mugr|UR ><] ue }ove|
= ALIGN BoA) EY BoB Wil B
an (Q) ANS shan YL ! =

2 ' v ; oo en ee
uuu uwiuwiuwiue |u| Ue |e | Ue] Le ‘UB pw) P<) Po [ur Gy
err pe = bond (Q)———p i BY wD Jen] w ww
4 pve ao =~ ( LY LIME aly an G oe fu

1) U8 |B |U8|U8|U6|Le| Ue
Seen ee
E ae 7 F

“, Joint coupler for YZF-R1

“*. Joint coupler for YZF-R1M

Is resistance 0 Q?
YES
— Go to “Short circuit check”.
NO
a . Replace the wire harness.
b. Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the
malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to “Short circuit check”.

© Short circuit check

TIP
Disconnect the ECU and IMU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
a4 blue/white—ground
Between ECU coupler “1” and ground blue/black—ground

blue/white—ground
Between IMU coupler “3” and ground blue/black—ground
red/white—ground

9-253
 U0125 (Fl)
Lines short circuit check “B”
blue/white—any other coupler terminal
ECU coupler blue/black—any other coupler terminal
blue/white—any other coupler terminal
Joint coupler “2 blue/black—any other coupler terminal
blue/white—any other coupler terminal
IMU coupler blue/black—any other coupler terminal
red/white—any other coupler terminal

“, Joint coupler for YZF-R1

“*. Joint coupler for YZF-R1M

Is resistance - 0?
YES
— Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the
malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 4.

4. Malfunction in IMU.
¢ Replace the IMU.
Refer to “GENERAL CHASSIS (1)” on page 4-1.
¢ Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the
malfunction mode of the YDT.

9-254
 U0125 (Fl)

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 5.

5. Malfunction in ECU.
* Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
6. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-255
 U0125 (SCU)

EASZ0648

U0125 (SCU)
EAS33128

TROUBLESHOOTING
ltem
Abnormal CAN communication (between IMU and SCU)
Fail-safe system
e Able to start engine
e Able to drive vehicle

Procedure
1. Connection of IMU coupler.
¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the
malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Service is completed.
NO
— Go to step 2.

2. Wire harness continuity.

¢ Disconnect the SCU coupler “1”, joint coupler “2” and IMU coupler “3”.
¢ Open circuit check
blue/white—blue/white
Between SCU coupler and joint coupler
blue/black—blue/black
blue/white—blue/white
Between the joint coupler and IMU coupler
blue/black—blue/black

9-256
 U0125 (SCU)

1
pulain|y [<< bal 3
co]

P| G |ymbydGy]B i
# LB) ><] Pr [are vie layeloyn DOO
fi) <<] PB]
GAL | YVB |W [Wai Wie NS]

Se ee

“, Joint coupler for YZF-R1

“*. Joint coupler for YZF-R1M

Is resistance 0 2?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the
malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Service is completed.
NO
— Go to “Short circuit check”.

© Short circuit check

TIP
Disconnect the SCU and IMU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SCU (for YZF-R1M)” on page 9-3.
Ground short circuit check “A”

Between SCU coupler “1” qn and ground blue/white—ground

blue/black—ground

Between IMU coupler “3” and ground blue/white—ground

blue/black—ground

Lines short circuit check “B”

blue/white—any other coupler terminal
SCU coupler blue/black—any other coupler terminal
blue/white—any other coupler terminal
Joint coupler °2 blue/black—any other coupler terminal
blue/white—any other coupler terminal
IMU coupler blue/black—any other coupler terminal

9-257
 U0125 (SCU)

A B

PiwiGiA| ¥ ME a a aie !
P| G jwAGacy| B IX eae Ba
pwilginY D<D<
OQ Ue |< [Pi java) vie eyBlayel <TH ! P| G lwabyaGy| Be [x] |
eye |GiL| vie | wy [walwe|wie} OQ Ue ><]Pafave vies !
iw) ><] pve |can | vies | [ate wire fee !
i

“, Joint coupler for YZF-R1

“*, Joint coupler for YZF-R1M

Is resistance -o 0)?
YES
— Go to step 3.
NO
a . Replace the wire harness.
b. Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the
malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Service is completed.
NO
— Go to step 3.

3. Replace the IMU.

* Replace the IMU, and complete the service.
Refer to “GENERAL CHASSIS (1)” on page 4-1.

9-258
 U0155 or Err (FI)

EASZ0649

U0155 or Err (Fl)

EAS33129

TROUBLESHOOTING
ltem
Multi-function meter: signals cannot be transmitted between the ECU and the multi-function meter.
Fail-safe system
e Able to start engine
e Able to drive vehicle

Procedure
TIP
“Err’ is displayed on the clock display of the multi-function meter, but the MIL does not come on.
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).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 2.

2. Connection of ECU coupler.

¢ Check the locking condition of the coupler.
¢ Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
— Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 3.

3. Wire harness continuity.

¢ Disconnect the meter assembly coupler “1”, joint coupler “2” and ECU coupler “S”.
* Open circuit check

9-259
 U0155 or Err (Fl)

_ blue/white—blue/white
Between meter assembly coupler and joint coupler Coles A dncade Baltes Asi ode

Between joint coupler and ECU coupler or eee Vdc aee

2 3
eae ¥ (- — —|-—~
[a =
ri pay] P<] VL | Gy

‘e?
=|

¥-
Fa

Ea
fe
tH
fa

fs
=
=

=
a

a
QO Lwi<D< ev wel pon[><Jen.[w E|

6)
ay <Jawi|G Gwe)
>< WIL

“, Joint coupler for YZF-R1

“*, Joint coupler for YZF-R1M

Is resistance 0 0?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to “Short circuit check”.

e Short circuit check

TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
blue/white—ground
Between meter assembly coupler “1” and ground blue/black—ground
blue/white—ground
Between ECU coupler “3” and ground blue/black—ground

Lines short circuit check “B”

blue/white—any other coupler terminal
Meter assembly coupler blue/black—any other coupler terminal
blue/white—any other coupler terminal
Joint coupler “2 blue/black—any other coupler terminal

9-260
 U0155 or Err (Fl)

blue/white—any other coupler terminal

ECU coupler blue/black—any other coupler terminal

*, Joint coupler for YZF-R1

“*. Joint coupler for YZF-R1iM

Is resistance oo Q?
YES
— Go to step 4.
NO
a . Replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 4.

4. Defective meter assembly.

¢ Replace the meter assembly.
Refer to “GENERAL CHASSIS (6)” on page 4-23.
¢ Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
— Go to step 6, and complete the service.
NO
— Go to step 5.

9-261
 U0155 or Err (FI)

5. Malfunction in ECU.
¢« Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
6. Delete the DTC and check that the MIL goes off.
¢ Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-262
 U0155 or Err (SCU)

EAS20650

U0155 or Err (SCU)

E4533130

TROUBLESHOOTING
ltem
Abnormal CAN communication (between meter assembly and SCU)
Fail-safe system
e Able to start engine
e Able to drive vehicle

Procedure
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).

Is the coupler condition normal?

YES
— Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the
malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Service is completed.
NO
— Go to step 2.

2. Wire harness continuity.

¢ Disconnect the SCU coupler “1”, joint coupler “2” and meter assembly coupler “3”.
¢ Open circuit check
blue/white—blue/white
Between SCU coupler and joint coupler
blue/black—blue/black
Between the joint coupler and meter assembly cou- | blue/white—blue/white
pler blue/black—blue/black

9-263
 U0155 or Err (SCU)

1 = 3
wn
pwiaial ¥ [>< [>< Baw
if Bh
te) >< rave viclayelayl IB}aNw| >< Bov)eB|Dg | Ch | wi fwry|ee¥] Lg [LIW|
LIB Ga
| Pie} GL | vie |W |W Win RIGipIGls G |eve)we}s] w ay

82)
Q 2 {Ww ¥____-
Q)
7
" ——
(uw |uiviuw | Liu) Linu |u| L/8 | U8 | L186 | Q

ee =
LWLWILMTLWILINI Li
Se —CaLaLaaLalneseee—
— Eo

“, Joint coupler for YZF-R1

“*. Joint coupler for YZF-R1M

Is resistance 0 2?
YES
— Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the
malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Service is completed.
NO
— Go to “Short circuit check”.

© Short circuit check

TIP
Disconnect the SCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SCU (for YZF-R1M)” on page 9-3.
Ground short circuit check “A”

Between SCU coupler “1” qn and ground blue/white—ground

i ailacicorelirad

eye blue/white—ground
Between meter assembly coupler “3S” and ground i eau

Lines short circuit check “B”

blue/white—any other coupler terminal
SCU coupler blue/black—any other coupler terminal
blue/white—any other coupler terminal
Joint coupler °2 blue/black—any other coupler terminal
blue/white—any other coupler terminal
Meter assembly coupler blue/black—any other coupler terminal

9-264
 U0155 or Err (SCU)

A B
1 to
pwleal ¥ '
P |G /vimiayelGy| B IX — PAW GIF) *¥ iy
2 Le ><] PHL [cre Yi GyiBISyrAl >< I ! P |G [yinGyiG Gy! B PY
P/B|G/L|¥iB | W [WAP WIB BL [><] PIL |t8| viGhowBfayAL Py]
PYB| GL] WS |W |WAIWIBIWIG]

3 Be
Bi] rh |B)Og | ch | WLIW IBc'y] Lo JL] Gi ! lawl}
>< Beware] Do} ch | wt fwley| Lg ILAWILIB ian) | |
ary]@ javehwelwelw envi) ' ) Fichvalsnwiertar|G \ars|welwis}Ww ily lt

“, Joint coupler for YZF-R1

“*, Joint coupler for YZF-R1M

Is resistance -o 0)?
YES
— Go to step 3.
NO
a . Replace the wire harness.
b. Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the
malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
— Service is completed.
NO
— Go to step 3.

3. Defective meter assembly.

¢ Replace the meter assembly, and complete the service.
Refer to “GENERAL CHASSIS (6)” on page 4-23.

9-265
 11_ABS

EAS20685

11_ABS
EAS3a3314

TROUBLESHOOTING
ltem
Front wheel sensor (intermittent pulses or no pulses)

Procedure
TIP
lf the rear wheel continues to turn for more than 20 seconds after the front wheel has stopped, this will
be recorded.
1. Foreign material adhered around the front wheel sensor
¢ Check the surface of the sensor rotor and wheel sensor for foreign material, such as metal particles.

Is check result OK?

YES
— Go to step 2.
NO
— Clean the sensor rotor and wheel sensor.

2. Incorrect installation of the front wheel

¢ Check the components for looseness, distortion, and bends.
Refer to “CHECKING THE FRONT WHEEL” on page 4-38.

Is check result OK?

YES
— Go to step 3.
NO
— Replace the wheel axle, tire, front wheel, wheel bearings or oil seals.

3. Defective sensor rotor or incorrect installation of the rotor

¢ Check the surface of the sensor rotor for damage.
Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR’ on page
4-40.

Is check result OK?

YES
— Go to step 4.
NO
— Replace the sensor rotor.

4. Defective front wheel sensor or incorrect installation of the sensor

* Check the wheel sensor for damage and the installed condition of the sensor.
Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR’ on page
4-40.

Is check result OK?

YES
— Replace the hydraulic unit assembly (ABS ECU).
NO
— Repair or replace the wheel sensor.

9-266
 12_ABS

EASZ0686

12_ABS
EAS33315

TROUBLESHOOTING
ltem
Rear wheel sensor (intermittent pulses or no pulses)

Procedure
1. Foreign material adhered around the rear wheel sensor
¢ Check the surface of the sensor rotor and wheel sensor for foreign material, such as metal particles.

Is check result OK?

YES
— Go to step 2.
NO
— Clean the sensor rotor and wheel sensor.

2. Incorrect installation of the rear wheel

¢ Check the components for looseness, distortion, and bends.
Refer to “CHECKING THE REAR WHEEL” on page 4-47.

Is check result OK?

YES
— Go to step 3.
NO
— Replace the wheel axle, tire, rear wheel, wheel bearings or oil seals.

3. Defective sensor rotor or incorrect installation of the rotor

¢ Check the surface of the sensor rotor for damage.
Refer to “MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR?’ on page
4-49.

Is check result OK?

YES
— Go to step 4.
NO
— Replace the sensor rotor.

4. Defective rear wheel sensor or incorrect installation of the sensor

¢ Check the wheel sensor for damage and the installed condition of the sensor.
Refer to “MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR’ on page
4-49.
Is check result OK?
YES
— Replace the hydraulic unit assembly (ABS ECU).
NO
— Repair or replace the wheel sensor.

9-267
 13, 26_ABS

EAS20687

13, 26_ABS
EAS33316

TROUBLESHOOTING
ltem
Front wheel sensor (abnormal pulse period)

Procedure
TIP
e If the front brake ABS operates continuously for 20 seconds or more, DTC No. 26 will be recorded. If
the front brake ABS operates continuously for 36 seconds or more, DTC No. 13 will be recorded.
e Vehicle possibly ridden on uneven roads.
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.

is check result OK?

YES
— Go to step 2.
NO
— Clean the sensor rotor and wheel sensor.

2. Incorrect installation of the front wheel

¢ Check the components for looseness, distortion, and bends.
Refer to “CHECKING THE FRONT WHEEL” on page 4-38.

Is check result OK?

YES
— Go to step 3.
NO
— Replace the wheel axle, tire, rear wheel, wheel bearings or oil seals.

3. Defective sensor rotor or incorrect installation of the rotor

¢ Check the surface of the sensor rotor for damage.
Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR’ on page
4-40.

Is check result OK?

YES
— Go to step 4.
NO
— Replace the sensor rotor.

4. Defective front wheel sensor or incorrect installation of the sensor

¢ Check the wheel sensor for damage and the installed condition of the sensor.
Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR’ on page
4-40.

Is check result OK?

YES
— Replace the hydraulic unit assembly (ABS ECU).
NO
— Repair or replace the wheel sensor.

9-268
 14, 27_ABS

EASZ0688

14, 27_ABS
EASa3317

TROUBLESHOOTING
ltem
Rear wheel sensor (abnormal pulse period)

Procedure
TIP
e lf the rear brake ABS operates continuously for 20 seconds or more, DTC No. 27 will be recorded. If
the rear brake ABS operates continuously for 36 seconds or more, DTC No. 14 will be recorded.
¢ Vehicle possibly ridden on uneven roads.
1. Foreign material adhered around the rear wheel sensor
¢ Check the surface of the sensor rotor and wheel sensor for foreign material, such as metal particles.

is check result OK?

YES
— Go to step 2.
NO
— Clean the sensor rotor and wheel sensor.

2. Incorrect installation of the rear wheel

¢« Check the components for looseness, distortion, and bends.
Refer to “CHECKING THE REAR WHEEL” on page 4-47.

Is check result OK?

YES
— Go to step 3.
NO
— Replace the wheel axle, tire, rear wheel, wheel bearings or oil seals.

3. Defective sensor rotor or incorrect installation of the rotor

¢ Check the surface of the sensor rotor for damage.
Refer to “MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR?’ on page
4-49,

Is check result OK?

YES
— Go to step 4.
NO
— Replace the sensor rotor.

4. Defective rear wheel sensor or incorrect installation of the sensor

¢ Check the wheel sensor for damage and the installed condition of the sensor.
Refer to “MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR?’ on page
4-49.

Is check result OK?

YES
— Replace the hydraulic unit assembly (ABS ECU).
NO
— Repair or replace the wheel sensor.

9-269
 15 ABS

EAS20662

15_ ABS
EASa3040

TROUBLESHOOTING
ltem
Front wheel sensor (open or short circuit)

Procedure
1. Defective coupler between the front wheel sensor and the hydraulic unit assembly
¢ Check the coupler for any pins that may be pulled out.
¢ Check the locking condition of the coupler.
TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.

Is check result OK?

YES
— Go to step 2.
NO
— If there is a malfunction, repair it and connect the coupler securely.

2. Wire harness continuity

¢ Disconnect the ABS ECU coupler “1” and front wheel sensor coupler “2”.
¢ Open circuit check
Between ABS ECU coupler and front wheel sensor | white—white
coupler black—black

1
eye)L | ¥ |G Jve)
B [Uw lew
a] ferolwal Le [w F B

Is resistance 0 (?
YES
— Go to “Short circuit check”.
NO
— Replace the wire harness.

© Short circuit check

TIP
Disconnect the ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4.
Ground short circuit check “A”
oe white—ground
Between ABS ECU coupler “1” and ground black—ground

9-270
 15 ABS

Lines short circuit check “B”

ABS ECU coupler white—any other coupler terminal
black—any other coupler terminal

A B

1 1 .----- 2-22 - eee.

el Le I

uw) (evel L | ¥ | G [ve]

B [LW
AW! levolwi] L | B Ww |
=

Is resistance co Q?
YES
— Go to step 3.
NO
— Replace the wire harness.

3. Defective front wheel sensor or hydraulic unit assembly

¢ lf 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 4-35 and “ABS (Anti-lock Brake System)” on page 4-74.

9-271
 16_ABS

EAS20663

16_ABS
EASa3a285

TROUBLESHOOTING
ltem
Rear wheel sensor (open or short circuit)

Procedure
1. Defective coupler between the rear wheel sensor and the hydraulic unit assembly
¢ Check the coupler for any pins that may be pulled out.
¢ Check the locking condition of the coupler.
TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.

Is check result OK?

YES
— Go to step 2.
NO
— If there is a malfunction, repair it and connect the coupler securely.

2. Wire harness continuity

¢ Disconnect the ABS ECU coupler “1” and rear wheel sensor coupler “2”.
¢ Open circuit check
Between ABS ECU coupler and rear wheel sensor | white—white
coupler black—black

1
eye L
pan] ferolwan

Is resistance 0 0?
YES
— Go to “Short circuit check”.
NO
— Replace the wire harness.

© Short circuit check

TIP
Disconnect the ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4.
Ground short circuit check “A”
oe white—ground
Between ABS ECU coupler “1” and ground black—ground

9-272
 16_ABS

Lines short circuit check “B”

ABS ECU coupler white—any other coupler terminal
black—any other coupler terminal

A B

Ez 1 ..-----
2. eee eee -----

Is resistance co Q?
YES
— Go to step 3.
NO
— Replace the wire harness.

3. Defective rear wheel sensor or hydraulic unit assembly

¢ lf 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 “REAR WHEEL’ on page 4-43 and “ABS (Anti-lock Brake System)” on page 4-74.

9-273
 21_ABS

EAS20690

21_ABS
EASa3320

TROUBLESHOOTING
ltem
Hydraulic unit assembly (defective solenoid drive circuit)

Procedure
1. Defective hydraulic unit assembly
¢ Replace the hydraulic unit assembly.
Refer to “ABS (Anti-lock Brake System)” on page 4-74.

9-274
 31_ABS

EAS20691

31_ABS
EsASaa321

TROUBLESHOOTING
Hydraulic unit assembly (defective ABS solenoid power circuit)

Procedure
1. Blown ABS solenoid fuse
« Check the ABS solenoid fuse.
Refer to “CHECKING THE FUSES” on page 8-41.

Is check result OK?

YES
— Go to step 2.
NO
— Replace the fuse and check the wire harness.

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.
TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.

Is check result OK?

YES
— Go to step 3.
NO
— If there is a malfunction, repair it and connect the coupler securely.

3. Wire harness continuity

¢ Disconnect the ABS solenoid fuse “1” and ABS ECU coupler “2”.
* Open circuit check
Between ABS solenoid fuse holder and ABS ECU
coupler blue/white—blue/white

1 2
onLo—\ oS a een
AW) fevolwl)Le | ww [us] B

Is resistance 0 Q?
YES
— Go to “Short circuit check”.
NO
— Replace the wire harness.

e Short circuit check

9-275
 31_ABS

TIP
Disconnect the ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4.
Ground short circuit check “A”
Between ABS ECU coupler “1” and ground blue/white—ground

Lines short circuit check “B”

ABS ECU coupler blue/white—any other coupler terminal

A B

1 i
1 _—
eee
um) (Gyi8] L | ¥ | G [rve] B [Li] lew ! jew] L | ¥ | G |p| 6 Lav} jen) |]
ol B | w] wus} | 6| | AS Geotwele
!
Te wwe] [8] | :

Is resistance -o 0)?
YES
— Go to step 4.
NO
— Replace the wire harness.

4. Defective hydraulic unit assembly

* Replace the hydraulic unit assembly.
Refer to “ABS (Anti-lock Brake System)” on page 4-74.

9-276
 33_ABS

EASeoea2

33_ABS
EASaaa22

TROUBLESHOOTING
ltem
Hydraulic unit assembly (abnormal ABS motor power supply)

Procedure
1. Blown ABS motor fuse
e Check the ABS motor fuse.
Refer to “CHECKING THE FUSES” on page 8-41.

Is check result OK?

YES
— Go to step 2.
NO
— Replace the fuse and check the wire harness.

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.
TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.

Is check result OK?

YES
— Go to step 3.
NO
— If there is a malfunction, repair it and connect the coupler securely.

3. Wire harness continuity

¢ Disconnect the starter relay coupler (ABS motor fuse) “1” and ABS ECU coupler “2”.
* Open circuit check
Wee eeu date 7 coupler (ABS motor fuse) and red/white—red/white

| uw) G8, L | ¥ |G [re] e Lav Jan

olin AW) (aolwal
LB [ww ]us] | 8

Is resistance 0 (2?
YES
— Go to “Short circuit check”.
NO
— Replace the wire harness.

e Short circuit check

9-277
 33_ABS

TIP
Disconnect the ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4.
Ground short circuit check “A”
Between ABS ECU coupler “1” and ground red/white—ground

Lines short circuit check “B”

ABS ECU coupler red/white—any other coupler terminal

A B

1 We ee eee :
Law] vel |v [ [ave] 6 [uw favw : fewalv | ¥ oe fe !
(aw) fevolwal L [8 [ww ]us] | B | || {ave} fevowal
c Tes [w[w Jus] [8 } |

Is resistance c- Q?
YES
— Go to step 4.
NO
— Replace the wire harness.

4. Defective hydraulic unit assembly

* Replace the hydraulic unit assembly.
Refer to “ABS (Anti-lock Brake System)” on page 4-74.

9-278
 34 _ABS

EAS20693

34_ABS
EASa3323

TROUBLESHOOTING
ltem
Hydraulic unit assembly (short circuit in ABS motor power supply circuit)

Procedure
1. Defective hydraulic unit assembly
¢ Replace the hydraulic unit assembly.
Refer to “ABS (Anti-lock Brake System)” on page 4-74.

9-279
 41_ABS

EAS20694

41_ABS
EsSaaa

TROUBLESHOOTING
ltem
Front wheel ABS (intermittent wheel speed pulses or incorrect depressurization)

Procedure
1. Incorrect installation of the front wheel sensor
¢ Check the components for looseness, distortion, and bends.
Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR’ on page
4-40.
Is check result OK?
YES
— Go to step 2.
NO
— Repair or replace the defective part.

2. Incorrect rotation of the front wheel

¢ Check that there is no brake disc drag on the wheel and make sure that it rotates smoothly.
Refer to “CHECKING THE FRONT WHEEL” on page 4-38 and “CHECKING THE FRONT BRAKE
DISCS” on page 4-57.

Is check result OK?

YES
— Go to step 3.
NO
— Repair or replace the defective part.

3. Front brake dragging

¢ Check that the brake fluid pressure is correctly transmitted to the brake caliper when the brake lever
is operated and that the pressure decreases when the lever is released.
Refer to “CHECKING THE FRONT BRAKE DISCS’ on page 4-57.

Is check result OK?

YES
— Go to step 4.
NO
— Repair or replace the defective part.

4. Defective hydraulic unit assembly

¢ Replace the hydraulic unit assembly.
Refer to “ABS (Anti-lock Brake System)” on page 4-74.

9-280
 42 ABS

EAS20695

42 ABS
EASsaaa24

TROUBLESHOOTING
ltem
Rear wheel ABS (intermittent wheel speed pulses or incorrect depressurization)

Procedure
1. Incorrect installation of the rear wheel sensor
¢ Check the components for looseness, distortion, and bends.
Refer to “MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR’ on page
4-49.
Is check result OK?
YES
— Go to step 2.
NO
— Repair or replace the defective part.

2. Incorrect rotation of the rear wheel

¢ Check that there is no brake disc drag on the wheel and make sure that it rotates smoothly.
Refer to “CHECKING THE REAR WHEEL’ on page 4-47 and “CHECKING THE REAR BRAKE
DISC” on page 4-68.

Is check result OK?

YES
— Go to step 3.
NO
— Repair or replace the defective part.

3. Rear brake dragging

¢ Check that the brake fluid pressure is correctly transmitted to the brake caliper when the brake pedal
is operated and that the pressure decreases when the pedal is released.
Refer to “CHECKING THE REAR BRAKE DISC” on page 4-68.

Is check result OK?

YES
— Go to step 4.
NO
— Repair or replace the defective part.

4. Defective hydraulic unit assembly

¢ Replace the hydraulic unit assembly.
Refer to “ABS (Anti-lock Brake System)” on page 4-74.

9-281
 43,45 ABS

EAS20696

43, 45_ ABS

EAS33390

TROUBLESHOOTING
ltem
Front wheel sensor (missing pulses)

Procedure
TIP
After the DTC 45 is recorded, DTC 43 will be recorded if a certain speed and time are exceeded.
1. Foreign material adhered around the front wheel sensor
¢ Check the surface of the sensor rotor and wheel sensor for foreign material, such as metal particles.

Is check result OK?

YES
— Go to step 2.
NO
— Clean the sensor rotor and wheel sensor.

2. Incorrect installation of the front wheel

¢ Check the components for looseness, distortion, and bends.
Refer to “CHECKING THE FRONT WHEEL’ on page 4-38.

Is check result OK?

YES
— Go to step 3.
NO
— Replace the wheel axle, tire, front wheel, wheel bearings or oil seals.

3. Defective sensor rotor or incorrect installation of the rotor

¢ Check the surface of the sensor rotor for damage.
Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR’ on page
4-40.
Is check result OK?
YES
— Go to step 4.
NO
— Replace the sensor rotor.

4. Defective front wheel sensor or incorrect installation of the sensor

¢ Check the wheel sensor for damage and the installed condition of the sensor.
Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR’ on page
4-40.
Is check result OK?
YES
— Replace the hydraulic unit assembly (ABS ECU).
NO
— Repair or replace the wheel sensor.

9-282
 44,46 _ABS

EAS20697

44, 46_ABS
EASaaq25

TROUBLESHOOTING
ltem
Rear wheel sensor (missing pulses)

Procedure
TIP
After the DTC 46 is recorded, DTC 44 will be recorded if a certain speed and time are exceeded.
1. Foreign material adhered around the rear wheel sensor
¢ Check the surface of the sensor rotor and wheel sensor for foreign material, such as metal particles.

Is check result OK?

YES
— Go to step 2.
NO
— Clean the sensor rotor and wheel sensor.

2. Incorrect installation of the rear wheel

¢ Check the components for looseness, distortion, and bends.
Refer to “CHECKING THE REAR WHEEL” on page 4-47.

Is check result OK?

YES
— Go to step 3.
NO
— Replace the wheel axle, tire, rear wheel, wheel bearings or oil seals.

3. Defective sensor rotor or incorrect installation of the rotor

¢ Check the surface of the sensor rotor for damage.
Refer to “MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR’ on page
4-49.
Is check result OK?
YES
— Go to step 4.
NO
— Replace the sensor rotor.

4. Defective rear wheel sensor or incorrect installation of the sensor

¢ Check the wheel sensor for damage and the installed condition of the sensor.
Refer to “MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR’ on page
4-49.
Is check result OK?
YES
— Replace the hydraulic unit assembly (ABS ECU).
NO
— Repair or replace the wheel sensor.

9-283
 51_ABS

EAS20698

51_ABS
EASaa326

TROUBLESHOOTING
ltem
Vehicle system power supply (voltage of ABS ECU power supply is high)

Procedure
1. Defective battery
¢ Recharge or replace the battery, and check again.
Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-42.
2. Disconnected battery terminal
¢ Check the connection.

is check result OK?

YES
— Go to step 3.
NO
— Replace or reconnect the terminal.

3. Defective charging system

¢ Check the charging system.
Refer to “CHARGING SYSTEM” on page 8-12.

Is check result OK?

YES
— Replace the hydraulic unit assembly (ABS ECU).
NO
— Confirm the cause of the problem and repair it, and check again.

9-284
 53_ABS

EAS20699

53_ABS
EASaaa27

TROUBLESHOOTING
ltem
Vehicle system power supply (voltage of ABS ECU power supply is low)

Procedure
1. Defective battery
¢ Recharge or replace the battery, and check again.
Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-42.
2. 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.
TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.

Is check result OK?

YES
— Go to step 3.
NO
— If there is a malfunction, repair it and connect the coupler securely.

3. Wire harness continuity

¢ Disconnect the ABS ECU fuse “1” and ABS ECU coupler “2”.
¢ Open circuit check
Between ABS ECU fuse holder and ABS ECU cou-
pler red/black—red/black

= @
1

2
eye) Lv |G aE Ty
aI GOW} L |B] ww {us iB

Is resistance 0 (2?
YES
— Go to “Short circuit check”.
NO
— Replace the wire harness.

¢ Short circuit check

TIP
Disconnect the ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4.
Ground short circuit check “A”
Between ABS ECU coupler “1” and ground red/black—ground

9-285
 53_ABS

Lines short circuit check “B”

ABS ECU coupler red/black—any other coupler terminal

A B

1 We eee eee eeeeee

oes | Sess .
i ere ! leohw] Le [rw [ue] ,

Is resistance - (?
YES
— Go to step 4.
NO
— Replace the wire harness.

4. Defective charging system

¢ Check the charging system.
Refer to “CHARGING SYSTEM” on page 8-12.

Is check result OK?

YES
— Replace the hydraulic unit assembly (ABS ECU).
NO
— Confirm the cause of the problem and repair it, and check again.

9-286
 55 ABS

EAS2o700

55 ABS
EASaa328

TROUBLESHOOTING
ltem
Hydraulic unit assembly (defective ABS ECU)

Procedure
1. Defective hydraulic unit assembly
¢ Replace the hydraulic unit assembly.
Refer to “ABS (Anti-lock Brake System)” on page 4-74.

9-287
 56_ ABS

EAS2o701

56_ABS
EASa3329

TROUBLESHOOTING
ltem
Hydraulic unit assembly (abnormal internal circuit)

Procedure
1. Defective hydraulic unit assembly
¢ Replace the hydraulic unit assembly.
Refer to “ABS (Anti-lock Brake System)” on page 4-74.

9-288
 57_ABS

EAS20666

57_ABS
EASaa292

TROUBLESHOOTING
ltem
Vehicle CAN communication line or power source of vehicle system

Procedure
1. Wire harness continuity.
¢ Disconnect the ECU coupler “1”, joint coupler “2” and ABS ECU coupler “3”.
¢ Open circuit check
blue/white—blue/white
Between ECU coupler and joint coupler
blue/black—blue/black
blue/white—blue/white
Between the joint coupler and ABS ECU coupler
blue/black—blue/black

FC cc —]e—_ oS
iLIB PAW) F V|L UR
Uw BY ay Bi <a.
Ly Gy >< aM G Gy

Eauoye

“, Joint coupler for YZF-R1

“*. Joint coupler for YZF-R1M

Is resistance 0 (2?
YES
— Go to “Short circuit check”
NO
— Replace the wire harness.

© Short circuit check

TIP
Disconnect the ECU and ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3 and “PARTS CONNECTED TO THE ABS
ECU” on page 9-4.
Ground short circuit check “A”
blue/white—ground
Between ECU coupler “1” and ground
blue/black—ground

9-289
 57_ABS

blue/white—ground
Between ABS ECU coupler “3” and ground blue/black—ground

Lines short circuit check “B”

blue/white—any other coupler terminal
ECU coupler blue/black—any other coupler terminal
blue/white—any other coupler terminal
Joint coupler 2 blue/black—any other coupler terminal
blue/white—any other coupler terminal
ABS ECU coupler blue/black—any other coupler terminal

3
vw} feyel eT y [
_—
[evel [uv fan
So
ie
Tf (uw) Gwe ['¥ [os Jrvel e [uw [aw]
cae Gaal]

“, Joint coupler for YZF-R1

“*. Joint coupler for YZF-R1M

Is resistance c- Q?
YES
— Go to step 2.
NO
— Replace the wire harness.

2. Defective battery
¢ Recharge or replace the battery, and check again.
Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-42.
3. 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.
TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.

Is check result OK?

YES

9-290
 57_ABS

— Go to step 4.
NO
— If there is a malfunction, repair it and connect the coupler securely.
4. Wire harness continuity
¢ Disconnect the ABS ECU fuse “1”, ABS solenoid fuse “2” and ABS ECU coupler “3”.
e Open circuit check
annual ABS ECU fuse holder and ABS ECU cou- fediblaek-redieack

coupler ABS solenoid fuse holder and ABS ECU blue‘white-biuefwhite

—\_C}+-—_ (Q)

9 3

ono (Q) al
el [rTres bf
| bw GiOWiL) L |B |W) WILE B

Is resistance 0 (2?
YES
— Go to “Short circuit check”
NO
— Replace the wire harness.

© Short circuit check

TIP
Disconnect the ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4.
Ground short circuit check “A”
red/black—ground
Between ABS ECU coupler “1” and ground blue/white—ground

Lines short circuit check “B”

red/black—any other coupler terminal
ABS ECU coupler blue/white—any other coupler terminal

A B

I
rs | i 1

uw) (evel L | ¥ [e [ae] 6 [a [aw ! yale [¥ [|e]

6 bo fam) |
ape WiLL) BO wee] |B i wolwal Le [1 wus B :
I
i i

Is resistance co ()?
YES

9-291
 57_ABS

— Go to step 5.
NO
— Replace the wire harness.
5. Defective charging system
¢ Check the charging system.
Refer to “CHARGING SYSTEM?” on page 8-12.

Is resistance « Q?
YES
— Replace the hydraulic unit assembly (ABS ECU).
NO
— Confirm the cause of the problem and repair it, and check again.

9-292
 62_ABS

EAS2o7r02

62_ABS
EASa3333

TROUBLESHOOTING
ltem
Power supply voltage failure in pressure sensor

Procedure
1. Defective hydraulic unit assembly
¢ Replace the hydraulic unit assembly.
Refer to “ABS (Anti-lock Brake System)” on page 4-74.

9-293
 68 ABS

EAS20705

68_ABS
EASa33396

TROUBLESHOOTING
ltem
Defective hydraulic unit assembly (defective front pressure sensor)

Procedure
1. Defective front brake line
¢ Check the front brake line.

Is check result OK?

YES
— Go to step 2.
NO
— If there is bending or blocking, replace the front brake line.

2. Defective hydraulic unit assembly

¢ Replace the hydraulic unit assembly.
Refer to “ABS (Anti-lock Brake System)” on page 4-74.

9-294
 89 ABS

EAS20669

89_ABS
EASaa299

TROUBLESHOOTING
ltem
CAN communication (between meter assembly and hydraulic unit assembly)

Procedure
1. Defective coupler between the meter assembly and the hydraulic unit assembly
¢ Check the coupler for any pins that may be pulled out.
¢ Check the locking condition of the coupler.
TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.

Is check result OK?

YES
— Go to step 2.
NO
— If there is a malfunction, repair it and connect the coupler securely.

2. Wire harness continuity.

¢ Disconnect the meter assembly coupler “1”, joint coupler “2” and ABS ECU coupler “3”.
¢ Open circuit check
blue/white—blue/white
Between meter assembly coupler and joint coupler
blue/black—blue/black
blue/white—blue/white
Between joint coupler and ABS ECU coupler
blue/black—blue/black

1
Sieeeenam
laN| rh /Bf8] Dg | Ch | WL |WNY|BnY] Lg PLAN)
LIB
igRiesuNeicr] G |arehwe)welw [>< Jaeiy

Q)
{¢ @)
Q—
{ry\

2 ww ew —_ J
C UwjUW|LVIUWUWIUVgLie|UB] Ue] Ue | UB] Le _ z elt |v 1a nel & =|
_— — eS ferofwal c Te [w] wus] | 8 |
7S ae a 1

—\pnieleislslslepe-aos—
— s ==
(Q)

“, Joint coupler for YZF-R1

“*, Joint coupler for YZF-R1M

Is resistance 0 (2?
YES
— Go to “Short circuit check”.
NO
— Replace the wire harness.

9-295
 89 ABS

e Short circuit check

TIP
Disconnect the ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4.
Ground short circuit check “A”
aan blue/white—ground
Between meter assembly coupler “1” and ground blue/black—around

Between ABS ECU coupler eye

“3” and ground blue/white—ground
blue/black—around

Lines short circuit check “B”

blue/white—any other coupler terminal
Meter assembly coupler blue/black—any other coupler terminal
blue/white—any other coupler terminal
Joint coupler “2 blue/black—any other coupler terminal
blue/white—any other coupler terminal
ABS ECU coupler blue/black—any other coupler terminal

1 Dee eee ee ece eee eee e ;

_ ff 8 he | _ ff oh :
Biv ele wehun Lg
Ce : deste Lg allie cn )
Lamm meee eee eee eee eee eee ee ee ee

Ln) bevel [¥ [evel 6 [Lm fa ! saab |

L [8 [w]w ue] |
am) [ola] ! fcojway L |e |W] w]ue !

“, Joint coupler for YZF-R1

“*. Joint coupler for YZF-R1M

Is resistance co Q?
YES
— Go to step 3.
NO
— Replace the wire harness.

9-296
 89 ABS

3. Defective meter assembly

¢« Replace the meter assembly, and check again.
4. Defective hydraulic unit assembly
¢ Replace the hydraulic unit assembly.

9-297
 90_ABS

EAS20670

90_ABS
Es4S33200

TROUBLESHOOTING
ltem
CAN communication (between ECU and hydraulic unit assembly)

Procedure
1. Defective coupler between the ECU and the hydraulic unit assembly
¢ Check the coupler for any pins that may be pulled out.
¢ Check the locking condition of the coupler.
TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.

Is check result OK?

YES
— Go to step 2.
NO
— If there is a malfunction, repair it and connect the coupler securely.

2. Wire harness continuity.

¢ Disconnect the ECU coupler “1”, joint coupler “2” and ABS ECU coupler “3”.
¢ Open circuit check
blue/white—blue/white
Between ECU coupler and joint coupler blue/black—blue/black

blue/white—blue/white
Between joint coupler and ABS ECU coupler blue/black—blue/black

eee) a
pw P<] vo (UR Gy|
lL BY ay Baw) Tan] w WIB
Gh G

——+
ela [wwe

“, Joint coupler for YZF-R1

“*. Joint coupler for YZF-R1M

Is resistance 0 (2?
YES
— Go to “Short circuit check”.

9-298
 90_ABS

NO
— Replace the wire harness.
e Short circuit check
TIP
Disconnect the ECU and ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU’ on page 9-3 and “PARTS CONNECTED TO THE ABS
ECU” on page 9-4.
Ground short circuit check “A”

Between ECU coupler “1” and ground blue/black-ground

Between ABS ECU coupler any “3” and ground blue/white—ground

blue/black—ground

Lines short circuit check “B”

blue/white—any other coupler terminal
ECU coupler blue/black—any other coupler terminal
blue/white—any other coupler terminal
Joint coupler °2 blue/black—any other coupler terminal
blue/white—any other coupler terminal
ABS ECU coupler blue/black—any other coupler terminal

ene es ces cet cee Pe es eee ce ce eee ce ef

) iz Evel | ¥ |G [rvs] B [uw =| :

eohwe]L |B |w]w |u| | 8

“, Joint coupler for YZF-R1

“*. Joint coupler for YZF-R1M

Is resistance co ()?
YES
— Go to step 3.
NO
— Replace the wire harness.

9-299
 90_ABS

3. Defective ECU
¢ Replace the ECU, and check again.
4. Defective hydraulic unit assembly
¢ Replace the hydraulic unit assembly.

9-300
 91_ABS

EAS20671

91_ABS
Essaaan

TROUBLESHOOTING
ltem
CAN communication (between IMU and hydraulic unit assembly)

Procedure
1. Defective coupler between the IMU and the hydraulic unit assembly
¢ Check the coupler for any pins that may be pulled out.
¢ Check the locking condition of the coupler.
TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.

Is check result OK?

YES
— Go to step 2.
NO
— If there is a malfunction, repair it and connect the coupler securely.

2. Wire harness continuity.

¢ Disconnect the IMU coupler “1”, joint coupler “2” and ABS ECU coupler “3”.
¢ Open circuit check
blue/white—blue/white
Between IMU coupler and joint coupler blue/black—blue/black

blue/white—blue/white
Between joint coupler and ABS ECU coupler blue/black—blue/black

“, Joint coupler for YZF-R1

“*, Joint coupler for YZF-R1M

Is resistance 0 (2?
YES
— Go to “Short circuit check”.
NO
— Replace the wire harness.

9-301
 91_ABS

© Short circuit check

TIP
Disconnect the ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4.
Ground short circuit check “A”

Between IMU coupler

a4n“1” and ground blue/white—ground
blue/black—around

Between ABS ECU coupler eye

“3” and ground blue/white—ground
blue/black—around

Lines short circuit check “B”

blue/white—any other coupler terminal
IMU coupler blue/black—any other coupler terminal
blue/white—any other coupler terminal
Joint coupler “2 blue/black—any other coupler terminal
blue/white—any other coupler terminal
ABS ECU coupler blue/black—any other coupler terminal

in| fel Ty [o [evel

e [Low fav
}AW levolwn! L |B [Ww] wus B

“, Joint coupler for YZF-R1

“*, Joint coupler for YZF-R1M

Is resistance - (?
YES
— Go to step 3.
NO
— Replace the wire harness.

3. Defective IMU
* Replace the IMU, and check again.

9-302
 91_ABS

4. Defective hydraulic unit assembly

¢ Replace the hydraulic unit assembly.

9-303
 91_ABS

9-304
 EAS20091
57. Primary injector #3 [Link] fan motor (left)
WIRING DIAGRAM 58. Primary injector #4 [Link] fuse (for YZF-R1M)
YZFR1L/YZFR1LC/YZFR1ML/ 59. Secondary injector #1 [Link] (Suspension Control
YZFR1MLC 2020 60. Secondary injector #2 Unit) (for ¥YZF-R1M)
AC magneto 61. Secondary injector #3 [Link] fork stepping motor (left)
=

Rectifier/regulator 62. Secondary injector #4 (for YZF-R1M)

PwOhN

Main switch 63. Intake funnel servo motor [Link] fork stepping motor
Main fuse 64. Throttle servo motor (right) (for YZF-R1M)
Radiator fan motor relay 65. Steering damper solenoid [Link] shock absorber assem-
ABS solenoid fuse 66. Hydraulic unit assembly (ABS bly stepping motor (compres-
CONDO

Fuel injection system fuse ECU) sion damping) (for YZF-R1M)

Electronic throttle valve fuse 67. Front wheel sensor 11/[Link] shock absorber assem-
. Backup fuse 68. Rear wheel sensor bly stepping motor (rebound
10. Sub radiator fan motor fuse 69. Throttle position sensor damping) (for YZF-R1M)
11. Radiator fan motor fuse 70. IMU (Inertial Measurement [Link] damper solenoid
12. Ignition fuse Unit) (OPTION) (for YZF-R1M)
13. Signaling system fuse /[Link] assembly *. Joint coupler for YZF-R1
14. ABS ECU fuse /2. Fuel level warning light ** Joint coupler for YZF-R1M
15. Hazard lighting fuse 73. MIL (Malfunction indicator light) A. Wire harness
16. Headlight fuse 74. Neutral indicator light B. Sub-wire harness (Intake sole-
17. Auxiliary fuse 75. Shift indicator light noid)
18. Engine ground 76. Multi-function meter C. Sub-wire hamess (Coolant
19. Battery 77. Stability control indicator light temperature sensor)
20. Starter relay 78. Oil pressure and coolant tem- D. Sub-wire harness (Intake air
[Link] motor fuse perature warning light temperature sensor)
22. Starter motor 79. Auxiliary system warning light E. Sub-wire harness (CCU (Com-
23. Joint coupler 80. Turn signal indicator light (right) munication Control Unit)) (for
24. Front brake light switch 81. Turn signal indicator light (left) YZF-R1M)
25. Handlebar switch (right) 82. Meter light F. Sub-wire harness (Oil pressure
26. Wheel switch [Link] warning light switch)
[Link]/engine stop switch 84. High beam indicator light G. Sub-wire harness (SCU, steer-
28. Accelerator position sensor 85. YDT coupler ing damper solenoid, sub-wire
29. Relay unit [Link] (Communication Control harness) (for YZF-R1M)
30. Starting circuit cut-off relay Unit) (for YZF-R1M) H. Sub-wire harness (front fork
31. Fuel pump relay [Link] unit (for YZF-R1M) stepping motor) (for YZF-R1M)
32. Neutral switch 88. Oil pressure switch |. Sub-wire hamess (Steering
33. Sidestand switch 89. Handlebar switch (left) damper solenoid), (OPTION)
34. Fuel sender 90. Mode switch (for YZF-R1M)
35. Fuel pump [Link]/LAP switch
36. Intake solenoid 92. Dimmer switch
37. Gear position sensor 93. Horn switch
38.0.5 sensor 1 (left side) 94. Tum signal switch
39.O. sensor 2 (right side) 95. Hazard switch
96. Horn
40. Shift sensor
97. Clutch switch
41.\Intake air pressure sensor
42. Atmospheric pressure sensor
98. Rear turn signal light (right)
43. Cylinder identification sensor 99. Rear turn signal light (left)
[Link] tum signal/position light
[Link] servo motor
45. Crankshaft position sensor (right)
[Link] tum signal/position light
46. Coolant temperature sensor
47.\ntake air temperature sensor
(left)
[Link] control unit
48. ECU (Engine Control Unit)
49. Spark plug [Link] (high beam)
50. Ignition coil #1
[Link] (low beam)
[Link] brake light switch
51. Ignition coil #2
52. Ignition coil #3
[Link]/brake light
[Link] plate light
53. Ignition coil #4
[Link] light
54. Air induction system solenoid
[Link] DC connector
55. Primary injector #1
[Link] radiator fan motor (right)
56. Primary injector #2
EAS30613
Y/R Yellow/Red
COLOR CODE
B Black
Br Brown
Ch Chocolate
Dg Dark green
DI Dark blue
G Green
Gy Gray
L Blue
Lg Light green
O Orange
P Pink
R Red
Sb Sky blue
V Violet
Ww White
Y Yellow
B/G Black/Green
B/L Black/Blue
B/R Black/Red
B/W Black/White
B/Y Black/Yellow
Br/B Brown/Black
Br/L Brown/Blue
Br/R Brown/Red
Br/W Brown/White
Br/Y Brown/Yellow
G/B Green/Black
G/L Green/Blue
G/O Green/Orange
G/R Green/Red
G/W Green/White
G/Y Green/Yellow
Gy/B Gray/Black
Gy/G Gray/Green
Gy/R Gray/Red
Gy/Y Gray/Yellow
L/B Blue/Black
L/IG Blue/Green
L/R Blue/Red
L/W Blue/White
L/Y Blue/Yellow
Lg/R Light green/Red
O/B Orange/Black
O/G Orange/Green
P/B Pink/Black
P/L Pink/Blue
P/W Pink/White
R/B Red/Black
R/G Red/Green
R/L Red/Blue
R/W Red/White
R/Y Red/Yellow
Sb/W Sky blue/White
W/B White/Black
WI/G White/Green
W/L White/Blue
W/R White/Red
WI/Y White/Yellow
Y/B Yellow/Black
Y/G Yellow/Green
Y/L Yellow/Blue
YZFR1IL/YZFR1LC/YZFR1ML/YZFR1MLC 2020 WIRING DIAGRAM

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