2022 Yamaha MT10-SP Workshop Manual

2022
SERVICE MANUAL
MT-10
MT-10SP
MT10N
MT10NC
MT10SPN
MT10SPNC
LIT-11616-35-64 B5Y-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, Y0A-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 in-
tended 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
• * 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.
EAS30001
IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential personal
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

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.
EAS20002
MT10N/MT10NC/MT10SPN/MT10SPNC
SERVICE MANUAL
©2022 by Yamaha Motor Corporation, U.S.A.
First edition, January 2022
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-11616-35-64
EAS20004
HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive ex-
planations of all installation, removal, disassembly, assembly, repair and check procedures are laid out
with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc. This step explains removal and disassembly procedure only. For installation
and assembly procedure, reverse the steps.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
1
2
4
5
6 7
G088877
EAS20005
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
Serviceable with engine mounted Gear oil

G
Filling fluid Molybdenum disulfide oil

M
Lubricant Brake fluid

BF
Special tool B Wheel bearing grease
Tightening torque LS Lithium-soap-based grease

T.
R.
Wear limit, clearance M Molybdenum disulfide grease
Engine speed S Silicone grease
Electrical data Apply locking agent (LOCTITE®).

LT
Engine oil New Replace the part with a new one.

E
TABLE OF CONTENTS
GENERAL INFORMATION 1
SPECIFICATIONS 2
PERIODIC CHECKS AND
ADJUSTMENTS 3
CHASSIS 4
ENGINE 5
COOLING SYSTEM 6
FUEL SYSTEM 7
ELECTRICAL SYSTEM 8
SELF DIAGNOSTIC 9
GENERAL INFORMATION
IDENTIFICATION ............................................................................................ 1-1

VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL.......................................................................................... 1-1
FEATURES...................................................................................................... 1-2
1
GLOSSARY............................................................................................... 1-2
DISPLAY ...................................................................................................1-2
MENU SCREEN ........................................................................................1-8
BASIC SERVICE INFORMATION.................................................................1-17

ELECTRICAL SYSTEM...........................................................................1-17
SPECIAL TOOLS .......................................................................................... 1-18

IDENTIFICATION
EAS20007
IDENTIFICATION
EAS30002
VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped
into the right side of the steering head pipe.
EAS30003
MODEL LABEL
The model label “1” is affixed to the frame under
the passenger seat. This information will be
needed to order spare parts.
1-1
FEATURES
EAS20008
TRACK MODE
FEATURES 1 2 3
EAS31706 QS LIF 1 EBM 1 12:00
GLOSSARY 1000 r/min
ABS - Anti-lock Brake System GEAR

9
ABS ECU - Anti-lock Brake System Electronic
12 34 12
Control Unit
BC - Brake Control
EBM - Engine Brake Management
8
LAP 09
56
MODE-A PWR
1234.5
MPH
1
TRIP-1
TCS 3 SCS 1
mile
A-1
N OFF
4
5
ECU - Engine Control Unit 7 6

ERS - Electronic Racing Suspension 1. YRC items QS/LIF/BC/EBM
IMU - Inertial Measurement Unit 2. Lap timer
LIF - Lift Control System 3. Clock
PWR - Power delivery mode 4. Transmission gear display
QS - Quick Shift 5. Information display
SC - Stability Control 6. Grip warmer indicator (if equipped)
SCS - Slide Control System 7. YRC items MODE/PWR/TCS/SCS/ERS
SCU - Suspension Control Unit (MT10SPN/MT10SPNC)
TCS - Traction Control System 8. Speedometer
YRC - Yamaha Ride Control 9. Tachometer
YVSL - Yamaha variable speed limiter EWA18210
EAS31707
WARNING
DISPLAY Stop the vehicle before making any setting
The display has two different main screen dis- changes. Changing settings while riding can
play modes, STREET MODE and TRACK distract the operator and increase the risk of
MODE. Most of the functions are viewable in ei- an accident.
ther mode, but the layout differs slightly. The fol-
lowing items can be found on the display. TIP
• This model uses a thin-film-transistor liquid-
crystal display (TFT LCD) for good contrast
STREET MODE
and readability in various lighting conditions.
1 2 3 However, due to the nature of this technology,
QS LIF 1 EBM 1 12:00 it is normal for a small number of pixels to be in-
1000 r/min
4 active.
10 • The display units can be switched between ki-
5
MPH
lometers/miles and celsius/ fahrenheit.
9 TRIP-1
TRIP-2
MODE-A PWR
9990.0 mile
9990.0 mile
1 TCS 3
1
SCS
N2
1 A-1 OFF
6
Speedometer
The speedometer shows the vehicle’s traveling
8 7
speed.
1. YRC items QS/LIF/BC/EBM
2. Speedometer Tachometer
3. Clock The tachometer shows the engine speed, as
4. Revolution peak hold indicator measured by the rotational velocity of the crank-
5. Fuel meter shaft, in revolutions per minute (r/min).
6. Transmission gear display
TIP
7. Grip warmer indicator (if equipped)
8. YRC items MODE/PWR/TCS/SCS/ERS • In TRACK MODE, the tachometer starts at
(MT10SPN/MT10SPNC) 5000 r/min.
9. Information display • In STREET MODE, the tachometer can be col-
10. Tachometer or-adjusted and has a revolution peak hold in-
dicator which can be turned on or off.
1-2
FEATURES
ECA19660
NOTICE
1 2
Do not operate the engine in the tachometer
red zone. GEAR
Fuel meter
The fuel meter indicates the amount of fuel in the
fuel tank. The display segments of the fuel meter
N LIM
MPH
disappear from “F” (full) towards “E” (empty) as

the fuel level decreases.
1. Transmission gear display
When the last segment starts flashing, or the fuel
2. YVSL display
level warning icon comes on, refuel as soon as
possible.
Revolution peak hold indicator
TIP This small bar momentarily appears within the
• If all the fuel meter display segments flash re- tachometer to mark the most recent peak engine
peatedly, have a Yamaha dealer check the re- speed.
lated circuits.
• When the YVSL system is operating in Warning icons
STREET MODE, the fuel meter is replaced by
the YVSL display.
1 2 3 4 5 6
1 2
Er:00
12 r
1000 r/min
LIM
MPH
1. SCU trouble warning “ ” (MT10SPN/

MT10SPNC)
2. Auxiliary system warning “ ”
1. Fuel meter 3. Coolant temperature warning “ ”
2. YVSL display 4. Oil pressure warning “ ”
5. Fuel level warning “ ”
Clock 6. Error mode warning “Err”
The clock uses a 12-hour time system.
When an error is detected, the following error-re-
Transmission gear display lated warning icons will then be viewable.
This shows which gear the transmission is in.
This model has 6 gears and a neutral position. SCU trouble warning (MT10SPN/MT10SPNC)
The neutral position is indicated by the neutral This icon appears if a problem is detected in the
indicator light “ ” and by the transmission gear front or rear suspension.
display “ ”.
Auxiliary system warning
TIP
This icon appears if a problem is detected in a
When the YVSL system is operating in TRACK
non-engine-related system.
MODE, the transmission gear display is re-
placed by the YVSL display.
1-3
FEATURES
Coolant temperature warning Information display

This icon appears when the coolant temperature The information display items are:
is high. Stop the vehicle and turn off the engine. A.TEMP: air temperature
Allow the engine to cool. C.TEMP: coolant temperature
ECA10022
TRIP-1: tripmeter 1
NOTICE TRIP-2: tripmeter 2
Do not continue to operate the engine if it is F-TRIP: fuel reserve tripmeter
overheating. ODO: odometer
“ ”: cruise control speed setting
Oil pressure warning FUEL AVG: average fuel consumption
This icon appears when the engine oil pressure CRNT FUEL: current fuel consumption
is low. When the main switch is first turned to FUEL CON: the amount of fuel consumed
ON, engine oil pressure has yet to build, so this TIP
icon will come on and stay on until the engine TRIP-1, TRIP-2, F-TRIP, FUEL CON, and FUEL
has been started. AVG items can be individually reset.
TIP
The display items are grouped into 4 customiz-
If a malfunction is detected, the oil pressure able pairs (DISPLAY 1-4). In TRACK MODE
warning icon will flash repeatedly. only a single item can be displayed at a time.
ECA26410 See “Display Setting”
NOTICE Rotating the wheel switch above cycles the DIS-
Do not continue to operate the engine if the PLAY groups in order:
oil pressure is low. STREET MODE: → DISPLAY-1 → DISPLAY-2
→ DISPLAY-3 → DISPLAY-4 → Grip warmer
function →
Fuel level warning
TRACK MODE: → FASTEST → AVERAGE →
This icon comes on when approximately 4.0 L
Grip warmer function → DISPLAY-1 → DIS-
(1.06 US gal, 0.88 Imp.gal) of fuel remains in the
PLAY-2 → DISPLAY-3 → DISPLAY-4 →
tank.
TIP
Error mode warning “Err” The grip warmer function will only be displayed if
When an internal error occurs (e.g., communica- equipped on the vehicle. See “Grip warmer”
tion with a system controller has been cut off),
the error mode warning will appear as follows. Air temperature:
“Err” and “ ” indicates an ECU error.
“Err” only indicates an ABS ECU error.
TIP 1 2
Depending on the nature of the error, the display
A. TEMP
may not function properly and YRC settings may A. TEMP 70 F 70 F
be impossible to change. Additionally, ABS may
not function properly. Use extra care when brak-
ing and check the vehicle immediately.
1. Display in STREET MODE

2. Display in TRACK MODE
The air temperature is displayed from –9 °C (16
°F) to 50 °C (122 °F) in 1 °C (1 °F) increments.
The temperature displayed may vary from the
actual ambient temperature.
1-4
FEATURES
TIP Fuel reserve tripmeter:

• “– –” will be displayed if the detected tempera-
ture is lower.
• “– –” will be displayed if the detected tempera- 1 2
ture is higher.
F-TRIP
F-TRIP 1.3 mile 4.5 mile
Coolant temperature:
1 2
C. TEMP
C. TEMP Lo F Lo F
When the fuel tank reserve level has been
reached, F-TRIP appears automatically and be-
gins recording distance traveled from that point.
After refueling and traveling some distance, F-
TRIP will automatically disappear.
2. Display in TRACK MODE TIP
The MENU cannot be accessed while F-TRIP is
The coolant temperature is displayed from 41 °C
displayed. To access the MENU while F-TRIP is
(106 °F) to 124 °C (255 °F) in 1 °C (1 °F) incre-
active, first switch the information display to an-
ments.
other item using the wheel switch.
TIP
• If the vehicle coolant temperature is below 41
°C (106 °F) the coolant temperature display will Odometer:
read “Lo”
• If the vehicle coolant temperature is above 124
°C (255 °F) the coolant temperature display will 1 2
read “Hi”
ODO 123456 mile 123456 mile
Tripmeters:
1 2
TRIP-1
TRIP-1 3330.0mile 1234.5mile
TRIP-2 The odometer shows the total distance traveled

TRIP-2 6660.0mile 1234.5mile by the vehicle.
TIP
1 2 ODO will lock at 999999 and cannot be reset.
TRIP-1 and TRIP-2 show the distance traveled
since they were last set to zero.
TIP
TRIP-1 and TRIP-2 will reset to 0 and begin
counting again after 9999.9 has been reached.
1-5
FEATURES
Cruise control speed setting: The current fuel consumption display can be set
to “km/L” or “L/100km”. When using miles, only
MPG will be available.
1 2 TIP
If traveling at speeds under 10 km/h (6 mi/h), “–
60 MPH 60 MPH
–.–” will be displayed.
Fuel consumption trip meter:
1. Display in STREET MODE 1 2

FUEL CON
Displays the selected speed setting for the FUEL CON 4.9 GAL 4.9
GAL
cruise control system.
Average fuel consumption:

1 2
FUEL AVG
30 Displays how much fuel has been consumed
FUEL AVG 30 MPG
MPG
since the trip meter was last reset.
TIP
The current fuel consumption function should be
used for general reference only. Do not use this
figure to estimate the distance that can be trav-
1. Display in STREET MODE eled on the current tank of fuel.
The average fuel consumption display can be To reset information display items
set to “km/L” or “L/100km”. When using miles, 1. Use the wheel switch to scroll through the dis-
only MPG will be available. play items until the item you want to reset ap-
TIP pears.
After resetting the average fuel consumption dis- 2. STREET MODE: Short push the wheel
play, “– –.–” will be shown until the vehicle has switch and the item group will flash for 5 sec-
traveled 1 km (0.6 mi). onds. If both items in the group are resetta-
ble, the top item will flash first. Scroll down to
select the bottom item.
Current fuel consumption:
TRACK MODE: Short push the wheel switch
and the information display will flash for 5
1 2 seconds.
3. While the item is flashing, long push the
CRNT FUEL wheel switch and the item will reset.
CRNT FUEL 30 MPG 30
MPG
Grip warmer indicator (if equipped)

The grip warmers can be used when the engine
is running. There are 3 customizable tempera-
ture presets that can be customized between 10
1. Display in STREET MODE different temperature levels.
2. Display in TRACK MODE The indicator displays the current temperature
setting as “OFF” or segments (LO/MIDDLE/
HIGH).
1-6
FEATURES
To activate the grip warmer MODE-A: suitable for track riding

1. Use the wheel switch to highlight the grip MODE-B: softer track-riding setting
warmer display with the cursor. MODE-C: suitable for road use
2. Short push the wheel switch and the indicator MODE-D: street use or rainy weather
will start flashing.
3. Rotate the wheel switch to select the tem- To change YRC modes or make setting chang-
perature preset. es
4. Short push the wheel switch to confirm the 1. Use the “MODE” switch to scroll left to right
selection and the grip warmer indicator will and highlight the item you want to adjust.
stop flashing. 2. Use the MODE up “ ” or MODE down “ ”
ECA17932
switches to change the selected item value.
NOTICE
TIP
• Be sure to wear gloves when using the grip
warmers. • When the engine trouble warning light “ ”,
• Do not use the grip warmers in warm the auxiliary system warning “ ”, or the
weather. coolant temperature warning “ ” are on, YRC
• If the handlebar grip or throttle grip be- settings cannot be adjusted.
comes worn or damaged, stop using the • When the SCU trouble warning “ ” is on, ERS
grip warmers and replace the grips. cannot be adjusted. (MT10SPN/MT10SPNC)
• When a YRC function is actively engaged that
YRC icons item cannot be adjusted. For example, when
The current YRC MODE preset and its related accelerating PWR cannot be adjusted.
settings are shown on various icons at the top • When a YRC item is highlighted but cannot be
and bottom of the main screen. adjusted, the YRC item box will return to black.
Settings for YRC items PWR, TCS, SCS, QS • If the ERS mode disappears from the ERS in-
dicator (the icon turns blank), stop the vehicle
“ ”, QS “ ”, LIF, EBM, BC “ ” and ERS
and wait a few seconds until the mode reap-
(MT10SPN/MT10SPNC) are organized into pre-
pears. (MT10SPN/MT10SPNC)
sets (MODE-A, MODE-B, MODE-C, and
MODE-D). The settings for each MODE preset
can be customized via the YRC setting menu.
TIP
QS LIF 1 EBM-1 -A
MODE :00 -A
12MODE
• YRC settings shown on the bottom of the main 1000 r/min
screen (PWR, TCS, SCS and ERS

(MT10SPN/MT10SPNC)) can be adjusted in- GEAR
12 34 12
dependently from the main screen.
• YRC settings shown on the top of the main
screen (QS “ ”, QS “ ”, LIF, BC “ ” and
LAP 09
56
MODE-A PWR
MPH
1
TRIP-1
1234.5
TCS 3 SCS 1
mile
A-1
N OFF
EBM) cannot be adjusted independently from

the main screen. To change these values, use Turning off the traction control system
the YRC Setting MENU. To turn off the traction control system, select
• The LIF icon only show as active/inactive but TCS with the “MODE” switch, then press and
have different setting levels that can be adjust- hold the MODE up “ ” switch until TCS OFF is
ed in the YRC Setting MENU. displayed.
• The BC “ ” and EBM icons show both active/ To turn the traction control system back on, se-
inactive as well as the current setting level. lect TCS OFF and then press the MODE down
The YRC modes come preset from the factory ” ” switch (the traction control system will re-
for different riding conditions. When using the turn to its previous setting).
factory presets, the suggested YRC modes are TIP
as follows. Turning off the traction control system will turn
off the SCS and LIF systems for all YRC mode
presets.
1-7
FEATURES
Lap timer EAS31708
MENU SCREEN
This stopwatch function measures and records
up to forty laps. On the main screen, the lap tim-
MENU GPS 10 : 00
er shows the current lap time and lap number MPH
(indicated by the LAP mark). Use the Dimmer/ Display Mode

Pass switch “ / /PASS” to mark lap times. YRC Setting
When a lap is completed, the lap timer will show Lap Time
the latest lap time (marked by the LATEST indi- Maintenance
cator) for five seconds. Unit
1 Wallpaper
QS LIF 1 EBM 1 12:00

1000 r/min The MENU screen contains the following setting
2 modules.
GEAR
12 34 12
N
Module Description
4 LAP 09
56 TRIP-1
1234.5 Switch the display between
MPH mile
MODE-A PWR 1 TCS 3 SCS 1 A-1 OFF

Display Mode STREET MODE and
TRACK MODE
3 Adjust YRC settings (all
1. Lap time YRC Setting models) and ERS settings
2. Latest lap time indicator “LATEST” (MT10SPN/MT10SPNC)
3. Information display item
Lap Time View and reset lap times
4. Lap number
View and reset mainte-
Maintenance
To use the lap timer nance interval tripmeters
1. While in TRACK MODE, short push the Set fuel consumption and
wheel switch. The information display and the Unit
distance units
grip warmer indicator (if equipped) will flash Wallpaper Set background colors
for five seconds.
2. While the information display item is flashing, Turn the shift indicator on/
rotate the wheel switch upward. The lap timer Shift Indicator off and adjust tachometer
settings
will flash for five seconds.
3. While the lap timer is flashing, long push the Select the information dis-
Display Setting
wheel switch to activate the lap timer or stop play groupings
the lap timer. Brightness Adjust screen brightness
4. When the lap timer has been activated and Grip Warmer Adjust grip warmer presets
the headlight is set on low beam, push the Setting (if equipped)
switch down towards “PASS” to flash the high
beam and start the timer. Clock Adjust the clock
TIP Return all settings to facto-
All Reset
ry defaults
• The engine must be running to use the lap tim-
er.
• Set the information display to FASTEST or AV-
ERAGE for additional lap time information.
• Accessing the MENU screen will automatically
stop the lap timer.
• Whenever the lap timer is stopped, the current
lap will not be recorded.
• The lap time record can be viewed and reset
from the MENU screen.
1-8
FEATURES
MENU access and operation TIP

Access the MENU by pressing and holding the • The traction control system has 5 setting levels
wheel switch (long push) while the vehicle is not and ERS has 6 modes.
in motion. • Whenever there are more selections (setting
Rotate the wheel switch up or down to highlight levels or modes) available than can be shown
modules/items or increase/decrease values. on the screen at one time, a scroll bar will ap-
Briefly press the wheel switch inward (short pear on the righthand side of the screen to no-
push) to select menus items and confirm setting tify you that additional selections are available
values. by scrolling.
Press and hold the wheel switch (long push) un-
til the screen returns to the main display to exit
the MENU at any time. PWR
TIP Select PWR-1 for the most aggressive throttle
response, PWR-2 and PWR-3 for smoother
• Certain menu screens have an upward point-
ing triangle mark item. Select the triangle mark throttle grip/engine response, and use PWR-4
for rainy days or whenever less engine power is
to save settings changes and exit the current
desirable.
screen.
• Should vehicle motion be detected, the screen
2
will automatically exit the MENU and return to
1 3
the main display.
• To ensure that the desired settings changes 4
are saved, be sure to exit each menu via the tri- 5
angle mark (if displayed). Exiting the settings
menu by pressing and holding (long push) the
wheel switch may not save settings changes.
6
“Display Mode” 1. PWR 1
There are two main screen display modes, 2. PWR 2
STREET MODE and TRACK MODE. 3. PWR 3
4. PWR 4
MPH Display Mode 10 : 00 5. Throttle valve opening
STREET MODE
6. Throttle grip operation
TRACK MODE Traction control system

This model uses a variable traction control sys-
tem. For each setting level, the farther the vehi-
cle is leaned over, the more traction control
(system intervention) is applied. There are 5 set-
ting levels available. Setting level 1 applies the
“YRC Setting” least system intervention, while setting level 5
This module allows you to customize the four applies the most overall traction control.
YRC mode presets (MODE-A, MODE-B, TIP
MODE-C, and MODE-D) by adjusting the setting • The traction control system can only be turned
levels (or on/off status as applicable) of YRC off completely via the main screen using the
items PWR, TCS, SCS, QS “ ”, QS “ ”, LIF, “MODE” switch and MODE up “ ” switch. See
EBM, BC and ERS (MT10SPN/MT10SPNC). “Turning off the traction control system”
• When TCS has been turned off, TCS, SCS,
LCS, and LIF will be set to OFF and cannot be
adjusted. When TCS is turned on again, these
related-traction control functions will return to
their previous setting levels.
1-9
FEATURES
1 3
1 4
5
2
3
21 1
LIF
TCS
2
2
1. System intervention
1. System intervention
2. Lean angle
2. Wheel lift
SCS
EBM
SCS can be set to OFF, 1, 2, and 3. OFF turns
This system has two settings. Level 1 provides
the slide control system off, setting level 1 pro-
the least system intervention, and therefore the
vides the least system intervention, and setting
strongest engine braking. Level 2 provides the
level 3 provides the intervention.
most system intervention, and therefore the
least engine braking.
1 3 BC
2
1
Select BC1 when only standard ABS is desired.
SCS Select BC2 to have the brake control system
also regulate brake pressure while cornering to
suppress lateral wheel slip.
TIP
2 For skilled riders and when riding at the track,
due to varying conditions, BC2 brake system en-
1. System intervention gagement may come on sooner than expected
2. Sideward slide relative to your desired cornering speed or in-
tended cornering line.
Quick shifter
The quick shifter is divided into QS (upshift) To customize a YRC mode or adjust a YRC
and QS (downshift) sections. QS and QS item
are not linked and can be independently 1. While the“YRC Setting” screen is displayed,
turned on or off. and the YRC mode box “YRC” is highlighted.
OFF turns the respective upshift or downshift Short push the wheel switch to enter the box
function off, and the clutch lever must then be and then select the YRC mode preset (A, B,
used when shifting in that direction. C or D) that you want to adjust.
LIF MPH YRC Setting 10 : 00
LIF can be set to 1, 2, 3, or OFF. Setting level 3 A 1 1 1 ON ON 1 1 1 A-1
most strongly reduces wheel lift, and setting lev- B 2 2 2 2 2 2 A-2
el 1 provides the least system intervention. OFF C 3 3 3 3 A-3
turns LIF off. D 4 4 M-1
5 OFF OFF OFF OFF M-2
YRC PWR TCS SCS QS QS LIF EBM BC ERS
1 2 3
1. Triangle mark
2. YRC mode box
3. YRC item
1-10
FEATURES
2. Select the YRC item PWR, TCS, SCS, QS , The ERS consists of three semi-active automat-
QS , LIF, EBM, BC, or ERS (MT10SPN/ ic presets (A-1, A-2, and A-3) and three manual
MT10SPNC) that you want to adjust. setting presets (M-1, M-2, and M-3). When an
automatic preset is selected, the SCU will adjust
MPH YRC Setting 10 : 00 the compression and rebound damping forces
4 A 1 1 1 ON ON 1 1 1 A-1 based on running conditions. For all presets,
3 B 2 2 2 2 2 2 A-2 spring preload must be physically adjusted by
C 3 3 3 3 A-3
hand.
2 D 4 4 M-1
TIP
5 OFF OFF OFF OFF M-2
YRC PWR TCS SCS QS QS LIF EBM BC ERS

The factory preset levels are intended as fol-
lows:
1 • A-1/M-1 are preset for track use with racing
slick tires.
1. YRC item • A-2/M-2 are preset for track use with street
2. Current level setting tires.
3. Factory preset level • A-3/M-3 are preset for road use with street
4. YRC mode tires.
TIP Semi-active automatic presets (A-1/ A-2/A-3)
• When a YRC item is selected, the current set- adjustable settings:
ting level is highlighted blue and the factory BRAKE SUPPORT: reduces nosedive (front-
preset level is highlighted gray. end pitch from braking)
• Factory preset levels vary depending on the CORNER SUPPORT: increases damping to ab-
selected YRC mode preset. sorb chassis fluctuations for smooth cornering.
3. When finished, select the triangle mark on Reduce this setting for increased rear wheel
the far left to return to the MENU screen; or grip.
select the “ ” mark to adjust the individual ACCEL SUPPORT: reduces rear-end squat
ERS (MT10SPN/MT10SPNC) presets. (rear-end pitch due to acceleration)
FRONT FIRM: hardens “H” or softens “S” overall
ERS (MT10SPN/MT10SPNC) damping of the front suspension
REAR FIRM: hardens “H” or softens “S” overall
MPH YRC Setting 10 : 00 damping of the rear suspension
1 A- 1 -2 +2 TIP
H H
A- 2 8 For the road preset A-3, CORNER SUPPORT
A- 3 7 and ACCEL SUPPORT cannot be adjusted and
are not visible in the menu.
S S
BRAKE CORNER ACCEL FRONT REAR
SETTING
SUPPORT SUPPORT SUPPORT FIRM FIRM
MPH YRC Setting 10 : 00
2 3 4 5 6 A- 1
H
-2
H
+2
A- 2
1. ERS mode 6
2. Braking support level 1 A- 3
5
3. Cornering support level S S
4. Acceleration support level SETTING

BRAKE
SUPPORT
FRONT
FIRM
REAR
FIRM
5. Front overall damping level
6. Rear overall damping level 2 3 4
7. Factory preset level
1. ERS mode
8. Current level
2. Braking support level
3. Front overall damping level
4. Rear overall damping level
6. Current level
1-11
FEATURES
Manual presets (M-1/M-2/M-3) adjustable set-

YRC Setting 10 : 00
tings: MPH
Fr COM: front compression damping M-1 8 18 22 22 4

Fr REB: front rebound damping M-2
Rr COM: rear compression damping M-3
Rr REB: rear rebound damping
To adjust the ERS mode settings SETTING Fr COM Fr REB Rr COM Rr REB
1. In the YRC setting module, select the ERS

preset (A-1/A-2/A-3/M- 1/M-2/M-3) you want 1 2 3
to adjust. 1. To YRC Setting menu
2. ERS mode selection box “SETTING”
MPH YRC Setting 10 : 00 3. Factory preset level
A 1 1 1 1 ON ON 1 1 1 A-1 4. Current level setting
B 2 2 2 2 2 2 2 A-2 3
C 3 3 3 3 A-3 “Lap Time”
D 4 4 M-1 This module allows you to view and delete the
2
5 OFF OFF OFF OFF OFF M-2 lap time record. The fastest lap and the average
YRC PWR TCS SCS LCS QS QS LIF EBM BC ERS lap time stored in the lap time record are dis-
played at the top of the screen. Use the wheel
1 switch to scroll and see all lap times. The top
1. To ERS menu three fastest laps will be highlighted in silver. Up
2. Manual modes to 40 laps can be stored in memory. If more than
3. Automatic modes 40 laps are recorded, the oldest laps (starting
from lap 1) will be overwritten.
TIP
The ERS setting menu is divided into automatic Lap Time GPS
GP 10 : 00
MPH
(A-1/A-2/A-3) and manual (M-1/M-2/M-3)
screens, and the two types are accessed sepa- 1 FASTEST / LAP 12 02:34.56
rately. Before moving to the ERS setting menu 2 AVERAGE 02:53.00
be sure you have selected the appropriate type 3 LAP 1 02:54.56
(automatic/manual) of ERS mode preset. LAP 2 02:55.20
LAP 3 02:56.04
2. In the YRC setting menu, select the “ ” LAP 4 02:56.80
mark, located to the right of ERS, and short
push the wheel switch.
1. Fastest lap
3. The display will change to the relevant sus-
2. Average lap time
pension setting screen (automatic/manual)
3. Lap time record
with the ERS mode selection box “SETTING”
highlighted. Short push the wheel switch, se- This module has two options. “Display” allows
lect the preset that you want to adjust, and you to view the lap time record. “Reset” allows
short push the wheel switch again. you to delete the lap time record data.
4. Scroll the different settings by rotating the
wheel switch. Once a setting is highlighted, MPH Lap Time 10 : 00
short push the wheel switch to select it and
Display
then rotate the wheel switch to adjust the set-
ting level.
Reset
5. To adjust other ERS modes of the same type,
repeat from step 3. To switch types or when
finished, select the “ ” mark to return to the
main “YRC Setting” menu.
1-12
FEATURES
“Maintenance” “Wallpaper”
This module allows you to record distance trav- This module allows you to individually set the
eled between engine oil changes (use the OIL STREET MODE and TRACK MODE display
item), and for two other items of your choice (use background colors to black or white for both day
INTERVAL 1 and INTERVAL 2). and night settings. A photo sensor equipped in
the instrument panel detects lighting conditions
To reset a maintenance item and will automatically change the display be-
1. Select the item you want to reset. tween its day and night settings. The photo sen-
sor also controls a subtle automatic brightness
MPH Maintenance GPS 10 : 00 adjustment function within both day and night
OIL 123456 mile modes to suit ambient light conditions.
INTERVAL 1 123456 mile
2. Long push the wheel switch to reset the item.
MPH Maintenance GPS 10 : 00
OIL 0 mile 1. Photo sensor

“Shift indicator”
The shift indicator module contains the following
modules.
Module Description
Set the shift indicator pat-
TIP tern to “ON”, “Flash”, or
Shift IND Set-
Maintenance item names cannot be changed. “OFF” and adjust at what r/
ting
min the indicator will come
on and go off.
“Unit” Shift IND Bright- Adjust the brightness of the
This module allows you to switch the display be- ness shift indicator.
tween kilometers and miles.
Set the tachometer color
When using kilometers, the fuel consumption
display to “ON” or “OFF”
units can be changed between km/L or L/ Tach IND Set-
and adjust at what r/min the
100km. When using miles, only MPG will be ting
tachometer will be green
available. and orange.
Set the tachometer peak
MPH Unit GPS
GP 10 : 00 Peak Rev IND
rev indicator to “ON” or
Setting
km or mile mile “OFF”.
MPG MPG
MPH MENU GPS 10 : 00
Shift Indicator
Display Setting
Brightness
Grip Warmer Setting
Clock
All Reset
1-13
FEATURES
To make setting changes

1. Select “Shift IND Setting”. MPH Shift Indicator 12 : 00
1000 r/min
MPH Shift Indicator GPS 10 : 00

GP
Shift IND Setting
Shift IND Setting IND Mode ON
Shift IND Brightness IND Start 8000 r/min
Tach IND Setting IND Stop 13000 r/min
Peak Rev IND Setting
6. Select “IND Stop” then rotate the wheel

switch to adjust the r/min at which the shift
2. Select “IND Mode”. timing indicator will go off. “IND Stop” opera-
tional range is 5500–13000 r/min.
MPH Shift Indicator 12 : 00 TIP
1000 r/min
The blue area on the tachometer indicates the
Shift IND Setting currently set operational range of the shift indica-
IND Mode ON tor light.
IND Start 6000 r/min
IND Stop 12000 r/min

“Shift IND Brightness”
The shift timing indicator light has six brightness
levels. Short push the wheel switch to confirm
3. Select “ON” to have the indicator light steadi- the setting and exit.
ly, “OFF” to turn the indicator off, or “Flash” to
have the shift indicator flash when the indica- MPH Shift Indicator GPS 10 : 00
tor start threshold has been reached.
Shift IND Brightness
MPH Shift Indicator 12 : 00

1000 r/min
3
Shift IND Setting
IND Mode ON
“Tach IND Setting”

This module allows you to turn the tachometer
4. Select “IND Start”. color display on or off. When turned off, the ta-
chometer will display all r/min levels below the
MPH Shift Indicator 12 : 00 red zone in black or white (depending on wallpa-
1000 r/min
per settings). When turned on, the mid and mid-
Shift IND Setting
to-high r/min zones can be set to come on in
IND Mode ON
green and then orange colors.
1. Select “IND Mode”.
1000 r/min
5. Rotate the wheel switch to adjust the r/min at Tach IND Setting
which the shift timing indicator light will come IND Mode ON
on. “IND Start” operational range is 5000– Tach IND 1st 5000 r/min
12800 r/min. Tach IND 2nd 8000 r/min
1-14
FEATURES
2. Select ON to turn the tachometer color dis- 5. Select “Tach IND 2nd”.
play mode on (or select OFF to turn this func-
tion off). MPH Shift Indicator 12 : 00
1000 r/min

Tach IND Setting
1000 r/min
IND Mode ON
Tach IND Setting Tach IND 1st 5000 r/min

IND Mode ON Tach IND 2nd 8000 r/min
Tach IND 1st 5000 r/min
Tach IND 2nd 8000 r/min
6. Set the orange color starting r/min by rotating

and then short pushing the wheel switch. All r/
3. Select “Tach IND 1st” to set the green zone min above this figure until the 11800 r/min red
starting r/min. zone, will be displayed in orange.
TIP
MPH Shift Indicator 12 : 00 Orange bar start setting range: 5000–11800 r/
1000 r/min
min.
Tach IND Setting
IND Mode ON
Tach IND 1st 5000 r/min 1000 r/min

Tach IND Setting
IND Mode ON
4. Set the starting r/min by rotating and then
short pushing the wheel switch. All r/min
above this value up to the “Tach IND 2nd”
setting value (or the 11800 r/min red zone),
will be displayed in green.
“Peak Rev IND Setting”
MPH Shift Indicator 12 : 00 This module allows you to turn the revolution
1000 r/min peak hold indicator on or off.
Tach IND Setting
“Display Setting”
IND Mode ON
This module allows you to set how the informa-
tion display items (like TRIP-1, ODO, C. TEMP,
etc.) are grouped on the main screen. There are
four display groups.
TIP
Green bar start setting range: 5000–11800 r/ 1000 r/min
min.
MPH
1 TRIP-1
TRIP-2
MODE-A PWR
9990.0 mile
9990.0 mile
1 TCS 3
1
SCS
N2
1 A-1 OFF
1. Information display item (STREET MODE)
1-15
FEATURES
TIP
The information display items which can be se-
1000 r/min lected are:
A.TEMP: air temperature
GEAR
C.TEMP: coolant temperature
12 34 12
LAP 09
56
MODE-A PWR
MPH
1
TRIP-1
1234.5
TCS 3 SCS 1
mile
A-1
N OFF
1
TRIP-1: tripmeter 1
TRIP-2: tripmeter 2
ODO: odometer
SPEED: cruise control speed setting
FUEL AVG: average fuel consumption
1. Information display item (TRACK MODE)
CRNT FUEL: current fuel consumption
To set the display groups FUEL CON: the amount of fuel consumed
1. “DISPLAY-1”, “DISPLAY-2”, “DISPLAY-3” 5. Select “STREET MODE 1-2” or “TRACK
and “DISPLAY-4” are displayed. MODE” to set the remaining DISPLAY-1
group items.
MPH Display Setting GPS 10 : 00
GP
DISPLAY-1 MPH Display Setting GPS 10 : 00
DISPLAY-2 DISPLAY-1
DISPLAY-3 STREET MODE 1-1 A.TEMP
DISPLAY-4 STREET MODE 1-2 C.TEMP
TRACK MODE C.TEMP
2. For example, let’s select “DISPLAY-1”.

3. Select “STREET MODE 1-1”. 6. Select the triangle symbol to exit. To set the
other display groups, repeat from step 3.
MPH Display Setting GPS 10 : 00
DISPLAY-1 “Brightness”
STREET MODE 1-1
This module allows you to adjust the general
A.TEMP
brightness level of the display screen.
STREET MODE 1-2 C.TEMP
TRACK MODE C.TEMP
“Grip Warmer Setting” (if equipped)
This module is for adjusting the temperature val-
ues for the grip warmer presets (LO/MIDDLE/
HIGH). Each preset can be set from 1 (low heat)
4. Select the desired information display item to 10 (high heat).
with the wheel switch.
“Clock”
MPH Display Setting GPS 10 : 00 This module allows you to set the clock.
DISPLAY-1
“All Reset”
STREET MODE 1-1 A.TEMP
This module resets everything, except the
STREET MODE 1-2 C.TEMP
odometer and clock, to its factory preset or de-
TRACK MODE C.TEMP
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.
1-16
BASIC SERVICE INFORMATION
EAS20010
BASIC SERVICE INFORMATION

EAS30014
ELECTRICAL SYSTEM
Electrical parts handling

ECA22611
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.
1-17
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-”.
• For others, use part numbers starting with “90890-”.
Reference
Tool name/Tool No. Illustration
pages
Yamaha diagnostic tool USB (US) 3-4, 4-68, 4-69,
90890-03269 7-17, 9-3, 9-32,
9-33
Yamaha diagnostic tool (A/I) 3-4, 4-68, 4-69,

90890-03264 7-17, 9-3, 9-32,
9-33
Thickness gauge 3-6, 3-7, 3-7,

90890-03268 3-7, 4-28, 4-38,
Feeler gauge set 5-32, 5-62
YU-26900-9
Vacuum gauge 3-10

90890-03094
Vacuummate
YU-44456
YU-44456
Carburetor angle driver 2 3-10

90890-03173
Steering nut wrench 3-20, 4-98

90890-01403
Exhaust flange nut wrench
YU-A9472
1-18
SPECIAL TOOLS
Reference
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
ø18
Oil pressure gauge set 3-31

90890-03120
Wheel bearing ring nut tool 4-33, 4-35

90890-01574
YM-01574
Fork spring compressor 4-78, 4-83

90890-01441
Fork spring compressor
YM-01441
Rod holder 4-78, 4-83

90890-01434
Damper rod holder double ended
YM-01434
Damper rod holder (ø30) 4-79, 4-81

90890-01506
Damper rod holder
YM-01506
Fork seal driver 4-81, 4-81,

90890-01442 4-82, 4-91, 4-91
Adjustable fork seal driver (36–46 mm)
YM-01442
1-19
SPECIAL TOOLS
Reference
pages
Rod puller 4-82, 4-83
90890-01437
Universal damping rod bleeding tool set
YM-A8703
YM-A8703
Rod puller attachment (M10) 4-82, 4-83

90890-01436
Universal damping rod bleeding tool set
YM-A8703
YM-A8703
Front fork cap bolt wrench 42mm 4-88, 4-88, 4-94

90890-01575
YM-01575
ø42

90890-01504
Damper rod holder
YM-01504
Front fork rod puller M7x0.75 4-91, 4-92

90890-01576
YM-01576 M7 0.75
Ring nut wrench 4-98

90890-01268
Spanner wrench
YU-01268
Ring nut wrench 4-110, 4-112

90890-01507
Ring nut wrench
YM-01507
1-20
SPECIAL TOOLS
Reference
pages
90890-01365
Drive chain cut & rivet tool 4-115, 4-117

90890-01550
Drive chain cut & rivet tool
YM-01550
Compression gauge 90890-03081 5-9

90890-03081
Engine compression tester
YU-33223
YU-33223
Pivot shaft wrench 5-15, 5-15

90890-01485
Frame mount insert wrench
YM-01485
Valve spring compressor 5-25, 5-28,

90890-04200 5-36, 5-40
Valve spring compressor
YM-04019
Valve spring compressor attachment 5-36, 5-40

(ø26)
90890-01243
Valve spring compressor attachment
(ø26)
YM-01253-1
Valve guide remover (ø4.5) 5-37
90890-04116
Valve guide remover (4.5 mm)
YM-04116
Valve guide remover (ø5) 5-37

90890-04097
YM-04097
1-21
SPECIAL TOOLS
Reference
pages
Valve guide installer (ø4.5) 5-37
90890-04117
Valve guide installer (4.5 mm)
YM-04117
Valve guide installer (ø5) 5-37

90890-04098
Valve guide installer (5.0 mm)
YM-04098
Valve guide reamer (ø4.5) 5-37

90890-04118
Valve guide reamer (4.5 mm)
YM-04118
Valve guide reamer (ø5) 5-37

90890-04099
YM-04099
15mm pin type rotor holding tool 5-44, 5-45

90890-04171
YM-04171
Crankshaft protector 5-44

90890-01382
Crankshaft protector
YM-01382
Flywheel puller 5-44

90890-01404
Flywheel puller
YM-01404
Yamaha bond No. 1215 5-45, 5-71

90890-85505
Three bond No. 1215®
Sheave holder 5-47, 5-47

90890-01903
Primary clutch holder
YS-01880-A
1-22
SPECIAL TOOLS
Reference
pages
Digital circuit tester (CD732) 5-50, 8-40,
90890-03243 8-41, 8-42,
Model 88 Multimeter with tachometer 8-43, 8-44,
YU-A1927 8-44, 8-45,
8-46, 8-46,
8-47, 8-48,
8-48, 8-49,
8-50, 8-50, 8-50
Clutch holder 5-61, 5-64
90890-04199
Universal clutch holder
YM-91042
Piston pin puller set 5-76

90890-01304
Piston pin puller
YU-01304
YU-01304
Connecting rod big end bearing installer 5-79, 5-82

ø8.1 ø9.1
90890-04193 ø7
Connecting rod big end bearing installer
YM-04193
Radiator cap tester 6-4, 6-5

90890-01325
Mityvac cooling system tester kit
YU-24460-A
YU-24460-A
1-23
SPECIAL TOOLS
Reference
pages
Radiator cap tester adapter 6-4, 6-5
90890-01352
Pressure tester adapter
YU-33984
YU-33984
Mechanical seal installer (ø33) 6-14

90890-04132
Water pump seal installer (ø33)
YM-33221-A
Middle driven shaft bearing driver 6-14

90890-04058
Middle drive bearing installer 40 & 50 mm
YM-04058
Pressure gauge 7-15, 7-16

90890-03153
Pressure gauge
YU-03153
Fuel injector pressure adapter 7-15

90890-03210
Fuel injector pressure adapter
YU-03210
Fuel pressure adapter 7-16

90890-03176
Fuel pressure adapter
YM-03176
Ignition checker 8-44

90890-06754
Oppama pet–4000 spark checker
YM-34487
Test harness– speed sensor (3P) 8-48

90890-03208
Test harness– speed sensor (3P)
YU-03208
1-24
SPECIAL TOOLS
TIP
Yamaha diagnostic tool (A/I) 90890-03264
This special tool includes the YDT sub harness (6P) (90890-03266).
TIP
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.
1-25
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
ENGINE SPECIFICATIONS ............................................................................2-2
CHASSIS SPECIFICATIONS ..........................................................................2-7
ELECTRICAL SPECIFICATIONS .................................................................2-10

2
TIGHTENING TORQUES .............................................................................. 2-12
ENGINE TIGHTENING TORQUES......................................................... 2-12
CHASSIS TIGHTENING TORQUES.......................................................2-12
CABLE ROUTING ......................................................................................... 2-15

GENERAL SPECIFICATIONS
EAS20013
GENERAL SPECIFICATIONS
Model
Model B5Y2 (MT10N)
B5Y3 (MT10NC)
BGG2 (MT10SPN)
BGG3 (MT10SPNC)
Dimensions
Overall length 2100 mm (82.7 in)
Overall width 800 mm (31.5 in)
Overall height 1165 mm (45.9 in)
Wheelbase 1405 mm (55.3 in)
Ground clearance 135 mm (5.31 in)
Minimum turning radius 3.4 m (11.16 ft)
Weight
Curb weight 213 kg (470 lb) (MT10N, MT10NC)
215 kg (474 lb) (MT10SPN, MT10SPNC)
Loading
Maximum load 170 kg (375 lb) (MT10SPN, MT10SPNC)
172 kg (379 lb) (MT10N, MT10NC)
Riding capacity 2 person
2-1
ENGINE SPECIFICATIONS
EAS20014
Engine
Combustion cycle 4-stroke
Cooling system Liquid cooled
Valve train DOHC
Displacement 998 cm³
Cylinder arrangement Inline
Number of cylinders 4-cylinder
Bore × stroke 79.0 × 50.9 mm (3.11 × 2.00 in)
Compression ratio 12.0 : 1
Compression pressure 1305–1680 kPa/250 r/min (13.1–16.8 kgf/cm²/
250 r/min, 185.6–238.9 psi/250 r/min)
Fuel
Recommended fuel Unleaded gasoline (E10 acceptable)
Octane number (RON) 95
Fuel tank capacity 17 L (4.5 US gal, 3.7 Imp.gal)
Fuel reserve amount 4.0 L (1.06 US gal, 0.88 Imp.gal)
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 Imp.qt)
With oil filter removal 4.10 L (4.33 US qt, 3.61 Imp.qt)
Quantity (disassembled) 4.90 L (5.18 US qt, 4.31 Imp.qt)
Oil filter
Oil filter type Cartridge
Oil pump
Oil pressure 150.0 kPa/3000 r/min (1.50 kgf/cm²/3000 r/min,
21.8 psi/3000 r/min)
Cooling system
Coolant quantity
Radiator (including all routes) 2.25 L (2.38 US qt, 1.98 Imp.qt)
Coolant reservoir (up to the maximum level
mark) 0.24 L (0.25 US qt, 0.21 Imp.qt)
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)
2-2
Spark plug(s)
Manufacturer/model NGK/LMAR9E-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
limit 0.080 mm (0.0032 in)
Camshaft lobe dimensions
Lobe height limit (Intake) 33.802 mm (1.3308 in)
Lobe height limit (Exhaust) 33.537 mm (1.3204 in)
Camshaft runout limit 0.030 mm (0.0012 in)
Rocker arm/rocker arm shaft

Rocker arm inside diameter limit 8.013 mm (0.3155 in)
Rocker arm shaft outside diameter 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 0.20–0.26 mm (0.0079–0.0102 in)
Valve dimensions
Valve seat contact width limit (intake) 1.6 mm (0.06 in)
Valve seat contact width limit (exhaust) 1.8 mm (0.07 in)
Valve stem diameter limit (intake) 4.945 mm (0.1947 in)
Valve stem diameter limit (exhaust) 4.430 mm (0.1744 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-guide clearance limit
(intake) 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance limit
(exhaust) 0.100 mm (0.0039 in)
Valve stem runout 0.020 mm (0.0008 in)
Valve spring
Free length limit (intake) 39.18 mm (1.54 in)
Free length limit (exhaust) 40.21 mm (1.58 in)
Cylinder
Bore 79.000–79.010 mm (3.1102–3.1106 in)
Wear limit 79.060 mm (3.1126 in)
2-3
Piston
Diameter 78.970–78.985 mm (3.1090–3.1096 in)
Measuring point (from piston skirt bottom) 8.0 mm (0.31 in)
Piston-to-cylinder clearance 0.015–0.040 mm (0.0006–0.0016 in)
Piston pin bore inside diameter limit 17.043 mm (0.6710 in)
Piston pin outside diameter limit 16.971 mm (0.6681 in)
Piston ring
Top ring
End gap limit 0.50 mm (0.0197 in)
Side clearance limit 0.115 mm (0.0045 in)
2nd ring
End gap limit 1.15 mm (0.0453 in)
Side clearance limit 0.115 mm (0.0045 in)
Connecting rod
Oil clearance 0.032–0.054 mm (0.0013–0.0021 in)
Bearing color code
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 0.027–0.045 mm (0.0011–0.0018 in)
Bearing color code
Code 1 Blue
Code 2 Black
Code 3 Brown
Code 4 Green
Code 5 Yellow
Code 6 Pink
Code 7 Red
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)
2-4
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)
Plate quantity 3 pcs
Friction plate 2 thickness 2.72–2.88 mm (0.107–0.113 in)
Clutch plate 1 thickness 2.46–2.74 mm (0.097–0.108 in)
Clutch plate 2 thickness 2.18–2.42 mm (0.086–0.095 in)
Clutch spring free length limit 44.52 mm (1.75 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 2.625 (42/16)
Final drive Chain
Shifting mechanism
Installed shift rod length 274.2–276.2 mm (10.80–10.87 in)
Air filter
Air filter element Oil-coated paper element
Fuel injector
Resistance 12.0 Ω
Accelerator position sensor

Resistance 1.08–2.52 kΩ
2-5
Idling condition
Engine idling speed 1200–1400 r/min
AI system Inactive
O2 feedback control Inactive
Coolant temperature 90–110 °C (194–230 °F)
Difference in vacuum pressure between the
cylinders 0 kPa–1.3 kPa (0 mmHg–10 mmHg, 0 inHg–0.4
inHg)
CO% 0.5–4.5 %
Fuel line pressure (at idle) 300–390 kPa (3.0–3.9 kgf/cm², 43.5–56.6 psi)
Air induction system

Solenoid resistance 18–22 Ω
2-6
CHASSIS SPECIFICATIONS
EAS20015
Chassis
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 0.5 mm (0.02 in)
Wheel axle bending limit 0.40 mm (0.02 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 0.5 mm (0.02 in)
Wheel axle bending limit 0.40 mm (0.02 in)
Front tire
Type Tubeless
Size 120/70ZR17M/C(58W)
Manufacturer/model BRIDGESTONE/BATTLAX HYPERSPORT
S22F
Rear tire
Type Tubeless
Size 190/55ZR17M/C(75W)
Manufacturer/model BRIDGESTONE/BATTLAX HYPERSPORT
S22R
Tire air pressure (measured on cold tires)

Front 250 kPa (2.50 kgf/cm², 36 psi)
Rear 290 kPa (2.90 kgf/cm², 42 psi)
Front brake
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 16.00 mm (0.63 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
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)
2-7
Master cylinder inside diameter 12.7 mm (0.50 in)

Caliper cylinder inside diameter 38.18 mm (1.50 in)
Specified brake fluid DOT 4
Front suspension
Shock absorber Hydraulic damper
Fork spring free length limit 214.5 mm (8.45 in) (MT10N, MT10NC)
254.8 mm (10.03 in) (MT10SPN, MT10SPNC)
Recommended oil Yamaha Suspension Oil 01 (MT10N, MT10NC)
Yamaha Suspension Oil M1 (MT10SPN,
MT10SPNC)
Inner tube bending limit 0.2 mm (0.01 in)
Quantity (left) 350.0 cm³ (11.83 US oz, 12.34 Imp.oz) (MT10N,
MT10NC)
448.0 cm³ (15.15 US oz, 15.80 Imp.oz)
(MT10SPN, MT10SPNC)
Quantity (right) 350.0 cm³ (11.83 US oz, 12.34 Imp.oz) (MT10N,
MT10NC)
448.0 cm³ (15.15 US oz, 15.80 Imp.oz)
(MT10SPN, MT10SPNC)
Level (left) 114 mm (4.5 in) (MT10N, MT10NC)
180 mm (7.1 in) (MT10SPN, MT10SPNC)
Level (right) 114 mm (4.5 in) (MT10N, MT10NC)
180 mm (7.1 in) (MT10SPN, MT10SPNC)
Spring preload
Unit for adjustment Turn
Adjustment value (Soft) 0
Adjustment value (STD) 11 (MT10SPN, MT10SPNC)
9 (MT10N, MT10NC)
Adjustment value (Hard) 15
Rebound damping
Unit for adjustment Click (MT10N, MT10NC)
Adjustment value from the start position
(Soft) 14 (MT10N, MT10NC)
(STD) 6 (MT10N, MT10NC)
(Hard) 1 (MT10N, MT10NC)
Compression damping
Unit for compression damping adjustment Click (MT10N, MT10NC)
2-8
Rear suspension
Shock absorber Gas-hydraulic damper
Spring preload
Adjustment value (Soft) 0.0 mm (0.00 in) (MT10SPN, MT10SPNC)
76.5 mm (3.01 in) (MT10N, MT10NC)
Adjustment value (STD) 4.0 mm (0.16 in) (MT10SPN, MT10SPNC)
80.5 mm (3.17 in) (MT10N, MT10NC)
Adjustment value (Hard) 84.5 mm (3.33 in) (MT10N, MT10NC)
9.0 mm (0.35 in) (MT10SPN, MT10SPNC)
Rebound damping
Compression damping
Fast compression damping
Unit for adjustment Turn (MT10N, MT10NC)
(Soft) 5.5 (MT10N, MT10NC)
Slow compression damping
Drive chain
Size 525
Chain type Sealed type
Number of links 113
Drive chain slack (Maintenance Stand) 25.0–35.0 mm (0.98–1.38 in)
Drive chain slack (Sidestand) 20.0–30.0 mm (0.79–1.18 in)
15-link length limit 239.1 mm (9.41 in)
2-9
ELECTRICAL SPECIFICATIONS
EAS20016
Voltage
System voltage 12 V
Ignition system
Ignition timing (B.T.D.C.) 3.0–7.0 °/1300 r/min
Engine control unit

Model TBDF8S
Ignition coil
Primary coil resistance 1.19–1.61 Ω
Secondary coil resistance 8.50–11.50 kΩ
Charging system
Charging system AC magneto
Standard output 14.0 V, 28.3 A at 5000 r/min
Stator coil resistance 0.112–0.168 Ω
Rectifier/regulator
Regulated voltage (DC) 14.3–14.7 V
Battery
Model YTZ10S
Voltage, capacity 12 V, 8.6 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
Engine oil and Coolant warning light LED
High beam indicator light LED
Turn signal indicator light LED
Engine trouble warning light LED
ABS warning light LED
Cruise control “SET” indicator light LED
Cruise control “ON” indicator light LED
Auxiliary system warning light LED
Shift timing indicator light LED
2-10
Starter motor
Brush overall length limit 5.5 mm (0.22 in)
Mica undercut (depth) 2.40 mm (0.09 in)
Fuel sender unit

Sender unit resistance (full) 9.0–12.0 Ω
Sender unit resistance (empty) 213.0–219.0 Ω
Fuel injection sensor

Crankshaft position sensor resistance 189–231 Ω
Cylinder identification sensor output voltage
(ON) 4.8 V
Cylinder identification sensor output voltage
(OFF) 0.8 V
Intake air temperature sensor resistance 5400–6600 Ω at 0 °C (5400–6600 Ω at 32 °F)
Intake air temperature sensor resistance 290–390 Ω at 80 °C (290–390 Ω at 176 °F)
Atmospheric pressure sensor output voltage 3.59–3.67 V at 101.3 kPa (3.59–3.67 V at 1.01
kgf/cm², 3.59–3.67 V at 14.7 psi)
Coolant temperature sensor resistance 2513–2777 Ω at 20 °C (2513–2777 Ω at 68 °F)
Coolant temperature sensor resistance 210–221 Ω at 100 °C (210–221 Ω at 212 °F)
Fuse(s)
Main fuse 50.0 A
Headlight fuse 10.0 A
Brake light fuse 1.0 A
Signaling system fuse 7.5 A
Ignition fuse 15.0 A
Radiator fan motor fuse 15.0 A
Sub radiator fan motor fuse 10.0 A
ABS ECU fuse 7.5 A
SCU fuse 7.5 A (MT10SPN, MT10SPNC)
Fuel injection system fuse 15.0 A
ABS motor fuse 30.0 A
ABS solenoid fuse 15.0 A
Terminal fuse 1 2.0 A
Cruise control fuse 1.0 A
Backup fuse 10.0 A
Electronic throttle valve fuse 7.5 A
2-11
TIGHTENING TORQUES
EAS20017
TIGHTENING TORQUES
EAS30016
ENGINE TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Exhaust pipe nut M8 8 20 N·m (2.0 kgf·m, 15 lb·ft)
EXUP valve pulley cover bolt M6 3 10 N·m (1.0 kgf·m, 7.4 lb·ft) E
Spark plug M10 4 13 N·m (1.3 kgf·m, 9.6 lb·ft)

Spark plug (new) M10 4 18 N·m (1.8 kgf·m, 13 lb·ft)
Cylinder head cover bolt M6 6 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Generator rotor bolt M12 1 75 N·m (7.5 kgf·m, 55 lb·ft) E
Generator cover bolt M6 8 12 N·m (1.2 kgf·m, 8.9 lb·ft)

Clutch boss nut M20 1 125 N·m (12.5 kgf·m, 92 lb·ft) Stake.
E
Clutch spring bolt M6 3 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Clutch cover bolt M6 10 12 N·m (1.2 kgf·m, 8.9 lb·ft)
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 lb·ft) E
Water pump drain bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Engine oil drain bolt M14 1 23 N·m (2.3 kgf·m, 17 lb·ft)
EAS30017
CHASSIS TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Front wheel axle nut M24 1 115 N·m (11.5 kgf·m, 85 lb·ft)
Front wheel axle pinch bolt M8 4 21 N·m (2.1 kgf·m, 15 lb·ft) See TIP.
Rear wheel sprocket nut M10 6 80 N·m (8.0 kgf·m, 59 lb·ft)
Rear wheel axle nut M24 1 190 N·m (19 kgf·m, 140 lb·ft)
Rear brake caliper bolt (front) M12 1 27 N·m (2.7 kgf·m, 20 lb·ft) LS
Rear brake caliper bolt (rear) M8 1 12 N·m (1.2 kgf·m, 8.9 lb·ft) LS
LT
Brake caliper bleed screw M8 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)
Upper handlebar holder bolt M8 4 22 N·m (2.2 kgf·m, 16 lb·ft)
Lower handlebar holder nut M10 2 40 N·m (4.0 kgf·m, 30 lb·ft)
Clutch cable locknut M8 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Lower bracket pinch bolt M8 4 23 N·m (2.3 kgf·m, 17 lb·ft) See TIP.
Upper bracket pinch bolt M8 2 26 N·m (2.6 kgf·m, 19 lb·ft)
Lower ring nut M30 1 See TIP.
Drive sprocket nut M22 1 140 N·m (14 kgf·m, 103 lb·ft) Stake.
E
2-12
TIGHTENING TORQUES
TIP
Lower ring nut
1. Tighten the ring nut to 52 N·m (5.2 kgf·m, 38 lb·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 lb·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 lb·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
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 lb·ft) in this order.
4 1
3 2
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”.
2-13
TIGHTENING TORQUES
2-14
CABLE ROUTING
EAS20021
CABLE ROUTING
Handlebar 1 (front view)
J J
K L
12 14
I I
14
11 12 11 13 3 2
1
H 2
10
G 3
Q 11 4,A
5
4
I B
12,R C
6
9 5 E 8 7
13 O 5,M
2 13 9
5 2
15
15
16
N P 13
5
2-15
CABLE ROUTING
1. Clutch cable N. Fasten the horn lead at the tape with the
2. Clutch switch lead clamp. Install the clamp at the same height
as the clutch switch lead mounting clamp.
3. Handlebar switch lead (left) Face the clamp opening face toward the
4. Clamp forward of the vehicle.
5. Handlebar switch lead (left) (to horn) O. For MT10SPN/MT10SPNC
6. Main switch lead P. Fasten the horn lead at the tape with the
7. Wire harness clamp. Install the clamp at the same height
as the clutch switch lead mounting clamp.
8. Horn connector Face the clamp opening face toward the
9. Horn bracket forward of the vehicle. Install the clamp
10. Bracket above the colgate tube of the front brake
11. Handlebar switch lead (right) hose.
12. Front brake light switch lead Q. Fix the front brake light switch lead and
handlebar switch leads (right) with the
13. Front brake hose clamp within the range of “H”. Install the
14. Handlebar clamp opening face toward the rearward of
15. Clutch switch lead mounting clamp the vehicle.
16. Heat shrinkable tube R. Arrange the front brake light switch lead
under the handlebar switch lead (right).
A. Fix the clutch switch lead, handlebar
switch lead (left) and handlebar switch lead
(left) (to horn) with the clamp under the
upper bracket. Face the clamp opening
face toward the left side of the vehicle.
B. Route the clutch switch lead, front brake
light switch lead and handlebar switch lead
(right) over the handlebar switch lead (left).
C. Clutch switch lead, wire harness, front
brake light switch lead
D. Route the handlebar switch lead (left) over
the wire harness.
E. Insert the projection on the horn lead
clamp into the hole in the horn bracket.
F. Handlebar switch lead (left), handlebar
switch leads (right)
G. Fasten the grommet part of the brake hose
with the clamp and install at the bracket.
Face the clamp opening face toward the
forward of the vehicle.
H. Install the clamp within the range shown in
the illustration.
I. Rear of the vehicle
J. Top of the vehicle
K. Fasten the front brake light switch lead and
handlebar switch leads (right) with a rubber
band. Face the buckle of the rubber band
upward with the end pointing rearward.
Fasten the rubber band to the curved por-
tion of the handlebar.
L. Fasten the clutch switch lead and handle-
bar switch leads (left) with a rubber band.
Face the buckle of the rubber band upward
with the end pointing rearward. Fasten the
rubber band to the curved portion of the
handlebar.
M. Route the handlebar switch lead (left) (to
horn) through the inner side of the horn
bracket.
2-16
CABLE ROUTING
1 1
4,C D
3,A
E
2
2 1
3 2,F
B
9 8,I
7
6,G 5
2-17
CABLE ROUTING
1. Handlebar switch lead (right)

2. Front brake light switch lead
3. Clutch switch lead
4. Clamp
5. Handlebar switch lead (left)
6. Main switch lead
7. Wire harness
8. Clutch cable
9. Front fork stepping motor sub-lead
A. Route the clutch switch lead through the

left side of the clamp.
B. Route the clutch switch lead to the outside
of the handlebar switch leads (right) and
front brake light switch lead. Do not cross
the handlebar switch leads (right), clutch
switch lead and front brake light switch
lead.
C. Align with the white tape on the handlebar
switch lead (right) and the blue tape on the
front brake light switch lead and install the
clamp.
Place the handlebar switch leads (right)
over the front brake light switch lead.
The direction of the clamp opening does
not matter. After installing the bracket, it is
no problem for each lead wire to be mis-
aligned.
D. Top of the vehicle
E. Right of the vehicle
F. Route the clutch switch lead through the
front side of the front brake light switch
lead.
G. The main switch lead in front of the vehicle
from the clamp pass through the left side
of the wire harness and the front side of
the handlebar switch lead (left).
H. For MT10SPN/MT10SPNC
I. Route the clutch cable through the outside
of the front fork stepping motor sub-lead.
2-18
CABLE ROUTING
D 2
1 1
H G
3,F 6
3,A
4,B
C D
E
2 2
1 1
a 2 a
1 5
2-19
CABLE ROUTING
1. Handlebar switch lead (left) (to horn)

3. Auxiliary DC jack lead
4. Auxiliary DC jack coupler
6. Wire harness guide
A. Route the auxiliary DC jack lead through

the upside on the clutch switch lead and
handlebar switch lead (left).
B. Insert the clamp of the auxiliary DC jack
coupler to the hole of the wire harness
guide.
C. Route the handlebar switch lead (left) and
clutch switch lead above the line in figure
“a”.
D. For MT10SPN/MT10SPNC
E. Route the handlebar switch lead (left),
clutch switch lead and front fork stepping
motor sub-lead (right) above the line in fig-
ure “a”.
F. Pass the auxiliary DC jack lead to the
inside of the “G” and right side of the “H”.
G. Range 1
H. Range 2
2-20
CABLE ROUTING
D D 12,G D
10 14
11 H
F 9
13
5
15
1
2
J I 5 4 3
6,A D 6
3
9
1
C 6,B
6,E
C
2
8 7
8 7
2-21
CABLE ROUTING
1. Horn lead
3. Main switch lead
4. Auxiliary DC jack lead
6. Plastic locking tie
7. Main switch
8. Wire harness guide
10. Front brake light switch lead
11. Front fork stepping motor coupler (right)
12. Clutch cable
13. Auxiliary DC jack cover
14. Front fork stepping motor coupler (left)
A. Arrange the plastic locking tie is fixed at

the “I” position.
B. Arrange the plastic locking tie is fixed
within the range of “H”. Fasten the clutch
switch lead, horn lead and main switch
lead with the plastic locking tie. The bind-
ing part of the plastic locking tie face rear-
ward of the vehicle. Cut off the excess end
of the plastic locking tie.
C. Route the main switch lead between the
wire harness guide and the main switch.
D. For MT10SPN/MT10SPNC
E. Install the plastic locking tie align to the
base of the main switch lead. Fasten the
clutch switch lead, horn lead, front fork
stepping motor sub-lead and main switch
lead with the plastic locking tie. Fasten the
stepping motor sub-lead align to the blue
tape. Fasten the horn lead align to the gray
tape. The binding part of the plastic locking
tie face rearward of the vehicle. Cut off the
excess end of the plastic locking tie.
F. Fasten the handlebar switch leads (right),
front brake light switch lead and front fork
stepping motor sub-lead align to the tape
of the handlebar switch leads (right) with a
clamp.
G. Route the clutch cable through the hole of
the auxiliary DC jack cover.
H. Fasten the handlebar switch leads (left),
clutch switch lead and front fork stepping
motor sub-lead align to the tape of the han-
dlebar switch leads (right) with a clamp
under the upper bracket. Install the clamp
opening face toward the left side of the
vehicle.
I. Clamp the horn lead within the range as
shown in the figure.
J. Fix the clamp at the position as shown in
the figure.
2-22
CABLE ROUTING
Handlebar 5 (side view)
G 4,H
3,F 1
1,A
2,B
2,E
3,C
11
D
2
4
4
3 5
2
I
11 a
10
6,J
D
8,R
O
7
6,N 9
Q O
10,P
M
7,L
2-23
CABLE ROUTING
1. Handlebar switch lead (right) Q. 10 mm (0.39 in) or less

2. Clutch switch lead R. With the plastic locking tie passed through
3. Front brake light switch lead the hose, install the plastic locking tie to
the range “a” as shown in the illustration.
4. Horn lead Cut off the excess end of the plastic lock-
5. Wire harness bracket (right) ing tie.
7. Main switch lead
9. Hose
10. Wire harness bracket (left)
11. Headlight bracket
A. Fasten the clamp of the handlebar switch

lead (right) into the hole in the wire har-
ness bracket (right).
B. Fasten the clamp of the clutch switch lead
into the hole in the wire harness bracket
(right).
C. Fasten the clamp of the front brake light
switch lead into the hole in the wire har-
ness bracket (right).
D. Do not cross other leads between the
clamps.
E. Fasten the clamp of the clutch switch lead
into the hole from the inside of the bracket.
F. Fasten the clamp of the front brake light
switch lead into the hole from the inside of
the bracket.
G. Fasten the clamp of the handlebar switch
lead (right) into the hole from the inside of
the bracket.
H. Route the horn lead between the clutch
switch lead and handlebar switch lead
(right).
I. Route the horn lead and clutch switch lead
to the inside of the handlebar switch lead
(left) clamp.
J. Fasten the clamp of the handlebar switch
lead (left) into the hole in the wire harness
guide.
K. Fasten the clamp of the main switch lead
into the hole in the wire harness guide.
L. Main switch lead should not come out in
front of the front fork when the handlebar is
in a straight position.
M. Fasten the clamp of the main switch lead
into the hole of the wire harness bracket
(left).
N. Fasten the clamp of the handlebar switch
lead (left) into the hole of the wire harness
bracket (left).
O. Tighten the plastic locking tie until the hose
contacts the lock part on the plastic locking
tie.
P. Install the plastic locking tie with the buckle
facing the inside of the vehicle and the end
facing the bottom of the vehicle.
2-24
CABLE ROUTING
Headlight (front view)
1,A
2
3
C
4,D
4,B
2-25
CABLE ROUTING
1. Auxiliary light coupler

2. Meter coupler (gray)
3. Wire harness
4. Main switch coupler
5. Headlight bracket
A. Insert the auxiliary light coupler into the rib

of the bracket.
B. Insert the main switch coupler into the rib
of the headlight bracket.
Fasten the main switch coupler below the
rib on the headlight assembly.
C. Insert the projection on the wire harness
clamp into the hole in the headlight
bracket.
D. Insert the projection on the main switch
coupler into the hole in the headlight
bracket.
2-26
CABLE ROUTING
Frame and engine 1 (left side view)
1 16,F 1 19
15,F 20
18
12
17,F
J G
14
E 13 2
1
21
4,H
3 I
4
12 13 14
9,D 4
11 5
B
10
8,C 7 6
2-27
CABLE ROUTING
1. Air scoop stay bracket

2. Wire harness
3. Air scoop stay (left)
4. Air filter case duct
5. Front brake hose bracket
6. Brake hose (front brake hose joint to front
brake calipers)
7. Brake hose (front brake master cylinder to
front brake hose joint)
8. Front wheel sensor lead
9. Clamp
10. Grommet
11. Radiator bracket
12. Radiator fan motor lead (right)
13. Radiator fan motor lead (left)
14. Turn signal/position light lead (left)
15. Radiator fan motor coupler (white)
16. Turn signal/position light coupler (left)
17. Radiator fan motor coupler (black)
18. AC magneto coupler (gray)
19. Rectifier/regulator
20. Rectifier/regulator coupler (black)
21. AC magneto lead
A. Route the wire harness through the hook

of the air scoop stay bracket.
B. Insert the projection on the front wheel
sensor lead coupler (white) into the hole in
the air filter case duct.
C. Fasten the positioning tape of the front
wheel sensor lead to the hook of the front
brake hose bracket. The front wheel sen-
sor lead positioning tape is located in front
of the vehicle from the hook on the front
brake hose bracket.
D. Install the clamp completely to the radiator
bracket in the grommet position. Face the
opening of the clamp forward.
E. Route the radiator fan motor lead (right),
radiator fan motor lead (left) and the turn
signal/position light lead (left) through the
notch of the air scoop stay.
F. Install the clamp of the wire harness cou-
pler to the bracket hole.
G. Left side of the vehicle
H. Route the wire harness, the rectifier/regu-
lator lead and the AC magneto lead
through the hook of the air filter case duct.
I. Route the AC magneto lead through the
inside of the wire harness.
J. Fix the clamp of the turn signal/position
light lead (left) to the air scoop stay
bracket.
2-28
CABLE ROUTING
Frame and engine 2 (left side view)
H 17
K 11 18,L
J
1 11
6,I
12 10
1,M
16 17 1
15
2
14,D
13
12 3
C
11
4
G
9 19
5
4 6,A
10 7
E 20 7
8
F
21
4
10 9,B
S
4 10
7
6
22,O O
9,O 22,N
4,R O 6
7
10,R 9,N Q
7,R P
10
2-29
CABLE ROUTING
1. Shift sensor lead K. Inside of the vehicle

2. Gear position sensor lead L. Fasten the thermostat housing cover and
3. Gear position sensor coupler (black) positioning tape of the shift sensor lead
with the plastic locking tie. Point the end of
4. Oil pressure switch lead the plastic locking tie forward. Do not cut
5. Shift sensor off the excess end of the plastic locking tie.
6. Clamp M. Route the shift sensor lead between the
7. Sidestand switch lead projections on the thermostat housing
cover.
8. Sidestand switch
9. Fuel tank drain hose N. The fuel tank drain hose and fuel tank
breather hose should extend out of the
10. O2 sensor lead (left) clamp by 50 mm (1.97 in) or more. Route
11. Thermostat housing cover the fuel tank drain hose and fuel tank
12. Throttle position sensor lead breather hose through the outer side of the
O2 sensor lead, oil pressure switch lead,
13. Stator coil lead and sidestand switch lead. The fuel tank
14. O2 sensor coupler (black) breather hose and fuel tank drain hose
15. Throttle position sensor coupler (black) may be routed in any order.
16. Throttle position sensor O. The fuel tank breather hose and fuel tank
drain hose may be routed in any order.
17. Coupler cover
P. Rear side of the vehicle
Q. Left side of the vehicle
19. Drive sprocket cover
R. The O2 sensor lead (left), oil pressure
20. Engine oil level check window switch lead and sidestand switch lead may
21. Oil pressure switch be routed in any order.
22. Fuel tank breather hose S. Except for California.
A. Fix the fuel tank drain hose, O2 sensor
lead, sidestand switch lead and oil pres-
sure switch lead with clamp and insert
them into the holder.
B. The fuel tank drain hose should extend out
of the clamp by 50 mm (1.97 in) or more.
Route the fuel tank drain hose through the
outer side of the O2 sensor lead, oil pres-
sure switch lead, and sidestand switch
lead.
C. Route the oil pressure switch lead, side-
stand switch lead, O2 sensor lead, shift
sensor lead and stator coil lead to the front
side of the thermostat housing cover.
D. After connecting the O2 sensor coupler
(black), attach the coupler cover.
E. Install the oil pressure switch terminal so
that it align the underside of the engine oil
level check window.
F. Line that touches the engine oil level check
window.
G. Route the oil pressure switch lead, side-
stand switch lead, O2 sensor lead and fuel
tank drain hose backside the drive
sprocket cover as shown in the illustration.
The oil pressure switch lead, sidestand
switch lead and O2 sensor lead may be
routed in any order.
H. Place the oil pressure switch lead, side-
stand switch lead, shift sensor lead, and
stator coil lead inside the clamp so that the
throttle position sensor lead is on the out-
side of the vehicle. Place the coupler cover
inside the vehicle.
I. Clamp opening
J. Front side of the vehicle
2-30
CABLE ROUTING
Frame and engine 3 (right side view)
14
15 16
3,P
10
13
1
F
E A
O
2
3
1
14
B
4 7
5,K
G H
5
4,L C
9,M
6,D I
5 11
7,N 4
11
8 J 12
12
2-31
CABLE ROUTING
1. Wire harness O. Route the sub-wire harness (SCU) into the

2. Relay unit C-shaped hole.
3. Front turn signal/position light lead (right) P. Insert the projection on the wire harness
clamp into the hole in the air scoop stay
4. Coolant reservoir breather hose bracket (right).
5. Clutch cable
6. O2 sensor lead (right)
7. Clamp
8. Radiator outlet hose
9. Cooling system air bleed hose
10. Intake air temperature sensor coupler
11. Bottom side cowling
12. Bottom side cowling (right)
13. SCU (Suspension Control Unit)
14. Air scoop stay (right)
15. Air scoop stay bracket (right)
16. Front turn signal/position light coupler (right)
A. Fasten the front turn signal/position light

coupler (right) to the air scoop stay
bracket.
B. Route the front turn signal/position light
lead (right) through the cutout in the air
scoop stay.
C. Fasten the clamp in position above the ver-
tical line on the frame bolt. Face the open-
ing of the clamp to the inside of the vehicle
to install it.
D. Insert the O2 sensor lead into the mating
surface of the clutch cover.
E. Route the wire harness into the C-shaped
hole.
F. Fix the front turn signal/position light lead
(right) to the hook of the air scoop stay
bracket.
G. Inside of the vehicle
H. Outside of the vehicle
I. For MT10SPN/MT10SPNC
J. Route the coolant reservoir breather hose
and clutch cable through the recesses in
the bottom cowling and the notches in the
bottom side cowling (right). The coolant
reservoir breather hose and the clutch
cable do not overlap in the lateral direction
of the vehicle.
K. Fasten the clamp of the clutch cable to the
bracket.
L. Route the coolant reservoir breather hose
to the outside of the cooling system air
bleed hose and clutch cable.
M. Route the clutch cable through the inner
side of the coolant reservoir breather hose
and cooling system air bleed hose.
N. Fasten the clutch cable at the paint mark
on the coolant reservoir breather hose.
Assemble the clamp so it contacts the
folded surface of the radiator fan bracket.
2-32
CABLE ROUTING
Frame 1 (top view)
24 1 2 3
23,J 4
5,A
22,J
6
21,J
7,B
8
20
9
10,C
19,J
D
18,I 11,E
F
17,H 12
G 13
16 15 14
26 27 26 N 7,K
26 N 7,P
25
M 14
M
12,O
L 25
L 25
31
28
30
29
2-33
CABLE ROUTING
1. Injector #4 coupler (gray) I. Insert the projection on the clutch switch

2. Injector #3 coupler (gray) coupler holder into the hole in the air filter
case duct.
3. Rear brake light switch coupler (black)
J. Insert the projection on the handlebar
4. O2 sensor coupler (right) (black) switch coupler (left) holder into the hole in
5. Neutral switch coupler the air filter case duct.
6. Rear brake light switch lead K. Use a plastic locking tie to fasten the
7. Plastic locking tie crankshaft position sensor coupler and
throttle position sensor lead to the fuel rail.
8. Fuel pump coupler (black)
L. The end of the plastic locking tie points to
9. Rear wheel sensor lead the range as shown in the illustration.
10. Rear wheel sensor coupler (white) M. Front of the vehicle
11. Engine ground N. Top of the vehicle
12. Starter motor lead O. Route the starter motor lead to the rear of
13. Injector #2 coupler (gray) the vehicle from the heat protector.
14. Crankshaft position sensor coupler (natural) P. Align the plastic locking tie with the small
15. Injector #1 coupler (gray) diameter part of the fuel rail and install it.
16. Intake air pressure sensor coupler (blue) Align with the white tape of the wire har-
ness and fasten the wire harness to the
17. Front brake light switch coupler (black) under side of the fuel rail with a plastic
18. Clutch switch coupler (dark gray) locking tie.
19. Handlebar switch coupler (left) (white)
20. Atmospheric pressure sensor coupler (blue)
21. Handlebar switch coupler (left) (black)
22. Handlebar switch coupler (left) (white)
23. Handlebar switch coupler (left) (natural)
24. Throttle servo motor coupler (black)
25. Wire harness
26. Fuel rail
27. Crankcase breather hose
28. Fuel hose
29. Heat protector
30. Canister purge hose (for California)
31. Shift sensor coupler
A. Connect to the engine side coupler on the

bottom of the wire harness.
B. Fasten the wire harness to the frame with a
plastic locking tie.
C. After connecting, push in the rear wheel
sensor coupler between the wire harness
and frame.
D. Route the negative battery lead, from the
bolt part to the taping part, on the outer
side of the wire harness.
E. Fasten the engine ground leads and nega-
tive battery lead with the bolt so that the
crimped section of the terminal is facing
upward. Install with the engine ground
leads on the bottom and the negative bat-
tery lead on top.
F. Route the fuse box lead under the negative
battery lead.
G. Insert the projection on the wire harness
clamp into the hole in the air filter case
duct.
H. Insert the projection on the front brake light
switch coupler holder into the hole in the
air filter case duct.
2-34
CABLE ROUTING
Frame 2 (top view)
D
E
15
14
F
13
16,G
J
10
12 8
11 10 9
7,B 5
E
15
1 18
K
3,A 19,H
16,I
1 17
4
2-35
CABLE ROUTING
1. Engine ground
2. Wire harness
3. Rear brake light switch lead
4. Canister
brake hose joint)
6. Brake hose (brake hose joint to front brake
caliper (left))
8. Sidestand switch coupler (black)
9. Coolant temperature sensor coupler (white)
10. Rear brake light switch coupler (black)
11. Shift sensor coupler (black)
12. Main frame
13. Sidestand switch lead
14. Junction coupler
15. Sub-wire harness (SCU (Suspension control
unit))
16. Clamp
17. Rear frame
18. Starter motor lead
unit)) coupler
A. Fasten the rear brake light switch lead to

the clamp of the canister.
B. Route the cooling system air bleed hose
under the brake hoses.
C. Route the clutch switch lead, front brake
light switch lead and wire harness (to
headlight and meter assembly) through the
left side of the steering head pipe. Place
the wire harness junction coupler on the
left side of the head pipe cavity.
D. Route the handlebar switch lead (left) and
handlebar switch lead (right) through the
right side of the steering head pipe.
E. For MT10SPN/MT10SPNC
F. Fasten the Sub-wire harness (SCU (Sus-
pension control unit)) with the hook on the
air filter case duct.
G. Insert the projection on the clamp into the
hole in the main frame and install the
clamp.
H. When connecting the Sub-wire harness
(SCU (Suspension control unit)) couplers,
connect the lead wire couplers with yellow
tapes and the lead wire couplers without
tape.
I. Fasten the starter motor lead and Sub-wire
harness (SCU (Suspension control unit))
with a clamp at the position in front of the
vehicle from the rear frame mounting part.
J. Assemble the Sub-wire harness (SCU
(Suspension control unit)) by aligning the
blue tape end face of the Sub-wire harness
(SCU (Suspension control unit)) with the
end face of the clamp.
K. For California
2-36
CABLE ROUTING
Frame 3 (top view)
C
3 4 5 6 7 8 12,D
2
13
9
1,B 10
11 14
A C
14,E
13
3
C 14,F
3 24,J
15
21 17
16 18,D C
G 14
3
17
22
23,I 1,H 20,D 19,D
2-37
CABLE ROUTING
1. Air induction system hose (air filter case to air

cut-off valve)
2. Ignition coil #1 coupler
3. Wire harness
5. Air cut-off valve
6. Cylinder identification sensor
8. Cylinder identification sensor coupler (black)
10. Air cut-off valve coupler (natural)
12. Front fork stepping motor coupler (white)
13. Main frame
unit))
15. Throttle body
17. Bracket
18. Accelerator position sensor coupler (black)
19. Handlebar switch coupler (right) (natural)
20. Handlebar switch coupler (right) (black)
21. Front brake light switch coupler (black)
22. Clutch switch coupler (dark gray)
23. AC magneto lead
24. Clamp
A. Route the air cut-off valve lead and cylin-

der identification sensor lead under the
wire harness.
B. Route the air induction system hose (air fil-
ter case to air cut-off valve) over the wire
harness.
C. For MT10SPN/MT10SPNC
D. Insert the projection on the coupler holder
into the hole in the air filter case duct.
E. Do not cross the sub-wire harness (SCU
(Suspension control unit)) to the wire har-
ness.
F. Push in the sub-wire harness (SCU (Sus-
pension control unit)) to the under of the
throttle body.
G. Insert the projection on the clamp of the
sub-wire harness (SCU (Suspension con-
trol unit)) into the hole in the bracket.
H. Route the air induction system hose (air fil-
ter case to air cut-off valve) between the
wire harness (frame side) and wire har-
ness (air filter case duct side).
I. Route the AC magneto lead through the
outside of the air induction system hose
(air filter case to air cut-off valve).
J. Insert the projection on the clamp into the
hole in the main frame.
2-38
CABLE ROUTING
Frame 4 (top view)
I 19 11 12
18 A
13,F 13,F
14
17
16 15
J
18 19 A 12
13,F 13,F
16 14
1
A
2
9
10,E I
B
7,D 6,C 5 4 3
2-39
CABLE ROUTING
1. Sidestand switch coupler (black)

2. Coolant temperature sensor coupler (white)
3. Sidestand switch lead
4. Rear brake light switch coupler
5. Shift sensor coupler
6. Shift sensor lead
7. Oil pressure switch lead
8. Wire harness
9. Wire harness (to joint coupler)
10. Coolant temperature sensor lead
11. Purge cut valve holder
12. Air filter case
13. Clamp
15. Canister purge hose (purge cut valve to hose
joint)
16. Fuel hose
17. Canister purge hose (purge cut valve to can-
ister)
18. Fuel tank drain hose
19. Fuel tank breather hose
A. Top of the vehicle

B. Left side of the vehicle
C. Route the shift sensor lead under the side-
stand switch lead.
D. Pass the oil pressure switch lead between
the wire harness and wire harness (joint
coupler).
E. Pass the coolant temperature sensor lead
between the hose joint of the throttle body.
F. Insert the projection on the wire harness
clamp from underside into the hole in the
air filter case.
G. Route the shift sensor lead and sidestand
switch lead from the canister purge hose
(purge cut valve to hose joint), canister
purge hose (purge cut valve to canister),
fuel tank breather hose, fuel tank drain
hose and crankcase breather hose to the
forward of the vehicle.
H. Route the shift sensor lead and sidestand
switch lead from the fuel tank breather
hose, fuel tank drain hose and crankcase
breather hose to the forward of the vehicle.
I. For California.
J. Except for California.
2-40
CABLE ROUTING
Rear fender 1 (top view)
I 28,J 1,H
29 31 29
27
25,G 1,A
30 26
30 28,J 2,B
5
32,K
6
7
27
8
7 11,L
9
10
27 11
24 12,C
23
D
1,F
22 13
21
19 15,E 14
20
17,M 18 34
16
34 25 17,M
33,N 34 34 35,O
17
2-41
CABLE ROUTING
1. Clamp K. Insert the rubber part of the YDT coupler

2. Starter motor lead into the step of the battery box rib.
3. Tail/brake light relay L. Route the positive battery lead under bat-
tery box 2 and wire it from the back to the
4. Radiator fan motor relay top of the starter relay.
5. Starter relay lead M. Install the license plate light lead securely
6. ABS ECU coupler to the claw of the plate 1.
7. Starter relay N. Route the tail/brake light lead (left) through
8. Starter relay coupler the hole of the plate.
9. Main fuse O. Route the tail/brake light lead (right) on the
plate to outside of the vehicle.
10. Battery
11. Positive battery lead
12. Fuse box 2
13. ECU coupler 1
14. ECU coupler 2
15. Wire harness (to EXUP servo motor lead)
16. EXUP servo motor coupler (black)
17. License plate light lead
18. Tail/brake light coupler (white)
19. License plate light coupler (white)
20. IMU coupler (natural)
21. ECU coupler 3
22. IMU lead
23. Fuse box 1
24. Negative battery lead
25. Wire harness (to fuse box)
26. Wire harness
27. Battery box 2
28. Fuse box 3
29. Rear frame
30. Battery box 1
31. Fuse box 4
32. YDT coupler
33. Tail/brake light lead (left)
34. Plate 1
35. Tail/brake light lead (right)
A. Fasten the starter motor lead to the clamp.

B. Place the white tape of the starter motor
lead than the clamp to the rearward of the
vehicle.
C. Insert fuse box 2 into the claw of the bat-
tery box 1.
D. Route the wire harness with a white tape
pass over the wire harness without a tape.
E. Route the wire harness (to EXUP servo
motor lead) to the right side of the vehicle
on the plate projection.
F. Insert the clamp into the hole in the plate.
G. Route the wire harness (to fuse box) to the
bottom the hydraulic unit assembly.
H. Insert the clamp into the hole in the battery
box 2.
I. For MT10SPN/MT10SPNC
J. Insert the fuse box 3 into the claws of the
battery box 1.
2-42
CABLE ROUTING
Rear fender 2 (top view)
3
1
4
2 8
3,C A
B B
F 3 1,E
2-43
CABLE ROUTING
1. Rear turn signal light lead (right)

2. Rear turn signal light resistor (right)
3. Rear turn signal light lead (left)
4. Rear turn signal light resistor (left)
5. Rear turn signal light lead (resistor side)
6. Tail/brake light lead
7. Rear turn signal light lead
8. License plate light lead
A. Route the rear turn signal light leads to the

forward of the vehicle on the plate projec-
tion.
B. Insert the end of the rear turn signal light
resistor into the pipe end of the rear frame
by the aiming.
C. Install the rear turn signal light lead (left)
securely to the claw of the plate.
D. Pass the rear turn signal light resistors to
the inside the rib of the battery box.
E. Route the rear turn signal light lead (right)
through the lower side of the rear turn sig-
nal light lead (left).
F. Install the rear turn signal light leads
securely to the claw of the plate.
2-44
CABLE ROUTING
Rear fender 3 (left side view)
15 1 A
G
14 2 2
13
14
12
10 9,C
11,D 2
3
4
5,B
8 7 6
12,13
F
E
2-45
CABLE ROUTING
1. Main fuse
2. Battery box 2
3. Positive battery lead
4. EXUP cable 1
5. EXUP cable 2
6. Wire harness (to ECU 1 coupler)
8. Battery box 1
9. Wire harness (fuse box)
11. Negative battery lead
12. Tail/brake light relay
13. Radiator fan motor relay
14. Starter relay
15. Starter relay cover
A. Insert the main fuse into the claw of the

battery box 2.
B. Place the EXUP cable 2 under the EXUP
cable 1.
C. Place the wire harness (to fuse box) inside
the wire harness (to ECU 3 coupler).
D. Arrange the Negative battery lead next to
the wire harness (to ECU 3 coupler).
E. The wire harness (to fuse box), wire har-
ness (to ECU 3 coupler) and negative bat-
tery lead can be offset as shown in the
figure.
Do not pinch the wire harness (to fuse
box), wire harness (to ECU 3 coupler) and
negative battery lead to the battery box 2.
F. Insert the brake light relay and the radiator
fan motor relay onto the claws the battery
box 1.
G. Push the starter relay cover completely
into the claw of the starter relay.
H. Push the starter relay completely into the
claw of the battery box 2.
2-46
CABLE ROUTING
EXUP cable (top side view)
A B
2
C
2-47
CABLE ROUTING
1. Battery box 1
2. EXUP cable 2
3. Cover
4. EXUP cable 1
A. Route the EXUP cable 1 and EXUP cable

2 to the outside of the vehicle of the battery
box 1 protrusion.
B. Route the EXUP cable 1 and EXUP cable
2 to the bottom side of the vehicle of the
battery box 1 protrusions.
C. Pass EXUP cable 1 and EXUP cable 2
through the opening of the cover on the
battery box 1.
2-48
CABLE ROUTING
Front brake hose 1 (left side view)
E K
2 1
2
3
I A
H
7,J B
5 3
3,C
B
G
E
D 5
6 4
5
6
3,D
2-49
CABLE ROUTING

front brake master cylinder hose joint)
2. Brake hose (front brake caliper hose joint
to front brake calipers)
3. Front wheel sensor lead
4. Front brake caliper
5. Front fork
6. Front wheel sensor protector
7. Clamp
A. Face the opening of the clamp toward the

front of the vehicle.
B. Clamp the brake hose (front brake caliper
hose joint to front brake calipers) with the
painted part.
C. Make the front wheel sensor lead to follow
the brake hose (front brake caliper hose
joint to front brake calipers) without slack-
ing.
D. When installing the brake hose (front brake
caliper hose joint to front brake calipers),
contact the pipe section of the brake hose
to the stopper of the front brake caliper and
tighten it.
E. For MT10SPN/MT10SPNC
F. Route the front wheel sensor lead through
the guide of the front wheel sensor protec-
tor.
G. Fasten the white tape portion of the front
wheel sensor lead with the holder.
H. Rearward
I. 45°
J. Align the clamp direction to the range as
shown in the illustration.
K. The clamp is located and installed on the
flange of the tube of the brake hose (front
brake caliper hose joint to front brake cali-
pers).
2-50
CABLE ROUTING
Front brake hose 2 (left side view)
9 7 B 5
10
10
3
C 8 4
1,A
2
3
4 5 6
10
9 8 7
10 1,A
9 2
2-51
CABLE ROUTING
1. Clamp
2. Brake hose bracket
3. Brake hose joint bracket
4. Brake hose (hydraulic unit to front brake cali-
per hose joint)
5. Brake hose (front brake master cylinder hose
joint to hydraulic unit)
6. Hydraulic unit assembly
7. Front brake master cylinder hose joint
8. Front brake caliper hose joint
front brake master cylinder hose joint)
10. Brake hose (front brake caliper hose joint to
front brake calipers)
A. Insert the clamp all the way to the rear of

the brake hose bracket.
B. When installing the brake hose (front brake
caliper hose joint to front brake calipers),
contact the pipe section of the brake hose
to the stopper of the brake hose joint
bracket and tighten it.
C. When installing the brake hose (front brake
master cylinder to front brake master cylin-
der hose joint), contact the pipe section of
the brake hose to the stopper of the brake
hose joint bracket and tighten it.
2-52
CABLE ROUTING
Rear brake hose 1 (right side view)
2
11,B
4
10,A 12
1
9 1
3
1
3
C
6
5 13,E
6
D
4 1
2 3
3,F
1,J 14 5
6
7
G
8,I
4,H
5
6 6 5 4
3 9
2-53
CABLE ROUTING
1. Rear brake hose (hydraulic unit to rear brake

caliper)
2. Rear brake light switch lead
3. Rear brake hose (rear brake master cylinder
to hydraulic unit)
4. Rear wheel sensor lead
5. EXUP cable 1
6. EXUP cable 2
7. Brake fluid reservoir hose
8. Rear wheel sensor lead hook
9. Rear brake master cylinder assembly
10. Rear brake hose bracket
11. Collar
12. Grommet
14. Main frame
A. Insert the stopper of the rear brake hose

bracket into the hole in the rear frame.
B. Install the plate part of the collar toward the
nut side.
C. Top of the vehicle
D. Inside of the vehicle
E. Fasten the caulked section of the rear
brake hose (hydraulic unit to rear brake
caliper) and the white tape section of the
rear wheel sensor lead with the plastic
locking tie. Face the buckle of the plastic
locking tie topward with the end pointing
inward. The rear wheel sensor lead and
rear brake light switch lead may be routed
in any order.
F. Route the rear brake hose (rear brake
master cylinder to hydraulic unit) between
the EXUP cables and the frame.
G. When installing the rear brake hose to the
master cylinder assembly, make sure that
the stopper contacts the outside of the pro-
jection on the master cylinder assembly.
H. Fasten the grommet of the rear wheel sen-
sor lead with the rear wheel sensor lead
hook.
I. Make sure that the stopper of the rear
wheel sensor lead hook contacts the rib of
the swingarm.
J. Fasten the grommet of the rear brake hose
(hydraulic unit to rear brake caliper) with
the clamp.
2-54
CABLE ROUTING
Rear brake hose 2 (right side view)
1,G 1,H
9
5
F
1
A 2
5
5
B
3 5 4,C 2
4,E
3 4,D
2-55
CABLE ROUTING

caliper)
2. Rear wheel sensor cover
3. Rear wheel sensor protector
4. Rear wheel sensor lead
5. Swingarm
6. Rear brake caliper
7. Rear brake hose holder
8. Clamp
9. Rear fender
A. The rear wheel sensor lead does not pro-

trude outside the rear wheel sensor cover.
B. Pass the rear wheel sensor lead between the
swingarm and the rear wheel sensor cover.
C. Install the rear wheel sensor lead grommet
securely to the claw of the rear wheel sensor
cover.
D. Install the rear wheel sensor lead grommet
securely to the claw of the rear wheel sensor
protector.
E. Install the rear wheel sensor lead securely to
the claw of the rear wheel sensor protector.
F. When installing the rear brake hose (hydrau-
lic unit to rear brake caliper) to the rear brake
caliper, fit the metal fitting of the rear brake
hose into the recess of the rear brake caliper.
G. Route the rear brake hose (hydraulic unit to
rear brake caliper) through the guide on the
rear brake hose holder.
H. Install the rear brake hose (hydraulic unit to
rear brake caliper) to the clamp of the rear
fender.
2-56
CABLE ROUTING
Hydraulic unit (top view)
1 2 3 4
A
D
2-57
CABLE ROUTING
1. Front brake hose (hydraulic unit to front brake

caliper hose joint)
2. Front brake hose (front brake master cylinder
hose joint to hydraulic unit)
3. Rear brake hose (rear brake master cylinder
to hydraulic unit)
caliper)
5. Hydraulic unit
A. 78.4°
B. 125.4°
C. 117.3°
D. 106°
E. Front of the vehicle
2-58
CABLE ROUTING
Fuel tank (front side view) (except for California)
A
1,B
3
2-59
CABLE ROUTING
1. Clip
3. Fuel tank breather hose
A. Face the white paint mark on the fuel tank

breather hose toward the front of the vehi-
cle.
B. Make sure that the clip does not go on top
of the spool part. The clips may be
installed any positions.
2-60
CABLE ROUTING
Canister (front side view) (for California)
3 9 H I J
7 5
K
1 1
G 1,L
A
1,B
C
F 3 C 5 1,D
E
7
1,D
9 9
8
5
7 6
2-61
CABLE ROUTING
1. Clip
2. Fuel tank breather hose (fuel tank to canis-
ter)
3. Purge cut valve
5. Canister purge hose (purge cut valve to
canister)
6. Canister
hose joint)
8. Fuel hose
9. Purge cut valve holder
A. Face the white paint mark on the fuel tank

breather hose (fuel tank to canister) toward
the front of the vehicle.
B. Make sure that the clip does not go on top
of the spool part. The clips may be
installed any positions.
C. To throttle body assembly
D. Align the center of the clip on end face of
the holder.
E. Yellow paint mark
F. White paint mark
G. Install the canister purge hose completely
onto the purge cut valve.
H. Details for clip assembly position.
I. 3 mm (0.12 in) or more
J. 45°
K. Paint mark
L. Paint marks and clips are assembled
according to each standard. Be careful do
not locate the clip onto the spool part.
2-62
CABLE ROUTING
Canister (top and left side view) (for California)
1
F A
E E
D B
2,C 2,C
4 3
10
9
8 4
I 5
H 2,G 6 3
2-63
CABLE ROUTING
1. Canister
2. Hose clamp
3. Fuel tank breather hose (fuel tank to canis-
ter)
canister)
5. Fuel hose
hose joint)
7. Throttle body assembly
9. Air filter case
A. Insert the fuel tank breather hose (fuel tank

to canister) to the position as shown in the
illustration.
B. Face the white paint mark on the fuel tank
breather hose (fuel tank to canister) down-
ward of the canister and install it.
C. Face the center of the hose clamp down-
ward of the canister.
D. Face the yellow paint mark on the canister
purge hose (purge cut valve to canister)
downward of the canister and install it.
E. 2 mm (0.08 in) or less
F. Insert the canister purge hose (purge cut
valve to canister) to the position as shown
in the illustration.
G. Face the center of the hose clamp down-
ward of the vehicle.
H. Insert the canister purge hose (purge cut
valve to hose joint) until stops.
I. Face the white paint mark on the canister
purge hose (purge cut valve to hose joint)
topward of the vehicle and install it.
2-64
CABLE ROUTING
Air filter case and throttle bodies (rear side view)
6 D
2,B
A
5
4 3 C
2-65
CABLE ROUTING
1. Air filter case

2. Hose clamp
hose joint) (for California)
4. Fuel hose
A. Install the crankcase breather hose com-

pletely.
B. Install the hose clamp so that the bottom
edge of the hose clamp is 0–5 mm (0–0.2
in) from the hose end. Point the end of the
hose clamp to the right.
C. Yellow paint mark
D. To purge cut valve (for California)
E. To fuel tank
2-66
CABLE ROUTING
Air cut-off valve (front side view)
A 1
B
C
5 5
7 6
2-67
CABLE ROUTING
1. Air filter case

2. Air induction system hose (air filter case to
air cut-off valve)
3. Cylinder head cover
4. Reed valve cover
5. Air induction system hose (air cut-off valve
to reed valve cover)
7. Cylinder identification sensor lead
A. Insert the air induction system hose (air

cut-off valve to read valve cover) until it
contacts the reed valve cover. Make sure
that the clamp does not go on top of the
flange of the hose.
B. Install the air induction system hose (air fil-
ter case to air cut-off valve) with its white
paint mark facing outward. Make sure that
the hose clamp does not go on top of the
spool part.
C. Point the end of the hose clamp to the left
side of the vehicle.
D. Point the end of the hose clamp to the right
side of the vehicle.
2-68
CABLE ROUTING
Radiator (both side view)
E
F G H
I L
7 J K
5 6,D
1,A
2
3
2-69
CABLE ROUTING
1. Clamp
2. Radiator
4. Radiator inlet hose
5. Coolant reservoir hose
6. Clip
7. Hose clamp
A. Fasten the radiator fan motor lead (left)

and radiator fan motor lead (right) with the
clamp.
B. Align the white paint mark on the radiator
inlet hose, projection on the radiator, and
opening of the hose clamp. Install the radi-
ator outlet hose up to the center of the pro-
jection on the radiator. After installing the
hose clamp, the end of the radiator outlet
hose should be over the projection on the
radiator.
C. Align the white paint mark on the radiator
outlet hose, projection on the radiator, and
opening of the hose clamp. Install the radi-
ator outlet hose up to the center of the pro-
jection on the radiator. After installing the
hose clamp, the end of the radiator outlet
hose should be over the projection on the
radiator.
D. Face the clip end to outside. Do not locate
the clip onto the spool part.
E. Hose clamp fixed position details.
F. Make sure that the projection on the center
of the hose clamp contacts with the cut out
in the end of the hose clamp.
G. 3 mm (0.12 in) or more
H. Do not locate the hose clamp onto the
spool part.
I. Install the hose clamp so that both ends
are parallel to each other.
J. Hose plug-in section
K. 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.
L. Make sure that the hose clamp is not
installed in a slanted position as shown in
the illustration.
2-70
CABLE ROUTING
Water hose (right side view)
G O I R
H I J 3,P S
K 2,A
Q
L L
L
3
N
1 2,A
F E
5 3,B 4
2-71
CABLE ROUTING

2. Clamp
3. Hose clamp
5. Water pump inlet pipe
A. Install the clamp with the end pointing

upward. Do not locate the clamp onto the
spool part.
B. Align the yellow paint mark on the radiator
outlet hose with the white paint mark on
the water pump inlet pipe. Insert the radia-
tor outlet hose to the center of the paint
mark on the water pump inlet pipe.
C. Yellow paint mark
D. Face the cover end to outside of the vehi-
cle.
E. Face the bolt head of the hose clamp to the
right side of the vehicle.
F. 45°
G. Hose clamp fixed position details.
H. Make sure that the projection on the center
I. 3 mm (0.12 in) or more
J. Do not locate the hose clamp onto the
spool part.
K. Install the hose clamp so that both ends
L. Hose plug-in section
M. Make sure to hook the end of the hose
hose clamp. (Do not install the hose clamp
as shown in the illustration.)
N. Make sure that the hose clamp is not
the illustration.
O. Hose clamp (screw band type) fixed posi-
tion details.
P. Do not locate the hose clamp (screw band
type) onto the spool part.
Q. 0–1 mm (0–0.04 in)
R. Clamp installation details
S. 2 mm (0.08 in) or more
2-72
CABLE ROUTING
Water hose (left side view)
F N
G H I O
J M 3,A
5 K L K
1 2 3,A
E D
2-73
CABLE ROUTING

3. Clamp
4. Thermostat assembly
5. Hose clamp
A. Face the clamp end to the white paint mark

on the cooling system air bleed hose. Do
not locate the clamp onto the spool part.
B. Align the white paint mark on the cooling
system air bleed hose with the projection
on the thermostat housing. Insert the cool-
ing system air bleed hose until it contacts
the projection on the thermostat housing.
C. Align the yellow paint mark on the radiator
inlet hose with the projection on the ther-
mostat housing cover and oval shaped pro-
jections on the hose clamp. Insert the
radiator inlet hose until it contacts the pro-
jection on the thermostat housing cover.
D. Oval shaped projection on the hose clamp
(2 locations)
E. Face the opening of the hose clamp to the
left side of the vehicle.
F. Hose clamp fixed position details.
G. Make sure that the projection on the center
H. 3 mm (0.12 in) or more
I. Do not locate the hose clamp onto the
spool part.
J. Install the hose clamp so that both ends
K. Hose plug-in section
L. Make sure to hook the end of the hose
hose clamp. Do not install the hose clamp
as shown in the illustration.
M. Make sure that the hose clamp is not
the illustration.
N. Clamp installation details
O. 2 mm (0.08 in) or more
2-74
CABLE ROUTING
Muffler (top and left side view)
7
7 4
6
2
1 B
A
B
7 C 6 5
2-75
CABLE ROUTING
1. Exhaust chamber
2. EXUP valve pulley cover
3. Muffler
4. EXUP servo motor
5. Right footrest assembly
6. EXUP cable 1
7. EXUP cable 2
A. Route the EXUP cables through the hole in

the front side of the battery box 1.
B. Locate the EXUP cable 2 to outside of the
vehicle and EXUP cable 1 to inside of the
vehicle.
C. Clamp the grommets of the EXUP cables.
Position EXUP cable 2 on the top and posi-
tion EXUP cable 1 on the bottom.
D. Hook the EXUP cables on the hook shape
of the bracket on the right footrest assem-
bly. Position EXUP cable 2 on the top and
position EXUP cable 1 on the bottom.
2-76
CABLE ROUTING
2-77
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE ............................................................................3-1

INTRODUCTION .......................................................................................3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM ...................................................................................................3-1
GENERAL MAINTENANCE AND LUBRICATION CHART .......................3-1
CHECKING THE VEHICLE USING THE YAMAHA DIAGNOSTIC
TOOL ........................................................................................................ 3-4
CHECKING THE FUEL LINE .................................................................... 3-4
CHECKING THE SPARK PLUGS ............................................................. 3-5
ADJUSTING THE VALVE CLEARANCE .................................................. 3-5
CHECKING THE ENGINE IDLING SPEED ..............................................3-9
SYNCHRONIZING THE THROTTLE BODIES.......................................... 3-9
CHECKING THE THROTTLE BODY JOINTS ........................................ 3-11
CHECKING THE CRANKCASE BREATHER HOSE ..............................3-11
CHECKING THE EXHAUST SYSTEM....................................................3-11
CHECKING THE CANISTER (for California) ..........................................3-12
3
CHECKING THE AIR INDUCTION SYSTEM..........................................3-12
REPLACING THE AIR FILTER ELEMENT ............................................. 3-12
ADJUSTING THE CLUTCH LEVER FREE PLAY................................... 3-13
CHECKING THE BRAKE OPERATION .................................................. 3-13
CHECKING THE BRAKE FLUID LEVEL................................................. 3-14
ADJUSTING THE FRONT DISC BRAKE................................................ 3-14
CHECKING THE FRONT BRAKE PADS ................................................ 3-15
ADJUSTING THE REAR DISC BRAKE .................................................. 3-15
CHECKING THE REAR BRAKE PADS .................................................. 3-15
CHECKING THE FRONT BRAKE HOSE................................................ 3-15
CHECKING THE REAR BRAKE HOSE .................................................. 3-16
BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)......................... 3-16
CHECKING THE WHEELS ..................................................................... 3-17
CHECKING THE TIRES..........................................................................3-17
CHECKING THE WHEEL BEARINGS ....................................................3-18
CHECKING THE SWINGARM OPERATION ..........................................3-18
LUBRICATING THE SWINGARM PIVOT ............................................... 3-18
DRIVE CHAIN SLACK............................................................................. 3-18
LUBRICATING THE DRIVE CHAIN ........................................................ 3-19
CHECKING AND ADJUSTING THE STEERING HEAD ......................... 3-20
LUBRICATING THE STEERING HEAD.................................................. 3-21
CHECKING THE STEERING DAMPER.................................................. 3-21
CHECKING THE CHASSIS FASTENERS .............................................. 3-21
LUBRICATING THE BRAKE LEVER ......................................................3-21
LUBRICATING THE CLUTCH LEVER....................................................3-21
LUBRICATING THE PEDAL ................................................................... 3-21
ADJUSTING THE SHIFT PEDAL............................................................ 3-21
CHECKING THE SIDESTAND................................................................3-21
LUBRICATING THE SIDESTAND........................................................... 3-21
CHECKING THE SIDESTAND SWITCH................................................. 3-21
CHECKING THE FRONT FORK ............................................................. 3-21
ADJUSTING THE FRONT FORK LEGS (for MT10N/MT10NC) ............. 3-21
ADJUSTING THE PRELOAD OF THE FRONT FORK LEGS
(for MT10SPN/MT10SPNC) ................................................................... 3-23
ADJUSTING THE DAMPING FORCE OF THE FRONT FORK LEGS
AND REAR SHOCK ABSORBER (for MT10SPN/MT10SPNC) ............. 3-24
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 3-25
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
(for MT10N/MT10NC) ............................................................................. 3-25
ADJUSTING THE PRELOAD OF THE REAR SHOCK ABSORBER
ASSEMBLY (for MT10SPN/MT10SPNC) ............................................... 3-28
CHECKING THE CONNECTING ARM AND RELAY ARM.....................3-28
CHECKING THE ENGINE OIL LEVEL....................................................3-28
CHANGING THE ENGINE OIL ...............................................................3-29
MEASURING THE ENGINE OIL PRESSURE ........................................ 3-30
CHECKING THE COOLANT LEVEL.......................................................3-31
CHECKING THE COOLING SYSTEM ....................................................3-32
CHANGING THE COOLANT................................................................... 3-32
ADJUSTING THE EXUP CABLES .......................................................... 3-34
CHECKING THE FRONT BRAKE LIGHT SWITCH ...............................3-35
ADJUSTING THE REAR BRAKE LIGHT SWITCH ................................3-35
CHECKING AND LUBRICATING THE CABLES ................................... 3-36
CHECKING THE THROTTLE GRIP........................................................ 3-36
CHECKING AND CHARGING THE BATTERY....................................... 3-36
CHECKING THE FUSES ........................................................................3-36
ADJUSTING THE HEADLIGHT BEAMS................................................. 3-36
PERIODIC MAINTENANCE
EAS20022
EAS30022
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a lon-
ger service life and reduce the need for costly overhaul work. This information applies to vehicles al-
ready in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
TIP
• From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi
(13000 km) or 12 months.
• Items marked with an asterisk require special tools, data and technical skills, have a Yamaha dealer
perform the service.
EAS30614
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

INITIAL ODOMETER READINGS
8000 mi 12000 mi 16000 mi 20000 mi

No. ITEM ROUTINE 600 mi 4000 mi (13000 (19000 (25000 (31000
(1000 km) (7000 km)
or or km) km) km) km)
or or or or
1 month 6 months 12 months 18 months 24 months 30 months
• Check fuel hoses for cracks or

1 * Fuel line damage. √ √ √ √ √
• Replace if necessary.
• Check condition. √ √ √
2 * Spark plugs • Adjust gap and clean.
• Replace. √ √
3 * Valve clearance • Check and adjust valve clear- Every 26600 mi (42000 km)
ance when engine is cold.
• Check breather hose for
Crankcase breath-
4 * er system cracks or damage. √ √ √ √ √
5 * Fuel injection • Adjust synchronization. √ √ √ √ √
• Check for leakage.
• Tighten if necessary.
6 * Exhaust system • Replace gasket(s) if neces- √ √ √ √ √
sary.
Evaporative emis-
sion control sys- • Check control system for
7 * damage. √ √
tem (for California • Replace if necessary.
only)
• Check the air cut-off valve,
reed valve, and hose for dam-
8 * Air induction sys- age. √ √
tem
• Replace any damaged parts if
necessary.
EAS30615
GENERAL MAINTENANCE AND LUBRICATION CHART

600 mi 4000 mi 8000 mi 12000 mi 16000 mi 20000 mi

No. ITEM ROUTINE (13000 (19000 (25000 (31000
(1000 km) (7000 km) km) km) km) km)
or or
1 month 6 months or or or or
12 months 18 months 24 months 30 months
• Perform dynamic inspection
Diagnostic sys-
1 * tem check using Yamaha diagnostic tool. √ √ √ √ √ √
• Check the error codes.
2 * Air filter element • Replace. Every 24000 mi (37000 km)
3-1
8000 mi 12000 mi 16000 mi 20000 mi

600 mi 4000 mi
No. ITEM ROUTINE (1000 km) (7000 km) (13000 (19000 (25000 (31000
km) km) km) km)
or or or or or or
1 month 6 months
• Check operation.
3 * Clutch • Adjust or replace cable. √ √ √ √ √ √
• Check operation, fluid level,

and for fluid leakage.
4 * Front brake • Adjust brake lever free play √ √ √ √ √ √
and replace brake pads if nec-
essary.
• Check operation, fluid level,
5 * Rear brake and for fluid leakage. √ √ √ √ √ √
• Replace brake pads if neces-
sary.
• Check for cracks or damage.
• Check for correct routing and √ √ √ √ √
6 * Brake hoses clamping.
• Replace. Every 4 years
7 * Brake fluid • Change. Every 2 years
• Check runout and for damage.
8 * Wheels √ √ √ √ √
• Check tread depth and for
damage.
9 * Tires • Replace if necessary. √ √ √ √ √
• Check air pressure.
• Correct if necessary.
• Check bearings for smooth
10 * Wheel bearings operation. √ √ √ √ √
• Check operation and for ex- √ √ √ √ √
Swingarm pivot cessive play.
11 * bearings
• Moderately repack with lithi-
Every 32000 mi (50000 km)
um-soap-based grease.
• Check chain slack, alignment
and condition.
Every 500 mi (800 km) and after washing the motorcycle, riding in the rain
12 Drive chain • Adjust and lubricate chain with or riding in wet areas
a special O-ring chain lubri-
cant thoroughly.
• Check bearing assemblies for
looseness. √ √ √ √ √ √
13 * Steering bearings
• Moderately repack with lithi- Every 16000 mi (25000 km)
um-soap-based grease.
• Check operation and for oil
14 * Steering damper √ √ √ √ √
leakage.
• Check all chassis fitting and
15 * Chassis fasteners fasteners. √ √ √ √ √
• Correct if necessary.
Brake lever pivot
16 * shaft • Apply silicone grease lightly. √ √ √ √ √
17 Brake pedal pivot • Apply lithium-soap-based √ √ √ √ √

shaft grease lightly.
Clutch lever pivot • Apply lithium-soap-based
18 √ √ √ √ √
shaft grease lightly.
Shift pedal pivot • Apply molybdenum disulfide
19 shaft grease lightly. √ √ √ √ √
20 Sidestand pivot • Apply lithium-soap-based √ √ √ √ √
grease lightly.
21 * Sidestand switch • Check operation and replace √ √ √ √ √ √

if necessary.
22 * Front fork leakage. √ √ √ √ √
3-2
8000 mi 12000 mi 16000 mi 20000 mi

600 mi 4000 mi
No. ITEM ROUTINE (1000 km) (7000 km) (13000 (19000 (25000 (31000
km) km) km) km)
or or or or or or
1 month 6 months
23 * Shock absorber leakage. √ √ √ √ √
assembly
Rear suspension • Check operation.
24 * link pivots • Correct if necessary. √ √
25 Engine oil • Change (warm engine before √ √ √ √ √ √

draining).
Engine oil filter
26 • Replace. √ √ √
cartridge
• Check hoses for cracks or
damage. √ √ √ √ √
27 * Cooling system • Replace if necessary.
• Change coolant. √
• Check operation, cable free
28 * EXUP system √ Every 12000 mi (19000 km)
play and pulley position.
Front and rear
29 * brake switches • Check operation. √ √ √ √ √ √
• Apply Yamaha cable lubricant

30 * Control cables or other suitable cable lubri- √ √ √ √ √ √
cant thoroughly.
31 * Throttle grip • Lubricate throttle grip housing √ √ √ √ √
tube guides.
32 * Lights, signals • Check operation. √ √ √ √ √ √

and switches • Adjust headlight beam.
TIP
• Air filter
• This model uses a disposable oil-coated paper element. This element cannot be cleaned with com-
pressed air, doing so will only damage it.
• Replace the air filter more frequently if you often ride in the rain or dusty conditions.
• Hydraulic brake service
• Regularly check the brake fluid levels. Replenish if necessary.
• Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
• Replace the brake hoses every four years or sooner if cracked or damaged.
3-3
EAS32024 EAS30619
CHECKING THE VEHICLE USING THE CHECKING THE FUEL LINE

YAMAHA DIAGNOSTIC TOOL The following procedure applies to all of the fuel,
Use the YDT and check the vehicle according to drain and breather hoses.
the following procedure. 1. Remove:
1. Remove: • Rider seat
• Rider seat Refer to “GENERAL CHASSIS (1)” on
Refer to “GENERAL CHASSIS (1)” on page 4-1.
page 4-1. • Air scoop
2. Remove the protective cap, and then connect • Fuel tank cover
the YDT to the YDT coupler. • Fuel tank side cover
Refer to “GENERAL CHASSIS (2)” on
Yamaha diagnostic tool USB page 4-8.
(US) • Fuel tank
90890-03269 Refer to “FUEL TANK” on page 7-1.
Yamaha diagnostic tool (A/I) 2. Check:
90890-03264 • Fuel hose “1”
• Fuel tank drain hose “2”
TIP • Fuel tank breather hose “3”
• Yamaha diagnostic tool (A/I) (90890-03264) in- Cracks/damage → Replace.
cludes YDT sub harness (6P) (90890-03266). Loose connection → Connect properly.
• If you already have Yamaha diagnostic tool (A/ ECA14940
I) (90890-03262), YDT sub harness (6P) NOTICE

(90890-03266) is separately required. Make sure the fuel tank breather hose is rout-
ed correctly.
Refer to “YDT” on page 9-3.
3. Check: TIP
• DTC Before removing the fuel hoses, place a few
TIP rags in the area under where it will be removed.
Use the “Diagnosis of malfunction” function of
the YDT to check the DTC. For information
2
about using the YDT, refer to the operation man-
ual that is included with the tool.
3
DTC number is displayed → Check and re-
pair the probable cause of the malfunction.
Refer to “SELF-DIAGNOSTIC FUNCTION
AND DIAGNOSTIC CODE TABLE” on 1
page 9-39.
4. Perform:
• Dynamic inspection 3. Install:
TIP • Fuel tank
Refer to “FUEL TANK” on page 7-1.
Use the “Dynamic inspection” function of the
• Fuel tank side cover
YDT version 3.0 and after to perform the dynam-
• Fuel tank cover
ic inspection. For information about using the
• Air scoop
YDT, refer to the operation manual that is includ-
ed with the tool.
page 4-8.
5. Install: • Rider seat
• Rider seat Refer to “GENERAL CHASSIS (1)” on
page 4-1.
3-4
EAS30620
CHECKING THE SPARK PLUGS

The following procedure applies to all of the
spark plugs.
1. Remove:
• Rider seat
page 4-1.
• Air scoop
• Fuel tank cover G088880
• Fuel tank side cover 7. Install:
Refer to “GENERAL CHASSIS (2)” on • Ignition coil
page 4-8. • Spark plug
• Fuel tank
Refer to “FUEL TANK” on page 7-1. Spark plug
• Air filter case 13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.
Refer to “AIR FILTER CASE” on page 7-6. Spark plug (new)
• Air cut-off valve 18 N·m (1.8 kgf·m, 13 lb·ft)
Refer to “AIR INDUCTION SYSTEM” on
page 7-18. TIP
2. Remove: • Before installing the spark plug, clean the
• Ignition coil spark plug and gasket surface.
• Spark plug • 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 • Air cut-off valve
with compressed air to prevent it from falling Refer to “AIR INDUCTION SYSTEM” on
into the cylinders. page 7-18.
• Air filter case
3. Check: Refer to “AIR FILTER CASE” on page 7-6.
• Spark plug type • Fuel tank
Incorrect → Change. Refer to “FUEL TANK” on page 7-1.
Manufacturer/model • Fuel tank cover
NGK/LMAR9E-J • Air scoop
4. Check: Refer to “GENERAL CHASSIS (2)” on
• Electrode “1” page 4-8.
Damage/wear → Replace the spark plug. • Rider seat
• Insulator “2” Refer to “GENERAL CHASSIS (1)” on
Abnormal color → Replace the spark plug. page 4-1.
Normal color is medium-to-light tan. EAS30622
5. Clean: ADJUSTING THE VALVE CLEARANCE

• Spark plug The following procedure applies to all of the
(with a spark plug cleaner or wire brush) valves.
6. Measure: TIP
• Spark plug gap “a” • Valve clearance adjustment should be made
(with a wire thickness gauge) on a cold engine, at room temperature.
Out of specification → Regap. • When the valve clearance is to be measured or
adjusted, the piston must be at top dead center
Spark plug gap (TDC) on the compression stroke.
0.6–0.7 mm (0.024–0.028 in)
3-5
1. Remove: a. Turn the crankshaft counterclockwise.

• Rider seat b. When piston #1 is at TDC on the compres-
Refer to “GENERAL CHASSIS (1)” on sion stroke, align the TDC mark “a” on the
page 4-1. generator rotor with the generator rotor cov-
• Air scoop er slot “b”.
• Fuel tank cover
• Fuel tank side cover a b
page 4-8.
• Fuel tank
• Air filter case
Refer to “AIR FILTER CASE” on page 7-6.
• Air cut-off valve
page 7-18. TIP
• Radiator
TDC on the compression stroke can be found
Refer to “RADIATOR” on page 6-3.
when the camshaft lobes are turned away from
2. Remove:
each other.
• Ignition coil
• Spark plug c. Measure the valve clearance #1 with a
• Cylinder head cover thickness gauge.
• Cylinder head cover gasket TIP
Refer to “CAMSHAFTS” on page 5-17. Measure the valve clearance between the cam
3. Remove: lobe and rocker arm “c”.
• Timing mark accessing bolt
• Crankshaft end cover
Refer to “GENERATOR” on page 5-42. Thickness gauge
4. Measure: 90890-03268
• Valve clearance Feeler gauge set
Out of specification → Adjust. YU-26900-9
Valve clearance (cold)

Intake c
0.09–0.17 mm (0.0035–0.0067
in) c
Exhaust
0.20–0.26 mm (0.0079–0.0102
in)
TIP
• If 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
3-6
i. Measure the valve clearance #2 with a

thickness gauge.
Thickness gauge
90890-03268
Feeler gauge set
YU-26900-9
j. Turn the crankshaft counterclockwise.

G088883 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 cov-
d. Turn the crankshaft counterclockwise. er slot “b”.
e. When piston #3 is at TDC on the compres-
sion stroke, align the TDC mark “d” on the f b
generator rotor with the generator rotor cov-
er slot “b”.
d b
l. Measure the valve clearance #4 with a

thickness gauge.
Thickness gauge
f. Measure the valve clearance #3 with a 90890-03268
thickness gauge. Feeler gauge set
YU-26900-9
Thickness gauge
90890-03268 5. Remove:
Feeler gauge set • Camshaft
YU-26900-9
TIP
g. Turn the crankshaft counterclockwise. • Refer to “CAMSHAFTS” on page 5-17.
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 cov- trieve it if it falls into the crankcase.
er slot “b”.
6. Adjust:
e b • Valve clearance
a. Pull the rocker arm “1” up, and then remove
the valve pad “2”.
3-7
TIP e. Round off the valve pad number according

• Cover the timing chain opening with a rag to to the following table, and then select the
prevent the valve pad from falling into the suitable valve pad.
crankcase. Last digit Rounded value
• Make a note of the position of each valve pad 0, 1, 2 0
so that they can be installed in the correct
place. 3, 4, 5, 6 5
7, 8, 9 10
b. Calculate the difference between the spec-
ified valve clearance and the measured
valve clearance. TIP
Example: Refer to the following table for the available
Specified valve clearance = 0.09–0.17 mm valve pads.
(0.004–0.007 in)
Measured valve clearance = 0.20 mm Valve pad range No. 160–240
(0.008 in) Valve pad thickness 1.60–2.40 mm
0.20 mm (0.008 in)–0.17 mm (0.007 in) = (0.0630–0.0944 in)
0.03 mm (0.001 in) Available valve pads 17 thicknesses in
c. Check the thickness of the current valve 0.05 mm (0.002 in) in-
pad. crements
TIP
The letter and number “a” marked on the valve Example:
pad indicate the valve pad thickness. Valve pad number = 163
Rounded value = 165
Example: New valve pad number = 165
If the valve pad is marked “160”, the pad f. Install the new valve pad “3” and then, push
thickness is 1.60 mm (0.063 in). the rocker arm “1” down.
TIP
• Lubricate the valve pad with molybdenum di-
a sulfide oil.
• Install the valve pad in the correct place.
G088886
3
d. Calculate the sum of the values obtained in
steps (b) and (c) to determine the required
valve pad thickness and the valve pad num-
ber.
Example: 1
1.60 mm (0.063 in) + 0.03 mm (0.001 in) = g. Install the exhaust and intake camshafts,
1.63 mm (0.064 in) timing chain and camshaft caps.
The valve pad number is 163.
Camshaft cap bolt
8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.
R.
Camshaft cap bolt (new)

10 N·m (1.0 kgf·m, 7.4 lb·ft)
3-8
TIP a. Connect the YDT.

• Refer to “CAMSHAFTS” on page 5-17. Use the diagnostic code number “67”.
• Lubricate the camshaft lobes and camshaft Refer to “SELF-DIAGNOSTIC FUNCTION
journals. AND DIAGNOSTIC CODE TABLE” on
• First, install the exhaust camshaft. page 9-39.
• Align the camshaft sprocket marks with the cyl- b. Check the ISC (Idle Speed Control) leaning
inder head surface. value.
• If the camshaft cap bolt is a new one, it is not EAS30797
necessary to apply engine oil onto the mating SYNCHRONIZING THE THROTTLE BODIES
surface and threads of the bolt. TIP
• If the camshaft cap bolt is a new one, tighten it Before synchronizing the throttle bodies, check
to 10 N·m (1.0 kgf·m, 7.4 lb·ft). the following items:
• Turn the crankshaft counterclockwise several • Valve clearance
full turns to seat the parts. • Spark plug
h. Measure the valve clearance again. • Air filter element
i. If the valve clearance is still out of specifica- • Throttle body joint
tion, repeat all of the valve clearance ad- • Fuel hose
justment steps until the specified clearance • Exhaust system
is obtained. • Breather hose
7. Install:
• All removed parts Checking the throttle body synchronization
TIP
1. Stand the vehicle on a level surface.
For installation, reverse the removal procedure. TIP
Place the vehicle on a maintenance stand.
EAS31017
2. Remove:
CHECKING THE ENGINE IDLING SPEED
• Rider seat
TIP Refer to “GENERAL CHASSIS (1)” on
Prior to checking the engine idling speed, the page 4-1.
throttle body synchronization should be adjusted • Air scoop
properly, the air filter element should be clean, • Fuel tank cover
and the engine should have adequate compres- • Fuel tank side cover
sion. Refer to “GENERAL CHASSIS (2)” on
1. Start the engine and let it warm up for several page 4-8.
minutes. • Fuel tank
2. Check: Refer to “FUEL TANK” on page 7-1.
• Engine idling speed • Air filter case
Out of specification → Go to next step. Refer to “AIR FILTER CASE” on page 7-6.
3. Remove:
Engine idling speed • Cap “1”
1200–1400 r/min
3. Check:
• ISC (Idle Speed Control) learning value 1
“00” or “01” → Check the intake system.
“02” → Clean the throttle bodies.
Refer to “CHECKING AND CLEANING THE
THROTTLE BODIES” on page 7-13.
3-9
4. Install: b. Using the throttle body that has the bypass

• Vacuum gauge “1” air screw “1” with a white paint mark as the
standard, adjust the other throttle bodies by
Vacuum gauge turning its bypass air screw in or out.
90890-03094 ECA21300
Vacuummate NOTICE
YU-44456 Do not turn the bypass air screw (white paint
mark) of the throttle body that is the stan-
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.
1 • After each step, rev the engine two or three
times, each time for less than a second, and
check the synchronization again.
5. Install: • If a bypass air screw was removed, turn the
• Air filter case screw in fully and be sure to synchronize the
Refer to “AIR FILTER CASE” on page 7-6. throttle bodies.
• Fuel tank • If the throttle body synchronization can not be
Refer to “FUEL TANK” on page 7-1. adjusted using the bypass air screw, clean or
6. Check: replace the throttle bodies.
• Throttle body synchronization • The difference in vacuum pressure between
a. Start the engine, warm it up for several min- the throttle bodies should not exceed 1.3 kPa
utes, and then let it run at the specified en- (10 mmHg).
gine idling speed.
Engine idling speed Carburetor angle driver 2

1200–1400 r/min 90890-03173
b. Check the vacuum pressure.
Difference in vacuum pressure 1

between the cylinders
0 kPa–1.3 kPa (0 mmHg–10
mmHg, 0 inHg–0.4 inHg)
If out of specification → Adjust the throttle

body synchronization.
Adjusting the throttle body synchronization

2. Stop the engine and remove the measuring
1. Adjust:
equipment.
• Throttle body synchronization
3. Install:
a. Start the engine, warm it up for several min- • Cap
utes, and then let it run at the specified en-
gine idling speed.
Engine idling speed

1200–1400 r/min
3-10
4. Install:
• Air filter case
Refer to “AIR FILTER CASE” on page 7-6. 1
• Fuel tank
• Fuel tank cover
• Air scoop
page 4-8.
• Rider seat 3. Install:
Refer to “GENERAL CHASSIS (1)” on • Fuel tank
page 4-1. Refer to “FUEL TANK” on page 7-1.
EAS31318
• Fuel tank cover
CHECKING THE THROTTLE BODY JOINTS
• Air scoop
1. Remove:
• Throttle body
page 4-8.
Refer to “THROTTLE BODIES” on page 7-9.
• Rider seat
2. Check:
• Throttle body joint
page 4-1.
Cracks/damage → Replace.
Refer to “THROTTLE BODIES” on page 7-9. EAS30625
3. Install: CHECKING THE EXHAUST SYSTEM

• Throttle body 1. Check:
Refer to “THROTTLE BODIES” on page 7-9. • Exhaust pipe “1”
• Exhaust chamber “2”
EAS30800
• Muffler “3”
CHECKING THE CRANKCASE BREATHER
HOSE
• Gasket “4”
1. Remove:
Exhaust gas leaks → Replace.
• Rider seat
2. Check:
Tightening torque
page 4-1.
• Exhaust pipe nut “5”
• Air scoop
• Exhaust pipe joint bolt “6”
• Fuel tank cover
• Exhaust chamber bolt “7”
• Muffler bolt “8”
• Muffler joint bolt “9”
page 4-8.
• Fuel tank
Exhaust pipe nut
Refer to “FUEL TANK” on page 7-1. 20 N·m (2.0 kgf·m, 15 lb·ft)
T.
2. Check:
R.
Exhaust pipe joint bolt

• Crankcase breather hose “1” 20 N·m (2.0 kgf·m, 15 lb·ft)
Cracks/damage → Replace. Exhaust chamber bolt
Loose connection → Connect properly. 20 N·m (2.0 kgf·m, 15 lb·ft)
ECA13450
Muffler bolt
NOTICE
20 N·m (2.0 kgf·m, 15 lb·ft)
Make sure the crankcase breather hose is Muffler joint bolt
routed correctly. 10 N·m (1.0 kgf·m, 7.4 lb·ft)
3-11
3. Install:
3 • Fuel tank
4
• Fuel tank cover
• Air scoop
9 Refer to “GENERAL CHASSIS (2)” on
8 page 4-8.
• Rider seat
7
4 page 4-1.
EAS30627
6 CHECKING THE AIR INDUCTION SYSTEM

Refer to “AIR INDUCTION SYSTEM” on page 7-
18.
7 2 EAS30628
REPLACING THE AIR FILTER ELEMENT

6
1. Remove:
4 (8) • Rider seat
1 5
EAS30626
page 4-1.
CHECKING THE CANISTER (for California)
• Air scoop
1. Remove:
• Fuel tank cover
• Rider seat
page 4-1.
page 4-8.
• Air scoop
• Fuel tank
• Fuel tank cover
2. Remove:
• Air filter case cover
page 4-8.
• Air filter element
• Fuel tank
3. Check:
2. Check:
• Air filter element
• Canister “1”
• Air filter seal
• Canister purge hose
Damage → Replace.
• Fuel tank breather hose
TIP
Loose connection → Connect properly. • Replace the air filter element every 37000 km
(24000 mi) of operation.
TIP
• The air filter needs more frequent service if you
Make sure that the canister breather “a” is not
are riding in unusually wet or dusty areas.
blocked, and if necessary, clean it.
3-12
4. Install: 2. Adjust:
• Air filter element • Clutch lever free play
• Air filter case cover Handlebar side
Refer to “AIR FILTER CASE” on page 7-6. a. Turn the adjusting bolt “1” until the specified
ECA20710
clutch lever free play is obtained.
NOTICE
Never operate the engine without the air filter
element installed. Unfiltered air will cause 1
rapid wear of engine parts and may damage
the engine. Operating the engine without the
air filter element will also affect throttle body
synchronization, leading to poor engine per-
formance and possible overheating.
5. Install:
G088888
• Fuel tank
Refer to “FUEL TANK” on page 7-1. TIP
• Fuel tank side cover If the specified clutch lever free play cannot be
• Fuel tank cover obtained on the handlebar side of the cable, use
• Air scoop the adjusting nut on the engine side.
page 4-8. Engine side
• Rider seat a. Loosen the locknut “1”.
Refer to “GENERAL CHASSIS (1)” on b. Turn the adjusting nut “2” until the specified
page 4-1. clutch lever free play is obtained.
EAS30629
c. Tighten the locknut “1”.
ADJUSTING THE CLUTCH LEVER FREE
PLAY Clutch cable locknut
1. Check: 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
• Clutch lever free play “a”

Out of specification → Adjust.
Clutch lever free play

10.0–15.0 mm (0.39–0.59 in)
a
1
2
EAS30801
CHECKING THE BRAKE OPERATION

1. Check:
G088887 • Brake operation
Brake not working properly → Check the
brake system.
Refer to “FRONT BRAKE” on page 4-39 and
“REAR BRAKE” on page 4-51.
TIP
Drive on the dry road, operate the front and rear
brakes separately and check to see if the brakes
are operating properly.
3-13
EAS30632 EAS30630
CHECKING THE BRAKE FLUID LEVEL ADJUSTING THE FRONT DISC BRAKE
1. Stand the vehicle on a level surface. 1. Adjust:
TIP • Brake lever position
• Place the vehicle on a maintenance stand. (distance “a” from the throttle grip to the brake
• Make sure the vehicle is upright. lever)
2. Check:
• Brake fluid level
Below the minimum level mark → Add the
specified brake fluid to the proper level. a
Front brake
Specified brake fluid
DOT 4
Rear brake G088889
Specified brake fluid a. Push the brake lever forward.
DOT 4 b. Turn the adjusting knob “1” until the brake
EWA13090 lever is in the desired position.
WARNING
• 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 1
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 EWA17050
not enter the brake fluid reservoir. Water WARNING
will significantly lower the boiling point of • After adjusting the brake lever position,
the brake fluid and could cause vapor lock. make sure the pin on the brake lever holder
ECA13540 is firmly inserted in the hole in the adjusting
NOTICE dial.
Brake fluid may damage painted surfaces • A soft or spongy feeling in the brake lever
and plastic parts. Therefore, always clean up can indicate the presence of air in the brake
any spilt brake fluid immediately. system. Before the vehicle is operated, the
air must be removed by bleeding the brake
TIP system. Air in the brake system will consid-
In order to ensure a correct reading of the brake erably reduce brake performance resulting
fluid level, make sure the top of the brake fluid in loss of control and possibly cause an ac-
reservoir is horizontal. cident. Therefore, check and if necessary,
bleed the brake system.
ECA13490
NOTICE
After adjusting the brake lever position,
make sure there is no brake drag.
3-14
EAS30633
CHECKING THE FRONT BRAKE PADS

The following procedure applies to all of the 2
brake pads.
1. Operate the brake.
2. Check: a
• Front brake pad
Wear indicators “1” almost touch the brake
1
disc → Replace the brake pads as a set.
Refer to “FRONT BRAKE” on page 4-39. b
2. Adjust:
• Rear brake light switch
Refer to “ADJUSTING THE REAR BRAKE
1 1 LIGHT SWITCH” on page 3-35.
EAS30634
CHECKING THE REAR BRAKE PADS

brake pads.
1. Operate the brake.
EAS30631 2. Check:
ADJUSTING THE REAR DISC BRAKE • Rear brake pad
1. Adjust: Wear indicator grooves “1” almost disap-
• Brake pedal position peared → Replace the brake pads as a set.
a. Loosen the locknut “1”. Refer to “REAR BRAKE” on page 4-51.
b. Turn the adjusting bolt “2” until the specified
brake pedal position is obtained.
EWA18830
WARNING
After adjusting the brake pedal position,
check that the end of the adjusting bolt “a” is 1 1
visible through the hole “b”.
c. Tighten the locknut “1” to specification.
Rear brake master cylinder lock-

nut EAS30635
T.
R.
18 N·m (1.8 kgf·m, 13 lb·ft) CHECKING THE FRONT BRAKE HOSE

EWA17030
brake hoses and brake hose holders.
WARNING
1. Check:
A soft or spongy feeling in the brake pedal
• Brake hose
can indicate the presence of air in the brake
Cracks/damage/wear → Replace.
system. Before the vehicle is operated, the
2. Check:
air must be removed by bleeding the brake
• Brake hose surface
system. Air in the brake system will consid-
Partly blackened surface on the brake hose
erably reduce braking performance.
→ Replace.
ECA13510 3. Check:
NOTICE • Brake hose holder
After adjusting the brake pedal position, Loose → Tighten the holder bolt.
make sure there is no brake drag. 4. Hold the vehicle upright and apply the brake
several times.
3-15
5. Check: TIP
• Brake hose • Be careful not to spill any brake fluid or allow
Brake fluid leakage → Replace the damaged the brake fluid reservoir to overflow.
hose. • When bleeding the ABS, make sure that there
Refer to “FRONT BRAKE” on page 4-39. is always enough brake fluid before applying
EAS30636 the brake. Ignoring this precaution could allow
CHECKING THE REAR BRAKE HOSE air to enter the ABS, considerably lengthening
1. Check: the bleeding procedure.
• Brake hose • If bleeding is difficult, it may be necessary to let
Cracks/damage/wear → Replace. the brake fluid settle for a few hours.
2. Check: • Repeat the bleeding procedure when the tiny
• Brake hose holder bubbles in the hose have disappeared.
Loose connection → Tighten the holder bolt.
1. Bleed:
3. Hold the vehicle upright and apply the rear
• ABS
brake several times.
4. Check: a. Fill the brake fluid reservoir to the proper
• Brake hose level with the specified brake fluid.
Brake fluid leakage → Replace the damaged b. Install the diaphragm (brake fluid reservoir).
hose. c. Connect a clear plastic hose “1” tightly to
Refer to “REAR BRAKE” on page 4-51. the bleed screw “2”.
A
EAS30893
BLEEDING THE HYDRAULIC BRAKE

SYSTEM (ABS)
EWA14000
WARNING 1
Always bleed the brake system when the
brake related parts are removed. 2
ECA22640
NOTICE
• Bleed the brake system in the following or- B
der.
• 1st step: Front brake master cylinder
• 2nd step: Front brake calipers 2
• 3rd step: Rear brake caliper
EWA16530
WARNING
Bleed the ABS whenever: 1
• the system is disassembled.
• a brake hose is loosened, disconnected or
replaced. C
• the brake fluid level is very low.
• brake operation is faulty. 1
A. Front brake master cylinder

B. Front brake caliper (left/right)
C. Rear brake caliper
3-16
d. Place the other end of the hose into a con- EWA13260
tainer. WARNING
e. Slowly apply the brake several times. Never attempt to make any repairs to the
f. Fully squeeze the brake lever or fully de- wheel.
press the brake pedal and hold it in position.
TIP
g. Loosen the bleed screw.
After a tire or wheel has been changed or re-
TIP
placed, always balance the wheel.
Loosening the bleed screw will release the pres-
sure and cause the brake lever to contact the EAS31429
throttle grip or the brake pedal to fully extend. CHECKING THE TIRES
h. Tighten the bleed screw and then release The following procedure applies to both of the
the brake lever or brake pedal. tires.
i. Repeat steps (e) to (h) until all of the air 1. Check:
bubbles have disappeared from the brake • Tire pressure
fluid in the plastic hose. Out of specification → Regulate.
EWA13181
j. Check the operation of the hydraulic unit. WARNING
Refer to “HYDRAULIC UNIT OPERATION
• The tire pressure should only be checked
TEST” on page 4-67.
ECA17061
and regulated when the tire temperature
NOTICE equals the ambient air temperature.
Make sure that the main switch is turned to • The tire pressure and the suspension must
“OFF” before checking the operation of the be adjusted according to the total weight
hydraulic unit. (including cargo, rider, passenger and ac-
cessories) and the anticipated riding
k. After operating the ABS, repeat steps (e) to speed.
(i), and then fill the brake fluid reservoir to • Operation of an overloaded vehicle could
the proper level with the specified brake flu- cause tire damage, an accident or an injury.
id. NEVER OVERLOAD THE VEHICLE.
l. Tighten the bleed screw to specification.
Front brake master cylinder Tire air pressure (measured on

bleed screw cold tires)
T.
Front
R.
6 N·m (0.6 kgf·m, 4.4 lb·ft)

Brake caliper bleed screw 250 kPa (2.50 kgf/cm², 36 psi)
5 N·m (0.5 kgf·m, 3.7 lb·ft) Rear
290 kPa (2.90 kgf/cm², 42 psi)
m. Fill the brake fluid reservoir to the proper Maximum load
level with the specified brake fluid. 170 kg (375 lb) (MT10SPN,
Refer to “CHECKING THE BRAKE FLUID MT10SPNC)
LEVEL” on page 3-14. 172 kg (379 lb) (MT10N,
EWA13110 MT10NC)
WARNING * Maximum load: Total weight of rider, pas-
After bleeding the hydraulic brake system, senger, cargo and accessories.
check the brake operation.
2. Check:
EAS31428
• Tire surfaces
CHECKING THE WHEELS Damage/wear → Replace the tire.
EWA13190
The following procedure applies to both of the
WARNING
wheels.
It is dangerous to ride with a worn-out tire.
1. Check:
When the tire tread reaches the wear limit, re-
• Wheel
place the tire immediately.
Damage/out-of-round → Replace.
3-17
Wear limit (front)

1
1.0 mm (0.04 in)
Wear limit (rear)
1.0 mm (0.04 in) 2
EWA14090
WARNING
After extensive tests, the tires listed below
have been approved by Yamaha Motor Co., G088891
Ltd. for this model. The front and rear tires
should always be by the same manufacturer EAS30641
CHECKING THE WHEEL BEARINGS

and of the same design. No guarantee con-
cerning handling characteristics can be giv-
wheel bearings.
en if a tire combination other than one
1. Check:
approved by Yamaha is used on this vehicle.
• Wheel bearings
Refer to “CHECKING THE FRONT WHEEL”
Front tire on page 4-24 and “CHECKING THE REAR
Size WHEEL” on page 4-34.
120/70ZR17M/C(58W)
EAS30802
Manufacturer/model CHECKING THE SWINGARM OPERATION
BRIDGESTONE/BATTLAX HY- 1. Check:
PERSPORT S22F
• Swingarm operation
Swingarm not working properly → Check the
Rear tire swingarm.
Size Refer to “SWINGARM” on page 4-108.
190/55ZR17M/C(75W) 2. Check:
Manufacturer/model • Swingarm excessive play
BRIDGESTONE/BATTLAX HY- Refer to “SWINGARM” on page 4-108.
PERSPORT S22R
EAS30643
EWA13210 LUBRICATING THE SWINGARM PIVOT
WARNING 1. Lubricate:
New tires have a relatively low grip on the • Oil seals
road surface until they have been slightly • Collars
worn. Therefore, approximately 100 km
should be traveled at normal speed before Recommended lubricant
any high-speed riding is done. Lithium-soap-based grease
TIP Refer to “INSTALLING THE SWINGARM” on

For tires with a direction of rotation mark “1”: page 4-111.
• Install the tire with the mark pointing in the di- EAS31923
rection of wheel rotation. DRIVE CHAIN SLACK
• Align the mark “2” with the valve installation
point. Checking the drive chain slack
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
3-18
ECA13550
NOTICE 2 1
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.
TIP
2. Check:
• Drive chain slack “a” • To maintain the proper wheel alignment, adjust
Out of specification → Adjust. both sides evenly.
• There should be no clearance between the ad-
TIP
justing block and adjusting bolt.
The measurement point of the drive chain is ap-
prox. 15 mm (0.59 in) “b” rearward from the edge c. Tighten the wheel axle nut to specification.
“c” of the swingarm.
Rear wheel axle nut
190 N·m (19 kgf·m, 140 lb·ft)
T.
Drive chain slack (Sidestand)
R.
20.0–30.0 mm (0.79–1.18 in) d. Tighten the locknuts to specification.
Drive chain slack (Maintenance
Stand) Chain puller adjusting bolt lock-
25.0–35.0 mm (0.98–1.38 in) nut
T.
R.
16 N·m (1.6 kgf·m, 12 lb·ft)
EAS30803
LUBRICATING THE DRIVE CHAIN

c b 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
a chain should be serviced, especially when the
vehicle is used in dusty areas.
This vehicle has a drive chain with small rubber
O-rings between each side plate. Steam clean-
Adjusting the drive chain slack ing, high-pressure washing, certain solvents,
EWA13120
and the use of a coarse brush can damage
WARNING these O-rings. Therefore, use only kerosene to
Securely support the vehicle so that there is clean the drive chain. Wipe the drive chain dry
no danger of it falling over. and thoroughly lubricate it with chain lubricant
that is suitable for O-ring chains. Do not use any
1. Loosen:
other lubricants on the drive chain since they
• Wheel axle nut
may contain solvents that could damage the O-
Refer to “REAR WHEEL” on page 4-30.
rings.
2. Adjust:
• Drive chain slack
Recommended lubricant
a. Loosen both locknuts “1”. Chain lubricant suitable for O-
b. Turn both adjusting bolts “2” until the spec- ring chains
ified drive chain slack is obtained.
3-19
EAS30645
CHECKING AND ADJUSTING THE

Steering nut wrench
STEERING HEAD 90890-01403
1. Stand the vehicle on a level surface. Exhaust flange nut wrench
EWA13120
WARNING YU-A9472
no danger of it falling over. Lower ring nut (initial tightening
torque)
T.
R.
TIP 52 N·m (5.2 kgf·m, 38 lb·ft)
Place the vehicle on a maintenance stand so
that the front wheel is elevated. c. Loosen the lower ring nut completely, then
tighten it to specification.
2. Check: EWA13140
• Steering head WARNING

Grasp the bottom of the front fork legs and Do not overtighten the lower ring nut.
gently rock the front fork.
Blinding/looseness → Adjust the steering
Lower ring nut (final tightening
head.
torque)
T.
3. Remove:
R.
14 N·m (1.4 kgf·m, 10 lb·ft)
• Upper bracket
4. Adjust: d. Check the steering head for looseness or
• Steering head binding by turning the front fork all the way
a. Remove the lock washer “1”, the upper ring in both directions. If any binding is felt, re-
nut “2”, and the rubber washer “3”. move the lower bracket and check the up-
per and lower bearings.
Refer to “STEERING HEAD” on page 4-96.
e. Install the rubber washer “3”.
f. Install the upper ring nut “2”.
g. Finger tighten the upper ring nut, then align
the slots of both ring nuts. If necessary, hold
the lower ring nut and tighten the upper ring
nut until their slots are aligned.
h. Install the lock washer “1”.
G088892
TIP
b. Loosen the lower ring nut “4” and then tight- Make sure the lock washer tabs “a” sit correctly
en it to specification with a steering nut in the ring nut slots “b”.
wrench “5”.
TIP
• Set the torque wrench at a right angle to the
steering nut wrench.
• Move the steering to the left and right a couple
of times to check that it moves smoothly.
G088894
5. Install:
• Upper bracket
Refer to “HANDLEBAR” on page 4-71.
G088893
3-20
EAS30646 EAS30651
LUBRICATING THE STEERING HEAD LUBRICATING THE SIDESTAND

1. Lubricate: Lubricate the pivoting point, metal-to-metal mov-
• Upper bearing ing parts and spring contact point of the side-
• Lower bearing stand.
• Bearing race
Recommended lubricant Lithium-soap-based grease
Lithium-soap-based grease
EAS30652
EAS31634 CHECKING THE SIDESTAND SWITCH

CHECKING THE STEERING DAMPER Refer to “ELECTRICAL COMPONENTS” on
Refer to “CHECKING THE STEERING DAMP- page 8-37.
ER” on page 4-99.
EAS30653
EAS31186 CHECKING THE FRONT FORK

CHECKING THE CHASSIS FASTENERS 1. Stand the vehicle on a level surface.
Make sure that all nuts, bolts, and screws are EWA13120
properly tightened. WARNING

Refer to “CHASSIS TIGHTENING TORQUES” Securely support the vehicle so that there is
on page 2-12. no danger of it falling over.
EAS30804 2. Check:
LUBRICATING THE BRAKE LEVER • Inner tube
Lubricate the pivoting point and metal-to-metal Damage/scratches → Replace.
moving parts of the lever. • Front fork leg
Oil leaks between inner tube and outer tube
Recommended lubricant → Replace the oil seal.
Silicone grease Refer to “FRONT FORK (for MT10N/
MT10NC)” on page 4-76 or refer to “FRONT
EAS30805
LUBRICATING THE CLUTCH LEVER FORK (for MT10SPN/MT10SPNC)” on

Lubricate the pivoting point and metal-to-metal page 4-86.
moving parts of the lever. 3. Hold the vehicle upright and apply the front
brake.
Recommended lubricant 4. Check:
Lithium-soap-based grease • Front fork operation
Push down hard on the handlebar several
EAS30649 times and check if the front fork rebounds
LUBRICATING THE PEDAL smoothly.
Lubricate the pivoting point and metal-to-metal Rough movement → Repair.
moving parts of the pedal. Refer to “FRONT FORK (for MT10N/
MT10NC)” on page 4-76 or refer to “FRONT
Recommended lubricant FORK (for MT10SPN/MT10SPNC)” on
Lithium-soap-based grease page 4-86.
EAS30851 EAS30806
ADJUSTING THE SHIFT PEDAL ADJUSTING THE FRONT FORK LEGS (for
Refer to “ADJUSTING THE SHIFT PEDAL” on MT10N/MT10NC)
page 4-118. The following procedure applies to both of the
front fork legs.
EAS30650 EWA13120
CHECKING THE SIDESTAND WARNING
1. Check: Securely support the vehicle so that there is
• Sidestand operation no danger of it falling over.
Check that the sidestand moves smoothly.
Rough movement → Repair or replace.
3-21
Spring preload a. Turn the adjusting bolt “1” in direction “a” or

EWA17040
“b”.
WARNING
Always adjust both front fork legs evenly.
Direction “a”
Uneven adjustment can result in poor han- Rebound damping is increased (sus-
dling and loss of stability. pension is harder).
ECA13590 Direction “b”
NOTICE Rebound damping is decreased (sus-
Never go beyond the maximum or minimum pension is softer).
adjustment positions.
1. Adjust: Rebound damping
• Spring preload Minimum (soft)
14 click(s) in direction “b”*
a. Turn the adjusting nut “1” in direction “a” or Standard
“b”. 6 click(s) in direction “b”*
Maximum (hard)
Direction “a” 1 click(s) in direction “b”*
Spring preload is increased (suspen-
* With the adjusting bolt fully turned in di-
sion is harder).
rection “a”
Direction “b”
Spring preload is decreased (suspen- TIP
sion is softer).
• Although the total number of clicks of a damp-
ing force adjusting mechanism may not exactly
Spring preload match the above specifications due to small
Minimum (soft) differences in production, the actual number of
0 turn(s) in direction “a”* clicks always represents the entire adjusting
Standard range. To obtain a precise adjustment, check
9 turn(s) in direction “a”* the number of clicks and modify the minimum
Maximum (hard) and standard specifications as necessary.
15 turn(s) in direction “a”* • When turning the damping force adjusting bolt
* With the adjusting nut fully turned in di- in direction “a”, the 0 click position and the 1
rection “b” click position may be the same.
1 1
b a b
a
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
3-22
a. Turn the adjusting bolt “1” in direction “a” or Spring preload

EWA17040
“b”.
WARNING
Always adjust both front fork legs evenly.
Direction “a”
Compression damping is increased Uneven adjustment can result in poor han-
(suspension is harder). dling and loss of stability.
Direction “b” ECA13590
Compression damping is decreased NOTICE

(suspension is softer). Never go beyond the maximum or minimum
Compression damping 1. Adjust:
Minimum (soft) • Spring preload
Standard a. Turn the main switch to “OFF”.
17 click(s) in direction “b”* b. Slide the rubber cover “1” back at each cou-
Maximum (hard) pler.
1 click(s) in direction “b”* c. Disconnect the coupler “2” on each front
* With the adjusting bolt fully turned in di- fork.
rection “a”
1
2
TIP
• Although the total number of clicks of a damp-
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. d. Turn the adjusting bolt “3” in direction “a” or
• When turning the damping force adjusting bolt “b”.
in direction “a”, the 0 click position and the 1
click position may be the same. Direction “a”
sion is harder).
Direction “b”
1 Spring preload is decreased (suspen-
sion is softer).
a b
Spring preload
Minimum (soft)
0 turn(s) in direction “a”*
Standard
11 turn(s) in direction “a”*
EAS31635 Maximum (hard)
ADJUSTING THE PRELOAD OF THE FRONT 15 turn(s) in direction “a”*
FORK LEGS (for MT10SPN/MT10SPNC) * With the adjusting nut fully turned in di-
The following procedure applies to both of the rection “b”
front fork legs.
EWA13120
WARNING
3-23
TIP
3 The factory preset levels are intended as fol-
lows:
• A-1/M-1 are preset for track use with racing
b slick tires.
a • A-2/M-2 are preset for track use with street
tires.
• A-3/M-3 are preset for road use with street
tires.
e. Connect the coupler on each fork. Semi-active automatic presets (A-1/ A-2/A-3)
f. Slide the rubber cover to the original posi- adjustable settings:
tion. BRAKE SUPPORT: reduces nosedive (front-
end pitch from braking)
EAS30941
CORNER SUPPORT: increases damping to ab-
ADJUSTING THE DAMPING FORCE OF THE sorb chassis fluctuations for smooth cornering.
FRONT FORK LEGS AND REAR SHOCK Reduce this setting for increased rear wheel
ABSORBER (for MT10SPN/MT10SPNC) grip.
ACCEL SUPPORT: reduces rear-end squat
YRC Setting 10 : 00
MPH
(rear-end pitch due to acceleration)
1 A- 1
H
-2
H
+2
FRONT FIRM: hardens “H” or softens “S” overall
A- 2 8 damping of the front suspension
A- 3 7 REAR FIRM: hardens “H” or softens “S” overall
S S damping of the rear suspension
SETTING
BRAKE CORNER ACCEL
SUPPORT SUPPORT SUPPORT
FRONT
FIRM
REAR
FIRM TIP
For the road preset A-3, CORNER SUPPORT
2 3 4 5 6 and ACCEL SUPPORT cannot be adjusted and
1. ERS mode are not visible in the menu.
2. Braking support level
3. Cornering support level MPH YRC Setting 10 : 00
4. Acceleration support level A- 1 -2 +2
H H
5. Front overall damping level A- 2
6. Rear overall damping level 6
1 A- 3
7. Factory preset level 5
8. Current level S S
BRAKE FRONT REAR
SETTING
SUPPORT FIRM FIRM
The ERS consists of three semi-active automat-
ic presets (A-1, A-2, and A-3) and three manual
setting presets (M-1, M-2, and M-3). When an 2 3 4
automatic preset is selected, the SCU will adjust 1. ERS mode
the compression and rebound damping forces 2. Braking support level
based on running conditions. For all presets, 3. Front overall damping level
spring preload must be physically adjusted by 4. Rear overall damping level
hand. 5. Factory preset level
6. Current level
Manual presets (M-1/M-2/M-3) adjustable set-
tings:
Fr COM: front compression damping
Fr REB: front rebound damping
Rr COM: rear compression damping
Rr REB: rear rebound damping
3-24
1. Adjust: f. The display will change to the relevant sus-

• Damping force pension setting screen (automatic/manual)
a. Turn the main switch to “ON”. with the ERS mode selection box “SET-
b. Long push the wheel switch to enter the TING” highlighted. Short push the wheel
MENU screen. switch, select the preset that you want to
adjust, and short push the wheel switch
MPH MENU GPS 10 : 00 again.
g. Scroll the different settings by rotating the
Display Mode
wheel switch. Once a setting is highlighted,
YRC Setting
short push the wheel switch to select it and
Lap Time then rotate the wheel switch to adjust the
Maintenance setting level.
Unit h. To adjust other ERS modes of the same
Wallpaper type, repeat from step (f). To switch types or
when finished, select the “ ” mark to re-
c. Select “YRC Setting”. turn to the main “YRC Setting” menu.
MENU GPS 10 : 00 MPH YRC Setting 10 : 00

MPH
Display Mode
M-1 8 18 22 22 4
M-2
YRC Setting
M-3
Lap Time
Maintenance
Unit SETTING Fr COM Fr REB Rr COM Rr REB
Wallpaper
1 2 3
d. Select the ERS preset (A-1/A-2/A-3/M- 1/ 1. To YRC Setting menu
M-2/M-3) you want to adjust. 2. ERS mode selection box “SETTING”
MPH YRC Setting 10 : 00
4. Current level setting
A 1 1 1 1 ON ON 1 1 1 A-1
B 2 2 2 2 2 2 2 A-2 3 EAS30808
C 3 3 3 3 A-3 CHECKING THE REAR SHOCK ABSORBER
D 4 4 M-1
2 ASSEMBLY
5 OFF OFF OFF OFF OFF M-2
Refer to “CHECKING THE REAR SHOCK AB-
YRC PWR TCS SCS LCS QS QS LIF EBM BC ERS
SORBER ASSEMBLY” on page 4-106.
1 EAS30655
ADJUSTING THE REAR SHOCK ABSORBER

1. To ERS menu ASSEMBLY (for MT10N/MT10NC)
2. Manual modes EWA13120
3. Automatic modes WARNING

TIP
The ERS setting menu is divided into automatic
(A-1/A-2/A-3) and manual (M-1/M-2/M-3)
screens, and the two types are accessed sepa- Spring preload
ECA13590
rately. Before moving to the ERS setting menu
NOTICE
be sure you have selected the appropriate type
(automatic/manual) of ERS mode preset. Never go beyond the maximum or minimum
e. Select the “ ” mark, located to the right of
ERS, and short push the wheel switch. 1. Adjust:
• Spring preload
3-25
a. Loosen the locknut “1”. Rebound damping

b. Adjust the spring preload with the special ECA13590
wrench included in the owner’s tool kit. NOTICE

c. Turn the adjusting ring “2” in direction “a” or Never go beyond the maximum or minimum
“b”. adjustment positions.
1. Adjust:
Direction “a” • Rebound damping
sion is harder). a. Turn the adjusting screw “1” in direction “a”
Direction “b” or “b”.
Spring preload is decreased (suspen-
sion is softer). Direction “a”
Rebound damping is increased (sus-
pension is harder).
Direction “b”
Rebound damping is decreased (sus-
pension is softer).
1 Rebound damping
b Minimum (soft)
2 23 click(s) in direction “b”*
a Standard
TIP Maximum (hard)
The spring preload setting is determined by 1 click(s) in direction “b”*
measuring distance “c”. The longer distance “c” * With the adjusting screw fully turned in
is, the higher the spring preload; the shorter dis- direction “a”
tance “c” is, the lower the spring preload.
TIP
c • Although the total number of clicks of a damp-
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.
• When turning the damping force adjusting
screw in direction “a”, the 0 click position and
the 1 click position may be the same.
Spring preload
Minimum
76.5 mm (3.01 in) 1
Standard a b
80.5 mm (3.17 in)
Maximum
84.5 mm (3.33 in)
d. Tighten the locknut to the specified torque.
Spring preload adjusting ring

locknut (for MT10N/MT10NC)
T.
R.
28 N·m (2.8 kgf·m, 21 lb·ft)
3-26
Compression damping (for fast compres- Compression damping (for slow compres-
sion damping) sion 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:
• Compression damping (for fast compression • Compression damping (for slow compression
damping) damping)
a. Turn the adjusting bolt “1” in direction “a” or a. Turn the adjusting screw “1” in direction “a”
“b”. or “b”.
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).
Fast compression damping Slow compression damping

Minimum (soft) Minimum (soft)
5.5 turn(s) in direction “b”* 18 click(s) in direction “b”*
Standard 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 0 click position and
the 1 click position may be the same.
1
a b
1
a b
3-27
EAS30942
ADJUSTING THE PRELOAD OF THE REAR

SHOCK ABSORBER ASSEMBLY (for
MT10SPN/MT10SPNC)
EWA13120
WARNING
c
Spring preload
ECA13590
NOTICE
Spring preload
Never go beyond the maximum or minimum
Minimum
0.0 mm (0.00 in)
1. Adjust: Standard
• Spring preload 4.0 mm (0.16 in)
a. Loosen the locknut “1”. Maximum
9.0 mm (0.35 in)
b. Adjust the spring preload with the special
wrench included in the owner’s tool kit. d. Tighten the locknut to the specified torque.
c. Turn the adjusting ring “2” in direction “a” or
“b”. Spring preload adjusting ring
T.
R. locknut (for MT10SPN/
Direction “a” MT10SPNC)
Spring preload is increased (suspen- 25 N·m (2.5 kgf·m, 18 lb·ft)
sion is harder).
Direction “b” EAS30809
Spring preload is decreased (suspen- CHECKING THE CONNECTING ARM AND
sion is softer). RELAY ARM
Refer to “CHECKING THE CONNECTING ARM
AND RELAY ARM” on page 4-106.
1
EAS30656
2 b CHECKING THE ENGINE OIL LEVEL

a
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 turn it off.
TIP
3. Check:
The spring preload setting is determined by • Engine oil level
measuring distance “c”. The longer distance “c” The engine oil level should be between the
is, the higher the spring preload; the shorter dis- minimum level mark “a” and maximum level
tance “c” is, the lower the spring preload. mark “b”.
recommended engine oil to the proper level.
3-28
3. Remove:
• Engine oil filler cap “1”
• Engine oil drain bolt “2”
• Gasket “3”
1
b
a
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 3
ECA13361
NOTICE 2
• Engine oil also lubricates the clutch and the
wrong oil types or additives could cause
clutch slippage. Therefore, do not add any 4. Drain:
chemical additives or use engine oils with a • Engine oil
grade of “CD” or higher and do not use oils (completely from the crankcase)
labeled “ENERGY CONSERVING II”. 5. If the oil filter cartridge is also to be replaced,
• Do not allow foreign materials to enter the perform the following procedure.
crankcase. a. Remove the bottom side cowling (left) (for
MT10SPN/MT10SPNC).
TIP
Before checking the engine oil level, wait a few page 4-8.
minutes until the oil has settled.
b. Remove the oil filter cartridge “1” with an oil
4. Start the engine, warm it up for several min- filter wrench “2”.
5. Check the engine oil level again. Oil filter wrench
TIP 90890-01426
Oil filter wrench
Before checking the engine oil level, wait a few YU-38411
minutes until the oil has settled.
EAS30657
CHANGING THE ENGINE OIL

1. Start the engine, warm it up for several min-
2. Place a container under the engine oil drain
bolt.
1
3-29
c. Lubricate the O-ring of the new oil filter car- EAS30810
MEASURING THE ENGINE OIL PRESSURE

tridge with a thin coat of lithium-soap-based
1. Check:
grease.
ECA25890 • Engine oil level
NOTICE Below the minimum level mark “a” → Add the
Make sure the O-ring is positioned correctly recommended engine oil to the proper level.
in the groove of the oil filter cartridge.
d. Tighten the new oil filter cartridge to specifi-
cation with an oil filter wrench.
Oil filter cartridge

17 N·m (1.7 kgf·m, 13 lb·ft)
T.
R.
e. Install the bottom side cowling (left) (for

a
MT10SPN/MT10SPNC).
page 4-8. 2. Remove:
• Bottom side cowling (left) (for MT10SPN/
6. Install: MT10SPNC)
• Engine oil drain bolt Refer to “GENERAL CHASSIS (2)” on
(along with the gasket New ) page 4-8.
3. Remove:
Engine oil drain bolt • Oil pressure switch joint bolt “1”
23 N·m (2.3 kgf·m, 17 lb·ft) • Oil pressure switch joint (with the oil pressure
T.
R.
switch) “2”
7. Fill: EWA12980
• Crankcase WARNING
(with the specified amount of the recom- The engine, muffler and engine oil are ex-
mended engine oil) tremely hot.
Engine oil quantity

Oil change
3.90 L (4.12 US qt, 3.43 Imp.qt)
With oil filter removal
4.10 L (4.33 US qt, 3.61 Imp.qt)
Quantity (disassembled)
4.90 L (5.18 US qt, 4.31 Imp.qt) 2
8. Install:
• Engine oil filler cap 1
(along with the O-ring New ) 4. Install:
9. Start the engine, warm it up for several min- • Oil pressure gauge joint 18 mm “1”
utes, and then turn it off. • Oil pressure switch joint bolt “2”
10.Check:
• Engine Oil pressure gauge joint 18 mm
(for engine oil leaks) 90890-04176
11.Check: YU-04176
• Engine oil level
Refer to “CHECKING THE ENGINE OIL Oil pressure switch joint bolt
LEVEL” on page 3-28. 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
3-30
8. Remove:
• Oil pressure gauge
• Adapter C
1 • Oil pressure switch joint bolt
• Oil pressure switch joint (with the O-ring)
9. Install:
• O-ring “1” New
2 • Oil pressure switch joint (with the oil pressure
switch) “2”
• Oil pressure switch joint bolt “3”
5. Install:
• Oil pressure gauge “1”
Oil pressure switch joint bolt
• Adapter C “2” 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
Oil pressure gauge set
90890-03120
1
2
3
1
10.Install:
• Bottom side cowling (left) (for MT10SPN/
MT10SPNC)
6. Start the engine, warm it up for several min- Refer to “GENERAL CHASSIS (2)” on
utes. page 4-8.
ECA13410
NOTICE EAS30811
CHECKING THE COOLANT LEVEL

When the engine is cold, the engine oil will
have a higher viscosity, causing the engine
oil pressure to increase. Therefore, be sure TIP
to measure the engine oil pressure after • Place the vehicle on a maintenance stand.
warming up the engine. • Make sure the vehicle is upright.
7. Measure: 2. Check:
• Engine oil pressure • Coolant level
(at the following conditions) The coolant level should be between the
maximum level mark “a” and minimum level
Oil pressure mark “b”.
150.0 kPa/3000 r/min (1.50 kgf/ Below the minimum level mark → Add the
cm²/3000 r/min, 21.8 psi/3000 r/ recommended coolant to the proper level.
min)
Engine oil pressure Possible causes

Below specification • Faulty oil pump
• Clogged oil filter
• Leaking oil passage F
a
• Broken or damaged L
oil seal
b
Above specification • Faulty oil filter
• Oil viscosity too high
3-31
ECA21281 EAS30813
NOTICE CHANGING THE COOLANT

• Adding water instead of coolant dilutes the 1. Remove:
antifreeze concentration of the coolant. If • Radiator cover (right)
water is used instead of coolant; check, • Coolant reservoir cover
and if necessary, correct the antifreeze Refer to “GENERAL CHASSIS (2)” on
concentration of the coolant. page 4-8.
• Use only distilled water. However, if dis- 2. Remove:
tilled water is not available, soft water may • Radiator cap bolt “1”
be used. • Radiator cap “2”
EWA13030
3. Start the engine, warm it up for several min- WARNING

utes, and then turn it off. A hot radiator is under pressure. Therefore,
4. Check: do not remove the radiator cap when the en-
• Coolant level gine is hot. Scalding hot fluid and steam may
TIP be blown out, which could cause serious in-
Before checking the coolant level, wait a few jury. When the engine has cooled, open the
minutes until it settles. radiator cap as follows:
Place a thick rag or a towel over the radiator
EAS30812
cap and slowly turn the radiator cap counter-
CHECKING THE COOLING SYSTEM clockwise toward the detent to allow any re-
1. Check: sidual pressure to escape. When the hissing
• Radiator “1” sound has stopped, press down on the radi-
• Radiator inlet hose “2” ator cap and turn it counterclockwise to re-
• Radiator outlet hose “3” move.
• Water pump inlet pipe “4”
• Water pump outlet pipe “5”
• Oil cooler “6”
• Oil cooler outlet hose “7”
• Oil cooler inlet hose “8” 1 2
Refer to “RADIATOR” on page 6-3, “OIL
COOLER” on page 6-6, “THERMOSTAT” on
page 6-8 and “WATER PUMP” on page 6-11.
3. Remove:
• Water pump drain bolt “1”
1 • Copper washer “2”
4
2
3 2
5
1
6 7
4. Drain:
• Coolant
(from the engine and radiator)
3-32
5. Install: 10.Fill:
• Water pump drain bolt • Cooling system
• Copper washer New (with the specified amount of the recom-
mended coolant)
Water pump drain bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft) Recommended antifreeze
T.
R.
High-quality ethylene glycol anti-

6. Remove: freeze containing corrosion
• Coolant reservoir cap “1” inhibitors for aluminum engines
Mixing ratio
1 : 1 (antifreeze : water)
Coolant quantity
Radiator (including all routes)
1 2.25 L (2.38 US qt, 1.98 Imp.qt)
Coolant reservoir (up to the max-
imum level mark)
0.24 L (0.25 US qt, 0.21 Imp.qt)
Handling notes for coolant

Coolant is potentially harmful and should be
7. Remove:
handled with special care.
• Coolant reservoir bolt “1” EWA13040
• Coolant reservoir “2” WARNING

• If coolant splashes in your eyes, thorough-
ly wash them with water and consult a doc-
tor.
• If coolant splashes on your clothes, quickly
wash it away with water and then with soap
1 and water.
2
• If coolant is swallowed, induce vomiting
and get immediate medical attention.
ECA21291
8. Drain: NOTICE
• Coolant • Adding water instead of coolant dilutes the
(from the coolant reservoir) antifreeze concentration of the coolant. If
9. Install: water is used instead of coolant; check,
• Coolant reservoir and if necessary, correct the antifreeze
• Coolant reservoir bolt concentration of the coolant.
• Use only distilled water. However, if dis-
Coolant reservoir bolt tilled water is not available, soft water may
7 N·m (0.7 kgf·m, 5.2 lb·ft) be used.
T.
R.
• If coolant comes into contact with painted

surfaces, immediately wash them with wa-
ter.
• Do not mix different types of antifreeze.
3-33
11.Fill: TIP
• Coolant reservoir Before checking the coolant level, wait a few
(with the recommended coolant to the maxi- minutes until the coolant has settled.
mum level mark “a”)
19.Install:
• Coolant reservoir cover
• Radiator cover (right)
page 4-8.
F
a EAS31389
ADJUSTING THE EXUP CABLES

1. Remove:
• EXUP valve pulley cover
Refer to “ENGINE REMOVAL” on page 5-11.
12.Install: 2. Check:
• Coolant reservoir cap • EXUP system operation
13.Loosen the water pump air bleed bolt “1” to
allow any trapped air to escape from the wa- a. Activate the diagnostic mode and select the
ter pump. diagnostic code number “53”.
Refer to “FUEL INJECTION SYSTEM” on
page 9-12.
1 b. Set the start/engine stop switch to “ ”.
c. Check that the EXUP valve operates prop-
erly.
TIP
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.
14.When coolant begins to flow out, tighten the
water pump air bleed bolt to the specified
torque.
b
Water pump air bleed bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
a
R.
15.Pour the specified coolant into the radiator

until it is full.
16.Install:
• Radiator cap
• Radiator cap bolt 3. Adjust:
• EXUP cable free play
Radiator cap bolt a. Remove the brake fluid reservoir bracket.
1.0 N·m (0.10 kgf·m, 0.73 lb·ft) b. Slide back the rubber cover “1”.
T.
R.
c. Turn the main switch to “ON”.

17.Start the engine, warm it up for several min-
d. Loosen the locknut “2”.
e. Turn the adjusting nut “3” until the projec-
18.Check:
tion “a” on the EXUP valve pulley slightly
• Coolant level
contacts the stopper “b” and make sure the
Refer to “CHECKING THE COOLANT LEV-
EXUP cable (black metal) “4” is not slack.
EL” on page 3-31.
3-34
f. Tighten the locknut. 4. Install:

• EXUP valve pulley cover
1 2 3
EXUP valve pulley cover bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
LOCTITE®
EAS31145
CHECKING THE FRONT BRAKE LIGHT

SWITCH
Refer to “ELECTRICAL COMPONENTS” on
page 8-37.
b 4 EAS31146
ADJUSTING THE REAR BRAKE LIGHT

SWITCH
a TIP
The rear brake light switch is operated by the
movement of the brake pedal.
Adjustment is correct when the brake light
comes on by depressing the brake pedal 5.5–
g. Slide back the rubber cover “5”.
12.0 mm (0.22–0.47 in) or more.
h. Loosen the locknut “6”.
i. Turn the adjusting nut “7” until the tension of 1. Check:
the EXUP cable (white metal) “8” is the • Rear brake light operation timing
same as that of the EXUP cable (black met- Incorrect → Adjust.
al) “4”. 2. Adjust:
j. Tighten the locknut. • Rear brake light operation timing
a. Hold the main body “1” of the rear brake
light switch so that it does not rotate and
turn the adjusting nut “2” until the rear brake
light comes on at the proper time.
5
6
7
2 1
4
2
k. Slide the rubber covers to its original posi-

tion.
3-35
EAS31147 EAS30664
CHECKING AND LUBRICATING THE ADJUSTING THE HEADLIGHT BEAMS

CABLES 1. Adjust:
The following procedure applies to all of the in- • Headlight beam (vertically)
ner and outer cables. TIP
EWA13270
WARNING To adjust the headlight beam (vertically), insert a

Damaged outer cable may cause the cable to crosshead screwdriver into the cutout “a” on the
corrode and interfere with its movement. Re- headlight unit cover and turn the adjusting
place damaged outer cable and inner cables screw.
as soon as possible. a. Turn the adjusting screws “1”.
1. Check:
• Outer cable
Damage → Replace.
2. Check: a a
• Cable operation
Rough movement → Lubricate.
1
Engine oil or a suitable cable lu-
bricant
2. Adjust:
TIP • Headlight beam (horizontally)
Hold the cable end upright and pour a few drops TIP
of lubricant into the cable sheath or use a suit- To adjust the headlight beam (horizontally), in-
able lubricating device. sert a crosshead screwdriver into the cutout “a”
on the headlight unit cover and turn the adjusting
EAS30815
screw.
CHECKING THE THROTTLE GRIP
1. Check: a. Removing the quick fastener “1”.
• Throttle grip movement
Rough movement → Lubricate or replace the
defective part(s).
Suitable cable lubricant
TIP 1
With the engine stopped, turn the throttle grip
slowly and release it. Make sure that the throttle
grip turns smoothly and returns properly when b. Removing the cover bolt “2”.
released.
Repeat this check with the handlebar turned all
the way to the left and right.
2
EAS30816
CHECKING AND CHARGING THE BATTERY

Refer to “CHECKING AND CHARGING THE
BATTERY” on page 8-41.
EAS30662
CHECKING THE FUSES

Refer to “CHECKING THE FUSES” on page 8-
40.
3-36
c. Removing the cover “3”.
d. Turn the adjusting screw “4”.
a
4
3. Install:
• Cover
a. Installing the cover bolt “1”.
Cover bolt
1.3 N·m (0.13 kgf·m, 0.95 lb·ft)
T.
R.
LOCTITE®
b. Installing the quick fastener “2”.
3-37
3-38
CHASSIS
GENERAL CHASSIS (1) ................................................................................. 4-1

REMOVING THE SEAT ............................................................................4-6
REMOVING THE REAR COWLING (CENTER) ....................................... 4-6
REMOVING THE ECU (engine control unit) .............................................4-6
INSTALLING THE IMU..............................................................................4-6
INSTALLING THE ECU (engine control unit) ............................................4-7
INSTALLING THE REAR COWLING (CENTER) ...................................... 4-7
INSTALLING THE SEAT ...........................................................................4-7
GENERAL CHASSIS (2) ................................................................................. 4-8

REMOVING THE AIR SCOOP................................................................4-12
REMOVING THE SIDE COVER (LEFT) ................................................. 4-12
REMOVING THE SIDE COVER (RIGHT) ............................................... 4-12
REMOVING THE FUEL TANK COVER .................................................. 4-13
REMOVING THE FUEL TANK SIDE COVER ASSEMBLY ....................4-13
INSTALLING THE FUEL TANK SIDE COVER ASSEMBLY ................... 4-13
INSTALLING THE FUEL TANK COVER................................................. 4-13
INSTALLING THE SIDE COVER (LEFT) ................................................ 4-14
INSTALLING THE SIDE COVER (RIGHT).............................................. 4-14
INSTALLING THE AIR DUCT COVER....................................................4-14
4
INSTALLING THE AIR SCOOP ..............................................................4-15
GENERAL CHASSIS (3) ............................................................................... 4-16
FRONT WHEEL............................................................................................. 4-21

REMOVING THE FRONT WHEEL.......................................................... 4-24
DISASSEMBLING THE FRONT WHEEL................................................ 4-24
CHECKING THE FRONT WHEEL .......................................................... 4-24
ASSEMBLING THE FRONT WHEEL......................................................4-25
MAINTENANCE OF THE FRONT WHEEL SENSOR AND
SENSOR ROTOR .................................................................................. 4-26
ADJUSTING THE FRONT WHEEL STATIC BALANCE ......................... 4-27
INSTALLING THE FRONT WHEEL (DISC BRAKE) ...............................4-27
REAR WHEEL ...............................................................................................4-30

REMOVING THE REAR WHEEL ............................................................ 4-33
DISASSEMBLING THE REAR WHEEL .................................................. 4-33
CHECKING THE REAR WHEEL............................................................. 4-34
CHECKING THE REAR WHEEL DRIVE HUB ........................................ 4-34
CHECKING AND REPLACING THE REAR WHEEL SPROCKET .........4-34
CHECKING THE REAR WHEEL SPROCKET BRACKET......................4-34
ASSEMBLING THE REAR WHEEL ........................................................ 4-34
MAINTENANCE OF THE REAR WHEEL SENSOR AND
SENSOR ROTOR .................................................................................. 4-36
ADJUSTING THE REAR WHEEL STATIC BALANCE............................ 4-36
INSTALLING THE REAR WHEEL (DISC BRAKE) .................................4-36
FRONT BRAKE ............................................................................................. 4-39
INTRODUCTION .....................................................................................4-45
CHECKING THE FRONT BRAKE DISCS............................................... 4-45
REPLACING THE FRONT BRAKE PADS .............................................. 4-45
REMOVING THE FRONT BRAKE CALIPERS ....................................... 4-47
DISASSEMBLING THE FRONT BRAKE CALIPERS..............................4-47
CHECKING THE FRONT BRAKE CALIPERS ........................................ 4-47
ASSEMBLING THE FRONT BRAKE CALIPERS.................................... 4-48
INSTALLING THE FRONT BRAKE CALIPERS ...................................... 4-48
REMOVING THE FRONT BRAKE MASTER CYLINDER .......................4-49
CHECKING THE FRONT BRAKE MASTER CYLINDER........................ 4-49
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ................... 4-49
INSTALLING THE FRONT BRAKE MASTER CYLINDER......................4-49
REAR BRAKE ...............................................................................................4-51

INTRODUCTION .....................................................................................4-57
CHECKING THE REAR BRAKE DISC....................................................4-57
REPLACING THE REAR BRAKE PADS................................................. 4-57
REMOVING THE REAR BRAKE CALIPER ............................................4-58
DISASSEMBLING THE REAR BRAKE CALIPER ..................................4-59
CHECKING THE REAR BRAKE CALIPER............................................. 4-59
ASSEMBLING THE REAR BRAKE CALIPER ........................................ 4-59
INSTALLING THE REAR BRAKE CALIPER...........................................4-59
REMOVING THE REAR BRAKE MASTER CYLINDER ......................... 4-60
CHECKING THE REAR BRAKE MASTER CYLINDER .......................... 4-61
ASSEMBLING THE REAR BRAKE MASTER CYLINDER......................4-61
INSTALLING THE REAR BRAKE MASTER CYLINDER ........................ 4-61
ABS (Anti-lock Brake System) .................................................................... 4-63

REMOVING THE HYDRAULIC UNIT ASSEMBLY .................................4-65
CHECKING THE HYDRAULIC UNIT ASSEMBLY..................................4-66
CHECKING THE BRAKE PIPES............................................................. 4-66
INSTALLING THE HYDRAULIC UNIT ASSEMBLY................................4-66
HYDRAULIC UNIT OPERATION TEST .................................................. 4-67
CHECKING THE ABS WARNING LIGHT ............................................... 4-70
HANDLEBAR ................................................................................................4-71
REMOVING THE HANDLEBAR..............................................................4-73
CHECKING THE HANDLEBAR ..............................................................4-73
INSTALLING THE HANDLEBAR ............................................................ 4-73
FRONT FORK (for MT10N/MT10NC) ........................................................... 4-76

REMOVING THE FRONT FORK LEGS.................................................. 4-78
DISASSEMBLING THE FRONT FORK LEGS ........................................ 4-78
CHECKING THE FRONT FORK LEGS .................................................. 4-80
ASSEMBLING THE FRONT FORK LEGS .............................................. 4-80
INSTALLING THE FRONT FORK LEGS ................................................ 4-84
FRONT FORK (for MT10SPN/MT10SPNC).................................................. 4-86
REMOVING THE FRONT FORK LEGS.................................................. 4-88
DISASSEMBLING THE FRONT FORK LEG ..........................................4-88
CHECKING THE FRONT FORK LEGS .................................................. 4-89
ASSEMBLING THE FRONT FORK LEGS .............................................. 4-90
INSTALLING THE FRONT FORK LEGS ................................................ 4-93
STEERING HEAD.......................................................................................... 4-96

REMOVING THE LOWER BRACKET.....................................................4-98
CHECKING THE STEERING HEAD .......................................................4-98
INSTALLING THE STEERING HEAD .....................................................4-99
CHECKING THE STEERING DAMPER.................................................. 4-99
REAR SHOCK ABSORBER ASSEMBLY ..................................................4-100

HANDLING THE REAR SHOCK ABSORBER ......................................4-104
DISPOSING OF A REAR SHOCK ABSORBER ...................................4-104
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY.................4-104
DISASSEMBLING THE REAR SHOCK ABSORBER ASSEMBLY.......4-105
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY .................4-106
CHECKING THE CONNECTING ARM AND RELAY ARM...................4-106
ASSEMBLING THE REAR SHOCK ABSORBER ASSEMBLY.............4-106
INSTALLING THE RELAY ARM............................................................4-106
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ...............4-107
SWINGARM.................................................................................................4-108
REMOVING THE SWINGARM..............................................................4-110
CHECKING THE SWINGARM ..............................................................4-111
INSTALLING THE SWINGARM ............................................................4-111
CHAIN DRIVE..............................................................................................4-113
REMOVING THE DRIVE CHAIN...........................................................4-115
CHECKING THE DRIVE CHAIN ...........................................................4-115
CHECKING THE DRIVE SPROCKET...................................................4-116
CHECKING THE REAR WHEEL SPROCKET......................................4-116
CHECKING THE REAR WHEEL DRIVE HUB ......................................4-116
INSTALLING THE DRIVE CHAIN .........................................................4-117
ADJUSTING THE SHIFT PEDAL..........................................................4-118
GENERAL CHASSIS (1)
EAS20026
GENERAL CHASSIS (1)

Removing the seat and battery
2.2 N•m (0.22 kgf•m, 1.6 lb•ft) 11
T.R
.
New
4
3 1
2
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

8
T.R
.
9
7
6
10
Order Job/Parts to remove Q’ty Remarks

1 Rider seat 1
2 Battery band 1
3 Negative battery lead 1 Disconnect.
4 Positive battery lead 1 Disconnect.
5 Battery 1
6 Starter relay 1
7 Main fuse 1
8 YDT coupler 1
9 Fuse box 1 1
10 Battery box 1
11 Seat back assembly 1
4-1
GENERAL CHASSIS (1)
Removing the rear side covers and rear cowlings
1.5 N•m (0.15 kgf•m, 1.1 lb•ft)

1.5 N•m (0.15 kgf•m, 1.1 lb•ft)
T.R
.
T.R
.
10 N・m (1.0 kgf・m, 7.4 ft・lb)
1.5 N•m (0.15 kgf•m, 1.1 lb•ft)
T.R
.
5
1
1.5 N•m (0.15 kgf•m, 1.1 lb•ft)

T.R
.
1.5 N•m (0.15 kgf•m, 1.1 lb•ft)
T.R
.
2
10 N•m (1.0 kgf•m, 7.4 lb•ft)

Rider seat page 4-1.
1 Rear cowling (center) 1
When removing the rear cowling (center) or
2 Rear side cover (left) 1 rear side cover, always remove them
together.
3 Rear cowling (left) 1
When removing the rear cowling (center) or
4 Rear side cover (right) 1 rear side cover, always remove them
together.
5 Rear cowling (right) 1
4-2
GENERAL CHASSIS (1)
Removing the tail/brake light and mudguard assembly
2.1 N•m (0.21 kgf•m, 1.5 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
9 7 N•m (0.7 kgf•m, 5.2 lb•ft)
(4)
T.R
.
(4) 11
(4)
(4) 1 3
10
(4)
(4) (4) 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
8 (4)
.
2
7 N•m (0.7 kgf•m, 5.2 lb•ft)

4
T.R
.
1.3 N•m (0.13 kgf•m, 0.95 lb•ft)
1.3 N•m (0.13 kgf•m, 0.95 lb•ft)
6 7

Rider seat/Rear cowling/Rear side cover page 4-1.
EXUP servo motor Refer to “ENGINE REMOVAL” on page 5-11.
1 Seat lock bracket 1
2 Tail/brake light coupler 1 Disconnect.
3 Tail/brake light 1
4 Tail/brake light bracket 1
5 Rear turn signal light coupler 2 Disconnect.
6 License plate light coupler 1 Disconnect.
7 Mudguard assembly 1
8 IMU coupler (sub-wire harness) 1 Disconnect.
9 Plate 1
10 IMU bottom cover 1
11 IMU 1
4-3
GENERAL CHASSIS (1)
Disassembling the mudguard assembly
FW 2
D
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.
R.
3
4 5
1
6
2.3 N•m (0.23 kgf•m, 1.7 lb•ft)
T.
R.
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)

T.
R.
LT
8
5 7
10
3.8 N•m (0.38 kgf•m, 2.8 lb•ft) 9
T.
R.
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)

T.
R.
9 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.
R.

1 Mudguard assembly cover 1
2 Stay 1
3 Plate 1
4 Stay 2
5 Rear turn signal light 2
6 Cover 1
7 License plate light 1
8 Rear reflector 1
9 Rear reflector 2
10 Reflector bracket 1
4-4
GENERAL CHASSIS (1)
Removing the battery box 1 and rear frame

1 4.3 N•m (0.43 kgf•m, 3.2 lb•ft)
T.R
.
8
5 7
4 2
50 N•m (5.0 kgf•m, 37 lb•ft)
3
LT
9
6
10
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
28 N•m (2.8 kgf•m, 21 lb•ft) LT

10
LT
28 N•m (2.8 kgf•m, 21 lb•ft)

Rider seat/Battery/Rear cowling/Rear side Refer to “GENERAL CHASSIS (1)” on
cover/Tail/brake light/Mudguard assembly page 4-1.
Air scoop/Fuel tank cover page 4-8.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Refer to “ABS (Anti-lock Brake System)” on
Hydraulic unit page 4-63.
1 ECU (Engine Control Unit) 1
2 Fuse box 2 1
3 Brake light relay 1
4 Radiator fan motor relay 1
5 Fuse box 3 1
6 Cover 1
7 Battery box 1
8 Seat lock assembly 1
9 Rear frame 1
10 Passenger footrest 2
4-5
GENERAL CHASSIS (1)
EAS32229
REMOVING THE SEAT

1. Remove:
a. Open the seat lock cover “1”, insert the key
into the seat lock “2”, and then turn the key
counterclockwise “3”.
b
2 1 a 1
EAS31636
INSTALLING THE IMU

ECA22611
3
NOTICE
• Do not perform angle adjustment of the IMU
and battery box by pinching the washer
b. While holding the key in that position, slide and related parts.
the seat backward and then lift the rear of • When installing the IMU, apply a thin coat of
the seat up, and then pull the seat off. silicone grease onto the washer where con-
EAS31841
tacting the IMU grommet.
REMOVING THE REAR COWLING (CENTER) • When installing the IMU, use only a genuine
1. Remove: bolt and washer, and tighten the bolt to the
• Rear cowling (center) “1” specified torque.
a. Remove the rear cowling screws (center) • Pay attention not to expose the IMU to
“2”. strong shocks, such as striking or drop-
b. Disengage the projection “a” of the rear ping it.
cowling (center) from the tail/brake light. • Do not place any foreign objects in and
around the battery box.
a • Do not obstruct breather opening “a” of the
1 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.
2
a
EAS31679
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. 1. Install:
• IMU (Inertial Measurement Unit) “1”
a. Connect the IMU coupler “2” to the IMU.
b. Install the grommets, collars, IMU “1”, plate
“3”, washers, IMU nuts and IMU bolts, and
then tighten the bolts to specification.
4-6
GENERAL CHASSIS (1)
EAS31842
TIP
INSTALLING THE REAR COWLING
Apply a thin coat of silicone grease onto the (CENTER)
washers where contacting the grommets. 1. Install:
• Rear cowling (center) “1”
Recommended lubricant a. Insert the projection “a” on the rear cowling
Silicone grease (center) into the tail / brake light.
b. Install the rear cowling screws (center) “2”
and tighten the screws to specification.
IMU bolt
2.1 N·m (0.21 kgf·m, 1.5 lb·ft)
T.
Rear cowling (center) screw

R.
1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
T.
R.
S
a
S 1
S
1
3
2
2
EAS31629
INSTALLING THE SEAT

1. Install:
• Seat
a. Insert the projections “1” into the seat hold-
ers “2” as shown.
1 1
EAS31680
INSTALLING THE ECU (engine control unit)

1. Connect:
• ECU coupler “1”
TIP
Connect the ECU coupler, and then push the
lock lever “a” of the coupler in the direction of the 2
arrow shown.
b. Push the rear of the seat down to lock it in
place.
TIP
Make sure that the seat is properly secured be-
fore riding.
4-7
GENERAL CHASSIS (2)
EAS20155
GENERAL CHASSIS (2)

Removing the radiator covers and air scoops
1.5 N•m (0.15 kgf•m, 1.1 lb•ft)
T.R
.
1.5 N•m (0.15 kgf•m, 1.1 lb•ft)
14
T.R
.
13 2
8 7 4
1
10
1.5 N・m (0.15 kgf・m, 1.11 ft・lb)

7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
6
3 5 (3)
12
9
(3)
11
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

1 Air scoop (left) 1
2 Air scoop (right) 1
3 Turn signal light coupler (left) 1 Disconnect.
4 Turn signal light coupler (right) 1 Disconnect.
5 Radiator cover (left) 1
6 Front side panel 1
7 Radiator cover (right) 1
8 Coolant reservoir cover 1
9 Turn signal light (left) 1
10 Turn signal light (right) 1
11 Side cover (left) 1
12 Side cover (right) 1
13 Air scoop cap (left) 1
14 Air scoop cap (right) 1
4-8
GENERAL CHASSIS (2)
Removing the fuel tank cover and air duct (left)

7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
6
7
4
1
5
0.8 N・m (0.08 kgf・m, 0.59 ft・lb)
8
0.4 N・m (0.04 kgf・m, 0.30 ft・lb)
9
(3)
3 2
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.
1.5 N•m (0.15 kgf•m, 1.1 lb•ft)

T.R
.
1.5 N•m (0.15 kgf•m, 1.1 lb•ft)

T.R
.

Air scoop page 4-8.
1 Fuel tank cover 1
2 Fuel tank side cover (left) 1
3 Fuel tank mole (left) 1
4 Air duct cover (left) 1
5 Air duct (left) 1
6 Air scoop stay (left) 1
7 Intake grill (left) 1
8 Outlet (left) 1
9 Side grille (left) 1
4-9
GENERAL CHASSIS (2)
Removing the fuel tank side cover and air duct (right)
6
5
4
0.8 N•m (0.08 kgf•m, 0.59 lb•ft)

7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
0.4 N•m (0.04 kgf•m, 0.30 lb•ft)
7
8
1
(3)
1.5 N•m (0.15 kgf•m, 1.1 lb•ft)

T.R
.
3.8 N•m (0.38 kgf•m, 2.8 lb•ft) 1.5 N•m (0.15 kgf•m, 1.1 lb•ft)
T.R
T.R
.

Air scoop page 4-8.
Fuel tank cover page 4-8.
1 Fuel tank side cover (right) 1
2 Fuel tank mole (right) 1
3 Air duct cover (right) 1
4 Air duct (right) 1
5 Air scoop stay (right) 1
6 Intake grill (right) 1
7 Outlet (right) 1
8 Side grille (right) 1
4-10
GENERAL CHASSIS (2)
Removing the bottom cowling (for MT10SPN/MT10SPNC)
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
6 0.3 N•m (0.03 kgf•m, 0.22 lb•ft)
T.R
.
2
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
5
7
4
1
3
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
0.3 N•m (0.03 kgf•m, 0.22 lb•ft)

T.R
.

1 Bottom side cowling (left) 1
2 Bottom side cowling (right) 1
3 Bottom cowling 1
4 Oil cooler cover 1
5 Upper bracket (left) 1
6 Upper bracket (right) 1
7 Lower bracket (left) 1
8 Lower bracket (right) 1
4-11
GENERAL CHASSIS (2)
EAS31772
REMOVING THE AIR SCOOP

The following procedure applies to both of the air
scoop. 1
1. Remove:
• Air scoop (left) “1” b
a
a. Remove the air scoop bolts (left) “2”.
b. Disengage projections “a” on the air scoop
(left) from air scoop stay.
c. Remove the air scoop (left).
a EAS32173
2 REMOVING THE SIDE COVER (RIGHT)

1. Remove:
• Side cover (right) “1”
1
a. Remove the side cover bolt “2”.
b. Unhook the projection “a” on the side cover
(right) from the bracket.
a TIP
2
Remove projections “b” on the side cover from
EAS31519
grommet “c”.
REMOVING THE SIDE COVER (LEFT)
1. Remove:
• Side cover (left) “1” a
a. Remove the side cover bolt “2”.
b. Unhook the projection “a” on the side cover 1
(left) from the bracket.
TIP c
Remove projections “b” on the side cover from b
grommet “c”. 2
2. Remove:
a
• Side cover bracket (right) “1”
1 a. Pull out the side cover bracket (right) down-
ward, and then unhook the projection “a” on
the side cover bracket (right) from the hole
“b” on the frame.
c
b
2 1
2. Remove:
• Side cover bracket (left) “1” a
a. Pull out the side cover bracket (left) down-
ward, and then unhook the projection “a” on
the side cover bracket (left) from the hole b
“b” on the frame.
4-12
GENERAL CHASSIS (2)
EAS31685 EAS33575
REMOVING THE FUEL TANK COVER INSTALLING THE FUEL TANK SIDE COVER
1. Remove: ASSEMBLY
• Fuel tank cover “1” The following procedure applies to both of the
a. Remove the quick fasteners “a”. fuel tank side cover assembly.
b. Disengage the projections “b” of the fuel 1. Install:
tank cover from the fuel tank side cover as- • Fuel tank side cover assembly (left) “1”.
sembly. a. Insert the projection “a” on the fuel tank side
cover assembly into the grommets “b” and
1 insert the projection “c” on the fuel tank side
b cover assembly into the hole.
b. Install the fuel tank side cover assembly up-
per bolt (left) “2”, fuel tank side cover as-
sembly front bolts “3” and fuel tank side
b cover assembly rear bolt “4”, and then tight-
en the bolts to specification.
a
fuel tank side cover upper bolt
0.4 N·m (0.04 kgf·m, 0.30 lb·ft)
T.
EAS33574
R.
REMOVING THE FUEL TANK SIDE COVER Fuel tank side cover front bolt
ASSEMBLY 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
The following procedure applies to both of the Fuel tank side cover rear bolt
fuel tank side cover assembly. 3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
1. Remove:
• Fuel tank side cover assembly (left) “1”. 2 c b
a. Remove the fuel tank side cover assembly
a
upper bolt (left) “2”, fuel tank side cover as-
sembly front bolts (left) “3” and fuel tank
side cover rear bolt (left) “4”.
b. Remove the fuel tank side cover assembly
3 4
(left).
TIP
1
• Remove projections “a” on the fuel tank side
cover assembly from grommets “b”. EAS31686
• Remove projections “c” on the fuel tank side INSTALLING THE FUEL TANK COVER
cover assembly from hole. 1. Install:
• Fuel tank cover “1”
2 c b a. Insert the projections “b” on the fuel tank
cover into the fuel tank side cover assem-
a bly.
b. Install the quick fasteners “a”.
1
3 4
b
1
4-13
GENERAL CHASSIS (2)
EAS31520 EAS32174
INSTALLING THE SIDE COVER (LEFT) INSTALLING THE SIDE COVER (RIGHT)
1. Install: 1. Install:
• Side cover bracket (left) “1” • Side cover bracket (right) “1”
a. Insert the projection “a” on the side cover a. Insert the projection “a” on the side cover
bracket (left) to the hole “b” on the frame. bracket (right) to the hole “b” on the frame.
1
1
a
b a
• Side cover (left) “1” • Side cover (right) “1”
a. Fit the projection “a” on the side cover (left) a. Fit the projection “a” on the side cover
to the side cover bracket (left). (right) to the side cover bracket (right).
b. Insert the projections “b” on the side cover b. Insert the projections “b” on the side cover
into the grommet “c”. into the grommet “c”.
c. Install the side cover bolt “2”, and then tight- c. Install the side cover bolt “2”, and then tight-
en the bolt to specification. en the bolt to specification.
Side cover bolt Side cover bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
T.
R.
R.
a
a
1
1
c c
b b
2 2
EAS33689
INSTALLING THE AIR DUCT COVER

Refer to “INSTALLING THE AIR DUCT COV-
ER” on page 7-8.
4-14
GENERAL CHASSIS (2)
EAS31773
INSTALLING THE AIR SCOOP

scoop.
1. Install:
• Air scoop (left) “1”
a. Insert the projections “a” on the air scoop
(left) into the air scoop stay.
b. Install the air scoop bolts (left) “2” and tight-
en the bolts to specification.
Air scoop bolt

1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
T.
R.
a
2
a
2
4-15
GENERAL CHASSIS (3)
EAS20156
GENERAL CHASSIS (3)

Removing the meter assembly and auxiliary light
2.8 N•m (0.28 kgf•m, 2.1 lb•ft) (3)

(3)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
(3)
(3)
9 7 (2)
6
0.4 N•m (0.04 kgf•m, 0.30 lb•ft) 5

7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
(3)
(4) (3)
8
1 (3)
0.8 N•m (0.08 kgf•m, 0.59 lb•ft)

3
(3) 4
1.3 N•m (0.13 kgf•m, 0.95 lb•ft)

1 Upper cover 1
2 Deflector 1
3 Bracket 1
4 Meter assembly cover 1
5 Meter assembly coupler 1 Disconnect.
6 Meter assembly 1
7 Auxiliary light coupler 2 Disconnect.
8 Meter stay 1
9 Auxiliary light 1
4-16
GENERAL CHASSIS (3)
Removing the headlight assembly and headlight stay
18 N•m (1.8 kgf•m, 13 lb•ft) 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
1.0 N•m (0.10 kgf•m, 0.73 lb•ft)
T.R
.
(4)
1
LT
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
3 5 6 LT
4
LT
2 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
18 N•m (1.8 kgf•m, 13 lb•ft)
1.3 N•m (0.13 kgf•m, 0.95 lb•ft)

T.R
.

1 Inner panel 1
2 Headlight cover (left) 1
3 Headlight cover (right) 1
4 Headlight assembly 1
5 Wire harness bracket (left) 1
6 Wire harness bracket (right) 1
7 Headlight bracket 1
4-17
GENERAL CHASSIS (3)
Disassembling the headlight assembly
1.2 N•m (0.12 kgf•m, 0.88 lb•ft)

1 Headlight control unit coupler 1 Disconnect.
2 Headlight control unit 1
4-18
GENERAL CHASSIS (3)
Removing the air scoop stay bracket (left)
6 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
1
2
3
4
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

Air scoop/Air scoop stay/Fuel tank cover/Fuel Refer to “GENERAL CHASSIS (2)” on
tank side cover/Air duct page 4-8.
1 AC magneto coupler 1 Disconnect.
2 Rectifier/regulator coupler 1 Disconnect.
3 Radiator fan motor coupler (left) 1 Disconnect.
4 Radiator fan motor coupler (right) 1 Disconnect.
5 Air scoop stay bracket (left) 1
6 Rectifier/regulator 1
4-19
GENERAL CHASSIS (3)
Removing the air scoop stay bracket (right)
3 1 4
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
*
5
2
* For MT10SPN/MT10SPNC
Air scoop/Air scoop stay/Fuel tank cover/Fuel Refer to “GENERAL CHASSIS (2)” on
tank side cover/Air duct page 4-8.
1 Relay unit coupler 1 Disconnect.
2 SCU coupler 1 Disconnect.
3 Air scoop stay bracket (right) 1
4 Relay unit 1
5 SCU (Suspension Control Unit) 1
4-20
FRONT WHEEL
EAS20028
FRONT WHEEL
Removing the front wheel and brake discs (for MT10N/MT10NC)
2 3 6 N・m (0.6 kgf・m, 4.4 lb・ft)
3.8 N・m (0.38 kgf・m, 2.8 lb・ft)
6 N・m (0.6 kgf・m, 4.4 lb・ft) 1 35 N・m (3.5 kgf・m, 26 lb・ft)
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.
5
3
21 N・m (2.1 kgf・m, 15 lb・ft)
8
10
11
6 1
2
7
4 5
115 N・m (11.5 kgf・m, 85 lb・ft)
9
11
17 N・m (1.7 kgf・m, 13 lb・ft)
10 7 N・m (0.7 kgf・m, 5.2 lb・ft)

2 Reflector 2
3 Front brake hose holder 2
4 Front wheel sensor 1
5 Front brake caliper 2
6 Wheel axle pinch bolt 4 Loosen.
7 Front wheel axle nut 1
8 Front wheel axle 1
9 Front wheel 1
10 Collar 2
11 Front brake disc 2
4-21
FRONT WHEEL
Removing the front wheel and brake discs (for MT10SPN/MT10SPNC)

2 3 6 N・m (0.6 kgf・m, 4.4 lb・ft)
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.
6 N・m (0.6 kgf・m, 4.4 lb・ft) 1 35 N・m (3.5 kgf・m, 26 lb・ft)
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.
6
3
21 N・m (2.1 kgf・m, 15 lb・ft)
9
11
12
7 1
2
8
5 6
4
7
115 N・m (11.5 kgf・m, 85 lb・ft)
10
7 N・m (0.7 kgf・m, 5.2 lb・ft)
12
17 N・m (1.7 kgf・m, 13 lb・ft)
11
2 Reflector 2
4 Front wheel sensor protector 1
5 Front wheel sensor 1
7 Wheel axle pinch bolt 4 Loosen.
8 Front wheel axle nut 1
9 Front wheel axle 1
10 Front wheel 1
11 Collar 2
12 Front brake disc 2
4-22
FRONT WHEEL
Disassembling the front wheel
New 2
3 New
New
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
LS
LT
4
New 3
New
New 2
1
8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
.

1 Front wheel sensor rotor 1
2 Oil seal 2
3 Wheel bearing 2
4 Spacer 1
5 Tire air valve 1
4-23
FRONT WHEEL
EAS30145
1. Remove:
REMOVING THE FRONT WHEEL
ECA20981
• Oil seal
NOTICE • Wheel bearing
• Keep any type of magnets (including mag- a. Clean the surface of the front wheel hub.
netic pick-up tools, magnetic screwdrivers, b. Remove the oil seals “1” with a flat-head
etc.) away from the front wheel sensor or screwdriver.
front wheel sensor rotor; otherwise, the TIP
sensor or rotor may be damaged, resulting To prevent damaging the wheel, place a rag “2”
in improper performance of the ABS sys- between the screwdriver and the wheel surface.
tem.
• Do not drop the front wheel sensor rotor or 2
subject it to shocks.
• If any solvent gets on the front wheel sen-
sor rotor, wipe it off immediately.
1
EWA13120
WARNING
no danger of it falling over. G088896
c. Remove the wheel bearings with a general

2. Remove:
bearing puller.
• Front brake caliper (left)
• Front brake caliper (right) EAS30147
• Front wheel sensor CHECKING THE FRONT WHEEL

ECA21440 1. Check:
NOTICE • Wheel axle
• Do not apply the brake lever when remov- Roll the wheel axle on a flat surface.
ing the brake calipers. Bends → Replace.
• Be sure not to contact the sensor electrode EWA13460
to any metal part when removing the front WARNING

wheel sensor from the sensor housing. Do not attempt to straighten a bent wheel ax-
le.
3. Elevate:
• Front wheel 2. Check:
TIP • Tire
Place the vehicle on a maintenance stand so • Front wheel
that the front wheel is elevated. Damage/wear → Replace.
Refer to “CHECKING THE TIRES” on
4. Loosen: page 3-17 and “CHECKING THE WHEELS”
• Wheel axle pinch bolt on page 3-17.
5. Remove: 3. Measure:
• Front wheel axle • Radial wheel runout “1”
• Front wheel • Lateral wheel runout “2”
Over the specified limits → Replace.
EAS30146
DISASSEMBLING THE FRONT WHEEL

ECA21340 Radial wheel runout limit
NOTICE 1.0 mm (0.04 in)
• Do not drop the wheel sensor rotor or sub- Lateral wheel runout limit
ject it to shocks. 0.5 mm (0.02 in)
• If any solvent gets on the wheel sensor ro-
tor, wipe it off immediately.
4-24
FRONT WHEEL
TIP
2 Place a suitable washer “1” between the socket
“2” and the bearing so that both the inner race
1
“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
4. Check:
• Wheel bearing
Front wheel turns roughly or is loose → Re-
place the wheel bearings.
• Oil seal
Damage/wear → Replace.
G088899
EAS30151
d. Install the new oil seals.
ASSEMBLING THE FRONT WHEEL
ECA21340
2. Install:
NOTICE • Front wheel sensor rotor
• Do not drop the wheel sensor rotor or sub-
ject it to shocks. Wheel sensor rotor bolt
• If any solvent gets on the wheel sensor ro- 8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.
R.
tor, wipe it off immediately. LOCTITE®

1. Install: ECA17200
• Wheel bearing New NOTICE

• Oil seal New Replace the wheel sensor rotor bolts with
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”.
TIP 1
Use a socket “4” that matches the diameter of
the wheel bearing outer race.
G088900
3. Measure:
• Wheel sensor rotor runout
Out of specification → Correct the wheel sen-
sor rotor runout or replace the wheel sensor
G088898
rotor.
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 4-26.
4-25
FRONT WHEEL
A. Direction of wheel rotation

Wheel sensor rotor runout limit B. Right side
0.25 mm (0.01 in)
EAS30155
4. Install: MAINTENANCE OF THE FRONT WHEEL
• Tire air valve “1” SENSOR AND SENSOR ROTOR
(along with the O-ring) New ECA21070
ECA27760 NOTICE
NOTICE • Handle the ABS components with care
• Do not allow grease to contact the O-ring. since they have been accurately adjusted.
• Use only the specified genuine YAMAHA Keep them away from dirt and do not sub-
tire air valve. Using a different air valve may ject them to shocks.
cause leakage. • The front wheel sensor cannot be disas-
• Make sure there are no foreign materials in sembled. Do not attempt to disassemble it.
the tire valve installation area of the wheel If faulty, replace with a new one.
rim. Foreign materials may cause leakage. • Keep any type of magnets (including mag-
netic pick-up tools, magnetic screwdrivers,
TIP etc.) away from the front wheel sensor or
The tire air valve original position is with the front wheel sensor rotor.
valve cap pointing to the right side of the vehicle, • Do not drop or shock the wheel sensor or
perpendicular (85–95 degree right angle) to the the wheel sensor rotor.
axis (center line) of the wheel.
1. Check:
a. Clean the tire valve installation area of the • Front wheel sensor
wheel rim. Cracks/bends/distortion → Replace.
b. Install the tire air valve with the new O-ring, Iron powder/dust → Clean.
and tighten the tire air valve nut “2” to spec- 2. Check:
ification. • Front wheel sensor rotor
Cracks/damage/scratches → Replace the
Tire air valve nut front wheel sensor rotor.
7 N·m (0.7 kgf·m, 5.2 lb·ft) Iron powder/dust/solvent → Clean.
T.
R.
TIP
• The wheel sensor rotor is installed on the inner
side of the wheel hub.
• When cleaning the wheel sensor rotor, be
careful not to damage the surface of the sensor
rotor.
1
3. Measure:
• Wheel sensor rotor deflection
2
Out of specification → Clean the installation
surface of the wheel sensor rotor and correct
the wheel sensor rotor deflection, or replace
a the wheel sensor rotor.
Wheel sensor rotor deflection

limit
0.25 mm (0.01 in)
a. 85–95°
4-26
FRONT WHEEL
a. Hold the dial gauge at a right angle against 2. Check:

the wheel sensor rotor surface. • Front brake disc
b. Measure the wheel sensor rotor deflection. Refer to “CHECKING THE FRONT BRAKE
DISCS” on page 4-45.
3. Lubricate:
• Oil seal lip
4. Install:
• Collar
G088902 • Front wheel
c. If the deflection is still above specification, • Front wheel axle
replace the wheel sensor rotor. • Front wheel axle nut
TIP
EAS30152
ADJUSTING THE FRONT WHEEL STATIC Apply lithium soap-based grease onto the mat-
BALANCE ing surface of the front wheel axle nut.
TIP 5. Tighten:
• After replacing the tire, wheel or both, the front • Front wheel axle nut
wheel static balance should be adjusted.
• Adjust the front wheel static balance with the Front wheel axle nut
brake disc installed. 115 N·m (11.5 kgf·m, 85 lb·ft)
T.
R.
• Refer to “ADJUSTING THE WHEEL STATIC

ECA14140
BALANCE” in “BASIC INFORMATION” (sepa-
NOTICE
rate volume).
Before tightening the wheel axle nut, push
1. Remove: down hard on the handlebar(s) several times
• Balancing weight(s) and check if the front fork rebounds smooth-
2. Find: ly.
• Front wheel’s heavy spot
3. Adjust: 6. Tighten:
• Front wheel static balance • Front wheel axle pinch bolt
4. Check: a. Tighten the pinch bolt “2”, pinch bolt “1”,
• Front wheel static balance and pinch bolt “2” to the specified torque in
this order.
EAS30154
INSTALLING THE FRONT WHEEL (DISC

BRAKE)
21 N·m (2.1 kgf·m, 15 lb·ft)
T.
1. Install:
R.
• Front brake discs b. Check that the right end “a” of the front axle
is flush with the front fork “b”. If necessary,
Front brake disc bolt manually push the front axle or lightly tap it
17 N·m (1.7 kgf·m, 13 lb·ft) with a soft hammer until its end is flush with
T.
R.
LOCTITE® the front fork. However, if the surface of the

ECA19150 front axle end is not parallel to the surface
NOTICE of the front fork, align a point on the outer
Replace the brake disc bolts with new ones. edge of the axle with the fork, making sure
that the axle does not protrude past the
TIP fork.
Tighten the brake disc bolts in stages and in a
crisscross pattern.
4-27
FRONT WHEEL
8. Measure:
• Distance “a”
b (between the front wheel sensor rotor “1” and
front wheel sensor “2”)
a 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,
c. Tighten the pinch bolt “4”, pinch bolt “3”, deformation caused by an impact during ser-
and pinch bolt “4” to the specified torque in vice and caught foreign materials). If there is
this order. any defective part, repair or replace the de-
fective part.
21 N·m (2.1 kgf·m, 15 lb·ft) Distance “a” (between the front
T.
R.
wheel sensor rotor and front

wheel sensor)
0.9–1.7 mm (0.035–0.067 in)
TIP
Measure the distance between the front wheel
sensor rotor and front wheel sensor in several
4 1 places in one rotation of the front wheel. Do not
3 2
turn the front wheel while the thickness gauge is
installed. This may damage the front wheel sen-
sor rotor and the front wheel sensor.
7. Install:
• Front wheel sensor
Thickness gauge
Front wheel sensor bolt 90890-03268
7 N·m (0.7 kgf·m, 5.2 lb·ft) Feeler gauge set
T.
YU-26900-9
R.
ECA21020
NOTICE
a
Make sure there are no foreign materials in
the front wheel sensor rotor and front wheel 1
sensor. Foreign materials cause damage to
the front wheel sensor rotor and front wheel 2
2
sensor.
1
TIP
• When installing the front wheel sensor, check
G088903
the front wheel sensor lead for twists.
• To route the front wheel sensor lead, refer to
“CABLE ROUTING” on page 2-15.
4-28
FRONT WHEEL
9. Install:
• Front wheel sensor protector (for MT10SPN/
MT10SPNC)
• Front brake caliper
• Front brake hose holder
Front wheel sensor protector

bolt (for MT10SPN/MT10SPNC)
T.
R.
7 N·m (0.7 kgf·m, 5.2 lb·ft)

Front brake caliper bolt
35 N·m (3.5 kgf·m, 26 lb·ft)
Front brake hose holder bolt
6 N·m (0.6 kgf·m, 4.4 lb·ft)
EWA13500
WARNING
Make sure the brake hose is routed properly.
4-29
REAR WHEEL
EAS20029
REAR WHEEL
Removing the rear wheel
7 N・m (0.7 kgf・m, 5.2 lb・ft) 2 11
190 N・m (19 kgf・m, 140 lb・ft)
5
6
9
8
10
7
4 3 3 4
16 N・m (1.6 kgf・m, 12 lb・ft) 16 N・m (1.6 kgf・m, 12 lb・ft)

Rear brake caliper Refer to “REAR BRAKE” on page 4-51.
1 Rear wheel sensor protector 1
2 Rear wheel sensor 1
3 Locknut 2 Loosen.
4 Adjusting bolt 2 Loosen.
5 Rear wheel axle nut 1
6 Washer 1
7 Rear wheel axle 1
8 Adjusting block (left) 1
9 Adjusting block (right) 1
10 Rear wheel 1
11 Brake caliper bracket 1
4-30
REAR WHEEL
Removing the brake disc and rear wheel sprocket
30 N•m (3.0 kgf•m, 22 lb•ft)

8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
.
8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
.
1
(5) 2
LT
LT (5) 3
7
(5)
11 9
10 8
12 5
4 6
(6)
80 N•m (8.0 kgf•m, 59 lb•ft)

1 Rear wheel sensor rotor 1
2 Brake disc carrier 1
3 Rear brake disc 1
4 Rear wheel sprocket bracket 1
5 Rear wheel sprocket 1
6 Collar 1
7 Collar 1
8 Oil seal 1
9 Bearing 1
10 Rear wheel drive hub 1
11 Rear wheel drive hub damper 6
12 Rear wheel 1
4-31
REAR WHEEL
Disassembling the rear wheel
80 N•m (8.0 kgf•m, 59 lb•ft)
New 4
7
5
6 New New
LT 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
3 .
New 2
1

1 Collar 1
2 Wheel bearing 1
3 Spacer 1
4 Oil seal 1
5 Wheel bearing ring nut 1
6 Wheel bearing 1
7 Tire air valve 1
4-32
REAR WHEEL
EAS30910
TIP
REMOVING THE REAR WHEEL
ECA21030 Push the rear wheel forward and remove the
NOTICE drive chain from the rear wheel sprocket.
• Keep any type of magnets (including mag-
netic pick-up tools, magnetic screwdrivers, EAS30158
etc.) away from the rear wheel sensor or DISASSEMBLING THE REAR WHEEL
ECA21340
rear wheel sensor rotor; otherwise, the sen-
NOTICE
sor or rotor may be damaged, resulting in
improper performance of the ABS system. • Do not drop the wheel sensor rotor or sub-
• Do not drop the rear wheel sensor rotor or ject it to shocks.
subject it to shocks. • If any solvent gets on the wheel sensor ro-
• If any solvent gets on the rear wheel sensor tor, wipe it off immediately.
rotor, wipe it off immediately. 1. Remove:
1. Stand the vehicle on a level surface. • Wheel bearing ring nut “1”
EWA13120 TIP
WARNING Use the wheel bearing ring nut tool “2” to remove
Securely support the vehicle so that there is the wheel bearing ring nut by turning it clockwise
no danger of it falling over. “a”.
TIP
Place the vehicle on a maintenance stand so Wheel bearing ring nut tool
that the rear wheel is elevated. 90890-01574
YM-01574
2. Remove:
• Rear brake caliper
• Rear wheel sensor protector 1
• Rear wheel sensor
ECA21040
NOTICE
• Do not depress the brake pedal when re-
moving the brake caliper.
• Be sure not to contact the sensor electrode
to any metal part when removing the rear
wheel sensor from the rear brake caliper
bracket.
3. Loosen: 2
• Locknut
• Adjusting bolt
4. Remove:
• Rear wheel axle nut
a
• Washer
• Rear wheel axle
• Rear wheel
• Brake caliper bracket
ECA21400
2. Remove:
NOTICE • Oil seal
Be sure to remove the rear wheel sensor be- • Wheel bearing
fore removing the brake caliper bracket, oth- Refer to “DISASSEMBLING THE FRONT
erwise the sensor could be damaged. WHEEL” on page 4-24.
4-33
REAR WHEEL
EAS30159
2. Replace:
CHECKING THE REAR WHEEL
• Rear wheel sprocket
1. Check:
• Wheel axle a. Remove the rear wheel sprocket nuts, rear
• Wheel bearing wheel sprocket bracket and the rear wheel
• Oil seal sprocket.
Refer to “CHECKING THE FRONT WHEEL” b. Clean the rear wheel drive hub with a clean
on page 4-24. cloth, especially the surfaces that contact
2. Check: the sprocket.
• Tire c. Install the new rear wheel sprocket and rear
• Rear wheel wheel sprocket bracket.
Refer to “CHECKING THE TIRES” on Rear wheel sprocket nut
page 3-17 and “CHECKING THE WHEELS” 80 N·m (8.0 kgf·m, 59 lb·ft)
T.
R.
on page 3-17.
TIP
3. Measure:
• Radial wheel runout Tighten the rear wheel sprocket nuts in stages
• Lateral wheel runout and in a crisscross pattern.
Refer to “CHECKING THE FRONT WHEEL”
EAS33361
on page 4-24.
CHECKING THE REAR WHEEL SPROCKET
EAS30160 BRACKET
CHECKING THE REAR WHEEL DRIVE HUB 1. Check:
1. Check: • Rear wheel sprocket bracket
• Rear wheel drive hub Cracks/damage → Replace.
EAS30163
• Rear wheel drive hub dampers
ASSEMBLING THE REAR WHEEL
Damage/wear → Replace. ECA21340
EAS30161
NOTICE
CHECKING AND REPLACING THE REAR • Do not drop the wheel sensor rotor or sub-
WHEEL SPROCKET ject it to shocks.
1. Check: • If any solvent gets on the wheel sensor ro-
• Rear wheel sprocket tor, wipe it off immediately.
More than 1/4 tooth “a” wear → Replace the
drive sprocket, the rear wheel sprocket and 1. Install:
the drive chain as a set. • Wheel bearing New
Bent teeth → Replace the drive sprocket, the • Oil seal New
rear wheel sprocket and the drive chain as a Refer to “ASSEMBLING THE FRONT
set. WHEEL” on page 4-25.
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.
G088904
b. Correct
1. Drive chain roller

2. Rear wheel sprocket
4-34
REAR WHEEL
a a
4. Install:
• Tire air valve “1”
(along with the O-ring) New
ECA27760
NOTICE
• Do not allow grease to contact the O-ring.
• Use only the specified genuine YAMAHA
LT LT tire air valve. Using a different air valve may
cause leakage.
• Make sure there are no foreign materials in
a. Width: two grooves of the threaded portion the tire valve installation area of the wheel
b. Length: more than 40 mm (1.57 in) rim. Foreign materials may cause leakage.
3. Tighten: TIP
• Wheel bearing ring nut “1”
The tire air valve original position is with the
TIP valve cap pointing to the right side of the vehicle,
Use the wheel bearing ring nut tool “2” to tighten perpendicular (85–95 degree right angle) to the
the wheel bearing ring nut by turning it counter- axis (center line) of the wheel.
clockwise “a”.
a. Clean the tire valve installation area of the
wheel rim.
Wheel bearing ring nut tool
b. Install the tire air valve with the new O-ring,
90890-01574
and tighten the tire air valve nut “2” to spec-
YM-01574
ification.
Wheel bearing ring nut Tire air valve nut

80 N·m (8.0 kgf·m, 59 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
T.
R.
R.
LOCTITE®
4-35
REAR WHEEL
3. Measure:
• Wheel sensor rotor runout
on page 4-26.
1 EAS30164
ADJUSTING THE REAR WHEEL STATIC

BALANCE
TIP
2 • After replacing the tire, wheel or both, the rear
wheel static balance should be adjusted.
a
• Adjust the rear wheel static balance with the
brake disc and rear wheel drive hub installed.
1. Adjust:
• Rear wheel static balance
Refer to “ADJUSTING THE FRONT WHEEL
STATIC BALANCE” on page 4-27.
EAS30165
INSTALLING THE REAR WHEEL (DISC

a. 85–95° BRAKE)
A. Direction of wheel rotation 1. Install:
B. Right side • Rear brake disc
EAS30167 Rear brake disc bolt

MAINTENANCE OF THE REAR WHEEL 30 N·m (3.0 kgf·m, 22 lb·ft)
T.
R.
SENSOR AND SENSOR ROTOR LOCTITE®

ECA21060
ECA21011
NOTICE
NOTICE
• Handle the ABS components with care
since they have been accurately adjusted. • Do not drop the wheel sensor rotor or sub-
Keep them away from dirt and do not subject it to shocks.
ject them to shocks. • If any solvent gets on the wheel sensor ro-
• The rear wheel sensor cannot be disassem- tor, wipe it off immediately.
bled. Do not attempt to disassemble it. If • Replace the brake disc bolts and wheel
faulty, replace with a new one. sensor rotor bolts with new ones.
• Keep any type of magnets (including mag- TIP
netic pick-up tools, magnetic screwdrivers,
Tighten the brake disc bolts in stages and in a
etc.) away from the rear wheel sensor or
crisscross pattern.
rear wheel sensor rotor.
• Do not drop or shock the wheel sensor or 2. Check:
the wheel sensor rotor. • Rear brake disc
Refer to “CHECKING THE REAR BRAKE
1. Check:
DISC” on page 4-57.
3. Lubricate:
• Oil seal lip
on page 4-26.
2. Check: Lithium-soap-based grease
• Rear wheel sensor rotor
on page 4-26.
4-36
REAR WHEEL
4. Install: 6. Tighten:
• Collar • Rear wheel axle nut
• Brake caliper bracket • Rear brake caliper bolt
• Rear wheel
• Adjusting block Rear wheel axle nut
• Rear wheel axle 190 N·m (19 kgf·m, 140 lb·ft)
T.
R.
• Washer Rear brake caliper bolt (front)
• Rear wheel axle nut 27 N·m (2.7 kgf·m, 20 lb·ft)
TIP Rear brake caliper bolt (rear)
22 N·m (2.2 kgf·m, 16 lb·ft)
• Do not install the brake caliper. LOCTITE®
• Align the slot “a” in the swingarm with the pro-
jection “b” of the brake caliper bracket. EWA13500
• Install the adjusting block so that projection “c” WARNING

faces to the front of the vehicle. 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”.
b
a
1 a
a
c
2 2
A. Left side
B. Right side
7. Install:
5. Adjust: • Rear wheel sensor protector
Refer to “Adjusting the drive chain slack” on Rear wheel sensor bolt
7 N·m (0.7 kgf·m, 5.2 lb·ft)
page 3-19.
T.
R.
Rear wheel sensor protector bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft)
20.0–30.0 mm (0.79–1.18 in) ECA21080
Drive chain slack (Maintenance NOTICE

Stand) Make sure there are no foreign materials in
25.0–35.0 mm (0.98–1.38 in) the rear wheel sensor rotor and rear wheel
sensor. Foreign materials cause damage to
the rear wheel sensor rotor and rear wheel
sensor.
TIP
When installing the rear wheel sensor, check the
rear wheel sensor lead for twists.
4-37
REAR WHEEL
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)
0.7–1.6 mm (0.028–0.063 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
1
2
1 2
4-38
FRONT BRAKE
EAS20030
FRONT BRAKE
Removing the front brake pads
6 N・m (0.6 kgf・m, 4.4 lb・ft)
5 6 5 N・m (0.5 kgf・m, 3.7 lb・ft)
3
7 4
2
1
FW
D
35 N・m (3.5 kgf・m, 26 lb・ft)

The following procedure applies to both of
the front brake calipers.
1 Brake pad clip 2
2 Brake pad pin 1
3 Brake pad spring 1
4 Brake pad 2
5 Reflector 1
8 Bleed screw 1
Right brake caliper side. (for MT10N/
9 Bleed screw 1 MT10NC)
4-39
FRONT BRAKE
Removing the front brake master cylinder
6
3
1.2 N•m (0.12 kgf•m, 0.88 lb•ft) 4
T.R
.
1
17 N•m (1.7 kgf•m, 13 lb•ft)
S
5
8
7
*
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)
T.R
.
S New
16 N•m (1.6 kgf•m, 12 lb•ft)
1.2 N•m (0.12 kgf•m, 0.88 lb•ft)

T.R
.
6 N•m (0.6 kgf•m, 4.4 lb•ft)

T.R
.
30 N•m (3.0 kgf•m, 22 lb•ft)
* This collar is press-fitted in the brake lever. When press-fitting the collar into the brake lever, press-fit it from
the chamfered side where the collar mounting hole.
Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-16.
1 Brake fluid reservoir cap stopper 1
2 Brake fluid reservoir cap 1
3 Brake fluid reservoir diaphragm holder 1
4 Brake fluid reservoir diaphragm 1
5 Brake fluid reservoir 1
6 Rearview mirror (right) 1
7 Brake fluid reservoir bracket 1
8 Brake fluid reservoir hose 1
4-40
FRONT BRAKE
Removing the front brake master cylinder
1.2 N•m (0.12 kgf•m, 0.88 lb•ft)

T.R
.
17 N•m (1.7 kgf•m, 13 lb•ft)
14
13 *
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)
T.R
.
S
9 10 New
12 11
S
16 N•m (1.6 kgf•m, 12 lb•ft)
1.2 N•m (0.12 kgf•m, 0.88 lb•ft)

T.R
.
6 N•m (0.6 kgf•m, 4.4 lb•ft)

T.R
.
30 N•m (3.0 kgf•m, 22 lb•ft)
* This collar is press-fitted in the brake lever. When press-fitting the collar into the brake lever, press-fit it from
the chamfered side where the collar mounting hole.
9 Brake hose 1
10 Brake hose gasket 2
11 Front brake master cylinder holder 1
12 Front brake light switch 1
13 Brake lever 1
14 Front brake master cylinder assembly 1
4-41
FRONT BRAKE
Disassembling the front brake master cylinder
6 N•m (0.6 kgf•m, 4.4 lb•ft)
T.R
.
New
2
3
4
BF
BF
1 New

1 Brake master cylinder kit 1
2 Cap 1
3 Bleed screw 1
4 Brake master cylinder body 1
4-42
FRONT BRAKE
Removing the front brake calipers
6 N・m (0.6 kgf・m, 4.4 lb・ft)
1 2
3 4
6
32 N・m (3.2 kgf・m, 24 lb・ft)
FW 35 N・m (3.5 kgf・m, 26 lb・ft)
D

Drain.
1 Reflector 1
3 Brake hose union bolt 1
5 Brake hose 1
4-43
FRONT BRAKE
Disassembling the front brake calipers

5 N・m (0.5 kgf・m, 3.7 lb・ft)
8
FW 9
D
5 N・m (0.5 kgf・m, 3.7 lb・ft)
3
2 4
1 S
6
5 7
6
S
BF
6 7
7
5
7
BF 6 S

1 Brake pad clip 2
2 Brake pad pin 1
4 Brake pad 2
5 Brake caliper piston 4
6 Brake caliper piston dust seal 4
7 Brake caliper piston seal 4
8 Bleed screw 1
Right brake caliper side. (for MT10N/
9 Bleed screw 1 MT10NC)
4-44
FRONT BRAKE
EAS30168
INTRODUCTION
EWA14101
WARNING
Disc brake components rarely require disas-
sembly. Therefore, always follow these pre-
ventive measures:
• Never disassemble brake components un-
less absolutely necessary.
• If any connection on the hydraulic brake G098641
system is disconnected, the entire brake
system must be disassembled, drained, 3. Measure:
cleaned, properly filled, and bled after reas- • Brake disc thickness
sembly. Measure the brake disc thickness at a few dif-
• Never use solvents on internal brake com- ferent locations.
ponents. Out of specification → Replace.
• Use only clean or new brake fluid for clean-
ing brake components. Brake disc thickness limit
• Brake fluid may damage painted surfaces 4.5 mm (0.18 in)
and plastic parts. Therefore, always clean
4. Adjust:
up any spilt brake fluid immediately.
• Brake disc runout
• Avoid brake fluid coming into contact with
the eyes as it can cause serious injury. a. Remove the brake disc.
FIRST AID FOR BRAKE FLUID ENTERING b. Rotate the brake disc by one bolt hole.
THE EYES: c. Install the brake disc.
• Flush with water for 15 minutes and get im-
mediate medical attention. Front brake disc bolt
17 N·m (1.7 kgf·m, 13 lb·ft)
T.
R.
EAS30169
LOCTITE®
CHECKING THE FRONT BRAKE DISCS ECA19150
The following procedure applies to both brake NOTICE

discs. Replace the brake disc bolts with new ones.
1. Check:
• Front brake disc TIP
Damage/galling → Replace. Tighten the brake disc bolts in stages and in a
2. Measure: crisscross pattern.
• Brake disc deflection
Out of specification → Correct the brake disc d. Measure the brake disc deflection.
runout or replace the brake disc. e. If out of specification, repeat the adjustment
steps until the brake disc deflection is within
Brake disc runout limit (as mea- specification.
sured on wheel) f. If the brake disc deflection cannot be
0.10 mm (0.0039 in) brought within specification, replace the
brake disc.
a. Place the vehicle on a maintenance stand EAS30170
so that the front wheel is elevated. REPLACING THE FRONT BRAKE PADS
b. Remove the brake caliper. The following procedure applies to both brake
c. Hold the dial gauge at a right angle against calipers.
the brake disc surface. TIP
d. Measure the deflection 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.
4-45
FRONT BRAKE
1. Remove: a. Connect a clear plastic hose “1” tightly to

• Brake pad clip “1” the bleed screw “2”. Put the other end of the
• Brake pad pin “2” hose into an open container.
• Brake pad spring “3” b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with
3
your finger.
1
2
1
2
2. Remove:
• Brake pad “1”
c. Tighten the bleed screw.
Brake caliper bleed screw

5 N·m (0.5 kgf·m, 3.7 lb·ft)
T.
R.
d. Install the brake pads and brake pad spring.
TIP
The arrow mark “a” on the brake pad spring
1
must point in the direction of disc rotation.
3. Measure:
• 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)
6. Install:
• Brake pad pin
a
• Brake pad clip
Front brake caliper bolt

35 N·m (3.5 kgf·m, 26 lb·ft)
T.
R.
4. Remove: 7. Check:
• Brake caliper • Brake fluid level
5. Install: Below the minimum level mark → Add the
• Brake pad specified brake fluid to the proper level.
• Brake pad spring Refer to “CHECKING THE BRAKE FLUID
TIP LEVEL” on page 3-14.
Always install new brake pads and new brake
pad spring as a set.
4-46
FRONT BRAKE
8. Check: c. Remove the brake caliper piston dust seals

• Brake lever operation 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
EAS30173
BRAKE SYSTEM (ABS)” on page 3-16. CHECKING THE FRONT BRAKE CALIPERS
EAS30171 The following procedure applies to both of the
REMOVING THE FRONT BRAKE CALIPERS brake calipers.
Recommended brake component
brake calipers.
replacement schedule
TIP
Brake pads If necessary
Before removing the brake caliper, drain the
brake fluid from the entire brake system. Piston seals Every two years
Piston dust seals Every two years
1. Remove:
• Brake hose union bolt Brake hoses Every four years
• Brake hose gasket Brake fluid Every two years and
• Brake hose whenever the brake is
TIP disassembled
Put the end of the brake hose into a container
and pump out the brake fluid carefully. 1. Check:
• Brake caliper piston
EAS30172
Rust/scratches/wear → Replace the brake
DISASSEMBLING THE FRONT BRAKE caliper pistons.
CALIPERS • Brake caliper cylinder
The following procedure applies to both of the Scratches/wear → Replace the brake caliper
brake calipers. assembly.
1. Remove: • Brake caliper body
• Brake caliper piston Cracks/damage → Replace the brake caliper
• Brake caliper piston dust seal assembly.
• Brake caliper piston seal • Brake fluid delivery passage
a. Secure the right side brake caliper pistons (brake caliper body)
with a piece of wood “a”. Obstruction → Blow out with compressed air.
EWA13611
b. Blow compressed air into the brake hose WARNING
joint opening “b” to force out the left side
Whenever a brake caliper is disassembled,
pistons from the brake caliper.
EWA17060
replace the brake caliper piston dust seals
WARNING and brake caliper piston seals.
• Never try to pry out the brake caliper pis-
tons.
• Do not loosen the bolts “4”.
a b
4-47
FRONT BRAKE
EAS30174
ASSEMBLING THE FRONT BRAKE 2

CALIPERS
EWA16560
a
WARNING
• Before installation, all internal brake com- 3 b
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 1
piston dust seals and brake caliper piston
seals to swell and distort. 2. Remove:
• Whenever a brake caliper is disassembled, • Front brake caliper
replace the brake caliper piston dust seals 3. Install:
and brake caliper piston seals. • Brake pads
• Brake pad spring
• Brake pad pin
Specified brake fluid • Brake pad clip
DOT 4 • 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 lb·ft)
T.
brake calipers. R.
Refer to “REPLACING THE FRONT BRAKE
1. Install:
PADS” on page 4-45.
• Front brake caliper “1”
4. Fill:
(temporarily)
• Brake master cylinder reservoir
• Brake hose gasket New (with the specified amount of the specified
• Brake hose “2” brake fluid)
• Brake hose union bolt “3”
Front brake hose union bolt DOT 4
32 N·m (3.2 kgf·m, 24 lb·ft)
T.
R.
EWA13090
EWA13531
WARNING
WARNING • Use only the designated brake fluid. Other
Proper brake hose routing is essential to in- brake fluids may cause the rubber seals to
sure safe vehicle operation. deteriorate, causing leakage and poor
ECA14170 brake performance.
NOTICE • Refill with the same type of brake fluid that
When installing the brake hose onto the is already in the system. Mixing brake fluids
brake caliper “1”, make sure the brake pipe may result in a harmful chemical reaction,
“a” touches the projection “b” on the brake leading to poor brake performance.
caliper. • When refilling, be careful that water does
not enter the brake fluid reservoir. Water
2 will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
b ECA13540
NOTICE
a 3 Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
1
4-48
FRONT BRAKE
5. Bleed: 4. Check:
• Brake system • Brake hose
Refer to “BLEEDING THE HYDRAULIC Cracks/damage/wear → Replace.
EAS30181
6. Check: ASSEMBLING THE FRONT BRAKE MASTER
• Brake fluid level CYLINDER
Below the minimum level mark → Add the EWA13520
specified brake fluid to the proper level. WARNING

Refer to “CHECKING THE BRAKE FLUID • Before installation, all internal brake com-
LEVEL” on page 3-14. ponents should be cleaned and lubricated
7. Check: with clean or new brake fluid.
• Brake lever operation • Never use solvents on internal brake com-
Soft or spongy feeling → Bleed the brake sys- ponents.
tem.
BRAKE SYSTEM (ABS)” on page 3-16. Specified brake fluid
DOT 4
EAS30179
REMOVING THE FRONT BRAKE MASTER EAS30182
CYLINDER INSTALLING THE FRONT BRAKE MASTER

TIP CYLINDER
Before removing the front brake master cylinder, 1. Install:
drain the brake fluid from the entire brake sys- • Front brake master cylinder
tem. • Front brake master cylinder holder
1. Remove: Front brake master cylinder hold-

• Brake hose union bolt er bolt
T.
R.
• Brake hose gasket 16 N·m (1.6 kgf·m, 12 lb·ft)

• Brake hose
(front brake master cylinder to hydraulic unit) TIP
TIP • Install the front brake master cylinder holder
To collect any remaining brake fluid, place a with the pin “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.
EAS30725
CHECKING THE FRONT BRAKE MASTER

CYLINDER
1. Check: a
• Brake master cylinder
Damage/scratches/wear → Replace.
• Brake fluid delivery passage
(brake master cylinder body)
Obstruction → Blow out with compressed air.
2. Check:
• Brake master cylinder kit
3. Check:
• Brake fluid reservoir
• Brake fluid reservoir diaphragm holder
• Brake fluid reservoir diaphragm
4-49
FRONT BRAKE
3. Fill:
• Brake master cylinder reservoir
b (with the specified amount of the specified
brake fluid)

DOT 4
EWA13540
WARNING
2. Install: • Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
• Brake hose gasket New
• Brake hose
brake performance.
• Brake hose union bolt
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
Front brake hose union bolt
30 N·m (3.0 kgf·m, 22 lb·ft)
T.
leading to poor brake performance.

R.
EWA13531 • When refilling, be careful that water does

WARNING not enter the brake master cylinder reser-
Proper brake hose routing is essential to in- voir. Water will significantly lower the boil-
sure safe vehicle operation. ing point of the brake fluid and could cause
vapor lock.
TIP
ECA13540
• When installing the brake hose onto the master
NOTICE
cylinder, make sure the brake pipe “a” touches
Brake fluid may damage painted surfaces
the projection “b” on the master cylinder.
• While holding the brake hose, tighten the union
bolt as shown.
• Turn the handlebars to the left and right to 4. Bleed:
make sure the brake hose does not touch other • Brake system
parts (e.g., wire harness, cables, leads). Cor- Refer to “BLEEDING THE HYDRAULIC
rect if necessary. BRAKE SYSTEM (ABS)” on page 3-16.
5. Check:
specified brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-14.
a 6. Check:
b • Brake lever operation
Soft or spongy feeling → Bleed the brake sys-
tem.
4-50
REAR BRAKE
EAS20031
REAR BRAKE
Removing the rear brake pads
27 N・m (2.7 kgf・m, 20 lb・ft)
D
5 N・m (0.5 kgf・m, 3.7 lb・ft) FW
8
S 2
1
7
LT
S
5
6 5
4 6
S
22 N・m (2.2 kgf・m, 16 lb・ft)
17 N・m (1.7 kgf・m, 13 lb・ft)
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)
T.R
.

1 Screw plug 1
2 Brake pad retaining bolt 1
3 Rear brake caliper 1
4 Brake pad 2
5 Brake pad shim 2
6 Brake pad insulator 2
8 Bleed screw 1
4-51
REAR BRAKE
Removing the rear brake master cylinder
9
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)
T.R
.
5
1
D
2 FW
3
32 N•m (3.2 kgf•m, 23 lb•ft) 4

7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
6
New 7
28 N•m (2.8 kgf•m, 20 lb•ft)
8 LT
11
10
New
30 N•m (3.0 kgf•m, 22 lb•ft)

20 N•m (2.0 kgf•m, 15 lb•ft)
23 N•m (2.3 kgf•m, 17 lb•ft)

Air scoop/Fuel tank cover/Fuel tank side cover page 4-8.
Drain.
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
8 Brake hose 1
9 Rear brake light switch coupler 1 Disconnect.
10 Right footrest assembly 1
11 Brake pedal 1
4-52
REAR BRAKE
Removing the rear brake master cylinder
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)
T.R
.
D
FW
32 N•m (3.2 kgf•m, 23 lb•ft)

7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
15
New 14
28 N•m (2.8 kgf•m, 20 lb•ft)
12
LT
13
New
30 N•m (3.0 kgf•m, 22 lb•ft)

20 N•m (2.0 kgf•m, 15 lb•ft)
23 N•m (2.3 kgf•m, 17 lb•ft)

12 Brake fluid reservoir hose 1
13 Rear brake master cylinder assembly 1
14 Rear brake light switch bracket 1
15 Rear brake light switch 1
4-53
REAR BRAKE
Disassembling the rear brake master cylinder
BF
BF
18 N・m (1.8 kgf・m, 13 lb・ft)

1 Brake master cylinder yoke 1
2 Brake master cylinder kit 1
3 Hose joint 1
4 Bushing 1
5 Brake master cylinder body 1
4-54
REAR BRAKE
Removing the rear brake caliper
D
FW
27 N・m (2.7 kgf・m, 20 lb・ft)
3
4
2 LT
1
S
32 N・m (3.2 kgf・m, 24 lb・ft)
22 N・m (2.2 kgf・m, 16 lb・ft)

Drain.
3 Brake hose 1
4 Rear brake caliper 1
4-55
REAR BRAKE
Disassembling the rear brake caliper
D
FW
5 N・m (0.5 kgf・m, 3.7 lb・ft) 10
S
BF
7 17 N・m (1.7 kgf・m, 13 lb・ft)

8
9
6
2
1
4
5 12
11
S
3
S T.R
.
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)
5
4

1 Screw plug 1
2 Brake pad retaining bolt 1
3 Brake pad 2
4 Brake pad shim 2
5 Brake pad insulator 2
7 Brake caliper piston 1
8 Brake caliper piston dust seal 1
9 Brake caliper piston seal 1
10 Bleed screw 1
11 Sleeve 1
12 Sleeve boot 1
4-56
REAR BRAKE
EAS30183
4. Adjust:
INTRODUCTION
EWA14101
WARNING Refer to “CHECKING THE FRONT BRAKE
Disc brake components rarely require disas- DISCS” on page 4-45.
sembly. Therefore, always follow these pre-
ventive measures: Rear brake disc bolt
• Never disassemble brake components un- 30 N·m (3.0 kgf·m, 22 lb·ft)
T.
R.
LOCTITE®
less absolutely necessary.
• If any connection on the hydraulic brake EAS30185
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
and plastic parts. Therefore, always clean pads as a set.
up any spilt brake fluid immediately.
• Avoid brake fluid coming into contact with Brake pad lining thickness limit
the eyes as it can cause serious injury. 1.0 mm (0.04 in)
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get im-
mediate medical attention. a
EAS30184
CHECKING THE REAR BRAKE DISC

1. Check:
• Rear brake disc
Damage/galling → Replace.
2. Measure:
2. Install:
• Brake pad insulator
Out of specification → Correct the brake disc
• Brake pad shim
runout or replace the brake disc.
(onto the brake pads)
Refer to “CHECKING THE FRONT BRAKE
• Brake pad spring
(into the rear brake caliper)
• Brake pad
Brake disc runout limit (as mea-
sured on wheel) TIP
0.15 mm (0.0059 in) Always install new brake pads, brake pad insu-
lators, brake pad shims, and brake pad spring as
3. Measure: a set.
• 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 the
Out of specification → Replace. hose into an open container.
Refer to “CHECKING THE FRONT BRAKE
Brake disc thickness limit

4.5 mm (0.18 in)
4-57
REAR BRAKE
b. Loosen the bleed screw and push the brake ECA14150
caliper piston into the brake caliper with NOTICE

your finger. • Do not allow grease to contact the brake
pads.
1 • Remove any excess grease.
4. Install:
2
• Brake pad retaining bolt
• Screw plug
Rear brake caliper bolt (front)

27 N·m (2.7 kgf·m, 20 lb·ft)
T.
R.
Rear brake caliper bolt (rear)
c. Tighten the bleed screw. 22 N·m (2.2 kgf·m, 16 lb·ft)
LOCTITE®
Brake caliper bleed screw Rear brake pad retaining bolt
5 N·m (0.5 kgf·m, 3.7 lb·ft) 17 N·m (1.7 kgf·m, 13 lb·ft)
T.
R.
Rear brake caliper screw plug

d. Install the brake pad insulators and brake 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
pad shims onto each brake pads.
TIP 5. Check:
Apply silicone grease between the brake pad in- • Brake fluid level
sulator and brake pad shim. Below the minimum level mark → Add the
ECA14150
NOTICE LEVEL” on page 3-14.
• Do not allow grease to contact the brake 6. Check:
pads. • Brake pedal operation
• Remove any excess grease. Soft or spongy feeling → Bleed the brake sys-
e. Install the brake pads and brake pad spring. tem.
TIP
The longer tangs “a” of the brake pad spring
must point in the direction of the brake caliper EAS30186
piston. REMOVING THE REAR BRAKE CALIPER

TIP
Before disassembling the brake caliper, drain
a the brake fluid from the entire brake system.
1. Remove:
• Brake hose gasket
• Brake hose
TIP
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
3. Lubricate:
• Rear brake caliper bolt
Silicone grease
4-58
REAR BRAKE
EAS30187
1. Check:
DISASSEMBLING THE REAR BRAKE
CALIPER
Rust/scratches/wear → Replace the brake
1. Remove:
caliper piston.
• Brake caliper cylinder
• Brake caliper piston dust seal
Scratches/wear → Replace the brake caliper
• Brake caliper piston seal
assembly.
a. Blow compressed air into the brake hose • Brake caliper body
joint opening “a” to force out the piston from Cracks/damage → Replace the brake caliper
the brake caliper. assembly.
EWA13550
• Brake fluid delivery passages
WARNING
(brake caliper body)
• Cover the brake caliper piston with a rag.
Be careful not to get injured when the pis- EWA13601
ton is expelled from the brake caliper. WARNING

• Never try to pry out the brake caliper pis- Whenever a brake caliper is disassembled,
ton. replace the brake caliper piston dust seal
and brake caliper piston seal.
a 2. Check:
• Rear brake caliper bracket
EAS30189
ASSEMBLING THE REAR BRAKE CALIPER

EWA17080
WARNING
• Before installation, all internal brake com-
b. Remove the brake caliper piston dust seal ponents should be cleaned and lubricated
and brake caliper piston seal. with clean or new brake fluid.
EAS30188
• Never use solvents on internal brake com-
CHECKING THE REAR BRAKE CALIPER ponents as they will cause the brake caliper
piston dust seal and brake caliper piston
Recommended brake component seal to swell and distort.
replacement schedule • Whenever a brake caliper is disassembled,
Brake pads If necessary replace the brake caliper piston dust seal
Piston seal Every two years and brake caliper piston seal.
Piston dust seal Every two years
Brake hoses Every four years Specified brake fluid
DOT 4
Brake fluid Every two years and
whenever the brake is EAS30190
disassembled INSTALLING THE REAR BRAKE CALIPER

1. Install:
(temporarily)
• Brake hose gasket New
• Brake hose
Rear brake hose union bolt

32 N·m (3.2 kgf·m, 24 lb·ft)
T.
R.
4-59
REAR BRAKE
EWA13531 EWA13090
WARNING WARNING
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
ECA19080
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” passes between the projections “b” on may result in a harmful chemical reaction,
the brake caliper. leading to poor brake performance.
• When refilling, be careful that water does
will significantly lower the boiling point of
a the brake fluid and could cause vapor lock.
ECA13540
NOTICE
b 1 and plastic parts. Therefore, always clean up
5. Bleed:
2. Remove: • 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 • 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 3-14.
• Rear brake caliper 7. Check:
Refer to “REPLACING THE REAR BRAKE • Brake pedal operation
PADS” on page 4-57. 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 lb·ft) BRAKE SYSTEM (ABS)” on page 3-16.
T.
R.
Rear brake caliper bolt (rear)

22 N·m (2.2 kgf·m, 16 lb·ft) EAS30193
LOCTITE® REMOVING THE REAR BRAKE MASTER

Rear brake pad retaining bolt CYLINDER
17 N·m (1.7 kgf·m, 13 lb·ft) 1. Remove:
Rear brake caliper screw plug • Brake hose union bolt
2.5 N·m (0.25 kgf·m, 1.8 lb·ft) • Brake hose gasket
• Brake hose
4. Fill: TIP
To collect any remaining brake fluid, place a
(with the specified amount of the specified
container under the master cylinder and the end
brake fluid)
of the brake hose.
DOT 4
4-60
REAR BRAKE
EAS30194 EWA13531
CHECKING THE REAR BRAKE MASTER WARNING

CYLINDER Proper brake hose routing is essential to in-
1. Check: sure safe vehicle operation.
• Brake master cylinder
ECA14160
NOTICE
• Brake fluid delivery passage
(brake master cylinder body) When installing the brake hose onto the
Obstruction → Blow out with compressed air. brake master cylinder, make sure the brake
2. Check: pipe touches the projection “a” as shown.
• Brake master cylinder kit
Damage/scratches/wear → Replace. a
3. Check:
• Brake fluid reservoir diaphragm holder
• Brake fluid reservoir diaphragm
4. Check:
• Brake hose
• Brake fluid reservoir hose 2. Fill:
Cracks/damage/wear → Replace. • Brake fluid reservoir
(with the specified amount of the specified
EAS30195
ASSEMBLING THE REAR BRAKE MASTER brake fluid)

CYLINDER
EWA13520 Specified brake fluid
WARNING DOT 4
• Before installation, all internal brake com- EWA13090
ponents should be cleaned and lubricated WARNING

with clean or new brake fluid. • Use only the designated brake fluid. Other
• Never use solvents on internal brake com- brake fluids may cause the rubber seals to
ponents. deteriorate, causing leakage and poor
brake performance.
Specified brake fluid • Refill with the same type of brake fluid that
DOT 4 is already in the system. Mixing brake fluids
1. Install: leading to poor brake performance.
• Brake master cylinder kit New • When refilling, be careful that water does
EAS30196
INSTALLING THE REAR BRAKE MASTER will significantly lower the boiling point of
CYLINDER the brake fluid and could cause vapor lock.
• Brake hose gasket New NOTICE

• Brake hose Brake fluid may damage painted surfaces
• Brake fluid reservoir hose and plastic parts. Therefore, always clean up
• Brake hose union bolt any spilt brake fluid immediately.
3. Bleed:
Rear brake hose union bolt • Brake system
32 N·m (3.2 kgf·m, 24 lb·ft) Refer to “BLEEDING THE HYDRAULIC
T.
R.
4-61
REAR BRAKE
4. Check:
Below the minimum level mark “a” → Add the
LEVEL” on page 3-14.
5. Adjust:
• Brake pedal position
Refer to “ADJUSTING THE REAR DISC
BRAKE” on page 3-15.
6. Adjust:
• Rear brake light operation timing
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” on page 3-35.
4-62
ABS (Anti-lock Brake System)
EAS20032

Removing the hydraulic unit assembly
32 N・m (3.2 kgf・m, 24 lb・ft)
9 N•m (0.9 kgf•m, 6.6 lb•ft) 6

T.R
.
4 New 16 N•m (1.6 kgf•m, 12 lb•ft)

3
1
5
New 4
3 16 N•m (1.6 kgf•m, 12 lb•ft)
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
LT
LT
2
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

Rider seat/Battery/Battery box page 4-1.
Fuel tank cover/Fuel tank side cover page 4-8.
Drain.
Refer to “REAR SHOCK ABSORBER
Rear shock absorber assembly ASSEMBLY” on page 4-100.
1 Protector 1
2 Fuel tank bracket 1
4 Gasket 4
Front brake hose (front brake master cylinder to
5 1
hydraulic unit)
Front brake hose (hydraulic unit to front brake
6 1
calipers)
4-63
Removing the hydraulic unit assembly
32 N・m (3.2 kgf・m, 24 lb・ft)
9 N•m (0.9 kgf•m, 6.6 lb•ft)

T.R
.
New 16 N•m (1.6 kgf•m, 12 lb•ft)
New
13 16 N•m (1.6 kgf•m, 12 lb•ft)
10 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
7
T.R
.
LT 12
8 11
LT
9
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

Rear brake hose (rear brake master cylinder to
7 1
hydraulic unit)
Rear brake hose (hydraulic unit to rear brake
8 1
caliper)
9 Rear brake hose bracket 1
10 ABS ECU coupler 1 Disconnect.
11 Hydraulic unit bracket 1
12 Hydraulic unit 1
13 Front brake hose bracket 1
4-64
EAS30197
REMOVING THE HYDRAULIC UNIT

ASSEMBLY
ECA18230
NOTICE
1
Unless necessary, avoid removing and in-
stalling the brake pipes of the hydraulic unit
assembly.
EWA13930
a
WARNING
Refill with the same type of brake fluid that is 2. Remove:
already in the system. Mixing fluids may re- • Brake hose
sult in a harmful chemical reaction, leading • Brake pipe
to poor braking performance. TIP
ECA19790 • Do not operate the brake lever and brake pedal
NOTICE while removing the brake hoses and brake
• Handle the ABS components with care pipes.
since they have been accurately adjusted. • Do not bend the brake pipe when loosening the
Keep them away from dirt and do not sub- brake pipe flare nuts.
ject them to shocks. ECA19800
• Do not set the main switch to “ON” when NOTICE

removing the hydraulic unit assembly. • When removing the brake hoses and brake
• Do not clean with compressed air. pipes, cover the area around the hydraulic
• Do not reuse the brake fluid. unit assembly to catch any spilt brake fluid.
• Brake fluid may damage painted surfaces Do not allow the brake fluid to contact other
and plastic parts. Therefore, always clean parts.
up any spilt brake fluid immediately. • Before disconnecting the brake pipes from
• Do not allow any brake fluid to contact the the hydraulic unit assembly, do not lift up
couplers. Brake fluid may damage the cou- or move the brake pipes.
plers and cause bad contacts.
• If the brake pipe flare nuts for the hydraulic 3. Remove:
unit assembly have been removed, be sure • Hydraulic unit assembly “1”
to tighten them to the specified torque and TIP
bleed the brake system. To avoid brake fluid leakage and to prevent for-
1. Disconnect: eign materials from entering the hydraulic unit
• ABS ECU coupler “1” assembly, insert a rubber plug “a” or a bolt (M10
× 1.00) into each flare nut hole.
TIP
ECA19810
While pushing the portion “a” of the ABS ECU
NOTICE
coupler, pull the lock lever up to release the lock.
When using a bolt, do not tighten the bolt un-
ECA20080
til the bolt head touches the hydraulic unit.
NOTICE
Otherwise, the brake pipe seating surface
Do not use a tool to disconnect the ABS ECU could be deformed.
coupler.
4-65
Hydraulic unit assembly bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
a
2
4
1
EAS30198
3
CHECKING THE HYDRAULIC UNIT
ASSEMBLY 1
1. Check:
• Hydraulic unit assembly 2. Remove:
Cracks/damage → Replace the hydraulic unit • Rubber plug or bolt (M10 × 1.0)
assembly and the brake pipes that are con- 3. Install:
nected to the assembly as a set. • Hydraulic unit brake pipe
4. Tighten:
EAS30935
CHECKING THE BRAKE PIPES • Hydraulic unit brake pipe flare nut
brake pipes. Hydraulic unit brake pipe flare
1. Check: nut
T.
R.
16 N·m (1.6 kgf·m, 12 lb·ft)

• Brake pipe end (flare nut)
Damage → Replace the hydraulic unit as- ECA19820
sembly, brake pipes, and related parts as a NOTICE

set. If the brake pipe flare nut does not turn easi-
EAS30200
ly, replace the hydraulic unit assembly,
INSTALLING THE HYDRAULIC UNIT brake pipes, and related parts as a set.
ASSEMBLY
TIP
1. Install:
• 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
• Gasket New
(M10 × 1.0) installed in the flare nut holes be-
fore installing the hydraulic unit assembly. • Brake hose union bolt
• Brake hose “1”
TIP
Do not allow any foreign materials to enter the Front brake hose union bolt
hydraulic unit assembly or the brake hoses or 32 N·m (3.2 kgf·m, 24 lb·ft)
T.
R.
brake pipes when installing the hydraulic unit as- ECA22800
sembly. NOTICE
When installing each brake hose onto the hy-
a. Install the hydraulic unit assembly “1” on draulic unit brake pipe joint, make sure that
the hydraulic unit bracket “2”. the brake pipe “a” touches the projection “b”
b. Temporarily tighten the hydraulic unit as- on the joint.
sembly bolts “3”, “4”.
c. Tighten the hydraulic unit assembly bolt “3”,
and bolt “4” to the specified torque in this or-
der.
4-66
ECA13540
NOTICE
b
a any spilt brake fluid immediately.
1
8. Bleed:
• Brake system
a Refer to “BLEEDING THE HYDRAULIC
6. Connect: 9. Check the operation of the hydraulic unit ac-
• ABS ECU coupler “1” cording to the brake lever and the brake ped-
al response. (Refer to “HYDRAULIC UNIT
TIP
OPERATION TEST” on page 4-67.)
Connect the ABS ECU coupler, and then push ECA14770
the lock lever “a” of the coupler in the direction of NOTICE

the arrow shown. Always check the operation of the hydraulic
unit according to the brake lever and the
brake pedal response.
10.Delete the DTC. (Refer to “SELF-DIAGNOS-
TIC FUNCTION AND DIAGNOSTIC CODE
1 TABLE” on page 9-39.)
11.Perform a trial run. (Refer to “CHECKING
a THE ABS WARNING LIGHT” on page 4-70.)
EAS30201
HYDRAULIC UNIT OPERATION TEST

7. Fill: The reaction-force pulsating action generated in
• Brake fluid reservoir the brake lever and brake pedal when the ABS is
(with the specified amount of the specified activated can be tested when the vehicle is
brake fluid) stopped.
The hydraulic unit operation can be tested using
Specified brake fluid the following two methods.
DOT 4 • Brake line routing confirmation: this test
checks the function of the ABS after the sys-
EWA17280
tem was disassembled, adjusted, or serviced.
WARNING • ABS reaction-force confirmation: this test gen-
• Use only the designated brake fluid. Other erates the same reaction-force pulsating action
brake fluids may cause the rubber seals to that is generated in the brake lever and brake
deteriorate, causing leakage and poor pedal when the ABS is activated.
brake performance.
• Refill with the same type of brake fluid that Brake line routing confirmation
is already in the system. Mixing brake fluids EWA13120
may result in a harmful chemical reaction, WARNING

leading to poor brake performance. Securely support the vehicle so that there is
• When refilling, be careful that water does no danger of it falling over.
not enter the brake master cylinder reser-
voir or brake fluid reservoir. Water will sig- TIP
nificantly lower the boiling point of the • For the brake line routing confirmation, use the
brake fluid and could cause vapor lock. diagnosis of function of the YDT.
• Before performing the brake line routing confir-
mation, make sure that no malfunctions have
been detected in the ABS ECU and that the
wheels are not rotating.
4-67
1. Place the vehicle on a maintenance stand. TIP

2. Turn the main switch to “OFF”. • The hydraulic unit operates 1 second after the
3. Remove: brake lever and brake pedal are operated si-
• Rider seat multaneously and continues for approximately
Refer to “GENERAL CHASSIS (1)” on 5 seconds.
page 4-1. • The operation of the hydraulic unit can be con-
4. Check: firmed using the indicator.
• Battery voltage On: The hydraulic unit is operating.
Lower than 12.8 V → Charge or replace the Flashing: The conditions for operating the hy-
battery. draulic unit have not been met.
Off: The brake lever and brake pedal are not
Battery voltage being operated.
Higher than 12.8 V
TIP 1
If 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 YDT to the YDT coupler (6P).
Yamaha diagnostic tool USB G088909 2

(US) 9. Check:
90890-03269 • Hydraulic unit operation
Yamaha diagnostic tool (A/I) Click “Actuator Check”, a single pulse will be
90890-03264 generated in the brake lever “1”, brake pedal
“2”, and again in the brake lever “1”, in this or-
TIP
der.
• Yamaha diagnostic tool (A/I) (90890-03264) in-
cludes YDT sub harness (6P) (90890-03266). 1
• If you already have Yamaha diagnostic tool (A/
I) (90890-03262), YDT sub harness (6P)
(90890-03266) is separately required.
6. Start the YDT and display the diagnosis of
function screen.
7. Select code No. 2, “Brake line routing confir- G088911 2
mation”.
8. Click “Actuator Check”, and then operate the TIP
brake lever “1” and brake pedal “2” simulta- “ON” and “OFF” on the tool screen indicate
neously. when the brakes are being applied and released
respectively.
4-68
ECA17371
5. Removing the protective cap, and then con-
NOTICE nect the YDT to the YDT coupler (6P).
• Check that the pulse is felt in the brake le-
ver, brake pedal, and again in the brake le- Yamaha diagnostic tool USB
ver, in this order. (US)
• If the pulse is felt in the brake pedal before 90890-03269
it is felt in the brake lever, check that the Yamaha diagnostic tool (A/I)
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 • Yamaha diagnostic tool (A/I) (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/
10.If the operation of the hydraulic unit is normal, (90890-03266) is separately required.
delete all of the DTC.
ABS reaction-force confirmation 6. Start the YDT and display the diagnosis of
EWA13120
function screen.
WARNING 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.
• For the ABS reaction-force confirmation, use
TIP
the diagnosis of function of the YDT. For more
information, refer to the operation manual of • The hydraulic unit operates 1 second after the
the YDT. brake lever and brake pedal are operated si-
• Before performing the ABS reaction-force con- multaneously and continues for approximately
firmation, make sure that no malfunctions have 5 seconds.
been detected in the ABS ECU and that the • The operation of the hydraulic unit can be con-
wheels are not rotating. firmed using the indicator.
On: The hydraulic unit is operating.
1. Place the vehicle on a maintenance stand. Flashing: The conditions for operating the hy-
2. Turn the main switch to “OFF”. draulic unit have not been met.
3. Remove: Off: The brake lever and brake pedal are not
• Rider seat being operated.
page 4-1. 1
4. Check:
• Battery voltage
Lower than 12.8 V → Charge or replace the
battery.
Battery voltage
Higher than 12.8 V
G088909 2
TIP
If the battery voltage is lower than 12.8 V, charge
the battery, and then perform ABS reaction-
force confirmation.
4-69
9. A reaction-force pulsating action is generated 11.After the pulsating action has stopped in the
in the brake lever “1” and continues for a few brake pedal, it is generated in the brake lever
seconds. and continues for a few seconds.
TIP TIP
• The reaction-force pulsating action consists of • The reaction-force pulsating action consists of
quick pulses. quick pulses.
• Be sure to continue operating the brake lever • “ON” and “OFF” on the tool screen indicate
and brake pedal even after the pulsating action when the brakes are being applied and re-
has stopped. leased respectively.
• “ON” and “OFF” on the tool screen indicate ECA17371
when the brakes are being applied and re- NOTICE
leased respectively. • Check that the pulse is felt in the brake le-
ver, brake pedal, and again in the brake le-
ver, in this order.
1
• 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
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-
G088913 rectly to the hydraulic unit assembly.
10.After the pulsating action has stopped in the
brake lever, it is generated in the brake pedal 12.Turn the main switch to “OFF”.
“1” and continues for a few seconds. 13.Remove the YDT from the YDT coupler, and
then install the protective cap.
TIP
14.Turn the main switch to “ON”.
• The reaction-force pulsating action consists of 15.Set the start/engine stop switch to “ ”.
quick pulses. 16.Check for brake fluid leakage around the hy-
• Be sure to continue operating the brake lever draulic unit.
and brake pedal even after the pulsating action Brake fluid leakage → Replace the hydraulic
has stopped. unit, brake pipes, and related parts as a set.
• “ON” and “OFF” on the tool screen indicate 17.If the operation of the hydraulic unit is normal,
when the brakes are being applied and re- delete all of the DTC.
leased respectively.
EAS30202
CHECKING THE ABS WARNING LIGHT

After all checks and servicing are completed, en-
sure that the ABS warning light goes off by walk-
ing the vehicle at a speed of faster than 5 km/h
(3.1 mi/h) or performing a trial run.
1
G088914
4-70
HANDLEBAR
EAS20033
HANDLEBAR
Removing the handlebar
11 N•m (1.1 kgf•m, 8.1 lb•ft) 22 N•m (2.2 kgf•m, 16 lb•ft)
2.5 N•m (0.25 kgf•m, 1.8 lb•ft) 1
T.R
.
1
17 N•m (1.7 kgf•m, 13 lb•ft)

17 N•m (1.7 kgf•m, 13 lb•ft)
26 N•m (2.6 kgf•m, 19 lb•ft)
3 4
*
2 7 6
5
3.5 N•m (0.35 kgf•m, 2.6 lb•ft)
T.R
.
8 9 3.5 N•m (0.35 kgf•m, 2.6 lb•ft)
T.R
.
6
26 N•m (2.6 kgf•m, 19 lb•ft)

1.8 N•m (0.18 kgf•m, 1.3 lb•ft) 16 N•m (1.6 kgf•m, 12 lb•ft)
T.R
.
40 N•m (4.0 kgf•m, 30 lb•ft) 1.2 N・m (0.12 kgf・m, 0.9 ft・lb)
* Lubricate the pivoting point and metal–to–metal moving parts of the lever.
1 Rearview mirror 2
2 Front brake master cylinder holder 1
3 Front brake light switch 1
4 Front brake master cylinder assembly 1
5 Handlebar switch (right) 1
6 Grip end 2
7 Throttle grip 1
8 Handlebar switch (left) 1
9 Handlebar switch holder 2
4-71
HANDLEBAR
Removing the handlebar

2.5 N•m (0.25 kgf•m, 1.8 lb•ft)
T.R
.
11 17 N•m (1.7 kgf•m, 13 lb•ft)
17 N•m (1.7 kgf•m, 13 lb•ft)
26 N•m (2.6 kgf•m, 19 lb•ft)
14
*
12
10
15
3.5 N•m (0.35 kgf•m, 2.6 lb•ft)
T.R
.
3.5 N•m (0.35 kgf•m, 2.6 lb•ft)
T.R
.
13
26 N•m (2.6 kgf•m, 19 lb•ft)

1.8 N•m (0.18 kgf•m, 1.3 lb•ft) 16 N•m (1.6 kgf•m, 12 lb•ft)
T.R
.
40 N•m (4.0 kgf•m, 30 lb•ft) 1.2 N・m (0.12 kgf・m, 0.9 ft・lb)
* Lubricate the pivoting point and metal–to–metal moving parts of the lever.
10 Clutch switch 1
11 Clutch cable 1
12 Clutch lever holder 1
13 Handlebar grip 1
14 Upper handlebar holder 2
15 Lower handlebar holder 2
4-72
HANDLEBAR
EAS30203 ECA18300
REMOVING THE HANDLEBAR NOTICE

1. Stand the vehicle on a level surface. First, tighten the bolts on the front side of the
EWA13120
handlebar holder, and then on the rear side.
WARNING
Securely support the vehicle so that there is TIP
no danger of it falling over. • Align the punch mark “a” on the handlebar with
2. Remove: the left side upper surface of the lower handle-
• Handlebar grip “1” bar holder (left) “3”.
TIP
• The upper handlebar holders should be in-
stalled with the punch marks “b” facing for-
Blow compressed air between the left handlebar
ward.
and the handlebar grip, and gradually push the
grip off the handlebar.
b
1
1
2
a
3
G088916
3. Tighten:
• Lower handlebar holder nut
EAS30204
CHECKING THE HANDLEBAR Lower handlebar holder nut

1. Check: 40 N·m (4.0 kgf·m, 30 lb·ft)
T.
R.
• Handlebar
Bends/cracks/damage → Replace. 4. Install:
EWA13690
• Handlebar switch (right)
WARNING • Throttle grip
Do not attempt to straighten a bent handle- • Grip end (right)
bar as this may dangerously weaken it.
Handlebar switch screw
EAS30205 3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
T.
R.
INSTALLING THE HANDLEBAR Grip end

1. Stand the vehicle on a level surface. 26 N·m (2.6 kgf·m, 19 lb·ft)
EWA13120
WARNING a. Fit the slot “a” in the throttle grip “1” into the
Securely support the vehicle so that there is projection “b” in the handlebar switch (right,
no danger of it falling over. front side) “2” and the throttle grip onto the
2. Install: handlebar “3”.
• Lower handlebar holder 2 b a 1
(temporarily)
• Handlebar “1”
• Upper handlebar holder “2”
Upper handlebar holder bolt

a
22 N·m (2.2 kgf·m, 16 lb·ft)
T.
R.
b
3
4-73
HANDLEBAR
b. Make sure that the throttle grip “1” turns 6. Install:

smoothly. • Clutch lever holder “1”
• Clutch cable
Clutch lever holder pinch bolt

1 11 N·m (1.1 kgf·m, 8.1 lb·ft)
T.
R.
TIP
Align the center of slit on the clutch lever holder
with the punch mark “a” on the handlebar.
c. Install the handlebar switch (right, rear side)

“4”. 1
TIP
Align the projection “c” on the handlebar switch
(right, rear side) with the hole “d” in the handle-
bar “3”.
a
3 d
c 7. Install:
• Handlebar switch holder
• Handlebar switch screw (left)
Handlebar switch holder screw

3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
T.
R.
Handlebar switch screw

4 3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
d. Install the grip end (right) “5”.
TIP
TIP
Align the projection “a” on the handlebar switch
There should be 1–5 mm (0.04–0.20 in) of clear-
holder with the hole “b” in the handlebar.
ance “e” between the throttle grip and the grip
end.
b
e 5 a
5. Install:
• Front brake master cylinder assembly
Refer to “INSTALLING THE FRONT BRAKE
MASTER CYLINDER” on page 4-49.
4-74
HANDLEBAR
8. Install:
• Handlebar grip
• Grip end (left) “1”
Grip end
26 N·m (2.6 kgf·m, 19 lb·ft)
T.
R.
a. Apply a thin coat of rubber adhesive onto

the end of the handlebar (left).
b. Slide the handlebar grip over the end of the
handlebar (left).
c. Wipe off any excess rubber adhesive with a
clean rag.
EWA13700
WARNING
Do not touch the handlebar grip until the rub-
ber adhesive has fully dried.
TIP
There should be 1–5 mm (0.04–0.20 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 3-13.

10.0–15.0 mm (0.39–0.59 in)
4-75
FRONT FORK (for MT10N/MT10NC)
EAS20034

Removing the front fork legs
3
2
1 4
26 N•m (2.6 kgf•m, 19 lb•ft)
5
23 N•m (2.3 kgf•m, 17 lb•ft)
6 N•m (0.6 kgf•m, 4.4 lb•ft)

T.R
.

the front fork legs.
Front wheel Refer to “FRONT WHEEL” on page 4-21.
1 Front fender 1
2 Upper bracket pinch bolt 1 Loosen.
3 Cap bolt 1 Loosen.
4 Lower bracket pinch bolt 2 Loosen.
5 Front fork leg 1
4-76

23 N・m (2.3 kgf・m, 17 lb・ft)
15 N・m (1.5 kgf・m, 11 lb・ft)
13
9
15
14
12
11
10
8
7
21 N・m (2.1 kgf・m, 15 lb・ft)

40 N・m (4.0 kgf・m, 30 lb・ft)

1 Cap bolt 1
2 O-ring 1
3 Guide 1
4 Spacer 1
5 Fork spring 1
6 Locknut 1
7 Dust seal 1
8 Oil seal clip 1
9 Outer tube 1
10 Oil seal 1
11 Washer 1
12 Outer tube bushing 1
13 Inner tube bushing 1
14 Damper rod assembly 1
15 Inner tube 1
4-77
EAS30206 EAS30207
REMOVING THE FRONT FORK LEGS DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the The following procedure applies to both of the
front fork legs. front fork legs.
1. Stand the vehicle on a level surface. 1. Turn the spring preload adjusting nut “1”
EWA13120
counterclockwise until it stops.
WARNING
no danger of it falling over. 1
TIP
that the front wheel is elevated.
2. Remove:
Refer to “FRONT BRAKE” on page 4-39.
• Front wheel 2. Remove:
Refer to “FRONT WHEEL” on page 4-21. • Cap bolt “1”
3. Loosen: (from the damper rod assembly)
• Upper bracket pinch bolt “1” • Guide “2”
• Cap bolt “2” • Spacer “3”
• Lower bracket pinch bolts “3” • Locknut “4”
EWA13640
a. Press down on the spacer with the fork
WARNING
spring compressor “5”.
Before loosening the upper and lower brack- b. Install the rod holder “6” between the lock-
et pinch bolts, support the front fork leg. nut “4” and the guide “2”.

90890-01441
1 YM-01441
Rod holder
90890-01434
2 YM-01434
TIP
Use the side of the rod holder that is marked “B”.
3 6
4
2
4. Remove: 3
• Front fork leg 5
4-78
c. Hold the cap bolt “1” and loosen the locknut

“4”.
ECA17390 1
NOTICE
When loosening the nut, be sure not to break
the projections on the cap bolt collar of the
cap bolt.
2
1 G088920
5. Remove:
• Outer tube
4 a. Hold the front fork leg horizontally.
b. Securely clamp the brake caliper bracket in
a vise with soft jaws.
c. Separate the outer tube from the inner tube
by pulling the outer tube forcefully but care-
fully.
d. Remove the cap bolt and guide. ECA19880
e. Remove the rod holder and fork spring NOTICE

compressor. Excessive force will damage the bushings.
f. Remove the spacer and locknut. Damaged bushings must be replaced.
3. Drain:
• Fork oil
TIP
Stroke the damper rod assembly “1” several
times while draining the fork oil.
6. Remove:
• Damper rod assembly
TIP
G088919 Remove the damper rod assembly with the
4. Remove: damper rod holder “1”.
• Dust seal “1”
• Oil seal clip “2” Damper rod holder (ø30)
(with a flat-head screwdriver) 90890-01506
ECA19100
Damper rod holder
NOTICE YM-01506
Do not scratch the outer tube.
4-79
4. Check:
• Cap bolt “1”
1 • Cap bolt collar projection “2”
EAS30208
CHECKING THE FRONT FORK LEGS

The following procedure applies to both of the 2
front fork legs.
1. Check: EAS30209
• Inner tube ASSEMBLING THE FRONT FORK LEGS

• Outer tube The following procedure applies to both of the
Bends/damage/scratches → Replace. front fork legs.
EWA13650 EWA18360
WARNING WARNING
Do not attempt to straighten a bent inner If both front fork legs are not filled with the
tube as this may dangerously weaken it. specified amount of the fork oil, it may cause
poor handling and a loss of stability.
2. Measure:
• Spring free length “a” TIP
Out of specification → Replace. • When assembling the front fork leg, be sure to
replace the following parts:
Fork spring free length limit – Inner tube bushing
214.5 mm (8.45 in) – 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.
1. Install:
ECA22560
G088921 NOTICE
3. Check: Allow the damper rod assembly to slide
• Damper rod slowly down the inner tube. Be careful not to
Damage/wear → Replace. damage the inner tube.
Obstruction → Blow out all of the oil passag-
es with compressed air. 2. Tighten:
ECA19110 • Damper rod assembly
NOTICE
• The front fork leg has a very sophisticated Front fork damper rod assembly
internal construction, which are particular- 40 N·m (4.0 kgf·m, 30 lb·ft)
T.
R.
ly sensitive to foreign material.

• When disassembling and assembling the TIP
front fork leg, do not allow any foreign ma- Tighten the damper rod assembly with the
terial to enter the front fork. damper rod holder “1”.
4-80
Damper rod holder (ø30)

90890-01506
Damper rod holder
YM-01506
1
G088922
5. Install:
• Outer tube
(to the inner tube)
6. Install:
• Outer tube bushing “1”
• Washer “2”
3. Lubricate: (with the fork seal driver “3”)
• Inner tube’s outer surface
Fork seal driver
Recommended oil 90890-01442
Yamaha Suspension Oil 01 Adjustable fork seal driver (36–
46 mm)
4. Install: YM-01442
• Dust seal “1” New
• Oil seal clip “2” New
• Oil seal “3” New
• Washer “4”
3
• Outer tube bushing “5” New
• Inner tube bushing “6” New 2
ECA19170
NOTICE 1
Make sure the numbered side of the oil seal
G088923
faces bottom side.
7. Install:
TIP • Oil seal “1”
• Before installing the oil seal, lubricate its lips (with the fork seal driver “2”)
with lithium-soap-based grease.
• Lubricate the outer surface of the inner tube Fork seal driver
with fork oil. 90890-01442
• Before installing the oil seal, cover the top of Adjustable fork seal driver (36–
the front fork leg with a plastic bag to protect 46 mm)
the oil seal during installation. YM-01442
3
4
5 2
6
1
1
2 G088924
4-81
8. Install:
• Oil seal clip “1”
TIP
Adjust the oil seal clip so that it fits into the outer
tube’s groove.
G088927
1
11.Fill:
• Front fork leg
(with the specified amount of the recom-
mended fork oil)
G088925
Recommended oil
9. Install: Yamaha Suspension Oil 01
• Dust seal “1” Quantity (left)
(with the fork seal driver “2”) 350.0 cm³ (11.83 US oz, 12.34
Imp.oz)
Fork seal driver Quantity (right)
90890-01442 350.0 cm³ (11.83 US oz, 12.34
Adjustable fork seal driver (36– Imp.oz)
46 mm) ECA14230
YM-01442
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
2 front fork leg, do not allow any foreign ma-
terial to enter the front fork.
1 12.After filling the front fork leg, slowly stroke the
damper rod “1” up and down (at least ten
G088926 times) to distribute the fork oil.
10.Install: 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”)
Rod puller
90890-01437
Universal damping rod bleeding
tool set
YM-A8703
Rod puller attachment (M10)
90890-01436
G088929
tool set
YM-A8703
4-82
13.Before measuring the fork oil level, wait ten

minutes until the oil has settled and the air
bubbles have dispersed.
TIP
Be sure to bleed the front fork leg of any residual
air.
14.Measure:
• Front fork leg oil level “a”
(from the top of the outer tube, with the outer G088931
tube fully compressed and without the fork c. Install the locknut all the way onto the
spring) damper rod assembly.
Out of specification → Correct. d. Install the rod puller and rod puller attach-
ment.
Level (left) e. Install the spacer and guide.
114 mm (4.5 in) f. Install the fork spring compressor.
Level (right) g. Press down on the spacer with the fork
114 mm (4.5 in) spring compressor “1”.
h. Pull up the rod puller and install the rod
holder “2” between the locknut “3” and the
guide “4”.
a
Rod puller
90890-01437
tool set
YM-A8703
Rod puller attachment (M10)
G088930
90890-01436
15.Install: Universal damping rod bleeding
• Fork spring tool set
• Spacer YM-A8703
• Locknut Fork spring compressor
• Damper adjusting rod 2 90890-01441
• Damper adjusting rod 1 Fork spring compressor
• Guide YM-01441
• Cap bolt Rod holder
(along with the O-ring New ) 90890-01434
a. Remove the rod puller and rod puller at- YM-01434
tachment.
b. Install the fork spring. TIP
TIP Use the side of the rod holder that is marked “B”.
Install the fork spring with the smaller diameter
“a” facing up “A”.
3
4
2
1
4-83
i. Remove the rod puller and rod puller at- TIP

tachment. When installing the front fork leg, set the groove
j. Install the damper adjusting rods and cap “a” on the outer tube is level with the top of the
bolt, and then finger tighten the cap bolt. upper bracket.
EWA13670
WARNING
Always use a new cap bolt O-ring.
k. Hold the cap bolt “5” and tighten the locknut a
“3” to specification. a
ECA17390
NOTICE
When loosening the nut, be sure not to break
the projections on the cap bolt collar of the
cap bolt.
2. Install:
Front fork cap bolt locknut • Protector “1” (right side only) New
15 N·m (1.5 kgf·m, 11 lb·ft) a. Before attaching the protector, clean the
T.
R.
front fork leg (right) surface.

5 b. Attach the protector with the reference to
the upper end of the lower bracket “2” as
4 shown in the illustration.
A
3
2
1
l. Remove the rod holder and fork spring

compressor.
16.Install: 1
• Cap bolt
(to the outer tube)
TIP
• Temporarily tighten the cap bolt. a
• When to tighten the cap bolt to the specified
torque is after installing the front fork leg to the b
vehicle and tightening the lower bracket pinch
bolts.
EAS30210
2
INSTALLING THE FRONT FORK LEGS A. Forward
front fork legs. a. 12 mm (0.47 in)
1. Install: b. 80 mm (3.15 in)
• Front fork leg
Temporarily tighten the upper and lower
bracket pinch bolts.
EWA13680
WARNING
Make sure the brake hoses are routed prop-
erly.
4-84
3. Install: 5. Tighten:
• Protector “1” (right side only) New • Cap bolt “1”
a. Before attaching the protector, clean the
Front fork cap bolt
23 N·m (2.3 kgf·m, 17 lb·ft)
T.
b. Attach the protector with the reference to
R.
the lower end of the lower bracket “2” as • Upper bracket pinch bolt “2”
Upper bracket pinch bolt
A 26 N·m (2.6 kgf·m, 19 lb·ft)
T.
R.
1
2 TIP
a
When installing the front fork legs, make sure
that the spring preload adjusting nuts are posi-
tioned at the angles shown in the illustration.
1
55-65° 55-65°
A. Forward
a. 24 mm (0.94 in)
4. Tighten:
• Lower bracket pinch bolts “1” and “2”

23 N·m (2.3 kgf·m, 17 lb·ft) 6. Check:
T.
R.
• Cable routing
TIP
TIP
Tighten each bolt to 23 N·m (2.3 kgf·m, 17 lb·ft)
Make sure the brake hose, clutch cable, and
in the order pinch bolt “1” → pinch bolt “2” →
handlebar switch leads are routed properly. Re-
pinch bolt “1” → pinch bolt “2”.
fer to “CABLE ROUTING” on page 2-15.
7. Adjust:
• Spring preload
• Rebound damping
• Compression damping
1
Refer to “ADJUSTING THE FRONT FORK
LEGS (for MT10N/MT10NC)” on page 3-21.
2
4-85
FRONT FORK (for MT10SPN/MT10SPNC)
EAS20169

26 N•m (2.6 kgf•m, 19 lb•ft)
2
3
1 5 4
23 N•m (2.3 kgf•m, 17 lb•ft)
6 N•m (0.6 kgf•m, 4.4 lb•ft)

T.R
.

1 Front fender 1
2 Upper bracket pinch bolt 1 Loosen.
3 Front fork stepping motor coupler 1 Disconnect.
4 Cap bolt (with front fork stepping motor) 1 Loosen.
5 Lower bracket pinch bolt 2 Loosen.
6 Front fork leg 1
4-86
Disassembling the front fork leg

20 N・m (2.0 kgf・m, 15 lb・ft) 19 N・m (1.9 kgf・m, 14 lb・ft)
12 13
11
10
9
8
21 N・m (2.1 kgf・m, 15 lb・ft)

68 N・m (6.8 kgf・m, 50 lb・ft)

1 Cap bolt 1
2 O-ring 1
3 Locknut 1
4 Upper spring seat 1
5 Fork spring 1
6 Spacer 1
7 Outer tube 1
8 Dust seal 1
9 Oil seal clip 1
10 Oil seal 1
11 Washer 1
12 Damper rod assembly 1
13 Inner tube 1
4-87
EAS31052
REMOVING THE FRONT FORK LEGS

front fork legs.
1. Stand the vehicle on a level surface. 4
EWA13120
WARNING
no danger of it falling over. 2
TIP
that the front wheel is elevated.
2. Remove:
• Front wheel
3
Refer to “FRONT WHEEL” on page 4-21.
3. Disconnect:
• Front fork stepping motor coupler
4. Loosen: 5. Remove:
• Upper bracket pinch bolt “1” • Front fork leg
EAS31053
• Lower bracket pinch bolt “3”
EWA13640
DISASSEMBLING THE FRONT FORK LEG
WARNING The following procedure applies to both of the
Before loosening the upper and lower brack- front fork legs.
et pinch bolts, support the front fork leg. 1. Turn the spring preload adjusting bolt “1”
counterclockwise until it stops.
TIP 2. Remove:
Loosen the cap bolt “2” using the front fork cap • Cap bolt “1”
bolt wrench “4”. (from the damper rod assembly)
• Locknut “2”
• Upper spring seat “3”
Front fork cap bolt wrench 42mm
a. Loosen the cap bolt “1” using the front fork
90890-01575
cap bolt wrench “4” and then remove it from
YM-01575
the outer tube.
Front fork cap bolt wrench 42mm

90890-01575
YM-01575
4-88
1
4
1
2
G088920
6. Remove:
b. Hold the spring preload adjusting bolt “5”
and loosen the locknut.
TIP
5 Remove the damper rod assembly with the
damper rod holder “1”.
Damper rod holder (ø37)

90890-01504
Damper rod holder
YM-01504
2
3
c. Remove the cap bolt, locknut and upper

spring seat. 1
3. Drain:
• Fork oil
TIP
Stroke the damper rod assembly “1” several
times while draining the fork oil.
EAS31650
CHECKING THE FRONT FORK LEGS

front fork legs.
1. Check:
• Inner tube
• Outer tube
Bends/damage/scratches → Replace.
G088919 EWA13650
4. Remove: WARNING
• Outer tube Do not attempt to straighten a bent inner
5. Remove: tube as this may dangerously weaken it.
• Dust seal “1”
2. Measure:
• Oil seal clip “2”
• Spring free length “a”
(with a flat-head screwdriver)
Out of specification → Replace.
• Oil seal
• Washer
Fork spring free length limit
254.8 mm (10.03 in)
4-89
3. Check: 2. Tighten:
• Damper rod • Damper rod assembly
Obstruction → Blow out all of the oil passag- Front fork damper rod assembly
es with compressed air. 68 N·m (6.8 kgf·m, 50 lb·ft)
T.
R.
ECA19110
NOTICE TIP
• The front fork leg has a very sophisticated Tighten the damper rod assembly with the
internal construction, which are particular- damper rod holder “1”.
ly sensitive to foreign material.
• When disassembling and assembling the
front fork leg, do not allow any foreign ma- Damper rod holder (ø37)
terial to enter the front fork.
T.
R. 90890-01504
Damper rod holder
4. Check: YM-01504
• Cap bolt
EAS31651
ASSEMBLING THE FRONT FORK LEGS 1

front fork legs.
EWA18360
WARNING
If both front fork legs are not filled with the
specified amount of the fork oil, it may cause
poor handling and a loss of stability.
3. Lubricate:
TIP • Inner tube’s outer surface
• When assembling the front fork leg, be sure to
replace the following parts: Recommended oil
– Oil seal Yamaha Suspension Oil M1
– Dust seal
– O-ring 4. Install:
• Before assembling the front fork leg, make • Dust seal “1” New
sure all of the components are clean. • Oil seal clip “2”
1. Install:
• Washer “4”
• Damper rod assembly “1” ECA19170
ECA22560
NOTICE
NOTICE
Make sure the numbered side of the oil seal
Allow the damper rod assembly to slide
faces bottom side.
slowly down the inner tube. Be careful not to
damage the inner tube.
4-90
TIP 7. Install:
• Before installing the oil seal, lubricate its lips • Oil seal clip “1”
with lithium-soap-based grease. TIP
• Lubricate the outer surface of the inner tube Adjust the oil seal clip so that it fits into the outer
with fork oil. tube’s groove.
• Before installing the oil seal, cover the top of
the front fork leg with a plastic bag to protect
the oil seal during installation.
1
3
4
G088925
1 8. Install:
2 • Dust seal “1”
(with the fork seal driver “2”)
Fork seal driver

90890-01442
Adjustable fork seal driver (36–
46 mm)
YM-01442
G088922
5. Install: 2
• Outer tube
(to the inner tube) 1
6. Install:
• Washer
• Oil seal “1” G088926
(with the fork seal driver “2”) 9. Install:

• Rod puller “1”
Fork seal driver (onto the damper rod “2”)
90890-01442
Adjustable fork seal driver (36– Front fork rod puller M7x0.75
46 mm) 90890-01576
YM-01442 YM-01576
1 2
G088924
4-91
10.Fill:
• Front fork leg Level (left)
(with the specified amount of the recom- 180 mm (7.1 in)
mended fork oil) Level (right)
180 mm (7.1 in)
Recommended oil
Yamaha Suspension Oil M1
Quantity (left)
448.0 cm³ (15.15 US oz, 15.80 a
Imp.oz)
Quantity (right)
448.0 cm³ (15.15 US oz, 15.80
Imp.oz)
ECA14230
NOTICE G088930
• Be sure to use the recommended fork oil. 14.Install:
Other oils may have an adverse effect on • Spacer
front fork performance. • Fork spring
• When disassembling and assembling the • Upper spring seat
front fork leg, do not allow any foreign ma- • Locknut
terial to enter the front fork. • Cap bolt
11.After filling the front fork leg, slowly stroke the (along with the O-ring New )
damper rod “1” up and down (at least ten a. Install the rod puller.
times) to distribute the fork oil. b. Install the spacer and fork spring.
TIP TIP
Be sure to stroke the damper rod slowly be- Install the fork spring with the marks “a” facing
cause the fork oil may spurt out. up “A”.
a
A
12.Before measuring the fork oil level, wait ten c. Install the upper spring seat “1”.
minutes until the oil has settled and the air d. Install the locknut “2” all the way onto the
bubbles have dispersed. damper rod assembly.
TIP
Be sure to bleed the front fork leg of any residual Front fork rod puller M7x0.75
air. 90890-01576
YM-01576
13.Measure:
• 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.
4-92
EWA13680
WARNING
Make sure the brake hoses are routed prop-
erly.
TIP
2
1 When installing the front fork leg, set the groove
“a” on the outer tube is level with the top of the
upper bracket.
e. Remove the rod puller.

f. Install the cap bolt completely, and then fin-
ger tighten the cap bolt. a a
EWA13670
WARNING
Always use a new cap bolt O-ring.
g. Hold the spring preload adjusting bolt “3”
and tighten the locknut “2” to specification.
2. Install:
Front fork cap bolt locknut
19 N·m (1.9 kgf·m, 14 lb·ft) • Protector “1” (right side only) New
T.
R.
a. Before attaching the protector, clean the

3 b. Attach the protector with the reference to
the upper end of the lower bracket “2” as
15.Install:
• Cap bolt
(to the outer tube) 1
TIP
• Temporarily tighten the cap bolt.
• When to tighten the cap bolt to the specified
torque is after installing the front fork leg to the a
vehicle and tightening the lower bracket pinch
bolts. b
EAS31652
INSTALLING THE FRONT FORK LEGS

The following procedure applies to both of the 2
front fork legs.
A. Forward
1. Install:
• Front fork leg a. 12 mm (0.47 in)
Temporarily tighten the upper and lower b. 80 mm (3.15 in)
bracket pinch bolts.
4-93
3. Install: TIP
• Protector “1” (right side only) New Tighten the cap bolt “1” using the front fork cap
a. Before attaching the protector, clean the bolt wrench “2”.
b. Attach the protector with the reference to Front fork cap bolt wrench 42mm
the lower end of the lower bracket “2” as 90890-01575
shown in the illustration. YM-01575
A
Front fork cap bolt
20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.
2
1
2 a
• Upper bracket pinch bolt “3”
Upper bracket pinch bolt

1 26 N·m (2.6 kgf·m, 19 lb·ft)
T.
R.
A. Forward
a. 24 mm (0.94 in)
4. Tighten:
• Lower bracket pinch bolts “1” and “2”

23 N·m (2.3 kgf·m, 17 lb·ft) 3
T.
R.
TIP TIP
Tighten each bolt to 23 N·m (2.3 kgf·m, 17 lb·ft) When installing the front fork legs, make sure
in the order pinch bolt “1” → pinch bolt “2” → that the front fork stepping motor couplers are
pinch bolt “1” → pinch bolt “2”. positioned at the angles shown in the illustration.
2
10° 10° 10° 10°
5. Tighten:
4-94
6. Check:
• Cable routing
TIP
Make sure the brake hose, clutch cable, and
handlebar switch leads are routed properly. Re-
fer to “CABLE ROUTING” on page 2-15.
7. Adjust:
• Spring preload
• Rebound damping
• Compression damping
Refer to “ADJUSTING THE PRELOAD OF
THE FRONT FORK LEGS (for MT10SPN/
MT10SPNC)” on page 3-23 and “ADJUST-
ING THE DAMPING FORCE OF THE
FRONT FORK LEGS AND REAR SHOCK
ABSORBER (for MT10SPN/MT10SPNC)” on
page 3-24.
4-95
STEERING HEAD
EAS20035
STEERING HEAD
Removing the lower bracket
7 N•m (0.7 kgf•m, 5.2 lb•ft) 1st 52 N•m (5.2 kgf•m, 38 lb•ft)
T.R
.
*2nd 14 N•m (1.4 kgf•m, 10 lb•ft)
T.
R
3 LT
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
115 N•m (11.5 kgf•m, 85 lb•ft)
8
T.R
.
LT
6
5
16 N•m (1.6 kgf•m, 12 lb•ft)
3 LT
1 LT 23 N•m (2.3 kgf•m, 17 lb•ft)
2
11 N•m (1.1 kgf•m, 8.1 lb•ft)
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

Air scoop/Air scoop stay page 4-1.
Meter assembly/Auxiliary light/Headlight assem- Refer to “GENERAL CHASSIS (3)” on
bly/Headlight stay page 4-16.
Handlebar Refer to “HANDLEBAR” on page 4-71.
Refer to “FRONT FORK (for MT10N/
Front fork legs MT10NC)” on page 4-76 or “FRONT FORK
(for MT10SPN/MT10SPNC)” on page 4-86.
1 Horn connector 2 Disconnect.
2 Horn 1
3 Front brake hose 1
4 Horn bracket 1
5 Steering damper body 1
6 Clutch switch lead 1
7 Handlebar switch lead (left) 1
8 Handlebar switch lead (right) 1
4-96
STEERING HEAD
Removing the lower bracket

7 N•m (0.7 kgf•m, 5.2 lb•ft) 1st 52 N•m (5.2 kgf•m, 38 lb•ft)
T.R
20
.
*2nd 14 N•m (1.4 kgf•m, 10 lb•ft)
T.
R
LT
9 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
23
115 N•m (11.5 kgf•m, 85 lb•ft)
T.R
.
10 12 11
13
14
LT 16
22
18
21
19
17
16 N•m (1.6 kgf•m, 12 lb•ft)
15
LT
LT 23 N•m (2.3 kgf•m, 17 lb•ft)
11 N•m (1.1 kgf•m, 8.1 lb•ft)
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

9 Steering stem nut 1
10 Upper bracket 1
11 Lock washer 1
12 Upper ring nut 1
13 Rubber washer 1
14 Lower ring nut 1
15 Lower bracket 1
16 Bearing cover 1
17 Lower bearing dust seal 1
18 Upper bearing 1
19 Lower bearing 1
20 Cap 1
21 Main switch 1
22 Wire harness guide 1
23 Auxiliary DC jack 1
4-97
STEERING HEAD
EAS30213
2. Check:
REMOVING THE LOWER BRACKET
• Bearing
EWA13120
• Bearing race
WARNING Damage/pitting → Replace the bearings and
Securely support the vehicle so that there is bearing races as a set.
no danger of it falling over. 3. Replace:
• Bearing
2. Remove: • Bearing race
• Upper ring nut “1” a. Remove the bearing races from the steer-
• Rubber washer ing head pipe “1” with a long rod “2” and
• Lower ring nut “2” hammer.
• Lower bracket b. Remove the bearing race “3” from the lower
EWA13730
WARNING bracket with a floor chisel “4” and hammer.

c. Install a new dust seal and new bearing rac-
Securely support the lower bracket so that
es.
there is no danger of it falling. ECA14270
NOTICE
TIP
If the bearing race is not installed properly,
• Hold the lower ring nut with steering nut
the steering head pipe could be damaged.
wrench, and then remove the upper ring nut
with the ring nut wrench “3”. TIP
• Remove the lower ring nut with the steering nut • Always replace the bearings and bearing races
wrench “4”. as a set.
• Whenever the steering head is disassembled,
Ring nut wrench replace the dust seal.
90890-01268
Spanner wrench
YU-01268
Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472
4 3
G088933
G088932 2
EAS30214
CHECKING THE STEERING HEAD G088934

1. Wash:
• Bearing 4. Check:
• Bearing race • Upper bracket
• Lower bracket
Recommended cleaning solvent (along with the steering stem)
Kerosene Bends/cracks/damage → Replace.
4-98
STEERING HEAD
EAS30216
INSTALLING THE STEERING HEAD

1. Lubricate:
• Upper bearing
• Lower bearing
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 3-20.
G088935
3. Install:
• Upper bracket
• Steering stem nut
TIP
Temporarily tighten the steering stem nut.
4. Install:
• Front fork legs
Refer to “FRONT FORK (for MT10N/
MT10NC)” on page 4-76 or “FRONT FORK
TIP
Temporarily tighten the upper and lower bracket
pinch bolts.
EAS30215
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.
4-99
REAR SHOCK ABSORBER ASSEMBLY
EAS20036

Removing the rear shock absorber assembly (for MT10N/MT10NC)
5
35 N•m (3.5 kgf•m, 26 lb•ft)
40 N•m (4.0 kgf•m, 30 lb•ft)

6
New
New 9 New
3 1
4
6
2 1
New 8 4
New 2 New
New
3
40 N•m (4.0 kgf•m, 30 lb•ft)
New
7

Rear wheel Refer to “REAR WHEEL” on page 4-30.
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
Rear shock absorber assembly upper nut/Col-
5 1/1/1
lar/Bolt
6 Relay arm nut/Bolt 1/1
7 Collar 1
8 Relay arm 1
9 Rear shock absorber assembly 1
4-100
Removing the rear shock absorber assembly (for MT10N/MT10NC)
35 N•m (3.5 kgf•m, 26 lb•ft)
40 N•m (4.0 kgf•m, 30 lb•ft)
New
New 12 13
New
13
12
11 11 New
New 10
New New
40 N•m (4.0 kgf•m, 30 lb•ft)
10
New

10 Oil seal/Bearing 2/1
11 Collar/Oil seal/Bearing 1/2/2
4-101
Removing the rear shock absorber assembly (for MT10SPN/MT10SPNC)
35 N•m (3.5 kgf•m, 26 lb•ft)
6 New
1
6 New
40 N•m (4.0 kgf•m, 30 lb•ft)

New
New
New
4 2
5
3 2
New 5
New 3 New
New
40 N•m (4.0 kgf•m, 30 lb•ft) 4
New

Fuel tank cover/Fuel tank side cover page 4-8.
Rear shock absorber assembly stepping motor
1 2 Disconnect.
coupler
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
Rear shock absorber assembly upper nut/Col-
6 1/1/1
lar/Bolt
4-102
Removing the rear shock absorber assembly (for MT10SPN/MT10SPNC)
35 N•m (3.5 kgf•m, 26 lb•ft)
14
New
14
New
7 40 N•m (4.0 kgf•m, 30 lb•ft)

New
New 13 10 15
New
15
13
7
12 9 12 New
New 11
New New
40 N•m (4.0 kgf•m, 30 lb•ft) 11
New 8

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
14 Collar/Dust seal/Circlip/Bushing 2/2/2/1
4-103
EAS30826
HANDLING THE REAR SHOCK ABSORBER A

EWA13740
WARNING
This rear shock absorber contains highly
compressed nitrogen gas. Before handling
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. B
• Do not tamper or attempt to open the rear
shock absorber.
• Do not subject the rear shock absorber to
an open flame or any other source of high
heat. High heat can cause an explosion due
to excessive gas pressure.
• Do not deform or damage the rear shock
absorber in any way. Rear shock absorber
damage will result in poor damping perfor-
mance. A. MT10N/MT10NC
B. MT10SPN/MT10SPNC
EAS30729
DISPOSING OF A REAR SHOCK ABSORBER EAS30219
REMOVING THE REAR SHOCK ABSORBER

1. Gas pressure must be released before dis-
ASSEMBLY
posing of a rear shock absorber. To release
the gas pressure, drill a 2–3 mm (0.08–0.12 EWA13120
in) hole through the rear shock absorber as WARNING
shown. Securely support the vehicle so that there is
EWA13760
WARNING no danger of it falling over.

Wear eye protection to prevent eye damage TIP
from released gas or metal chips. Place the vehicle on a maintenance stand so
that the rear wheel is elevated.
2. Remove:
• Connecting arm upper nut
• Connecting arm upper bolt “1”
• Rear shock absorber assembly lower nut
• Rear shock absorber assembly lower bolt “2”
• Connecting arm lower nut
• Connecting arm lower bolt “3”
• Connecting arm “4”
TIP
When removing the bolt, hold the swingarm so
that it does not drop down.
4-104
3
1
2
4
3. Remove: 3. Remove:
• Rear shock absorber assembly upper nut • Bushing “1” (for MT10SPN/MT10SPNC)
• Rear shock absorber assembly upper bolt TIP
4. Remove: Remove the bushing with a socket “2” that
• Relay arm nut “1” matches its outside diameter.
• Relay arm bolt “2”
• Collar “3”
• Relay arm “4”
TIP 2
Pull out the collar “3” from the left side of the ve-
1
hicle.
1 4. Remove:
• Oil seal
• Bearing “1”
3 4 TIP
2 Remove the bearing with a socket “2” that
matches its outside diameter.
5. Remove:
• Rear shock absorber assembly
EAS31653
DISASSEMBLING THE REAR SHOCK 2

ABSORBER ASSEMBLY
1. Remove:
• Collar (for MT10SPN/MT10SPNC) 1
• Dust seal (for MT10SPN/MT10SPNC)
2. Remove:
• Circlip “1” (for MT10SPN/MT10SPNC)
(with a flat-head screwdriver)
4-105
EAS30220
CHECKING THE REAR SHOCK ABSORBER

ASSEMBLY
1. Check: 2
• Rear shock absorber rod
Bends/damage → Replace the rear shock a
absorber assembly.
• Rear shock absorber assembly 1
Gas leaks/oil leaks → Replace the rear shock
absorber assembly.
• Spring
• Bearing 2. Install:
• Collar • Bushing “1” (for MT10SPN/MT10SPNC)
Damage/wear → Replace. • Circlip (for MT10SPN/MT10SPNC) New
• Bushing • Dust seal (for MT10SPN/MT10SPNC) New
Damage/wear → Replace the bushings. TIP
• Bolt Install the bushing with a socket “2” that matches
Bends/damage/wear → Replace. its outside diameter.
EAS30221
CHECKING THE CONNECTING ARM AND

RELAY ARM Installed depth “a”
3.0 mm (0.12 in)
1. Check:
• Connecting arm
• Relay arm
2
2. Check: a
• Bearing
• Oil seal 1
Damage/pitting → Replace.
3. Check:
• Collar
Damage/scratches → Replace.
EAS31654
EAS30222
ASSEMBLING THE REAR SHOCK INSTALLING THE RELAY ARM
ABSORBER ASSEMBLY 1. Lubricate:
1. Install: • Collar
• Bearing “1” • Oil seal
• Oil seal New
TIP Recommended lubricant
Install the bearing with a socket “2” that matches Lithium-soap-based grease
its outside diameter.
2. Install:
• Bearing “1”
Installed depth “a” (to the relay arm)
4.0 mm (0.16 in) • Oil seal “2” New
(to the relay arm)
Installed depth “a”

4.5 mm (0.18 in)
Installed depth “b”
3.5 mm (0.14 in)
4-106
TIP 2. Tighten:
• When installing the oil seals “2” to the relay • Relay arm nut
arm, face the character stamp of the oil seals • Rear shock absorber assembly upper nut
outside. • Connecting arm lower nut
• Press in the oil seal so it does not protrude • Rear shock absorber assembly lower nut
from the end surface of the relay arm. • Connecting arm upper nut
• Install the connecting arm so that the stamp
mark “B67” is facing outward. The stamp mark Relay arm nut
can be facing either up or down. 40 N·m (4.0 kgf·m, 30 lb·ft)
T.
R.
Rear shock absorber assembly
upper nut
2 a
6 35 N·m (3.5 kgf·m, 26 lb·ft)
Connecting arm lower nut
40 N·m (4.0 kgf·m, 30 lb·ft)
Rear shock absorber assembly
b 1 1 b lower nut
40 N·m (4.0 kgf·m, 30 lb·ft)
Connecting arm upper nut
40 N·m (4.0 kgf·m, 30 lb·ft)
3
2
4
4
3. Relay arm
4. Connecting arm
5. Rear shock absorber assembly
6. Frame
A. Left side
B. Right side
EAS30225
INSTALLING THE REAR SHOCK

ABSORBER ASSEMBLY
1. Install:
• Relay arm
• Connecting arm
TIP
• 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.
4-107
SWINGARM
EAS20037
SWINGARM
Removing the swingarm
65 N•m (6.5 kgf•m, 48 lb•ft)
7 N•m (0.7 kgf•m, 5.2 lb•ft)
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
T.R
.
7 2
8
LT
1
6 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
16 N•m (1.6 kgf•m, 12 lb•ft)
11
10
105 N•m (10.5 kgf•m, 76 lb•ft) 4

T.R
.
9
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
5
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.

Refer to “REAR SHOCK ABSORBER
Rear shock absorber assembly ASSEMBLY” on page 4-100.
Drive sprocket Refer to “CHAIN DRIVE” on page 4-113.
1 Drive chain guard 1
2 Rear fender 1
3 Cover 1
4 Drive chain guide 1
5 Rear wheel sensor lead cover 1
6 Pivot shaft nut/Washer 1/1
7 Pivot shaft ring nut/Washer 1/1
8 Pivot shaft 1
9 Rear wheel sensor lead hook 1
10 Swingarm 1
11 Drive chain 1
4-108
SWINGARM
Removing the swingarm

65 N•m (6.5 kgf•m, 48 lb•ft)
7 N•m (0.7 kgf•m, 5.2 lb•ft)
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
T.R
.
LT
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
16 N•m (1.6 kgf•m, 12 lb•ft)
13
15
12
105 N•m (10.5 kgf•m, 76 lb•ft)

T.R
.
14 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
15 12
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.

12 Dust cover 2
13 Washer 1
14 Bushing 1
15 Bearing 2
4-109
SWINGARM
EAS30226
5. Remove:
REMOVING THE SWINGARM
• Pivot shaft nut
EWA13120
• Pivot shaft ring nut “1”
WARNING 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
Place the vehicle on a maintenance stand so Ring nut wrench
that the rear wheel is elevated. 90890-01507
Ring nut wrench
2. Remove: YM-01507
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 4-100.
3. Measure:
1
• Swingarm side play
• Swingarm vertical movement
a. Measure the tightening torque of the pivot
shaft nut.
Pivot shaft nut 2

105 N·m (10.5 kgf·m, 77 lb·ft)
T.
6. Remove:
R.
Pivot shaft ring nut

65 N·m (6.5 kgf·m, 48 lb·ft) • Pivot shaft “1”
Pivot shaft TIP
7 N·m (0.7 kgf·m, 5.2 lb·ft) Loosen the pivot shaft with the damper rod hold-
er “2”.
b. Check the swingarm side play “A” by mov-
ing the swingarm from side to side.
If the swingarm has side-to-side play, check Damper rod holder (ø22)
the collars, bearings, and dust covers. 90890-01365
c. Check the swingarm vertical movement “B”
by moving the swingarm up and down.
If the swingarm vertical movement is not
smooth or if there is binding, check the pivot 2
shaft, collars, bearings, and dust covers. 1
B
A
7. Remove:
• Swingarm
G088936
4. Remove:
• Drive chain
Refer to “REMOVING THE DRIVE CHAIN”
on page 4-115.
4-110
SWINGARM
EAS30227 EAS30228
CHECKING THE SWINGARM INSTALLING THE SWINGARM

1. Check: 1. Lubricate:
• Swingarm • Dust cover
Bends/cracks/damage → Replace. • Pivot shaft
2. Check: • Oil seal
• Pivot shaft • Collar
Roll the pivot shaft on a flat surface. • Bushing
Bends → Replace.
EWA13770
WARNING Lithium-soap-based grease
Do not attempt to straighten a bent pivot
shaft. 2. Install:
• Bearing “1”
3. Wash: (to the swingarm)
• Pivot shaft
• Dust cover
(to the swingarm)
• Collar
• Bushing
Installed depth “a”
• Washer 0–1.0 mm (0–0.04 in)
Installed depth “b”
Recommended cleaning solvent 4.0 mm (0.16 in)
Kerosene
TIP
4. Check:
• Dust cover “1” • When installing the oil seals to the swingarm,
• Oil seal “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.
• Bearing “4”
• Bushing “5”
a 1 1a
1
4
5 2 1 2
24 4
1
3
42
b
A. Left side
B. Right side
4-111
SWINGARM
• Swingarm • Pivot shaft nut
• Pivot shaft “1”
Pivot shaft nut
Pivot shaft 105 N·m (10.5 kgf·m, 77 lb·ft)
T.
R.
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
6. Install:
R.
TIP • Drive chain

Tighten the pivot shaft with the damper rod hold- Refer to “INSTALLING THE DRIVE CHAIN”
er “2”. on page 4-117.
Refer to “REAR SHOCK ABSORBER AS-
Damper rod holder (ø22) SEMBLY” on page 4-100.
90890-01365 • Rear wheel
7. Adjust:
2 Refer to “Adjusting the drive chain slack” on
page 3-19.
1
Stand)
25.0–35.0 mm (0.98–1.38 in)
20.0–30.0 mm (0.79–1.18 in)
4. Install:
• Pivot shaft ring nut “1”
Pivot shaft ring nut

65 N·m (6.5 kgf·m, 48 lb·ft)
T.
R.
TIP
Tighten the pivot shaft ring nut with the ring nut
wrench “2”.
Ring nut wrench

90890-01507
Ring nut wrench
YM-01507
2 1
4-112
CHAIN DRIVE
EAS20038
CHAIN DRIVE
Removing the drive chain
10 N•m (1.0 kgf•m, 7.4 lb•ft)
5
1
6
2
140 N•m (14 kgf•m, 103 lb•ft) LT
T.R
.
3
2
4
2
New
8 7
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
LT
6
LT

Fuel tank cover/Air scoop/Fuel tank side cover page 4-8.
1 Shift sensor coupler 1 Disconnect.
2 Locknut 3
3 Shift sensor 1
4 Shift rod 1
5 Shift arm 1
6 Shift rod joint 2
7 Shift pedal 1
8 Drive sprocket cover 1
4-113
CHAIN DRIVE
Removing the drive chain

10 N•m (1.0 kgf•m, 7.4 lb•ft)
140 N•m (14 kgf•m, 103 lb•ft) LT
T.R
.
11
13
12
New 10
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
9
LT
LT

9 Drive chain guide 1
10 Drive sprocket nut 1
11 Washer 1
12 Drive sprocket 1
13 Drive chain 1
4-114
CHAIN DRIVE
EAS30229
a. Measure the length “a” between the inner
REMOVING THE DRIVE CHAIN
sides of the pins and the length “b” between
EWA13120
the outer sides of the pins on a 15-link sec-
WARNING tion of the drive chain as shown in the illus-
Securely support the vehicle so that there is tration.
TIP
2. Straighten the drive sprocket nut rib “a”.
G088937
b. Calculate the 15-link section length “c” of

a
the drive chain using the following formula.
Drive chain 15-link section length “c” =
a (length “a” between pin inner sides + length
“b” between pin outer sides)/2
TIP
• When measuring a 15-link section of the drive
3. Remove: chain, make sure that the drive chain is taut.
• Drive chain • Perform this procedure 2–3 times, at a different
ECA17410
location each time.
NOTICE
Be sure to put on safety goggles when work-
ing.
TIP
Cut the drive chain with the drive chain cut & riv-
et tool.

90890-01550 G088938
YM-01550 2. Check:
• Drive chain
EAS30230 Stiffness → Clean and lubricate or replace.
CHECKING THE DRIVE CHAIN
1. Measure:
• 15-link section length “c” of the drive chain
Out of specification → Replace the drive
chain.
15-link length limit

239.1 mm (9.41 in)
G088939
4-115
CHAIN DRIVE
3. Clean:
• Drive chain
a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosene and remove
any remaining dirt.
c. Remove the drive chain from the kerosene
and completely dry it.
ECA19090
NOTICE
G088943
• This vehicle has a drive chain with small
rubber O-rings “1” between the drive chain 5. Lubricate:
side plates. Never use high-pressure water • Drive chain
or air, steam, gasoline, certain solvents
(e.g., benzine), or a coarse brush to clean Recommended lubricant
the drive chain. High-pressure methods Chain lubricant suitable for O-
could force dirt or water into the drive ring chains
chain’s internals, and solvents will deterio- EAS30231
rate the O-rings. A coarse brush can also CHECKING THE DRIVE SPROCKET
damage the O-rings. Therefore, use only 1. Check:
kerosene to clean the drive chain. • Drive sprocket
• Do not soak the drive chain in kerosene for More than 1/4 tooth “a” wear → Replace the
more than ten minutes, otherwise the O- drive sprocket, the rear wheel sprocket and
rings can be damaged. the drive chain as a set.
Bent teeth → Replace the drive sprocket, the
rear wheel sprocket and the drive chain as a
set.
G088940
G088904
b. Correct
1. Drive chain roller

2. Drive sprocket
EAS30232
CHECKING THE REAR WHEEL SPROCKET

G088941 Refer to “CHECKING AND REPLACING THE
REAR WHEEL SPROCKET” on page 4-34.
4. Check:
• O-ring “1” EAS30233
Damage → Replace the drive chain. CHECKING THE REAR WHEEL DRIVE HUB
• Drive chain roller “2” Refer to “CHECKING THE REAR WHEEL
Damage/wear → Replace the drive chain. DRIVE HUB” on page 4-34.
• Drive chain side plate “3”
Damage/wear/cracks → Replace the drive
chain.
4-116
CHAIN DRIVE
EAS30234
c. After riveting, make sure the space “c”,
INSTALLING THE DRIVE CHAIN
which is inside of the connecting link “3” and
1. Install:
inside of the connecting plate “1”, is 15.10–
• Drive chain
ECA17410
15.30 mm (0.594–0.602 in).
NOTICE
Be sure to put on safety goggles when work-
ing.
TIP
Install the drive chain joint with the drive chain
cut & rivet tool.

90890-01550
Drive chain cut & rivet tool 2. Lubricate:
YM-01550 • Drive chain
a. When press fitting the connecting plate “1”, Recommended lubricant

make sure the space “a” between the end Chain lubricant suitable for O-
of the connecting pin “2” and the connecting ring chains
plate is 1.3–1.4 mm (0.05–0.06 in).
3. Install:
TIP
• Drive sprocket
Apply lithium soap-based grease onto the con- • Washer “1”
necting pin “2”.
• Drive sprocket nut “2” New
Drive sprocket nut

140 N·m (14 kgf·m, 103 lb·ft)
T.
R.
TIP
• While applying the rear brake, tighten the drive
sprocket nut.
• Install washer “1” with the “OUT” mark “a” fac-
ing out.
• Stake the drive sprocket nut “2” at cutouts “b” in
b. After riveting, make sure the diameter be- the drive axle.
tween the edges “b” of the connecting pin
“2” is 5.5–5.8 mm (0.22–0.23 in). 2
1
b
4. Install:
• Shift arm “1”
TIP
Before installing, make sure to align the mark “a”
of the shift shaft with the slot “b” of the shift arm.
4-117
CHAIN DRIVE
6. Adjust:
Shift arm bolt • Installed shift rod length
T.
R. 10 N·m (1.0 kgf·m, 7.4 lb·ft) Refer to “ADJUSTING THE SHIFT PEDAL”
on page 4-118.
7. Adjust:
1
Refer to “Adjusting the drive chain slack” on
b page 3-19.

a Stand)
25.0–35.0 mm (0.98–1.38 in)
20.0–30.0 mm (0.79–1.18 in)
• Shift rod joint “1” NOTICE
• Shift sensor “2”
A drive chain that is too tight will overload
• Shift rod “3”
the engine and other vital parts, and one that
TIP is too loose can skip and damage the swing-
• Install the shift rod joint and shift sensor in the arm or cause an accident. Therefore, keep
direction shown in the illustration. the drive chain slack within the specified lim-
• The allowable twist of the shift rod joint and its.
shift sensor is ±5°.
• Install the shift rod so that the side “b” faces up- EAS31729
ward as shown in the illustration. ADJUSTING THE SHIFT PEDAL

TIP
Shift rod joint bolt The shift pedal position is determined by the in-
10 N·m (1.0 kgf·m, 7.4 lb·ft) stalled shift rod length.
T.
R.
LOCTITE®
1. Measure:
Shift sensor locknut
• Installed shift rod length “a”
7 N·m (0.7 kgf·m, 5.2 lb·ft)
Incorrect → Adjust.
Installed shift rod length

a 274.2–276.2 mm (10.80–10.87
1 in)
b
a
a. 25.2 mm (0.99 in)
4-118
CHAIN DRIVE
2. Adjust:
• Installed shift rod length
a. Loosen both locknuts.
b. Turn the shift rod until the specified installed
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 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
d. Make sure the installed shift rod length is

within specification.
4-119
ENGINE
LUBRICATION SYSTEM CHART AND DIAGRAMS...................................... 5-1

ENGINE OIL LUBRICATION CHART .......................................................5-1
LUBRICATION DIAGRAMS ...................................................................... 5-2
ENGINE INSPECTION .................................................................................... 5-9

MEASURE THE COMPRESSION PRESSURE........................................ 5-9
ENGINE REMOVAL ......................................................................................5-11

REMOVING THE ENGINE ...................................................................... 5-15
INSTALLING THE ENGINE..................................................................... 5-15
INSTALLING THE EXHAUST PIPE AND MUFFLER..............................5-16
CAMSHAFTS.................................................................................................5-17
REMOVING THE CAMSHAFTS..............................................................5-22
REMOVING THE ROCKER ARMS AND ROCKER ARM SHAFTS........ 5-22
CHECKING THE CAMSHAFTS ..............................................................5-22
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........ 5-24
CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET .........5-24
CHECKING THE TIMING CHAIN GUIDES............................................. 5-24
CHECKING THE TIMING CHAIN TENSIONER...................................... 5-25
ASSEMBLING THE TIMING CHAIN COVER .........................................5-25
INSTALLING THE ROCKER ARMS AND ROCKER ARM SHAFTS ...... 5-25
INSTALLING THE TIMING CHAIN COVER............................................5-26
INSTALLING THE CAMSHAFTS ............................................................ 5-27
5
CYLINDER HEAD.......................................................................................... 5-31
REMOVING THE CYLINDER HEAD.......................................................5-32
CHECKING THE CYLINDER HEAD .......................................................5-32
INSTALLING THE CYLINDER HEAD .....................................................5-32
VALVES AND VALVE SPRINGS.................................................................. 5-34

REMOVING THE VALVES...................................................................... 5-36
CHECKING THE VALVES AND VALVE GUIDES ..................................5-36
CHECKING THE VALVE SEATS ............................................................ 5-38
CHECKING THE VALVE SPRINGS........................................................ 5-39
CHECKING THE VALVE SPRING SEAT................................................ 5-40
INSTALLING THE VALVES .................................................................... 5-40
GENERATOR ................................................................................................5-42
REMOVING THE GENERATOR ............................................................. 5-44
INSTALLING THE GENERATOR............................................................ 5-44
STARTER CLUTCH ......................................................................................5-46
REMOVING THE STARTER CLUTCH ...................................................5-47
CHECKING THE STARTER CLUTCH ....................................................5-47
INSTALLING THE STARTER CLUTCH .................................................. 5-47
ELECTRIC STARTER ...................................................................................5-48

CHECKING THE STARTER MOTOR .....................................................5-50
ASSEMBLING THE STARTER MOTOR................................................. 5-50
OIL PUMP...................................................................................................... 5-51

REMOVING THE OIL PAN...................................................................... 5-54
CHECKING THE SPROCKET AND CHAIN............................................5-54
CHECKING THE OIL PUMP ................................................................... 5-54
CHECKING THE RELIEF VALVE ........................................................... 5-54
CHECKING THE OIL DELIVERY PIPES ................................................ 5-54
CHECKING THE OIL STRAINER ........................................................... 5-54
ASSEMBLING THE OIL PUMP...............................................................5-54
INSTALLING THE OIL PUMP .................................................................5-55
INSTALLING THE OIL PAN .................................................................... 5-56
CLUTCH ........................................................................................................5-57
REMOVING THE CLUTCH ..................................................................... 5-61
CHECKING THE FRICTION PLATES.....................................................5-61
CHECKING THE CLUTCH PLATES .......................................................5-61
CHECKING THE CLUTCH SPRINGS.....................................................5-62
CHECKING THE CLUTCH HOUSING ....................................................5-62
CHECKING THE CLUTCH BOSS........................................................... 5-63
CHECKING THE PRESSURE PLATE ....................................................5-63
CHECKING THE PRIMARY DRIVE GEAR............................................. 5-63
CHECKING THE PRIMARY DRIVEN GEAR ..........................................5-63
CHECKING THE PULL LEVER SHAFT AND PULL ROD ......................5-63
INSTALLING THE CLUTCH.................................................................... 5-63
SHIFT SHAFT................................................................................................5-66
CHECKING THE SHIFT SHAFT ............................................................. 5-67
CHECKING THE STOPPER LEVER ......................................................5-67
INSTALLING THE SHIFT SHAFT ........................................................... 5-67
CRANKCASE ................................................................................................5-68
DISASSEMBLING THE CRANKCASE....................................................5-71
CHECKING THE CRANKCASE ..............................................................5-71
ASSEMBLING THE CRANKCASE.......................................................... 5-71
INSTALLING THE OIL PRESSURE SWITCH.........................................5-74
INSTALLING THE GEAR POSITION SENSOR...................................... 5-74
CONNECTING RODS AND PISTONS .......................................................... 5-75
REMOVING THE CONNECTING RODS AND PISTONS.......................5-76
CHECKING THE CYLINDER AND PISTON ...........................................5-76
CHECKING THE PISTON RINGS........................................................... 5-77
CHECKING THE PISTON PIN ................................................................5-78
CHECKING THE CONNECTING RODS................................................. 5-78
INSTALLING THE CONNECTING ROD AND PISTON .......................... 5-81
CRANKSHAFT AND BALANCER SHAFT ...................................................5-86

REMOVING THE CRANKSHAFT AND BALANCER SHAFT.................. 5-87
CHECKING THE OIL NOZZLES ............................................................. 5-87
CHECKING THE CRANKSHAFT ............................................................ 5-87
CHECKING THE BALANCER SHAFT ....................................................5-89
INSTALLING THE CRANKSHAFT .......................................................... 5-91
INSTALLING THE THRUST BEARING...................................................5-91
INSTALLING THE BALANCER ASSEMBLY...........................................5-92
TRANSMISSION............................................................................................ 5-93
REMOVING THE TRANSMISSION ........................................................ 5-97
CHECKING THE SHIFT FORKS............................................................. 5-97
CHECKING THE SHIFT DRUM ASSEMBLY..........................................5-98
CHECKING THE TRANSMISSION ......................................................... 5-98
ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ..............................5-99
INSTALLING THE TRANSMISSION .......................................................5-99
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20298

EAS32362
ENGINE OIL LUBRICATION CHART
1. Oil strainer 17. Exhaust 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 21. Mission 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
5-1
EAS32363
LUBRICATION DIAGRAMS
Crankcase, cylinder, and cylinder head (left side view)
1. Intake camshaft
2. Oil nozzle
3. Oil delivery pipe 2
4. Oil filter cartridge
5. Crankshaft
6. Exhaust camshaft
7. Sub gallery
5-2
Crankcase and cylinder (right side view)
1. Timing chain tensioner

2. Intake camshaft
3. Exhaust camshaft
4. Crankshaft
5. Relief valve
6. Oil pipe 1
8. Oil pan
9. Oil strainer
10. Oil pump
11. Shift fork guide bar
12. Shift fork-C
13. Drive axle
5-3
Timing chain cover and oil pipe (right side view)
1. Timing chain cover

2. Oil pipe 3
3. Oil pipe 2
4. Crankshaft
5. Crankcase
5-4
Oil pump and oil cooler (bottom view)
1. Oil cooler
3. Oil cooler outlet hose
4. Oil filter cartridge
7. Oil strainer
8. 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
5-5
Camshaft and balancer shaft (top view)
1. Cylinder head
2. Exhaust camshaft
3. Intake camshaft
4. Balancer shaft
5-6
Crankshaft (rear view)
1. Oil nozzle
2. Oil pipe 3
3. Timing chain cover
4. Crankshaft
5. Oil pipe 2
7. Generator rotor
8. Shaft
5-7
Crankshaft and transmission (top view)
1. Oil pump
2. Main axle
3. Clutch housing
4. Drive axle
5-8
ENGINE INSPECTION
EAS20041
ENGINE INSPECTION 1
EAS30249
MEASURE THE COMPRESSION PRESSURE

The following procedure applies to all of the cyl-
inders.
TIP
Insufficient compression pressure will result in a
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- (d).
ANCE” on page 3-5.
2. Start the engine, warm it up for several min- Compression pressure
utes, and then turn it off. 1305–1680 kPa/250 r/min (13.1–
3. Remove: 16.8 kgf/cm²/250 r/min, 185.6–
• Rider seat 238.9 psi/250 r/min)
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.
EWA17100
• Air cut-off valve WARNING
Refer to “AIR INDUCTION SYSTEM” on To prevent sparking the plug, remove all ig-
page 7-18. nition coil couplers and fuel injector cou-
• Ignition coil plers before cranking the engine.
• Spark plug
TIP
Refer to “CAMSHAFTS” on page 5-17.
ECA13340 The difference in compression pressure be-
NOTICE tween cylinders should not exceed 100 kPa (1
Before removing the spark plugs, use com- kgf/cm², 15 psi).
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.
d. 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.
5-9
ENGINE INSPECTION
Compression pressure (with oil applied into

the cylinder)
Reading Diagnosis
Higher than without Piston ring(s) wear or
oil damage → Repair.
Same as without oil Piston, valves, cylin-
der head gasket pos-
sibly defective →
Repair.
6. Install:
• Spark plug
Spark plug
13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.
Spark plug (new)

18 N·m (1.8 kgf·m, 13 lb·ft)
TIP
• Before installing the spark plug, clean the
spark plug and gasket surface.
• If the spark plug is a new one, tighten it to 18
N·m (1.8 kgf·m, 13 lb·ft).
7. Install:
• Ignition coil
page 7-18.
• Air filter case
• Fuel tank
• Rider seat
page 4-1.
5-10
ENGINE REMOVAL
EAS20042
ENGINE REMOVAL
Removing the muffler and exhaust pipe
2.0 N•m (0.20 kgf•m, 1.5 lb•ft)
20 N•m (2.0 kgf•m, 15 lb•ft)
4 New
1
3
10 N•m (1.0 kgf•m, 7.4 lb•ft)
23 N•m (2.3 kgf•m, 17 lb•ft)
5
20 N•m (2.0 kgf•m, 15 lb•ft)
New
LT
20 N•m (2.0 kgf•m, 15 lb•ft)
10 N•m (1.0 kgf•m, 7.4 lb•ft) New (8)

for MT10SPN/MT10SPNC
Bottom cowling Refer to “GENERAL CHASSIS (2)” on
page 4-8.
Radiator Refer to “RADIATOR” on page 6-3.
Oil cooler Refer to “OIL COOLER” on page 6-6.
1 Muffler joint 1
2 Muffler 1
3 Ring 1
4 Gasket 1
5 EXUP valve pulley cover 1
5-11
ENGINE REMOVAL
Removing the muffler and exhaust pipe

2.0 N•m (0.20 kgf•m, 1.5 lb•ft) 14
13
15
16
20 N•m (2.0 kgf•m, 15 lb•ft)
New
8
10 N•m (1.0 kgf•m, 7.4 lb•ft)

23 N•m (2.3 kgf•m, 17 lb•ft)
8
7
6
20 N•m (2.0 kgf•m, 15 lb•ft)
10 11 New
LT 9
12 20 N•m (2.0 kgf•m, 15 lb•ft)
10 N•m (1.0 kgf•m, 7.4 lb•ft) New (8)

6 EXUP cable 2 1
7 EXUP cable 1 1
8 O2 sensor coupler 2 Disconnect.
9 Exhaust pipe 1
10 Exhaust chamber 1
11 Gasket 4
12 Gasket 2
13 Band 1
14 EXUP servo motor coupler 1 Disconnect.
15 EXUP servo motor 1
16 EXUP servo motor cover 1
5-12
ENGINE REMOVAL
Disconnecting the leads and hoses
3 3
6
6 N•m (0.6 kgf•m, 4.4 lb•ft)
4
5 7 N•m (0.7 kgf•m, 5.2 lb•ft)
8
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
1

Disconnect.
Stator coil coupler Refer to “GENERAL CHASSIS (3)” on
page 4-16.
Air filter case Refer to “AIR FILTER CASE” on page 7-6.
Air filter case duct/Air cut-off valve page 7-18.
Canister For California.
Throttle body/Neutral switch connector Refer to “THROTTLE BODIES” on page 7-9.
Thermostat assembly Refer to “THERMOSTAT” on page 6-8.
Shift arm/Drive sprocket Refer to “CHAIN DRIVE” on page 4-113.
1 Clutch cable 1 Disconnect.
2 Cylinder identification sensor coupler 1 Disconnect.
3 Ignition coil coupler 4 Disconnect.
Coolant temperature sensor coupler (sub-wire
4 1 Disconnect.
harness)
5 Crankshaft position sensor coupler 1 Disconnect.
6 Starter motor lead 1 Disconnect.
7 Gear position sensor coupler 1 Disconnect.
8 Oil pressure switch lead 1 Disconnect.
5-13
ENGINE REMOVAL
Removing the engine

56 N•m (5.6 kgf•m, 41 lb•ft)
5
70 N•m (7.0 kgf•m, 52 lb•ft)
4
5
6
1 2
3
6
8
56 N•m (5.6 kgf•m, 41 lb•ft)
70 N•m (7.0 kgf•m, 52 lb•ft) 7
8
8 N•m (0.8 kgf•m, 5.9 lb•ft) FW
D

1 Engine mounting bolt (right front side) 1
2 Collar 2
3 Collar 1
4 Engine mounting bolt (left front side) 1
Engine mounting bolt (rear upper side)/Engine
5 1/1
mounting nut (rear upper side)
Engine mounting bolt (rear lower side)/Engine
6 1/1
mounting nut (rear lower side)
7 Engine 1
8 Engine mounting adjust bolt 2
5-14
ENGINE REMOVAL
EAS30250
5. Install:
REMOVING THE ENGINE
• Collar “5”
1. Loosen:
• Collar “6”
• Engine mounting adjust bolt
• Engine mounting bolt (right front side) “7”
TIP (temporarily tighten)
Loosen the engine mounting adjust bolt with the 6. Tighten:
pivot shaft wrench “1”. • Engine mounting adjust bolt “1”
TIP
Pivot shaft wrench • Tighten the engine mounting adjust bolt to
90890-01485 specification with the pivot shaft wrench.
Frame mount insert wrench • Make sure that the flange on the engine
YM-01485 mounting adjust bolt contacts the engine.
Engine mounting adjust bolt

8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.
R.
1
Pivot shaft wrench
90890-01485
Frame mount insert wrench
YM-01485
7. Install:
• Engine mounting nut (rear lower side) “8”
• 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 lb·ft)
T.
R.
9. Tighten:
1 • Engine mounting nut (rear upper side) “9”
EAS30251 Engine mounting nut

INSTALLING THE ENGINE 56 N·m (5.6 kgf·m, 41 lb·ft)
T.
R.
1. Install:
• Engine mounting adjust bolt “1” 10.Tighten:
(temporarily tighten) • Engine mounting bolt (left front side) “4”
2. Install:
• Engine Engine mounting bolt
70 N·m (7.0 kgf·m, 52 lb·ft)
3. Install:
T.
R.
• Engine mounting bolt (rear lower side) “2”

• Engine mounting bolt (rear upper side) “3”
TIP
Apply lithium-soap-based grease onto the
threads of the bolt.
4. Install:
• Engine mounting bolt (left front side) “4”
(temporarily tighten)
5-15
ENGINE REMOVAL
11.Tighten:
• Engine mounting bolt (right front side) “7”
Engine mounting bolt

70 N·m (7.0 kgf·m, 52 lb·ft)
T.
R.
3
9 4
2
7 5
6
8 1
EAS30252
INSTALLING THE EXHAUST PIPE AND

MUFFLER
1. Install:
• Exhaust pipe
• Gasket “1” New
(to exhaust chamber)
• 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)
5-16
CAMSHAFTS
EAS20043
CAMSHAFTS
Removing the cylinder head cover
1 1
4
13 N•m (1.3 kgf•m, 9.6 lb•ft)
(6)
3
S
LT
*
FW 8 N•m (0.8 kgf•m, 5.9 lb•ft)
D
10 N•m (1.0 kgf•m, 7.4 lb•ft)
* Three bond No. 1541C®

Rider seat/Air scoop page 4-1.
Fuel tank cover page 4-8.
Air cut-off valve page 7-18.
1 Ignition coil coupler 4 Disconnect.
2 Ignition coil 4
If the spark plug is a new one, tighten it to 18
3 Spark plug 4 N·m (1.8 kgf·m, 13 lb·ft).
4 Cylinder identification sensor coupler 1 Disconnect.
5-17
CAMSHAFTS
Removing the cylinder head cover
13 N•m (1.3 kgf•m, 9.6 lb•ft)
(6)
5
7
10 LT
* 9
FW 8 N•m (0.8 kgf•m, 5.9 lb•ft)
D
10 N•m (1.0 kgf•m, 7.4 lb•ft)
* Three bond No. 1541C®

5 Cylinder identification sensor 1
6 Heat protector 1
7 Cylinder head cover 1
8 Cylinder head cover gasket 1
9 Cylinder head cover gasket 1
10 Timing chain guide (top side) 1
5-18
CAMSHAFTS
Removing the camshafts
10 N•m (1.0 kgf•m, 7.4 lb•ft) 8 N•m (0.8 kgf•m, 5.9 lb•ft)
8 N•m (0.8 kgf•m, 5.9 lb•ft)
1
LS
LT
E (4)
2 (4)
E
(4)
(4)
(4)
5 FW
M D
6

Crankshaft end cover/Timing mark accessing Refer to “GENERATOR” on page 5-42.
bolt
1 Timing chain tensioner 1
2 Timing chain tensioner gasket 1
• If the camshaft cap bolt is a new one, it is
not necessary to apply engine oil onto the
3 Camshaft cap 1 4 mating surface and threads of the bolt.
• If the camshaft cap bolt is a new one,
tighten it to 10 N·m (1.0 kgf·m, 7.4 lb·ft).
• If the camshaft cap bolt is a new one, it is
not necessary to apply engine oil onto the
4 Camshaft cap 2 1 mating surface and threads of the bolt.
• If the camshaft cap bolt is a new one,
tighten it to 10 N·m (1.0 kgf·m, 7.4 lb·ft).
5 Intake camshaft 1
6 Exhaust camshaft 1
5-19
CAMSHAFTS
Removing the timing chain and timing chain guide
72 N•m (7.2 kgf•m, 53 lb•ft)
E 7
11 10 5
8 9
13
3 12
LT 6
(5) 4
14
2 1
LS LS
LT
LS
10 N•m (1.0 kgf•m, 7.4 lb•ft)

FW
12 N•m (1.2 kgf•m, 8.9 lb•ft) D

Install the oil pipe to the timing chain cover,
1 Oil pipe 3 1 and then install them to the crankcase.
Install the oil pipe to the timing chain cover,
2 Timing chain cover 1 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
10 Straight key 1
11 Circlip 1
12 Washer 1
13 Oil seal 1
When removing the oil pipe 2, also remove
14 Oil pipe 2 1 the water pump inlet pipe.
Refer to “WATER PUMP” on page 6-11.
5-20
CAMSHAFTS
Removing the rocker arms
10 N•m (1.0 kgf•m, 7.4 lb•ft)
1 6 N•m (0.6 kgf•m, 4.4 lb•ft)

E
2
LT 3
LT
4
3
E
E
2
3
LT
FW
10 N•m (1.0 kgf•m, 7.4 lb•ft) D

Engine Refer to “ENGINE REMOVAL” on page 5-11.
Intake camshaft/Exhaust camshaft Refer to “CAMSHAFTS” on page 5-17.
1 Rocker arm shaft bolt 4
2 Straight plug (rocker arm shaft) 3
3 Rocker arm shaft 4
4 Rocker arm 16
5-21
CAMSHAFTS
EAS30256
5. Remove:
REMOVING THE CAMSHAFTS
• Intake camshaft
1. Remove:
• Exhaust camshaft
TIP
• Crankshaft end cover
Refer to “GENERATOR” on page 5-42. To prevent the timing chain from falling into the
2. Align: crankcase, fasten it with a wire “1”.
• 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°
mark “a” on the generator rotor with the
generator rotor cover slot “b”.
TIP
BTDC105° on the compression stroke can be 1
found when the camshaft lobes are turned away
from each other. EAS31655
REMOVING THE ROCKER ARMS AND

b ROCKER ARM SHAFTS
1. Remove:
• Rocker arm shaft bolt
• Straight plug
a • Rocker arm shaft
• Rocker arm
EAS30257
CHECKING THE CAMSHAFTS

1. Check:
• Camshaft lobe
3. Remove: Blue discoloration/pitting/scratches → Re-
• Timing chain tensioner place the camshaft.
• Timing chain tensioner gasket 2. Measure:
4. Remove: • Camshaft lobe dimensions “a”
• Camshaft cap Out of specification → Replace the camshaft.
ECA13720
NOTICE
Camshaft lobe dimensions
To prevent damage to the cylinder head, Lobe height limit (Intake)
camshafts or camshaft caps, loosen the 33.802 mm (1.3308 in)
camshaft cap bolts in stages and in a criss- Lobe height limit (Exhaust)
cross pattern, working from the outside in. 33.537 mm (1.3204 in)
G088946
5-22
CAMSHAFTS
3. Measure:
a b a b
• Camshaft runout
Camshaft runout limit

0.030 mm (0.0012 in)
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
TIP
4. Measure: • If the camshaft cap bolt is a new one, it is not
• Camshaft-journal-to-camshaft-cap clearance necessary to apply engine oil onto the mating
Out of specification → Measure the camshaft surface and threads of the bolt.
journal diameter. • If the camshaft cap bolt is a new one, tighten it
to 10 N·m (1.0 kgf·m, 7.4 lb·ft).
Camshaft-journal-to-camshaft- • Tighten the camshaft cap bolts in stages and in
cap clearance limit a crisscross pattern, working from the inner
0.080 mm (0.0032 in) caps out.
• Do not turn 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 lb·ft)
T.
R.

1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
d. Remove the camshaft caps and then mea-

sure the width of the Plastigauge® “1”.
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.
5-23
CAMSHAFTS
a
Camshaft journal diameter
25.459–25.472 mm (1.0023–
1.0028 in)
G088952
EAS30258
CHECKING THE TIMING CHAIN AND

CAMSHAFT SPROCKET
G088949
1. Check:
• Timing chain
EAS30259
Damage/stiffness → Replace the timing
CHECKING THE ROCKER ARMS AND
chain and camshaft and camshaft sprocket
ROCKER ARM SHAFTS as a set.
2. Check:
rocker arms and rocker arm shafts.
• Camshaft sprocket
1. Check: More than 1/4 tooth wear “a” → Replace the
• Rocker arm
camshaft sprockets and the timing chain as a
set.
2. Check:
• Rocker arm shaft
Blue discoloration/excessive wear/pitting/ 1
a
scratches → Replace or check the lubrication
system. b
3. Measure:
• Rocker arm inside diameter “a”
Out of specification → Replace. 2
Rocker arm inside diameter limit G088950

8.013 mm (0.3155 in) a. 1/4 tooth
b. Correct
1. Timing chain
2. Camshaft sprocket
a EAS30265
CHECKING THE TIMING CHAIN GUIDES

camshaft sprockets and timing chain guides.
1. Check:
• Timing chain guide (exhaust side)
• Timing chain guide (intake side)
4. Measure: • Timing chain guide (top side)
• Rocker arm shaft outside diameter “a” Damage/wear → Replace the defective
Out of specification → Replace. part(s).
Rocker arm shaft outside diame-

ter limit
7.936 mm (0.3124 in)
5-24
CAMSHAFTS
EAS30266
CHECKING THE TIMING CHAIN TENSIONER 5

1. Check: c
• Timing chain tensioner
d
Cracks/damage/rough movement → Re-
place. 4
a. Using the valve spring compressor “1”,
push and insert timing chain tensioner rod
“2” into the timing chain tensioner housing.
TIP
Push the timing chain tensioner rod in direction
EAS31744
“a”, and turn the timing chain tensioner body “3”
ASSEMBLING THE TIMING CHAIN COVER
in direction “b” until it stops.
1. Install:
Valve spring compressor TIP
90890-04200
Install the oil seal with a socket “2” that matches
YM-04019
a Installed depth “a”

1 4.0–4.5 mm (0.16–0.18 in)
1 2
2
b 3 a
1 2. Install:
• Washer
• Circlip New
EAS31657
INSTALLING THE ROCKER ARMS AND

ROCKER ARM SHAFTS
b. Keep pressing the timing chain tensioner 1. Install:
rod, mount clip “4” into groove “5”, and lock • Rocker arm
the timing chain tensioner rod. • Rocker arm shaft “1”
c. Push the timing chain tensioner rod in di- • Rocker arm shaft bolt “2”
rection “c”. • Straight plug “3”
d. Make sure that the timing chain tensioner TIP
rod can smoothly move out from the timing • Align the end surface “a” of the rocker arm
chain tensioner housing in direction “d”. If shaft with the surface “b” of the cylinder head.
not smooth, replace the timing chain ten- • After installing the rocker arm shaft bolt, make
sioner assembly. sure that the rocker arm shaft turns smoothly.
5-25
CAMSHAFTS
Rocker arm shaft bolt

T.
R. 6 N·m (0.6 kgf·m, 4.4 lb·ft)
LOCTITE®
Straight plug (rocker arm shaft)
10 N·m (1.0 kgf·m, 7.4 lb·ft)
LOCTITE® 2
b 1
c. Install the oil pipe bolt “3” and tighten it tem-

porarily until there is no clearance at “a”
a (timing chain cover to oil pipe) and “b” (oil
pipe to oil pipe bolt).
1 2 1 3 TIP
Apply locking agent (LOCTITE®) onto the oil
pipe bolt.
a
b
3
3 1 2 1 3
EAS31715
INSTALLING THE TIMING CHAIN COVER d. Install the timing chain cover assembly and
1. Install: a new timing chain cover gasket.
• Timing chain cover e. Install timing chain cover bolts and tighten
• Oil pipe 3 them.
a. Install new O-rings to the oil pipe.
Timing chain cover bolt
TIP 12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.
Apply lithium-soap-based grease evenly on new

O-rings. f. Install the oil pipe bolts “4” and tighten them
temporarily.
b. Install the oil pipe “1” to the timing chain TIP
cover “2”.
Apply locking agent (LOCTITE®) onto the oil
TIP pipe bolts.
• While turning the oil pipe, install it to the timing
chain cover so that the grease applied to the O-
rings is distributed.
• If the oil pipe is not turned smoothly, the O-
rings might be caught.
5-26
CAMSHAFTS
g. Tighten the oil pipe bolts to the specified TIP

torque following the tightening order shown • Hang the timing chain on the sprocket from the
in the illustration. exhaust camshaft to the intake camshaft.
• The intake camshaft sprocket timing mark “a”
Oil pipe 3 bolt and exhaust camshaft sprocket timing mark “b”
10 N·m (1.0 kgf·m, 7.4 lb·ft) should align with the cylinder head surface “c”.
T.
R.
LOCTITE®
• Check the timing mark position of the camshaft
sprocket using a mirror.
• The timing chain (exhaust side) should be
4 stretched and the timing chain (intake side)
should be sagged.
c a 2 1 b c
1 2
3
EAS30269
INSTALLING THE CAMSHAFTS

1. Remove:
• Crankshaft end cover 4. Install:
Refer to “GENERATOR” on page 5-42. • Camshaft cap
2. Align: TIP
• Mark “a” on the generator rotor Make sure each camshaft cap is installed in its
(with the generator rotor cover slot “b”) original place. Refer to the identification marks
a. Turn the crankshaft counterclockwise. as follows:
b. When piston #1 is at BTDC105°, align the “1”: camshaft cap mark for cylinder #1
BTDC105° mark “a” on the generator rotor “2”: camshaft cap mark for cylinder #2
with the generator rotor cover slot “b”. “3”: camshaft cap mark for cylinder #3
“4”: camshaft cap mark for cylinder #4
b
4 3 2 1
3. Install:
• Exhaust camshaft “1” 5. Tighten:
• Intake camshaft “2” • Camshaft cap bolt
Camshaft cap bolt

8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.
R.

10 N·m (1.0 kgf·m, 7.4 lb·ft)
5-27
CAMSHAFTS
TIP
• If the camshaft cap bolt is a new one, it is not Valve spring compressor
necessary to apply engine oil onto the mating 90890-04200
surface and threads of the bolt. Valve spring compressor
YM-04019
• If the camshaft cap bolt is a new one, tighten it
to 10 N·m (1.0 kgf·m, 7.4 lb·ft).
• Tighten the camshaft cap bolts in stages and in a
a crisscross pattern, working from the inner 1
caps out.
ECA17430
NOTICE 2
• Lubricate the camshaft cap bolts with the
engine oil.
• The camshaft cap bolts must be tightened b 3
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. 1
ECA23010
NOTICE
There are two kinds of camshaft cap bolts
with different lengths. Be sure to install each
bolt onto the correct position.
b. Keep pressing the timing chain tensioner
a b a b
rod, mount clip “4” into groove “5”, and lock
the timing chain tensioner rod.
a. Camshaft cap bolt (black): 40 mm (1.57 in)

b. Camshaft cap bolt (silver): 35 mm (1.38 in)
A. Intake side c. In the status of step (b), install the rod as-
B. Exhaust side sembly in the cylinder block.
6. Install: TIP
• Timing chain tensioner Always use a new gasket.
• Timing chain tensioner gasket New
a. Using the valve spring compressor “1”, Timing chain tensioner bolt
push and insert timing chain tensioner rod 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
“2” into the timing chain tensioner housing. LOCTITE®

TIP
Push the timing chain tensioner rod in direction d. Unlock the timing chain tensioner by turning
“a”, and turn the timing chain tensioner body “3” the crankshaft clockwise, and tension the
in direction “b” until it stops. timing chain.
5-28
CAMSHAFTS
7. Turn: 10.Install:
• Crankshaft • Timing mark accessing bolt
(several turns counterclockwise)
8. Check: Timing mark accessing bolt
• Mark “a” 15 N·m (1.5 kgf·m, 11 lb·ft)
T.
R.
Make sure the mark “a” on the generator rotor
is aligned with the generator rotor cover slot • Crankshaft end cover
“b”.
• Camshaft sprocket timing mark “c” Crankshaft end cover
15 N·m (1.5 kgf·m, 11 lb·ft)
Make sure the camshaft sprocket timing mark
T.
R.
“c” is aligned with the cylinder head mating Refer to “GENERATOR” on page 5-42.
surface “d”. 11.Install:
Out of alignment → Adjust. • Timing chain guide (top side)
Refer to the installation steps above.
• Cylinder head cover gasket “1” New
TIP
• Cylinder head cover gasket “2” New
Check the timing mark position of the camshaft
• Cylinder head cover
sprocket using a mirror.
Cylinder head cover bolt
b 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
TIP
a • Apply Three Bond No. 1541C® onto the mat-
ing surfaces of the cylinder head cover and cyl-
inder head cover gasket.
• After installing the cylinder head cover gasket
“2” to the cylinder head cover, cut off the “a”
section.
d c c d
9. Measure:
• Valve clearance 2
1
Out of specification → Adjust.
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-5.
a
a
5-29
CAMSHAFTS
12.Install:
• Spark plug
• Ignition coil “1”
Spark plug
13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.
Spark plug (new)

18 N·m (1.8 kgf·m, 13 lb·ft)
TIP
• Before installing the spark plug, clean the
spark plug and gasket surface.
• If the spark plug is a new one, tighten it to 18
N·m (1.8 kgf·m, 13 lb·ft).
• Make sure that the ignition coil does not con-
tact the reed valve cover.
5-30
CYLINDER HEAD
EAS20044
CYLINDER HEAD
Removing the cylinder head
12 N•m (1.2 kgf•m, 8.9 lb•ft)
15 N•m (1.5 kgf•m, 11 lb•ft) 1
E
LS
4
5
1st 10 N•m (1.0 kgf•m, 7.4 lb•ft)

2nd 25 N•m (2.5 kgf•m, 18 lb•ft)
3rd 45 N•m (4.5 kgf•m, 33 lb•ft)
15 N•m (1.5 kgf•m, 11 lb•ft)
4th
Specified angle 160˚
FW
D
*
Following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque.
Intake camshaft/Exhaust camshaft Refer to “CAMSHAFTS” on page 5-17.
1 Coolant temperature sensor 1
2 Cylinder head 1
3 Cylinder head gasket 1
4 Dowel pin 2
5 Oil delivery pipe 1
5-31
CYLINDER HEAD
EAS30276
REMOVING THE CYLINDER HEAD

1. Remove:
• Intake camshaft
Refer to “REMOVING THE CAMSHAFTS”
on page 5-22.
2. Remove:
• Cylinder head bolt (M6) (× 2)
• Cylinder head bolt (M9) (× 10) G088956
TIP a. Place a straightedge “1” and a thickness
• Loosen the bolts in the proper sequence as gauge “2” across the cylinder head.
shown.
• Loosen each bolt 1/2 of a turn at a time. After Thickness gauge
all of the bolts are fully loosened, remove them. 90890-03268
Feeler gauge set
YU-26900-9
5 7 11 9 3 1
1 2
4 6 2
10 12 8 2
10
EAS30277
G088957
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 the
TIP
surface plate and resurface the cylinder
Do not use a sharp instrument to avoid damag- head using a figure-eight sanding pattern.
ing or scratching:
TIP
• Spark plug bore threads
• Valve seats To ensure an even surface, rotate the cylinder
head several times.
2. Check:
• Cylinder head EAS30282
Damage/scratches → Replace. INSTALLING THE CYLINDER HEAD

• Cylinder head water jacket 1. Install:
Mineral deposits/rust → Eliminate. • Cylinder head gasket New
3. Measure: • Dowel pins
• Cylinder head warpage 2. Install:
Out of specification → Resurface the cylinder • Cylinder head
head. • Cylinder head bolt (M6) (× 2)
• Cylinder head bolt (M9) (× 10) New
Warpage limit
TIP
0.10 mm (0.0039 in)
• Pass the timing chain through the timing chain
cavity.
• Lubricate the cylinder head bolt (M9) thread
and mating surface with engine oil.
5-32
CYLINDER HEAD
3. Tighten:
• Cylinder head bolt “1”–“10”
• Cylinder head bolt “11”, “12”
Cylinder head bolt “1”–“10”

1st: 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
2nd: 25 N·m (2.5 kgf·m, 18 lb·ft)

3rd: 45 N·m (4.5 kgf·m, 33 lb·ft)
*4th: 15 N·m (1.5 kgf·m, 11 lb·ft)
Specified angle 160°
Cylinder head bolt “11”, “12”
12 N·m (1.2 kgf·m, 8.9 lb·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.
8 6 2 4 10 12
9 7 11
3 1 5 2
10
4. Install:
• Intake camshaft
Refer to “INSTALLING THE CAMSHAFTS”
on page 5-27.
5-33
VALVES AND VALVE SPRINGS
EAS20045

Removing the valves and valve springs
9
M
10
M
1
2
3
4
M
8 6
7
5
FW
D
M

Cylinder head Refer to “CYLINDER HEAD” on page 5-31.
1 Exhaust valve pad 8
2 Exhaust valve cotter 16
3 Exhaust valve spring retainer 8
4 Exhaust valve spring 8
5 Exhaust valve 8
6 Exhaust valve stem seal 8
7 Exhaust valve spring seat 8
8 Exhaust valve guide 8
9 Intake valve pad 8
10 Intake valve cotter 16
5-34
Removing the valves and valve springs
11
12
M
14
15
16
17
13
FW
D
M

11 Intake valve spring retainer 8
12 Intake valve spring 8
13 Intake valve 8
14 Intake valve stem seal 8
15 Intake valve spring seat 8
16 Circlip 8
17 Intake valve guide 8
5-35
EAS30283
REMOVING THE VALVES

The following procedure applies to all of the 90890-04200
valves and related components. Valve spring compressor
TIP YM-04019
Before removing the internal parts of the cylinder Valve spring compressor attach-
head (e.g., valves, valve springs, valve seats), ment (ø26)
make sure the valves properly seal. 90890-01243
Valve spring compressor attach-
1. Remove: ment (ø26)
• 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:
• 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 5-38.
G088959
a. Pour a clean solvent “a” into the intake and
4. Remove:
exhaust ports.
• Valve spring retainer
b. Check that the valves properly seal.
• Valve spring
TIP
• Valve
There should be no leakage at the valve seat “1”. • Valve stem seal
• Valve spring seat
TIP
Identify the position of each part very carefully so
that it can be reinstalled in its original place.
EAS30284
CHECKING THE VALVES AND VALVE

GUIDES
G088958 valves and valve guides.
3. Remove: 1. Measure:
• Valve cotter • Valve-stem-to-valve-guide clearance
Out of specification → Replace the valve
TIP
guide.
Remove the valve cotters by compressing the
valve spring with the valve spring compressor • Valve-stem-to-valve-guide clearance =
“1” and the valve spring compressor attachment Valve guide inside diameter “a” –
Valve stem diameter “b”
“2”.
Valve-stem-to-valve-guide clear-
ance limit (intake)
0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clear-
ance limit (exhaust)
0.100 mm (0.0039 in)
5-36
G088960 G088963
a. Valve guide position

c. After installing the valve guide, bore the
valve guide with the valve guide reamer “3”
to obtain the proper valve-stem-to-valve-
guide clearance.
G088961
2. Replace:
• Valve guide
TIP
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder G088964
head to 100 °C (212 °F) in an oven. TIP
a. Remove the valve guide with the valve After replacing the valve guide, reface the valve
guide remover “1”. seat.
Valve guide remover (ø4.5)

90890-04116
YM-04116
Valve guide remover (ø5)
90890-04097
YM-04097
G088962
Valve guide installer (ø4.5)
b. Install the new valve guide with the valve 90890-04117
guide installer “2” and valve guide remover Valve guide installer (4.5 mm)
“1”. YM-04117
Valve guide installer (ø5)
Valve guide position (intake) 90890-04098
12.0–12.4 mm (0.47–0.49 in) Valve guide installer (5.0 mm)
Valve guide position (exhaust) YM-04098
17.5–17.9 mm (0.69–0.70 in) Valve guide reamer (ø4.5)
90890-04118
YM-04118
Valve guide reamer (ø5)
90890-04099
YM-04099
5-37
3. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
4. Check:
• Valve face
Pitting/wear → Grind the valve face.
• Valve stem end
Mushroom shape or diameter larger than the
body of the valve stem → Replace the valve. G088966
5. Measure:
a. Apply blue layout fluid “b” onto the valve
• Valve stem runout
face.
Out of specification → Replace the valve.
TIP
• When installing a new valve, always replace
the valve guide.
• If the valve is removed or replaced, always re-
place the valve stem seal.
Valve stem runout

0.020 mm (0.0008 in) G088967
b. Install the valve into the cylinder head.

c. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
d. Measure the valve seat contact width.
TIP
Where the valve seat and valve face contacted
one another, the blue layout fluid will have been
removed.
G088965
EAS30285 4. Lap:
CHECKING THE VALVE SEATS • Valve face
The following procedure applies to all of the • Valve seat
valves and valve seats.
TIP
1. Eliminate:
After replacing the cylinder head or replacing the
• Carbon deposits
valve and valve guide, the valve seat and valve
(from the valve face and valve seat)
face should be lapped.
2. Check:
• Valve seat ECA22580
Pitting/wear → Replace the cylinder head. NOTICE

3. Measure: This model uses titanium intake valves.
• Valve seat contact width “a” Titanium valves that have been used to lap
Out of specification → Replace the cylinder the valve seats must not be used. Always re-
head. place lapped valves with new valves.
Valve seat contact width limit (in-

take)
1.6 mm (0.06 in)
Valve seat contact width limit
(exhaust)
1.8 mm (0.07 in)
5-38
TIP g. Apply blue layout fluid “b” onto the valve

• When replacing the intake valves, replace the face.
intake valves without lapping the valve seats
and valve faces.
• 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.
ECA13790 G088967
NOTICE h. Install the valve into the cylinder head.

Do not let the lapping compound enter the i. Press the valve through the valve guide and
gap between the valve stem and the valve onto the valve seat to make a clear impres-
guide. sion.
j. Measure the valve seat contact width “c”
again. If the valve seat width is out of spec-
ification, reface and lap the valve seat.
G088968
b. Apply molybdenum disulfide oil onto the

valve stem. G088970
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve EAS30286
seat are evenly polished, then clean off all CHECKING THE VALVE SPRINGS
of the lapping compound. The following procedure applies to all of the
valve springs.
TIP
1. Measure:
For the best lapping results, lightly tap the valve • Valve spring free length “a”
seat while rotating the valve back and forth be- Out of specification → Replace the valve
tween your hands.
spring.
Free length limit (intake)

39.18 mm (1.54 in)
Free length limit (exhaust)
40.21 mm (1.58 in)
G088969
e. Apply a fine lapping compound to the valve

face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from
the valve face and valve seat. G088971
5-39
EAS31716
CHECKING THE VALVE SPRING SEAT

valve lifters.
1. Check:
• Valve spring seat
Damage/scratches → Replace the valve
spring seat.
EAS30288
INSTALLING THE VALVES G088973
The following procedure applies to all of the b. Smaller pitch

valves and related components.
4. Install:
1. Deburr:
• Valve cotters
• Valve stem end
TIP
(with an oil stone)
Install the valve cotters by compressing the
valve spring with the valve spring compressor
“1” and the valve spring compressor attachment
“2”.

90890-04200
YM-04019
G088972
Valve spring compressor attach-
2. Lubricate: ment (ø26)
• Valve stem 90890-01243
• Valve stem seal Valve spring compressor attach-
(with the recommended lubricant) ment (ø26)
YM-01253-1
Molybdenum disulfide oil
3. Install:
• Valve spring seat “1”
• Valve stem seal “2” New
• Valve “3”
• Valve spring “4”
• Valve spring retainer “5”
(into the cylinder head)
G088959
TIP
• Make sure each valve is installed in its original
place.
• Install the valve springs with the larger pitch “a”
facing up.
5-40
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.
G088975
6. Lubricate:
• Valve pad
(with the recommended lubricant)
Molybdenum disulfide oil
7. Install:
• Valve pad
TIP
Each valve pad must be reinstalled in its original
position.
5-41
GENERATOR
EAS20134
GENERATOR
Removing the stator coil and generator rotor
10 N•m (1.0 kgf•m, 7.4 lb•ft)
6 N•m (0.6 kgf•m, 4.4 lb•ft) LT
10 N•m (1.0 kgf•m, 7.4 lb•ft)
LT
1 4
8
7
5
LT 75 N•m (7.5 kgf•m, 55 lb•ft)

6
10 N•m (1.0 kgf•m, 7.4 lb•ft)
3
(8) 2 *
12 N•m (1.2 kgf•m, 8.9 lb•ft)
15 N•m (1.5 kgf•m, 11 lb•ft) FW

D
* YAMAHA bond No. 1215 (Three bond No. 1215®)

Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-29.
Disconnect.
AC magneto coupler Refer to “GENERAL CHASSIS (3)” on
page 4-16.
1 Crankshaft position sensor coupler 1 Disconnect.
2 Generator cover 1
3 Generator cover gasket 1
4 Dowel pin 2
5 Stator coil lead holder 1
Stator coil assembly (stator coil/crankshaft posi-
6 1
tion sensor)
7 Shaft 1
8 Generator rotor 1
5-42
GENERATOR
Removing the stator coil and generator rotor
10 N•m (1.0 kgf•m, 7.4 lb•ft)
6 N•m (0.6 kgf•m, 4.4 lb•ft) LT
10 N•m (1.0 kgf•m, 7.4 lb•ft)
LT
10
LT 75 N•m (7.5 kgf•m, 55 lb•ft)
10 N•m (1.0 kgf•m, 7.4 lb•ft)

11
(8) *
12 N•m (1.2 kgf•m, 8.9 lb•ft)
15 N•m (1.5 kgf•m, 11 lb•ft) FW

D
* YAMAHA bond No. 1215 (Three bond No. 1215®)

9 Woodruff key 1
10 Crankshaft end cover 1
11 Timing mark accessing bolt 1
5-43
GENERATOR
EAS30829
REMOVING THE GENERATOR

Flywheel puller
1. Remove: 90890-01404
• Generator rotor bolt “1” Flywheel puller
• Washer YM-01404
TIP
While holding the generator rotor “2” with the
15mm pin type rotor holding tool “3”, loosen the
generator rotor bolt. 1
15mm pin type rotor holding tool

90890-04171
2
YM-04171
G088977
EAS30830
INSTALLING THE GENERATOR

2
1. Install:
• Woodruff key
• Generator rotor
• Washer “1”
• Shaft “2”
3 1 • 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.
Crankshaft protector • Install the shaft to the hole of the generator ro-
90890-01382 tor bolt.
Crankshaft protector • Lubricate the generator rotor bolt threads and
YM-01382 washer mating surfaces with engine oil.
1
1 2
3
a
3. Remove: 2. Tighten:
• Generator rotor “1” • Generator rotor bolt “1”
(with the flywheel puller “2”)
• Woodruff key Generator rotor bolt
75 N·m (7.5 kgf·m, 55 lb·ft)
T.
TIP
R.
Install the flywheel puller to the generator rotor.
5-44
GENERATOR
TIP 5. Connect:
While holding the generator rotor “2” with the • AC magneto coupler
15mm pin type rotor holding tool “3”, tighten the • Crankshaft position sensor coupler
generator rotor bolt. TIP
To route the stator coil assembly lead, refer to
“CABLE ROUTING” on page 2-15.
15mm pin type rotor holding tool
90890-04171
YM-04171
3 1
3. Apply:
• Sealant
(onto the stator coil assembly lead grommet)
Yamaha bond No. 1215

90890-85505
Three bond No. 1215®
G088980
4. Install:
• Generator cover gasket New
• Generator cover
• Generator cover bolt
Generator cover bolt

12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.
TIP
Tighten the generator cover bolts in stages and
in a crisscross pattern.
5-45
STARTER CLUTCH
EAS20049
STARTER CLUTCH
Removing the starter clutch
E
14 N•m (1.4 kgf•m, 10 lb•ft)
1
2
LT
3
E
E 4
FW
D

Clutch housing assembly Refer to “CLUTCH” on page 5-57.
1 Starter clutch gear 1
2 Bearing 1
3 Starter clutch assembly 1
4 Circlip 1
5 Starter clutch idle gear 1
5-46
STARTER CLUTCH
EAS30305
c. When turning the starter clutch gear coun-
REMOVING THE STARTER CLUTCH
terclockwise “B”, it should turn freely, other-
1. Remove:
wise the starter clutch is faulty and must be
• Starter clutch bolt “1”
replaced.
TIP
• While holding the clutch housing assembly “2” A 1
with the sheave holder “3”, remove the starter
clutch bolts.
• Fix the flat surface of the clutch housing as-
sembly with the sheave holder.
B
Sheave holder
90890-01903 2
YS-01880-A EAS30309
INSTALLING THE STARTER CLUTCH

1 1. Install:
• Starter clutch
Starter clutch holder bolt

2 14 N·m (1.4 kgf·m, 10 lb·ft)
T.
R.
LOCTITE®
TIP
3 • Install the starter clutch so that the side of the
starter clutch roller assembly with the arrow
EAS30306 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 roller clutch holder bolts “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
Burrs/chips/roughness/wear → Replace the Sheave holder
90890-01903
defective part(s).
3. Check:
YS-01880-A
• Starter clutch gear’s contacting surfaces
Damage/pitting/wear → Replace the starter
clutch gear. 3
4. Check:
• Starter clutch operation
a. Install the starter clutch gear “1” onto the
clutch housing assembly “2” and hold the 1
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 2
starter clutch is faulty and must be re-
placed.
5-47
ELECTRIC STARTER
EAS20052
ELECTRIC STARTER
Removing the starter motor
10 N•m (1.0 kgf•m, 7.4 lb•ft)
6 N•m (0.6 kgf•m, 4.4 lb•ft)

1
FW
D

Throttle body/Heat protector Refer to “THROTTLE BODIES” on page 7-9.
Thermostat assembly Refer to “THERMOSTAT” on page 6-8.
1 Starter motor lead 1 Disconnect.
2 Starter motor 1
5-48
ELECTRIC STARTER
Disassembling the starter motor
D
6 FW
5
7 3
1
2
4.5 N・m (0.45 kgf・m, 3.3 lb・ft)

1 O-ring 1
2 Starter motor front cover 1
3 Starter motor yoke 1
4 Armature assembly 1
5 Gasket 2
6 Brush holder set 1
7 Starter motor rear cover 1
5-49
ELECTRIC STARTER
EAS30325
4. Measure:
CHECKING THE STARTER MOTOR
• Brush length “a”
1. Check:
Out of specification → Replace the brush
• Commutator
holder set.
Dirt → Clean with 600 grit sandpaper.
2. Measure:
Brush overall length limit
• Mica undercut “a” 5.5 mm (0.22 in)
Out of specification → Scrape the mica to the
proper measurement with a hacksaw blade
that has been grounded to fit the commutator.
Mica undercut (depth)

2.40 mm (0.09 in)
TIP
The mica of the commutator must be undercut to
ensure proper operation of the commutator.
G088989
5. Check:
• Gear teeth
Damage/wear → Replace the starter motor.
6. Check:
• Bearing
• Oil seal
Damage/wear → Replace the starter motor
front cover.
G088986 EAS30326
3. Check: ASSEMBLING THE STARTER MOTOR

• Armature assembly 1. Install:
a. Connect the digital circuit tester and check • Starter motor rear cover “1”
the continuity. • Starter motor yoke “2”
• Starter motor front cover “3”
Digital circuit tester (CD732) TIP
90890-03243 Align the match mark “a” on the starter motor
Model 88 Multimeter with ta- yoke with the match mark “b” on the starter mo-
chometer tor front cover.
YU-A1927
b. If there is no continuity, replace the starter a b

motor.
1 2 3
5-50
OIL PUMP
EAS20054
OIL PUMP
Removing the oil pan and oil pump
10 N•m (1.0 kgf•m, 7.4 lb•ft)
10 N•m (1.0 kgf•m, 7.4 lb•ft)

E
10 N•m (1.0 kgf•m, 7.4 lb•ft)

LT
LT
FW
D
10 N•m (1.0 kgf•m, 7.4 lb•ft)
LT
1
LT
LT
LT (10) LT 3
LT
LT
23 N•m (2.3 kgf•m, 17 lb•ft) 10 N•m (1.0 kgf•m, 7.4 lb•ft) 10 N•m (1.0 kgf•m, 7.4 lb•ft)

for MT10SPN/MT10SPNC
Bottom cowling Refer to “GENERAL CHASSIS (2)” on
page 4-8.
Drain.
page 3-29.
Clutch Refer to “CLUTCH” on page 5-57.
Exhaust pipe/Muffler Refer to “ENGINE REMOVAL” on page 5-11.
1 Oil pan 1
2 Oil pan gasket 1
3 Oil strainer 1
5-51
OIL PUMP
Removing the oil pan and oil pump

9 10 N•m (1.0 kgf•m, 7.4 lb•ft)
10
11 E
10 N•m (1.0 kgf•m, 7.4 lb•ft) 12

E 8
10 N•m (1.0 kgf•m, 7.4 lb•ft)
LT
LT
15
FW
D
10 N•m (1.0 kgf•m, 7.4 lb•ft)
LT
7 14
4 13
6
LT
LT
5
LT (10) LT
LT
LT
23 N•m (2.3 kgf•m, 17 lb•ft) 10 N•m (1.0 kgf•m, 7.4 lb•ft) 10 N•m (1.0 kgf•m, 7.4 lb•ft)

4 Oil delivery pipe 1 1
5 Oil pipe 1 1
6 Relief valve assembly 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
5-52
OIL PUMP
Disassembling the oil pump
3
6
1
10 N•m (1.0 kgf•m, 7.4 lb•ft)
E
FW
D

1 Oil pump cover 1
2 Dowel pin 2
3 Oil pump outer rotor 1
4 Oil pump inner rotor 1
5 Pin 1
6 Oil pump driven sprocket 1
5-53
OIL PUMP
EAS30333 EAS30338
REMOVING THE OIL PAN CHECKING THE RELIEF VALVE

• Oil pan • Relief valve body “1”
• Gasket • Relief valve “2”
• Dowel pin • Spring “3”
TIP • Damage/wear → Replace the defective
Loosen each bolt 1/4 of a turn at a time, in stag- part(s).
es and in a crisscross pattern. After all of the
bolts are fully loosened, remove them.
EAS30336
CHECKING THE SPROCKET AND CHAIN

1. Check:
• Oil pump drive sprocket
2. Check:
• Oil pump drive chain
Damage/stiffness → Replace the oil pump EAS30339
drive chain and oil pump drive sprocket as a CHECKING THE OIL DELIVERY PIPES
set. The following procedure applies to all of the oil
EAS30337
delivery pipes.
CHECKING THE OIL PUMP 1. Check:
1. Check: • Oil delivery pipe 1
• Oil pump driven sprocket • Oil delivery pipe 2
• Oil pump housing • Oil pipe 1
• Oil pump inner rotor Damage → Replace.
• Oil pump outer rotor Obstruction → Wash and blow out with com-
• Oil pump cover pressed air.
Cracks/damage/wear → Replace the oil EAS30340
pump assembly. CHECKING THE OIL STRAINER
2. Check: 1. Check:
• Oil pump operation • Oil strainer
Rough movement → Repeat steps (1) and Damage → Replace.
(2) or replace the oil pump assembly. Contaminants → Clean with solvent.
EAS30342
ASSEMBLING THE OIL PUMP

1. Lubricate:
• Inner rotor
• Outer rotor
• Oil pump shaft
G088997 Recommended lubricant

Engine oil
5-54
OIL PUMP
• Oil pump driven sprocket “1” • Washer
• Pin “2” • Oil pump drive chain “1”
• Inner rotor “3” • Oil pump drive sprocket “2”
• Outer rotor “4” • Collar
• Oil pump cover “5” TIP
• Oil pump housing bolt Install the oil pump drive chain “1” onto the oil
pump drive sprocket “2”.
Oil pump housing bolt
ECA22830
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
NOTICE
R.
TIP After installing the oil pump drive chain and

When installing the inner rotor, align the pin “2” drive sprocket, make sure the oil pump turns
in the oil pump shaft with the groove in the inner smoothly.
rotor “3”.
2 2
5
1
3
4 1 3. Install:
3. Check: • Oil pump drive chain guide
• Oil pump operation
Refer to “CHECKING THE OIL PUMP” on Oil pump drive chain guide bolt
page 5-54. 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
LOCTITE®
EAS30343
INSTALLING THE OIL PUMP 4. Install:

1. Install: • O-ring New
• Dowel pin • Oil pipe 1
• Oil pump “1”
• Oil pump bolt “2” Oil pipe 1 bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
Oil pump bolt LOCTITE®

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
• O-ring New
• Oil delivery pipe 1
2 • Oil strainer
Oil strainer bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
LOCTITE®
2 • O-ring New
1 • Relief valve assembly
Relief valve assembly bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
LOCTITE®
5-55
OIL PUMP
5. Install:
• O-ring New
• Oil delivery pipe 2
Oil delivery pipe 2 bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
LOCTITE®
EAS30345
INSTALLING THE OIL PAN

1. Install:
• Oil pan gasket New
• Oil pan
• Oil pan bolt (× 12)
TIP
Tighten the oil pan bolts in stages and in a criss-
cross pattern.
2. Tighten:
• Oil pan bolt
Oil pan bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
LOCTITE®
3. Install:
• Engine oil drain bolt
• Gasket New
Engine oil drain bolt

23 N·m (2.3 kgf·m, 17 lb·ft)
T.
R.
5-56
CLUTCH
EAS20055
CLUTCH
Removing the clutch cover
5
4
2
3
7 N•m (0.7 kgf•m, 5.2 lb•ft)

(10) 1
12 N•m (1.2 kgf•m, 8.9 lb•ft) FW

D

Drain.
page 3-29.
2 Clutch cover 1
3 Clutch cover gasket 1
4 Dowel pin 2
5 Oil filler cap 1
5-57
CLUTCH
Removing the pull lever shaft
8
7
6
5
E
3
2
1
D
FW

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
5-58
CLUTCH
Removing the clutch
125 N•m (12.5 kgf•m, 92 lb•ft)
6
8 3
4
2 5
E 1
9
7
E E
FW
6 E
D
10 N•m (1.0 kgf•m, 7.4 lb•ft)

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
5-59
CLUTCH
Removing the clutch
125 N•m (12.5kgf•m, 92 lb•ft)
E
10 11
18
17
13
16
12
15
14
11
10
E E
FW
E
D
10 N•m (1.0 kgf•m, 7.4 lb•ft)

10 Clutch damper spring 1
11 Clutch damper spring seat 1
12 Clutch boss nut 1
13 Conical spring washer 1
14 Clutch boss 1
15 Thrust plate 1
16 Clutch housing assembly 1
17 Bearing 1
18 Washer 1
5-60
CLUTCH
EAS30346
REMOVING THE CLUTCH

1. Remove:
• Clutch cover 3 1
• Gasket
TIP
Loosen each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern.
2
After all of the bolts are fully loosened, remove
them. G088993
6. Remove:
2. Remove: • Clutch boss nut
• Compression spring bolt • Conical spring washer
• Pressure plate 1 • Clutch boss
• Compression spring • Thrust plate
• Pressure plate 2 • Clutch housing assembly
• Pull rod • Bearing
3. Remove: • Washer
• Friction plate 1
• Clutch plate 1 EAS30348
• Clutch plate 2 CHECKING THE FRICTION PLATES

• Friction plate 2 The following procedure applies to all of the fric-
• Clutch damper spring tion plates.
• Clutch damper spring seat 1. Check:
• Friction plate 1 (blackish shoe)
TIP
• Friction plate 2 (whitish shoe)
Be sure to mark the friction plates and clutch Damage/wear → Replace the friction plates
plates or note the position of each part so that as a set.
they are installed in their original positions. 2. Measure:
4. Straighten the clutch boss nut rib “a”. • Friction plate 1, 2 thickness
Out of specification → Replace the friction
a 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)
5. Loosen: Friction plate 2 thickness
• Clutch boss nut “1” 2.72–2.88 mm (0.107–0.113 in)
Wear limit
TIP
2.62 mm (0.103 in)
• While holding the clutch boss “2” with the
clutch holder “3”, loosen the clutch boss nut. EAS30349
• Do not use an impact wrench for removing the CHECKING THE CLUTCH PLATES
clutch boss nut. The following procedure applies to all of the
clutch plates.
1. Check:
Clutch holder • Clutch plate 1, 2
90890-04199 Damage → Replace the clutch plates as a
Universal clutch holder set.
YM-91042
5-61
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 1
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
3. Measure: CHECKING THE CLUTCH SPRINGS

• Assembly width “a” of the friction plates and The following procedure applies to all of the
clutch plates clutch springs.
Out of specification → Adjust. 1. Check:
• Clutch spring
Assembly width Damage → Replace the clutch springs as a
48.3–49.3 mm (1.90–1.94 in) set.
2. Measure:
TIP • Clutch spring free length
• Perform the thickness measurement without Out of specification → Replace the clutch
applying the oil. springs as a set.
• This step should be performed only if the fric-
tion plates and clutch plates were replaced. Clutch spring free length limit
44.52 mm (1.75 in)
• To measure the total width of the friction plates
and clutch plates, combine 10 friction plates EAS30352
and 9 clutch plates as shown. CHECKING THE CLUTCH HOUSING
1. Check:
• Clutch housing dog
Damage/pitting/wear → Deburr the clutch
a housing dogs or replace the clutch housing.
TIP
a Pitting on the clutch housing dogs will cause er-
ratic clutch operation.
a. Assembly width adjusted by clutch plate

“1”.
b. Select the clutch plate from the following ta-
ble.
G088994
5-62
CLUTCH
2. Check: EAS30358
CHECKING THE PULL LEVER SHAFT AND

• Bearing
PULL ROD
Damage/wear → Replace the bearing and
1. Check:
clutch housing.
• Pull lever shaft pinion gear teeth
EAS30353 • Pull rod teeth
CHECKING THE CLUTCH BOSS Damage/wear → Replace the pull rod and
1. Check: pull lever shaft as a set.
• Clutch boss splines 2. Check:
Damage/pitting/wear → Replace the clutch • Pull rod bearing
boss. Damage/wear → Replace.
TIP
EAS30363
Pitting on the clutch boss splines will cause er- INSTALLING THE CLUTCH
ratic clutch operation. TIP
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
G088995
plate will be reduced to optimum condition by
EAS30354 clutch operation.
CHECKING THE PRESSURE PLATE
1. Check: 1. Install:
• Pressure plate 1 • Washer
• Pressure plate 2 • Bearing
Cracks/damage → Replace. • Clutch housing assembly “1”
ECA22570
• Bearing NOTICE
Make sure to fit the projections “a” of the oil
EAS30356 pump drive sprocket to the concave “b” of
CHECKING THE PRIMARY DRIVE GEAR the clutch housing assembly.
1. Check:
• Primary drive gear TIP
Damage/wear → Replace the crankshaft and When installing the clutch housing assembly,
clutch housing as a set. turn the crankshaft so that the crankshaft web “c”
Excessive noise during operation → Replace cannot be seen.
the crankshaft and clutch housing as a set.
EAS30357
1
CHECKING THE PRIMARY DRIVEN GEAR a
1. Check:
• Primary driven gear
Damage/wear → Replace the clutch housing
and crankshaft as a set. a b
Excessive noise during operation → Replace
the clutch housing and crankshaft as a set.
5-63
CLUTCH
2. Install: 3. Lubricate:
• Thrust plate • Friction plates
• Clutch boss “1” • Clutch plates
• Conical spring washer “2” (with the recommended lubricant)
• Clutch boss nut “3” New
Clutch boss nut Engine oil
125 N·m (12.5 kgf·m, 92 lb·ft)
T.
4. Install:
R.
TIP • Clutch damper spring seat

• Clutch damper spring
• Install the conical spring washer on the main
• Friction plates 1
axle with the “OUT” mark “a” facing away from
• Clutch plates 2
the vehicle.
• Friction plates 2
• While holding the clutch boss “1” with the
• Clutch plate 1
clutch holder “4”, tighten the clutch boss nut.
• Do not use an impact wrench for installing the TIP
clutch boss nut. • First, install a friction plate and then alternate
• Stake the clutch boss nut at cutouts “b” in the between a clutch plate and a friction plate.
main axle. • Install the last friction plate “1” offset from the
other friction plates “2”, making sure to align a
projection on the friction plate with the punch
Clutch holder mark “a” on the clutch housing.
90890-04199
Universal clutch holder
YM-91042
1
2
a
a 2
4 3 2 1
5-64
CLUTCH
• Pull rod • Pull lever spring “1”
• Pressure plate 2 • Pull lever “2”
• Clutch spring • Washer
• Pressure plate 1 • Circlip New
• Clutch spring bolt TIP
• The end of the pull lever should be closest to
Clutch spring bolt
the clutch cover match mark “a” when there is
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
no free play of the pull lever.

R.
TIP • Make sure that the pull rod teeth and pull lever
shaft pinion gear are engaged.
• Tighten the clutch spring bolts in stages and in
a crisscross pattern.
• Apply lithium-soap-based grease onto the pull 1
rod.
• Position the pull rod so that the teeth “a” face
towards the rear of the vehicle. Then, install the
clutch cover. 2
a
9. Adjust:
• Clutch lever free play
Refer to “ADJUSTING THE CLUTCH LEVER
FREE PLAY” on page 3-13.
a
10.0–15.0 mm (0.39–0.59 in)
6. Install:
• Dowel pins
• Clutch cover gasket New
• Clutch cover
• Clutch cover bolt New
7. Tighten:
• Clutch cover bolt
Clutch cover bolt

12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.
TIP
Tighten the clutch cover bolts in stages and in a
crisscross pattern.
5-65
SHIFT SHAFT
EAS20057
SHIFT SHAFT
Removing the shift shaft and stopper lever
12
5 4
E
6
9
E 10
3
LT
8
7 11
E
22 N•m (2.2 kgf•m, 16 lb•ft)
13
14
2
1
FW
D

Clutch assembly Refer to “CLUTCH” on page 5-57.
Shift arm Refer to “CHAIN DRIVE” on page 4-113.
1 Circlip 1
2 Washer 1
3 Shift shaft 1
4 Washer 1
5 Circlip 1
6 Washer 1
7 Stopper lever 1
8 Stopper lever spring 1
9 Collar 1
10 Shift shaft spring 1
11 Shift shaft spring stopper 1
12 Bearing 1
13 Oil seal 1
14 Bearing 1
5-66
SHIFT SHAFT
EAS30377
2. Install:
CHECKING THE SHIFT SHAFT
• Bearing
1. Check:
• Shift shaft • Oil seal New
Bends/damage/wear → Replace. • Washer
• Shift shaft spring • Circlip New
• Collar TIP
Damage/wear → Replace. Lubricate the oil seal lips with lithium-soap-
EAS30378
based grease.
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

22 N·m (2.2 kgf·m, 16 lb·ft)
T.
R.
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.
1
3
4 5
5-67
CRANKCASE
EAS20059
CRANKCASE
Removing the crankcase breather cover and switches
12 N•m (1.2 kgf•m, 8.9 lb•ft) (8)
FW
D
6
LT
17 N•m (1.7 kgf•m, 13 lb•ft)
70 N•m (7.0 kgf•m, 52 lb•ft)
*
E
5
3
17 N•m (1.7 kgf•m, 13 lb•ft)
4
2 10 N•m (1.0 kgf•m, 7.4 lb•ft)
1
LT
* YAMAHA bond No. 1215 (Three Bond No.1215®)

Cylinder head cover/Intake camshaft/Exhaust Refer to “CAMSHAFTS” on page 5-17.
camshaft
Cylinder head Refer to “CYLINDER HEAD” on page 5-31.
Generator rotor Refer to “GENERATOR” on page 5-42.
Refer to “ELECTRIC STARTER” on page 5-
Starter motor 48.
Water pump Refer to “WATER PUMP” on page 6-11.
Clutch housing assembly Refer to “CLUTCH” on page 5-57.
Oil strainer/Oil pump/Relief valve assembly Refer to “OIL PUMP” on page 5-51.
1 Gear position sensor 1
2 Oil pressure switch 1
3 Oil pressure switch joint 1
4 Oil filter cartridge 1
5 Oil filter cartridge union bolt 1
6 Crankcase breather cover 1
5-68
CRANKCASE
Removing the crankcase breather cover and switches

12 N•m (1.2 kgf•m, 8.9 lb•ft) (8)
FW
D
7 LT
17 N•m (1.7 kgf•m, 13 lb•ft)
70 N•m (7.0 kgf•m, 52 lb•ft)
*
E
10 9
17 N•m (1.7 kgf•m, 13 lb•ft)
10 N•m (1.0 kgf•m, 7.4 lb•ft)
11 LT
* YAMAHA bond No. 1215 (Three Bond No.1215®)

7 Crankcase breather cover gasket 1
8 Clutch cable holder 1
9 Neutral switch 1
10 Gasket 1
11 Holder 1
5-69
CRANKCASE
Separating the crankcase

10 N・m (1.0 kgf・m, 7.4 lb・ft) 1st 20 N・m (2.0 kgf・m, 15 lb・ft)
*2nd 15 N・m (1.5 kgf・m, 11 lb・ft)
4 24 N・m (2.4 kgf・m, 18 lb・ft)
3rd Specified angle 75˚
10 N・m (1.0 kgf・m, 7.4 lb・ft)
10 N・m (1.0 kgf・m, 7.4 lb・ft)
(10)
(2)
E
4 (2)
4 E
(6)
2 E (2)
LT (5)
(4)
E
3
2 (8)
1
10 N・m (1.0 kgf・m, 7.4 lb・ft) E
24 N・m (2.4 kgf・m, 18 lb・ft)

FW
D
8 N・m (0.8 kgf・m, 5.9 lb・ft)
* Following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque.
1 Plug (oil gallery) 2
2 Plug (balancer shaft end) 2
3 Lower crankcase 1
4 Dowel pin 4
5-70
CRANKCASE
EAS30389
4. Remove:
DISASSEMBLING THE CRANKCASE
• Dowel pin
1. Place the engine upside down.
5. Remove:
2. Remove:
• Crankshaft journal lower bearing
• Crankcase bolt (× 40)
• Balancer shaft journal bearing
TIP (from the lower crankcase)
• Loosen each bolt 1/4 of a turn at a time, in stag- TIP
es and in a crisscross pattern. After all of the
Identify the position of each part very carefully so
bolts are fully loosened, remove them.
• Loosen the bolts in the proper sequence as
shown.
EAS30390
• The numbers embossed on the crankcase in- CHECKING THE CRANKCASE
dicate the crankcase tightening sequence. 1. Thoroughly wash the crankcase halves in a
mild solvent.
2. Thoroughly clean all the gasket surfaces and
crankcase mating surfaces.
20 7 3. Check:
10
26 9 8 • Crankcase
24 30 28 Cracks/damage → Replace.
23 25 18 29 27 6 • Oil delivery passages
11 Obstruction → Blow out with compressed air.
34 36 40 38 32
EAS30397
12 31 37 39 35 33 ASSEMBLING THE CRANKCASE

19 1. Lubricate:
13 15 17 • Crankshaft journal bearing inner surface
16 22
14 (with the recommended lubricant)
3 21 Recommended lubricant
1 Engine oil
2 4 5
2. Apply:
• Sealant
40 (onto the crankcase mating surfaces)
3. Remove:
• Lower crankcase Yamaha bond No. 1215
ECA13900 90890-85505
NOTICE Three bond No. 1215®
Tap on one side of the crankcase with a soft-
face hammer. Tap only on reinforced por- TIP
tions of the crankcase, not on the crankcase • Do not allow any sealant to come into contact
mating surfaces. Work slowly and carefully with the oil gallery or crankshaft journal bear-
and make sure the crankcase halves sepa- ings, or balancer shaft journal bearings.
rate evenly. • Remove the sealant from the area “a” as
• Make sure that the sealant does not get into
the groove “b” in the crankcase.
5-71
CRANKCASE
6. Install:
a a • Crankcase bolt (× 40)
TIP
• Lubricate the bolts “1”–“10” thread, mating sur-
faces and washers with engine oil.
• 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.
• Lubricate the bolts “28”, “40” mating surfaces
with engine oil.
• Apply the bolts “28”, “40” thread with LOC-
TITE®.
• M9 × 100 mm (3.94 in) bolts with washers:
“1”–“10” New
• M8 × 58 mm (2.28 in) bolts with new O-rings:
“11”–“18”
• M8 × 60 mm (2.36 in) bolts: “19”, “20”
b
• M6 × 65 mm (2.56 in) bolts: “21”, “22”
3. Install: • M6 × 70 mm (2.76 in) bolt: “23”
• Dowel pins • M6 × 60 mm (2.36 in) bolts: “24”–“27”, “35”,
4. Set the shift drum assembly and transmission “38”
gears in the neutral position. • M6 × 50 mm (1.97 in) bolts: “31”–“34”
5. Install: • M6 × 50 mm (1.97 in) bolts (LOCTITE®):
• Lower crankcase “1” “28”, “40”
(onto the upper crankcase “2”) • M6 × 40 mm (1.57 in) bolts: “29”, “30”, “36”,
ECA13980
“37”, “39”
NOTICE
Before tightening the crankcase bolts, make
sure the transmission gears shift correctly
when the shift drum assembly is turned by 21 34
31
hand. 15 32 33
17 11 13
18 16 23 12 14 35
30
1 7 5 1 3 9
29 10 4 2 6 8
28 26 24 22
25 19
27
2
38 20
40
39 37 36
40
5-72
CRANKCASE
7. Tighten: 8. Tighten:
• Crankcase bolts “1”–“10” • Crankcase bolts “11”–“40”
Crankcase bolts “1”–“10” Crankcase bolts “11”–“20”

1st: 20 N·m (2.0 kgf·m, 15 lb·ft) 24 N·m (2.4 kgf·m, 18 lb·ft)
T.
T.
R.
R.
*2nd: 15 N·m (1.5 kgf·m, 11 lb·ft) Crankcase bolts “21”–“40”
3rd: Specified angle 75° 10 N·m (1.0 kgf·m, 7.4 lb·ft)
*
Following the tightening order, loosen the TIP
bolt one by one and then retighten it to the Tighten the bolts “11”–“18” in the tightening se-
specific torque. quence cast on the crankcase.
EWA16610
WARNING
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 21 34
31
one and perform the procedure again. 15 32 33
17 11 13
ECA20890
18 16 23 12 14 35
NOTICE
30
Do not use a torque wrench to tighten the
bolt to the specified angle.
29
TIP
28 26 24 22
Tighten the bolts in the tightening sequence cast 25 19
on the crankcase. 27
38 20
40
39 37 36
30
7 5 1 3 9
10 4 2 6 8
10
5-73
CRANKCASE
EAS31071 EAS31658
INSTALLING THE OIL PRESSURE SWITCH INSTALLING THE GEAR POSITION SENSOR
• Oil pressure switch “1” NOTICE

• Oil pressure switch lead “2” To prevent damage to the gear position sen-
sor, keep magnets (including any pickup tool
Oil pressure switch with a magnet, magnetized screwdrivers,
13 N·m (1.3 kgf·m, 9.6 lb·ft) etc.) away from the gear position sensor.
T.
R.
Oil pressure switch lead bolt

1. Install:
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
• O-ring New
TIP • Gear position sensor “1”
• Apply Three Bond No. 1215B® to the threads
“a” of the oil pressure switch. However, do not Gear position sensor bolt
apply Three Bond No. 1215B® to the portion 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
T.
R.
“b” of the oil pressure switch. LOCTITE®
• Install the oil pressure switch terminal so that it
TIP
align the underside of the engine oil level check
window. • Lubricate the O-ring with lithium-soap-based
grease.
• Fit the end “a” of the shift drum assembly into
the opening “b” in the gear position sensor “1”.
1
1
a
b
a
b
1 2
5-74
CONNECTING RODS AND PISTONS
EAS20132

Removing the connecting rods and pistons
1st 24 N•m (2.4 kgf•m, 18 lb•ft)
(8) 2nd Specified angle 150˚
M 1
M
2
E
3
4
13 E
5
13
6
12 5
7
E
10
E
9
11 E 8 FW
D

Lower crankcase Refer to “CRANKCASE” on page 5-68.
1 Connecting rod cap 4
2 Big end lower bearing 4
3 Big end upper bearing 4
4 Connecting rod 4
5 Piston pin clip 8
6 Piston pin 4
7 Piston 4
8 Top ring 4
9 2nd ring 4
10 Oil ring 4
11 Cylinder 1
12 Cylinder gasket 1
13 Dowel pin 2
5-75
EAS30745
3. Remove:
REMOVING THE CONNECTING RODS AND
• Top ring
PISTONS
• 2nd ring
The following procedure applies to all of the con-
• Oil ring
necting rods and pistons.
TIP
1. Remove:
• Connecting rod cap When removing a piston ring, open the end gap
• Connecting rod with your fingers and lift the other side of the ring
• Big end bearing over the piston crown.
TIP
• Identify the position of each big end bearing so
• 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.
2. Remove:
• Piston pin clip G088999
• Piston pin “1”
EAS30747
• Piston “2” CHECKING THE CYLINDER AND PISTON
ECA13810
NOTICE 1. Check:
• Piston wall
Do not use a hammer to drive the piston pin
• Cylinder wall
out.
Vertical scratches → Replace the cylinder
TIP block, and replace the pistons and piston
• For reference during installation, put identifica- rings as a set.
tion marks on the piston crown. 2. Measure:
• Before removing the piston pin, deburr the pis- • Piston-to-cylinder clearance
ton pin clip groove and the piston pin bore ar- a. Measure cylinder bore “C” with the cylinder
ea. If both areas are deburred and the piston bore gauge.
pin is still difficult to remove, remove it with the TIP
piston pin puller set “3”. Measure cylinder bore “C” by taking side-to-side
and front-to-back measurements of the cylinder.
Piston pin puller set
90890-01304 Bore
Piston pin puller 79.000–79.010 mm (3.1102–
YU-01304 3.1106 in)
Wear limit
2 1 79.060 mm (3.1126 in)
“C” = maximum of D1, D2, D3, D4, D5, D6
G088998 3
G089000
5-76
b. If out of specification, replace the cylinder,

and replace the piston and piston rings as a Piston ring
set. Top ring
c. Measure piston skirt diameter “b” with the Side clearance limit
micrometer. 0.115 mm (0.0045 in)
2nd ring
Piston Side clearance limit
Diameter 0.115 mm (0.0045 in)
78.970–78.985 mm (3.1090–
3.1096 in)
a
b
G089002
2. Install:
G089001 • Piston ring
a. 8.0 mm (0.31 in) from the bottom edge of the (into the cylinder)
piston TIP
d. If out of specification, replace the piston and Use the piston crown to level the piston ring near
piston rings as a set. bottom of cylinder “a”, where cylinder wear is
e. Calculate the piston-to-cylinder clearance lowest.
with the following formula. 3. Measure:
Piston-to-cylinder clearance = Cylinder bore • Piston ring end gap
“C” – Piston skirt diameter “b” Out of specification → Replace the piston
ring.
TIP
Piston-to-cylinder clearance The oil ring expander spacer’s end gap cannot
0.015–0.040 mm (0.0006–0.0016 be measured. If the oil ring rail’s gap is exces-
in)
sive, replace all three piston rings.
f. If out of specification, replace the cylinder,
and replace the piston and piston rings as a Top ring
set. End gap limit
EAS30748
0.50 mm (0.0197 in)
CHECKING THE PISTON RINGS 2nd ring
1. Measure: End gap limit
• Piston ring side clearance 1.15 mm (0.0453 in)
Out of specification → Replace the piston
and piston rings as a set.
TIP
Before measuring the piston ring side clearance,
eliminate any carbon deposits from the piston
ring grooves and piston rings.
5-77
EAS30750
CHECKING THE CONNECTING RODS

1. Measure:
• Crankshaft-pin-to-big-end-bearing clearance
a Out of specification → Replace the big end
bearings.
Oil clearance
b 0.032–0.054 mm (0.0013–0.0021
in)
b. Upper of cylinder The following procedure applies to all of the con-

EAS30749
necting rods.
ECA13930
CHECKING THE PISTON PIN
NOTICE
The following procedure applies to all of the pis-
Do not interchange the big end bearings and
ton pins.
connecting rods. To obtain the correct
1. Measure:
crankshaft-pin-to-big-end-bearing clear-
• Piston pin outside diameter “a”
ance and prevent engine damage, the big
Out of specification → Replace the piston pin.
end bearings must be installed in their origi-
nal positions.
Piston pin outside diameter limit
16.971 mm (0.6681 in) a. Clean the big end bearings, crankshaft
pins, and the connecting rods with oil clean-
er.
TIP
When cleaning the connecting rod, clean the
bearing surface “a” of the connecting rod bolt
and threads “b”.
G089004
2. Measure:
• Piston pin bore inside diameter “b”
Out of specification → Replace the piston.
Piston pin bore inside diameter a b

limit
17.043 mm (0.6710 in)
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 bear-
ing into the connecting rod cap with the
connecting rod big end metal installer “1”.
b
G089005
5-78
TIP d. Put a piece of Plastigauge® “1” on the

• From the 3 types, choose the connecting rod crankshaft pin.
big end metal installer “1” that fits exactly, and
install it to the connecting rod and connecting
1
rod cap as shown in the illustration.
• 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.
G089008
Connecting rod big end bearing e. Assemble the connecting rod halves.
installer ECA18390
90890-04193 NOTICE
Connecting rod big end bearing Tighten the connecting rod bolts using the
installer plastic-region tightening angle method. Al-
YM-04193 ways install new bolts.
TIP
1 • Clean the connecting rod bolts and lubricate
the bolt threads and seats with molybdenum
disulfide oil.
• Make sure that the projection “a” on the con-
necting rod cap faces the same direction as the
“Y” mark “b” on the connecting rod.
• After installing the big end bearing, assemble
1 the connecting rod and connecting rod cap
without installing them onto the crankshaft.
a
b b
a
TIP
Install by carrying out the following procedures in
order to assemble in the most suitable condition.
1 f. Tighten the connecting rod bolt while

checking that the sections shown “a” and
2 “b” are flush with each other by touching the
surface.
Connecting rod bolt

30 N·m (3.0 kgf·m, 22 lb·ft)
T.
R.
5-79
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.
d
c
b
h. Tighten the connecting rod bolts with a

torque wrench.
a
Connecting rod bolt (1st)
24 N·m (2.4 kgf·m, 18 lb·ft)
T.
R.
a. Side machined face
b. Thrusting faces i. Put a mark “1” on the corner of the connect-
ing rod bolt “2” and the connecting rod cap
g. Loosen the connecting rod bolt, remove the “3”.
connecting rod and connecting rod cap and
install these parts to the crankshaft with the
big end bearing kept in the current condi-
tion.
TIP
• Do not move the connecting rod or crankshaft
until the clearance measurement has been
completed.
• Make sure that the projection “a” on the con-
“Y” mark “b” on the connecting rod. j. Tighten the connecting rod bolts further to
• Make sure the “Y” marks “b” on the connecting reach the specified angle 145°–155°.
rods face towards the left side of the crank-
shaft. Connecting rod bolt (final)
• Install the connecting rod so that the Plasti- Specified angle 145°–155°
T.
R.
gauge® is in position “c” or “d”.
b
a
150˚
EWA16610
WARNING
tighten it. Instead, replace the bolt with a new
one and perform the procedure again.
5-80
k. After the installation, check that the section

shown “a” is flush with each other by touch- Bearing color code
ing the surface. Code 2
Black
Code 3
Brown
Code 4
Green
Code 5
Yellow
Code 6
Pink
a
l. Remove the connecting rod and big end

bearings.
m. Measure the compressed Plastigauge®
width on the crankshaft pin. If the crank- P3
shaft-pin-to-big-end-bearing clearance is P1 P4
out of specification, select replacement big P2
end bearings.
P1 P2 P3 P4
2. Select:
• Big end bearing (P1–P4)
TIP
• The numbers “A” stamped into the crankshaft
web and the numbers “1” on the connecting
rods are used to determine the replacement
big end bearings sizes.
• “P1”–“P4” refer to the bearings shown in the
crankshaft illustration.
For example, if the connecting rod “P1” and 1
the crankshaft web “P1” numbers are 6 and 2
respectively, then the bearing size for “P1” is: EAS30751
“P1” (connecting rod) – “P1” (crankshaft web) INSTALLING THE CONNECTING ROD AND
= 6 – 2 = 4 (green) PISTON
The following procedure applies to all of the con-
necting rods and pistons.
1. Install:
• Big end bearing
• Connecting rod cap
(onto the connecting rod)
5-81
TIP
• Clean the big end bearings, crankshaft pins, c
and the connecting rods with oil cleaner, and d
then wait five minutes to dry the remaining oil
cleaner component.
• 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.
• 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.
• Align the projections “c” on the big end bear-
ings with the notches “d” in the connecting rods 1
and connecting rod caps.
• Push the big end bearing “2” down and install it 2
to the connecting rod and connecting rod cap.
• Make sure that the projection “e” on the con-
“Y” mark “f” on the connecting rod. f
e
Connecting rod big end bearing
installer
90890-04193
Connecting rod big end bearing
installer
YM-04193
2. Tighten:
• Connecting rod bolt New
ECA18390
NOTICE
Tighten the connecting rod bolts using the
plastic-region tightening angle method. Al-
ways install new bolts.
TIP
a b
• Install by carrying out the following procedures
in order to assemble in the most suitable con-
dition.
1 • Install the new connecting rod bolt without
cleaning and without any oil.
a. Replace the connecting rod bolts with new

ones.
b. Clean the connecting rod bolts and lubri-
cate the bolt threads and seats with molyb-
1 denum disulfide oil.
c. After installing the big end bearing, assem-
ble the connecting rod and connecting rod
cap without installing them onto the crank-
shaft.
5-82
d. Tighten the connecting rod bolt while 4. Install:

checking that the sections shown “a” and • Piston “1”
“b” are flush with each other by touching the (onto the respective connecting rod “2”)
surface. • Piston pin “3”
• Piston pin clips “4” New
Connecting rod bolt TIP
30 N·m (3.0 kgf·m, 22 lb·ft)
T.
• Apply engine oil onto the piston pin.

R.
TIP • Make sure that the “Y” mark “a” on the connect-
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
• Make sure that the clip ends “c” are positioned
should not be out of alignment.
away from the cutout “d” in the piston as shown
in the illustration.
b • Reinstall each piston into its original cylinder.
a b
1
a 2
3
a. Side machined face 4
b. Thrusting face
e. Loosen the connecting rod bolt, remove the
connecting rod and connecting rod cap and c
install these parts to the crankshaft with the d
big end bearing kept in the current condi-
tion.
3. Install:
• Top ring “1”
(into the piston)
• 2nd ring “2”
• Upper oil ring rail “3”
• Oil ring expander “4” 5. Lubricate:
• Lower oil ring rail “5” • Piston
TIP
• Piston ring
• Cylinder
Be sure to install the piston rings so that the
manufacturer’s marks or numbers “a” face up.
Engine oil
G089011
5-83
6. Offset: 9. Install:
• Piston ring end gap • Cylinder gasket New
• Dowel pin
d • Cylinder assembly
• Connecting rod cap
• Connecting rod bolt
TIP
b,e a,c • Make sure the “Y” marks “a” on the connecting
rods face towards the left side of the crank-
shaft.
• Make sure that the projection “b” on the con-
a. Top ring “Y” mark “a” on the connecting rod.
b. 2nd ring • Apply Molybdenum disulfide oil to the bolt
c. Upper oil ring rail threads and seats.
d. Oil ring expander
e. Lower oil ring rail a
A. Exhaust side
b
7. Lubricate:
• Crankshaft pin
• Connecting rod big end bearing inner surface
and side surface
Engine oil 10.Tighten:
• Connecting rod bolt “1”
8. Install:
• Piston assembly “1”
(into the cylinder “2”)
TIP 1
• 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”.
TIP
1 Tighten the connecting rod bolts using the fol-
lowing procedure.
a. Tighten the connecting rod bolts with a
torque wrench.
a
Connecting rod bolt (1st)
2
24 N·m (2.4 kgf·m, 18 lb·ft)
T.
R.
5-84
b. Put a mark “1” on the corner of the connect-

ing rod bolt “2” and the connecting rod cap
“3”.
c. Tighten the connecting rod bolts further to

reach the specified angle 145°–155°.
Connecting rod bolt (final)

Specified angle 145°–155°
T.
R.
150˚
EWA16610
WARNING
tighten it. Instead, replace the bolt with a new
one and perform the procedure again.
d. After the installation, check that the section
shown “a” is flush with each other by touch-
ing the surface.
EWA17120
WARNING
If the connecting rod and cap are not flush
with each other, remove the connecting rod
bolts and big end bearing and restart from
step (1). In this case, make sure to replace
the connecting rod bolts.
5-85
CRANKSHAFT AND BALANCER SHAFT
EAS20178

Removing the crankshaft and balancer shaft
9 5
3.0 N•m (0.30 kgf•m, 2.2 lb•ft)
9
4
E
2
1
E LT
6
2
10 N•m (1.0 kgf•m, 7.4 lb•ft)
LT
8 E 3
E
FW
D

Refer to “REMOVING THE CONNECTING
Connecting rod RODS AND PISTONS” on page 5-76.
1 Balancer shaft 1
2 Balancer shaft journal lower bearing 4
3 Balancer shaft journal upper bearing 4
4 Crankshaft 1
5 Crankshaft journal lower bearing 5
6 Crankshaft journal upper bearing 5
7 Thrust bearing 2
8 Oil nozzle 1 4
9 Oil nozzle 2 5
5-86
EAS31171
2. Check:
REMOVING THE CRANKSHAFT AND
• Crankshaft journal surfaces
BALANCER SHAFT
• Crankshaft pin surfaces
1. Remove:
Scratches/wear → Replace the crankshaft.
• Balancer shaft “1”
• Bearing surfaces
• Balancer shaft journal bearing
Scratches/wear → Replace the crankshaft
• Crankshaft assembly “2”
journal bearing.
• Crankshaft journal bearing
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

0.027–0.045 mm (0.0011–0.0018
in)
ECA13920
NOTICE
2 Do not interchange the crankshaft journal
bearings. To obtain the correct crankshaft-
journal-to-crankshaft-journal-bearing clear-
1
ance and prevent engine damage, the crank-
shaft journal bearings must be installed in
EAS31174
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 of
1. Check:
the crankcase.
• Oil nozzle 1
b. Place the upper crankcase upside down on
• Oil nozzle 2
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
crankcase.
EAS31075 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
1
0.030 mm (0.0012 in)
a
b
G089019
G089018
5-87
d. Put a piece of Plastigauge® “1” on each

crankshaft journal.
TIP
a
Do not put the Plastigauge® over the oil hole in
the crankshaft journal.
G089021
4. Select:
• Crankshaft journal bearing (J1–J5)
TIP
• The numbers “A” stamped into the crankshaft
G089020 web and the numbers “B” stamped into the
e. Install the crankshaft journal lower bearings lower crankcase are used to determine the re-
“1” into the lower crankcase and assemble placement crankshaft journal bearing sizes.
the crankcase halves. • “J1”–“J5” refer to the bearings shown in the
TIP crankshaft and lower crankcase illustration.
• Align the projections “a” of the crankshaft jour- For example, if the crankcase “J1” and crank-
nal lower bearings with the notches “b” in the shaft web “J1” numbers are 5 and 2 respec-
lower crankcase.
tively, then the bearing size for “J1” is:
• Do not move the crankshaft until the clearance
measurement has been completed. “J1” (crankcase) – “J1” (crankshaft web) + 3
= 5 – 2 + 3 = 6 (pink)
1 Bearing color code

a Code 1
Blue
b Code 2
Black
Code 3
G089019
Brown
Code 4
f. Tighten the bolts to specification in the tight- Green
ening sequence cast on the crankcase. Code 5
Refer to “CRANKCASE” on page 5-68. Yellow
g. Remove the lower crankcase and the Code 6
crankshaft journal lower bearings. Pink
h. Measure the compressed Plastigauge® Code 7
width “a” on each crankshaft journal. Red
If the crankshaft-journal-to-crankshaft-jour-
nal-bearing clearance is out of specifica-
tion, select replacement crankshaft journal
bearings.
J1 J2 J3 J4 J5
5-88
J1 J2 J3 J4 J5
Balancer shaft journal to balanc-
er shaft bearing clearance
0.028–0.046 mm (0.0011–0.0018
in)
ECA18400
NOTICE
Do not interchange the balancer shaft jour-
nal bearings. To obtain the correct balancer
shaft-journal-to-balancer shaft-journal-bear-
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 on
a bench.
J 1 J2 J 3 J4 J5 c. Install the balancer shaft journal upper
bearings “1” and the balancer shaft into the
EAS31076
upper crankcase.
CHECKING THE BALANCER SHAFT
1. Measure: TIP
• Balancer shaft runout Align the projections “a” on the balancer shaft
Out of specification → Replace the balancer journal upper bearings with the notches “b” in the
shaft. upper crankcase.
Balancer shaft runout limit

0.030 mm (0.0012 in)
1
a
b
G089019
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 surface
Scratches/wear → Replace the balancer
shaft. 1
• Bearing surface
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
shaft journal bearings. G089020
5-89
e. Install the balancer shaft journal lower bear- For example, if the crankcase “J1” and bal-
ings “1” into the lower crankcase and as- ancer shaft web “J1” numbers are 6 and 2 re-
semble the crankcase halves. spectively, then the bearing size for “J1” is:
TIP
“J1” (crankcase) – “J1” (balancer shaft web) –
• Align the projections “a” of the balancer shaft 1
journal lower bearings with the notches “b” in = 6 – 2 – 1 = 3 (brown)
the crankcase.
• Do not move the balancer shaft until the clear-
ance measurement has been completed. Bearing color code
Code 0
White
Code 1
1 Blue
a Code 2
Black
b Code 3
Brown
Code 4
G089019 Green
f. Tighten the bolts to specification in the tight- Code 5
Yellow
ening sequence cast on the crankcase. Re-
Code 6
fer to “CRANKCASE” on page 5-68.
Pink
g. Remove the lower crankcase and the bal-
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 J1 J2 J3 J4
shaft journal bearings.
a
J1 J 2 J 3 J 4
G089021
4. Select:
• Balancer shaft journal bearing (J1–J4)
TIP
• 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.
• “J1”–“J4” refer to the bearings shown in the bal-
ancer shaft and lower crankcase illustration.
5-90
1 a
J 1 J2 J 3 J4
EAS31077 a. Insert the thrust bearing “1” into the slot of
INSTALLING THE CRANKSHAFT the upper crankcase as shown in the illus-
1. Install: tration and slide it in the direction of the ar-
• Crankshaft journal upper bearing row.
(into the upper crankcase) TIP
• Crankshaft journal lower bearing When installing the thrust bearing, shift the
(into the lower crankcase) crankshaft to the left to widen the gap between
• Crankshaft the crankshaft and the crankcase.
TIP
• Align the projections “a” on the crankshaft jour- 1
nal bearings “1” with the notches “b” in the
crankcase.
• Be sure to install each crankshaft journal bear-
ings in its original place.
1
a
b. Insert the thrust bearing “2” into the slot of
b the upper crankcase as shown in the illus-
tration and slide it in the direction of the ar-
row.
G089019
TIP
When installing thrust bearing “2”, shift the
EAS31799
INSTALLING THE THRUST BEARING crankshaft to the right to widen the gap between
1. Install: the crankshaft and the crankcase.
• Thrust bearing “1”
TIP 2
• Install the thrust bearings to the both side of the
journal #4 of the upper crankcase.
• The thickness of the thrust bearing is only one.
No need to adjust the clearance between the
thrust bearing and the crankshaft.
• Install the thrust bearing with the grooves “a”
side is facing the crankshaft.
• Apply engine oil on the grooves “a” side of the
thrust bearing.
5-91
c. Check that the thrust bearing is inserted

properly into the groove of the crankcase.
EAS31172
INSTALLING THE BALANCER ASSEMBLY

1. Install:
• Balancer shaft journal upper bearing
(into the upper crankcase)
• Balancer shaft journal lower bearing
(into the lower crankcase)
TIP
• 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.
1
a
b
G089019
2. Install:
• Balancer shaft
TIP
Install by aligning the crankshaft match mark “a”
and the balancer shaft match marks “b”.
a
b
5-92
TRANSMISSION
EAS20062
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks
5
E
1 6
E
13 8
E
9
LT
LT
12 N・m (1.2 kgf・m, 8.9 lb・ft) E
13
7
3
10 N・m (1.0 kgf・m, 7.4 lb・ft)
4
E
3
4 2
LT
12
10
F WD LT
11
LT
10 N・m (1.0 kgf・m, 7.4 lb・ft)

1 Drive axle assembly 1
2 Shift drum retainer 2
3 Spring 2
4 Shift fork guide bar 2
5 Shift fork-L 1
6 Shift fork-R 1
7 Shift drum assembly 1
8 Shift fork-C 1
9 Main axle assembly 1
11 O-ring 3
12 Oil baffle plate 1
13 Bearing 2
5-93
TRANSMISSION
Disassembling the main axle assembly
1
2
3
4
5
M
9
6
7 M
8 M
10 15
M 11
12 14
13
D
FW
E

Make sure the chamfered side of the pinion
1 2nd pinion gear 1 gear faces to the left.
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
5-94
TRANSMISSION
Disassembling the drive axle assembly
12 M
11
10
9 M
8
7
6
5
M M
4
3
2
M
M
D
FW
E
M
1

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
5-95
TRANSMISSION
Disassembling the drive axle assembly

22
23
25
E
26
21
16 24 20
15 19
14 18
13 17
M
M M
M
D
FW
E
M

13 4th 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
5-96
TRANSMISSION
EAS30430 EAS30431
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 retainer “2” 1. Check:
• Shift fork guide bar • Shift fork cam follower “1”
• Shift fork-L • Shift fork pawl “2”
• Shift fork-R Bends/damage/scoring/wear → Replace the
• Shift drum assembly shift fork.
• Shift fork-C
1
G089022
2
2. Check:
2. Remove: • Shift fork guide bar
• Bearing housing “1” Roll the shift fork guide bar on a flat surface.
• Main axle assembly “2” Bends → Replace.
EWA12840
a. Insert two bolts “3” of the proper size, as
WARNING
shown in the illustration, into the main axle
Do not attempt to straighten a bent shift fork
assembly bearing housing.
guide bar.
1 2 3. Check:
• Shift fork movement
(along the shift fork guide bar)
Rough movement → Replace the shift forks
and shift fork guide bar as a set.
3
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
crankcase.
G089023
3. Remove:
• Oil delivery pipe 3 “1” 4. Check:
• Bearing “2” • Shift fork guide bar (for the shift fork-C) oil
passage
2 Clogging/damage → Replace the shift fork
guide bar (for the shift fork-C).
1
5-97
TRANSMISSION
EAS30432
CHECKING THE SHIFT DRUM ASSEMBLY

1. Check:
1
• Shift drum groove
Damage/scratches/wear → Replace the shift
drum assembly.
• Shift drum segment “1”
Damage/wear → Replace the shift drum as-
sembly.
• Shift drum bearing “2”
Damage/pitting → Replace the shift drum as-
sembly. 3. Check:
• Transmission gear
Blue discoloration/pitting/wear → Replace
the defective gear(s).
• Transmission gear dog
Cracks/damage/rounded edges → Replace
the defective gear(s).
G089024
EAS30433
CHECKING THE TRANSMISSION

1. Measure:
• Main axle runout
(with a centering device and dial gauge “1”) G089025
Out of specification → Replace the main axle.
4. Check:
• Transmission gear engagement
Main axle runout limit
0.08 mm (0.0032 in) (each pinion gear to its respective wheel
gear)
Incorrect → Reassemble the transmission
axle assemblies.
1 5. Check:
• Transmission gear movement
Rough movement → Replace the defective
part(s).
6. Check:
• Circlips
Bends/damage/looseness → Replace.
2. Measure:
• Drive axle runout
(with a centering device and dial gauge “1”)
Out of specification → Replace the drive axle.
Drive axle runout limit

0.08 mm (0.0032 in)
5-98
TRANSMISSION
EAS30435
ASSEMBLING THE MAIN AXLE AND DRIVE A

c 1
AXLE b
1. Install: 2
2
• Toothed washer “1” 1
• Circlip “2” New
TIP
• Be sure the circlip sharp-edged corner “a” is a
positioned opposite side to the toothed washer
and gear. b
• Install the circlip so that a spline “b” is in the B c
center of the gap between the circlip ends “c” 1 b
as shown. 2 2
1
a
b
A. Main axle
B. Drive axle
EAS30438
INSTALLING THE TRANSMISSION

c 1. Install:
• Bearing “1”
• Oil delivery pipe 3 “2”
TIP
Face the seal side of bearing to the outside.
Oil delivery pipe 3 bolt

b 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
2. Install: LOCTITE®
• Toothed lock washer retainer “1”
• Toothed lock washer “2”
TIP 1
• With the toothed lock washer retainer in the 2
groove “a” in the axle, align the projection on
the retainer with an axle spline, and then install
the toothed lock washer.
• 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.
5-99
TRANSMISSION
2. Install:
• Main axle assembly “1”
• Bearing housing “2”
Main axle bearing housing bolt

12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.
LOCTITE®
3
b
2 1
3
b
3. Install:
• Shift fork-C “1”
• Shift drum assembly “2”
• Shift fork guide bar “3” 4. Install:
• Shift fork-R “1”
TIP
• Shift fork-L “2”
• The embossed marks on the shift forks should • Shift fork guide bar
face towards the right side of the engine and be • Shift drum retainer “3”
in the following sequence: “R”, “C”, “L”. • Bearing
• Carefully position the shift forks so that they
are installed correctly into the transmission • Oil seal New
gears. • Circlip “4” New
• Install shift fork-C into the groove “a” in the 3rd • Drive axle assembly “5”
pinion gear on the main axle.
• Install the shift fork guide bar “3” in the crank- Shift drum retainer bolt
case with the cap “b” facing toward the direc- 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
tion shown in the illustration. LOCTITE®
TIP
• Install shift fork-R into the groove “a” in the 5th
a wheel gear and shift fork-L into the groove “b”
in the 6th wheel gear on the drive axle.
• Install the shift drum retainer with its “OUT”
mark “c” facing outward.
2 • Make sure that the projection “d” on the drive
3
axle assembly is inserted into the slot in the
1 crankcase.
• Make sure that the drive axle bearing circlip “4”
is inserted into the groove “e” in the upper
crankcase.
5-100
TRANSMISSION
a b 5
4
1 2 e
d
3
c
5. Check:
• Transmission
Rough movement → Repair.
TIP
Oil each gear, shaft, and bearing thoroughly.
5-101
COOLING SYSTEM
COOLING SYSTEM DIAGRAMS .................................................................... 6-1
RADIATOR ...................................................................................................... 6-3

REMOVING THE RADIATOR ...................................................................6-4
CHECKING THE RADIATOR.................................................................... 6-4
INSTALLING THE RADIATOR..................................................................6-5
OIL COOLER...................................................................................................6-6
CHECKING THE OIL COOLER ................................................................6-7
INSTALLING THE OIL COOLER .............................................................. 6-7
THERMOSTAT ................................................................................................6-8
REMOVING THE THERMOSTAT ASSEMBLY......................................... 6-9
CHECKING THE THERMOSTAT.............................................................. 6-9
ASSEMBLING THE THERMOSTAT ASSEMBLY..................................... 6-9
INSTALLING THE THERMOSTAT ASSEMBLY ....................................... 6-9
WATER PUMP...............................................................................................6-11
DISASSEMBLING THE WATER PUMP.................................................. 6-13
CHECKING THE WATER PUMP ............................................................ 6-13
ASSEMBLING THE WATER PUMP........................................................ 6-13
INSTALLING THE WATER PUMP .......................................................... 6-14
6
COOLING SYSTEM DIAGRAMS
EAS20299
1
2
6
7

5. Radiator
6. Water pump outlet pipe
7. Water pump
6-1
1
1
3
7
4
5

2. Radiator
6. Water pump outlet pipe
7. Water pump
6-2
RADIATOR
EAS20063
RADIATOR
Removing the radiator
8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
.
5
6 10
New 10
10 N•m (1.0 kgf•m, 7.4 lb•ft)
7
1 10 N•m (1.0 kgf•m, 7.4 lb•ft)
4
7 N•m (0.7 kgf•m, 5.2 lb•ft)

2
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
1.0 N•m (0.10 kgf•m, 0.73 lb•ft) 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
T.R
.

Radiator cover/Coolant reservoir cover/Air Refer to “GENERAL CHASSIS (2)” on
scoop page 4-8.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-32.
1 Coolant reservoir hose 1
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
6-3
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
• 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 cm², 15.6–19.9 psi)
directed as shown in the illustration.
a. Install the radiator cap tester “1” and radia-
tor cap tester adapter “2” to the radiator cap
a “3”.
Radiator cap tester

90890-01325
YU-24460-A
1 Radiator cap tester adapter
2 90890-01352
G089027
2. Disconnect: YU-33984
• Radiator inlet hose
• Radiator outlet hose
3. Remove:
• Radiator
EAS30439
CHECKING THE RADIATOR

1. Check:
• Radiator fin
Obstruction → Clean.
Apply compressed air to the rear of the radia- G089029
tor.
b. Apply the specified pressure, and then
Damage → Repair or replace.
make sure that there is no drop in pressure
TIP for 10 seconds. If it is not keep the pres-
Straighten any flattened fins with a thin, flat-head sure, replace it.
screwdriver.
4. Check:
• Radiator fan
Damage → Replace.
Malfunction → Check and repair.
Refer to “COOLING SYSTEM” on page 8-29.
G089028
2. Check:
• Radiator hoses
6-4
RADIATOR
EAS30440
INSTALLING THE RADIATOR

1. Install:
• Radiator
2. Connect:
• Radiator inlet hose 2
• Radiator outlet hose
3. Install:
• Hose clamp (Clic-R) “1” New
G089031 1
TIP
• Install the hose clamp using the hose clamp pli- b. Apply the specified pressure.
ers “2”.
• When installing the hose clamp, make sure Cooling system leak test pres-
that the thin tip “a” of the hose clamp pliers is sure
137.3 kPa (1.37 kgf/cm², 19.9
directed as shown in the illustration.
psi)
• For more information about installing the hose,
refer to “CABLE ROUTING” on page 2-15. ECA24270
NOTICE
• Do not apply such a high pressure as ex-
a 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.
New 1
G089030 2 6. Check:
4. Fill: • Pressure value
• Cooling system No stay for 5 to 10 seconds at the test pres-
(with the specified amount of the recom- sure value → Repair.
mended coolant) • Radiator
Refer to “CHANGING THE COOLANT” on • Radiator hose connection
page 3-32. Coolant leaks → Repair or replace.
5. Check: • Radiator hose
• Cooling system Bulges → Replace.
EWA19090
Leaks → Repair or replace any faulty part.
WARNING
a. Attach the radiator cap tester “1” and radia- When the radiator cap tester is removed,
tor cap tester adapter “2” to the radiator. coolant will spout; therefore, cover it with a
cloth beforehand.
Radiator cap tester
90890-01325
YU-24460-A
Radiator cap tester adapter
90890-01352
YU-33984
6-5
OIL COOLER
EAS20064
OIL COOLER
Removing the oil cooler
10 N•m (1.0 kgf•m, 7.4 lb•ft)
New
LT
3
LT
10 N•m (1.0 kgf•m, 7.4 lb•ft)
4 *
10 N•m (1.0 kgf•m, 7.4 lb•ft)
New
2 New
LT **
**
**
1
LT 9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)

10 N•m (1.0 kgf•m, 7.4 lb•ft)
* For MT10N/MT10NC
** For MT10SPN/MT10SPNC
Drain.
page 3-29.
1 Oil cooler cover 1
Disconnect. When removing the oil cooler
inlet hose, also remove the water pump inlet
2 Oil cooler inlet hose 1 pipe.
Refer to “WATER PUMP” on page 6-11.
3 Oil cooler outlet hose 1
4 Oil cooler 1
6-6
OIL COOLER
EAS30441
4. Tighten:
CHECKING THE OIL COOLER
• Radiator bolt
1. Check:
• Oil cooler
Radiator bolt
Cracks/damage → Replace. 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
• Oil cooler fin
R.
Obstruction → Clean. 5. Fill:
Apply compressed air to the rear of the oil • Crankcase
cooler. (with the specified amount of the recom-
Damage → Repair or replace. mended engine oil)
TIP Refer to “CHANGING THE ENGINE OIL” on
Straighten any flattened fins with a thin, flat-head page 3-29.
screwdriver. 6. Measure:
• Engine oil pressure
Refer to “MEASURING THE ENGINE OIL
PRESSURE” on page 3-30.
G089028
2. Check:
• Oil cooler inlet hose
• Oil cooler outlet hose
EAS30442
INSTALLING THE OIL COOLER

1. Install:
• Oil cooler
• O-ring New
• Oil cooler bolt (upper)
• Oil cooler bolt (lower)
• Radiator bolt
TIP
Apply lithium-soap-based grease to the O-ring.
2. Tighten:
• Oil cooler bolt (upper)
Oil cooler bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
3. Tighten:
• Oil cooler bolt (lower)
Oil cooler bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
6-7
THERMOSTAT
EAS20065
THERMOSTAT
Removing the thermostat
New 7
6
2
1
5
3 4 New
10 N•m (1.0 kgf•m, 7.4 lb•ft)

Throttle body assembly Refer to “THROTTLE BODIES” on page 7-9.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-32.
1 Cooling system air bleed hose 1
2 Radiator inlet hose 1
3 Thermostat housing cover 1
4 O-ring 1
5 Thermostat 1
6 Thermostat housing 1
7 O-ring 1
6-8
THERMOSTAT
EAS31660 EAS30444
REMOVING THE THERMOSTAT ASSEMBLY ASSEMBLING THE THERMOSTAT

1. Remove: ASSEMBLY
• Hose clamp (Clic-R) 1. Install:
Refer to “REMOVING THE RADIATOR” on • Thermostat housing “1”
page 6-4. • Thermostat “2”
• Radiator inlet hose • O-ring “3” New
2. Remove: • Thermostat housing cover “4”
• Thermostat assembly
EAS30443
Thermostat housing cover nut
CHECKING THE THERMOSTAT 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
1. Check:
• Thermostat TIP
When the water temperature in the specified Install the thermostat with its breather hole “a”
value, the thermostat does not fully open. → facing up.
Replace.
a
Valve full open temperature 1
85.0 °C (185.00 °F)
2
4
a. Suspend the thermostat “1” in a container
“2” filled with water.
b. Slowly heat the water “3”.
c. Place a thermometer “4” in the water.
d. While stirring the water, observe the ther- 3 2
mostat and thermometer’s indicated tem-
EAS30445
perature.
INSTALLING THE THERMOSTAT
ASSEMBLY
1. Install:
• Thermostat assembly
2. Install:
• Radiator inlet hose
• Hose clamp (Clic-R) New
Refer to “INSTALLING THE RADIATOR” on
page 6-5.
G089032 TIP
TIP For more information about installing the hose,
If the accuracy of the thermostat is in doubt, re- refer to “CABLE ROUTING” on page 2-15.
place it. A faulty thermostat could cause serious
3. Fill:
overheating or overcooling.
• Cooling system
2. Check:
mended coolant)
• Thermostat housing
Refer to “CHANGING THE COOLANT” on
• Thermostat housing cover
page 3-32.
4. Check:
• Cooling system
Leaks → Repair or replace any faulty part.
Refer to “INSTALLING THE RADIATOR” on
page 6-5.
6-9
THERMOSTAT
5. Measure:
• Radiator cap valve opening pressure
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-4.
6-10
WATER PUMP
EAS20066
WATER PUMP
Removing the water pump
5
5
New
3 10 N•m (1.0 kgf•m, 7.4 lb•ft)
4
New 5
New 1
10 N•m (1.0 kgf•m, 7.4 lb•ft)
10 N•m (1.0 kgf•m, 7.4 lb•ft)
2
New LT

Muffler/Exhaust pipe Refer to “ENGINE REMOVAL” on page 5-11.
1 Water pump outlet pipe 1
2 Water pump inlet pipe 1
4 Water pump assembly 1
5 Oil cooler stay 3
6-11
WATER PUMP
Disassembling the water pump
3
D
6 FW
7
4 2
10 N・m (1.0 kgf・m, 7.4 lb・ft)
10 N・m (1.0 kgf・m, 7.4 lb・ft)

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
6-12
WATER PUMP
EAS30446 EAS30447
DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP

• Mechanical seal (housing side) “1” • Water pump housing cover
TIP • Impeller shaft
Remove the mechanical seal (housing side) Cracks/damage/wear → Replace.
from the inside of the water pump housing “2”. • Water pump housing
Cracks/damage/wear → Replace the water
pump assembly.
2. Check:
• Bearing
Rough movement → Replace.
1 2 3. Check:
• Water pump inlet pipe
• Water pump outlet pipe
EAS30448
ASSEMBLING THE WATER PUMP

2. Remove: 1. Install:
• Bearing “1”
• Oil seal “2”
• Bearing “2” New
TIP
(into the water pump housing “3”)
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)
1 TIP
2 Install the oil seal with a socket “4” that matches
3
3. Remove: 3
• Mechanical seal (impeller side) “1” 1
a
(from the impeller, with a thin, flat-head
screwdriver) 2
TIP
Do not scratch the impeller shaft. 2. Install:
• Mechanical seal (housing side) “1” New
ECA20330
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.
6-13
WATER PUMP
EAS30449
INSTALLING THE WATER PUMP

Mechanical seal installer (ø33)
90890-04132 1. Install:
Water pump seal installer (ø33) • Water pump assembly “1”
YM-33221-A TIP
Middle driven shaft bearing driv- Align the slit “a” on the impeller shaft with the
er projection “b” on the oil pump driven sprocket.
90890-04058
Middle drive bearing installer 40
& 50 mm
YM-04058
1 a
1 2. Fill:
• Cooling system
mended coolant)
2. Water pump housing Refer to “CHANGING THE COOLANT” on
3. Mechanical seal installer page 3-32.
4. Middle driven shaft bearing driver 3. Check:
• Cooling system
A. Push down Leaks → Repair or replace the faulty part.
3. Install: 4. Measure:
• Mechanical seal (impeller side) “1” New • Radiator cap valve opening pressure
TIP
radiator cap.
• Before installing the mechanical seal (impeller Refer to “CHECKING THE RADIATOR” on
side), apply tap water or coolant onto its outer page 6-4.
surface.
• If the top of the mechanical seal is dirty, clean
it.
G089035
6-14
WATER PUMP
6-15
FUEL SYSTEM
FUEL TANK..................................................................................................... 7-1

REMOVING THE FUEL TANK ..................................................................7-3
REMOVING THE FUEL PUMP .................................................................7-3
CHECKING THE FUEL PUMP BODY.......................................................7-3
CHECKING THE FUEL PUMP OPERATION............................................7-3
CHECKING THE PURGE CUT VALVE (for California)............................. 7-4
INSTALLING THE FUEL PUMP................................................................7-4
INSTALLING THE FUEL TANK.................................................................7-4
AIR FILTER CASE .......................................................................................... 7-6

REMOVING THE AIR FILTER CASE........................................................7-7
REMOVING THE INTAKE FUNNEL ASSEMBLY ..................................... 7-7
CHECKING THE AIR FILTER CASE SEAL ..............................................7-7
CHECKING THE INTAKE FUNNEL .......................................................... 7-7
INSTALLING THE INTAKE FUNNEL AND AIR FILTER CASE ................ 7-7
INSTALLING THE AIR FILTER CASE COVER ........................................ 7-7
INSTALLING THE AIR DUCT COVER......................................................7-8
THROTTLE BODIES .......................................................................................7-9

CHECKING THE INJECTORS (BEFORE REMOVING) ......................... 7-12
REMOVING THE FUEL HOSE (FUEL RAIL SIDE) ................................7-12
REMOVING THE INJECTORS ...............................................................7-12
CHECKING THE INJECTORS ................................................................7-12
CHECKING AND CLEANING THE THROTTLE BODIES.......................7-13
REPLACING THE THROTTLE BODIES ................................................. 7-14
INSTALLING THE INJECTORS ..............................................................7-15
CHECKING THE INJECTOR PRESSURE.............................................. 7-15
CHECKING THE FUEL PRESSURE ......................................................7-16
INSTALLING THE FUEL HOSE (FUEL RAIL SIDE) ...............................7-16
ADJUSTING THE THROTTLE POSITION SENSOR..............................7-17
AIR INDUCTION SYSTEM ............................................................................7-18

CHECKING THE AIR INDUCTION SYSTEM..........................................7-21
INSTALLING THE AIR INDUCTION SYSTEM........................................ 7-22 7
FUEL TANK
EAS20067
FUEL TANK
Removing the fuel tank
4.0 N•m (0.40 kgf•m, 3.0 lb•ft)
T.R
.
9 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
(2)
(2)
New 8
7
6
3 4
2
(4)
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
4.0 N•m (0.40 kgf•m, 3.0 lb•ft)

T.R
.

1 Fuel hose connector 1 Disconnect.
2 Fuel pump coupler 1 Disconnect.
3 Fuel tank breather hose 1 Disconnect.
4 Fuel tank drain hose 1 Disconnect.
5 Fuel tank 1
6 Fuel pump bracket 1
7 Fuel pump 1
8 Fuel pump gasket 1
9 Fuel tank cap 1
7-1
FUEL TANK
Removing the purge cut valve and canister (for California)

3
5 2
6
7
8
1
10 N•m (1.0 kgf•m, 7.4 lb•ft)

Canister purge hose (purge cut valve to canis-
1 1
ter)
2 Fuel tank breather hose (fuel tank to canister) 1
3 Canister holder 1
4 Canister 1
5 Canister bracket 1
6 Purge cut valve holder 1
7 Purge cut valve 1
Canister purge hose (purge cut valve to hose
8 1
joint)
7-2
FUEL TANK
EAS30450
REMOVING THE FUEL TANK

1. Extract the fuel in the fuel tank through the c
1
fuel tank cap with a pump.
2. Remove:
• Rider seat
page 4-1.
• Air scoop
• Fuel tank cover/Fuel tank side cover
page 4-8.
3. Disconnect:
• Fuel hose (fuel tank side) a
• Fuel pump coupler b
• Fuel tank drain hose
EWA17320
WARNING
b
Cover fuel hose connections with a cloth
when disconnecting them. Residual pres-
sure in the fuel lines could cause fuel to 4. Remove:
spurt out when removing the hose. • Fuel tank
TIP
ECA17490
NOTICE Do not set the fuel tank down so that the instal-
lation surface of the fuel pump is directly under
Be sure to disconnect the fuel hose by hand.
the tank. Be sure to lean the fuel tank in an up-
Do not forcefully disconnect the hose with
right position.
tools.
TIP EAS30451
• While pushing the ends “a” of the fuel hose REMOVING THE FUEL PUMP
connector cover “1” in direction “b”, slide the 1. Remove:
fuel hose connector cover in direction “c”, and • Fuel pump
ECA14721
then remove the hose from the fuel pump. NOTICE
• Before removing the hose, place a few rags in • Do not drop the fuel pump or give it a
the area under where it will be removed. strong shock.
• It is prohibited to wear the cotton work gloves • Do not touch the base section of the fuel
or equivalent coverings. sender.
EAS30454
CHECKING THE FUEL PUMP BODY

1. Check:
• Fuel pump body
Obstruction → Clean.
Cracks/damage → Replace fuel pump as-
sembly.
EAS30455
CHECKING THE FUEL PUMP OPERATION

1. Check:
• Fuel pump operation
Refer to “CHECKING THE FUEL PRES-
SURE” on page 7-16.
7-3
FUEL TANK
EAS33654
CHECKING THE PURGE CUT VALVE (for 2

California)
1. Check: a
A 3
• Purge cut valve “1”
Damage/faulty → Replace.
TIP
Check that air flows smoothly only in the direc- 4
tion of the arrow shown in the illustration. 1
A. Forward
1 EAS30457
INSTALLING THE FUEL TANK

1. Install:
• Fuel tank
• Rear fuel tank bolt
• Fuel tank nut
TIP
Temporarily tighten the rear fuel tank bolt.
EAS30456
INSTALLING THE FUEL PUMP 2. Connect:

1. Install: • Fuel hose (fuel tank side)
ECA17500
• Fuel pump gasket New NOTICE

• Fuel pump When installing the fuel hose, make sure that
• Fuel pump bracket it is securely connected, and that the fuel
• Fuel pump bolt hose connector cover on the fuel hose is in
the correct position, otherwise the fuel hose
Fuel pump bolt will not be properly installed.
4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
T.
R.
TIP
TIP • Install the fuel hose onto the fuel pump secure-
• Do not damage the installation surfaces of the ly, and slide the fuel hose connector cover “1”
fuel tank when installing the fuel pump. in the direction shown in the illustration.
• Always use a new fuel pump gasket. • It is prohibited to wear the cotton work gloves
• Install the fuel pump gasket so that the lip side or equivalent coverings.
turns to the inside of the fuel tank.
• Install the fuel pump as shown in the illustra-
tion.
• Align the projection “a” on the fuel pump with 1
the slot in the fuel pump bracket.
• Tighten the fuel pump bolts in the proper tight-
ening sequence as shown.
3. Connect:
• Fuel tank drain hose
• Fuel pump coupler
7-4
FUEL TANK
4. Tighten:
• Front fuel tank bolt
Front fuel tank bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
5. Tighten:
• Rear fuel tank bolt
Rear fuel tank bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
7-5
AIR FILTER CASE
EAS20068
AIR FILTER CASE

Removing the air filter case
0.8 N•m (0.08 kgf•m, 0.59 lb•ft)
T.R
.
2.0 N•m (0.20 kgf•m, 1.5 lb•ft)
T.R
.
2.0 N•m (0.20 kgf•m, 1.5 lb•ft)
0.8 N•m (0.08 kgf•m, 0.59 lb•ft)
T.R
.
T.R
.
2
4.0 N•m (0.40 kgf•m, 3.0 lb•ft) 5 3
T.R
4
.
(12)
1 6
11
New
10
12
New 9 12 (3)
(3) 8
8 N•m (0.8 kgf•m, 5.9 lb•ft)

T.R
.

1 Air duct (left) 1
2 Air duct (right) 1
3 Air duct cover (left) 1
4 Air duct cover (right) 1
5 Intake air temperature sensor 1
6 Air filter case cover 1
7 Air filter element 1
8 Intake funnel assembly bolt 6 Loosen.
9 Crankcase breather hose 1 Disconnect.
10 Air induction system hose 1 Disconnect.
11 Air filter case 1
12 Intake funnel assembly 2
7-6
AIR FILTER CASE
EAS31663 EAS31664
REMOVING THE AIR FILTER CASE CHECKING THE AIR FILTER CASE SEAL
• Air filter case cover • Air filter case seal
2. Loosen: Damage → Replace.
• Intake funnel assembly bolt “1”
EAS30463
CHECKING THE INTAKE FUNNEL

1 1. Check:
• Intake funnel assembly
EAS31665
INSTALLING THE INTAKE FUNNEL AND AIR

FILTER CASE
1. Install:
1 1
• Air filter case “1”
3. Disconnect: • Intake funnel assembly “2”
• Crankcase breather hose a. Install the intake funnel assembly and air fil-
• Air induction system hose ter case.
4. Remove: b. Tighten the Intake funnel assembly bolt “3”.
• Air filter case
EAS30461
Intake funnel assembly bolt
REMOVING THE INTAKE FUNNEL T.
R.
8 N·m (0.8 kgf·m, 5.9 lb·ft)
ASSEMBLY
1. Remove: 2 2
3
• Intake funnel assembly
ECA26860
NOTICE
• Do not disassemble the intake funnel as-
sembly.
• Do not remove the intake funnel bolts from
the intake funnel joint. 1
3 3
a. Keep the two tabs “a” pushed in the direc-
tion shown in the illustration and separate EAS31731
the intake funnel assembly from air filter INSTALLING THE AIR FILTER CASE COVER
case. 1. Install:
• Air filter case cover
Air filter case cover screw

2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
T.
R.
7-7
AIR FILTER CASE
EAS33675
INSTALLING THE AIR DUCT COVER

duct cover.
1. Install:
• Air duct cover “1”
a. Wrap the air duct cover around the air duct,
and then fix the ends of the portion “a” into
the slit “b” as shown in the illustration.
b a
1
b. Contacts the end “c” of the air duct cover to

the air filter case cover “2”, and then align
the cutout “d” on the air duct cover with the
rib “e” on the air filter case cover.
e
1 d
7-8
THROTTLE BODIES
EAS20070
THROTTLE BODIES
Removing the throttle bodies
3.0 N•m (0.30 kgf•m, 2.2 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
6
2 LT
1
LT
5
5

Air scoop/Fuel tank cover/Fuel tank side cover/ Refer to “GENERAL CHASSIS (2)” on
Air duct page 4-8.
1 Throttle position sensor coupler 1 Disconnect.
2 Intake air pressure sensor coupler 1 Disconnect.
3 Throttle servo motor coupler 1 Disconnect.
Coolant temperature sensor coupler (Sub-wire
4 1 Disconnect.
harness)
5 Injector coupler 4 Disconnect.
6 Fuel hose 1
7-9
THROTTLE BODIES
Removing the throttle bodies

8
3.0 N•m (0.30 kgf•m, 2.2 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
10
7
9
7
LT
LT
11
11

7 Throttle body joint clamp screw 4 Loosen.
8 Throttle body assembly 1
9 Neutral switch connector 1 Disconnect.
10 Heat protector 1
11 Throttle body joint 2
7-10
THROTTLE BODIES
Removing the sensors

T.R
T.R
.
.
3.5 N•m (0.35 kgf•m, 2.6 lb•ft)
New
T.R
.
5 New
1
1 New
New
1 9
2 1 2 9
7
1 9
New
9
8
7 New
New
New
3
3 4
3 4
3
6
3.5 N•m (0.35 kgf•m, 2.6 lb•ft) 3 4 3
T.R
.

1 Negative pressure hose 5
2 Hose joint 2
3 Canister purge hose 6 For California.
4 Hose joint 3 For California.
5 Intake air pressure sensor 1
6 Throttle position sensor 1
7 Fuel rail 1
8 Injector joint 1
9 Injector 2
7-11
THROTTLE BODIES
EAS30475 EAS30476
CHECKING THE INJECTORS (BEFORE REMOVING THE INJECTORS

REMOVING) EWA17330
1. Check: WARNING
• Injector • Check the injectors in a well-ventilated area
Use the diagnostic code numbers “36”–“39”. free of combustible materials. Make sure
Refer to “SELF-DIAGNOSTIC FUNCTION that there is no smoking or use of electric
AND DIAGNOSTIC CODE TABLE” on tools in the vicinity of the injectors.
page 9-39. • Be careful when disconnecting the fuel
hose. Any remaining pressure in the fuel
EAS31158
hose may cause the fuel to spray out. Place
REMOVING THE FUEL HOSE (FUEL RAIL
a container or rag under the hose to catch
SIDE)
any fuel that spills. Always clean up any
1. Disconnect:
spilt fuel immediately.
• Fuel hose (fuel rail side)
ECA17490
• Turn the main switch to “OFF” and discon-
NOTICE nect the negative battery lead from the bat-
Be sure to disconnect the fuel hose by hand. tery terminal before removing the injectors.
Do not forcefully disconnect the hose with 1. Remove:
tools. • Fuel rail “1”
TIP a. Remove the fuel rail screws “2”.
• While pushing the ends “a” of the fuel hose 2
connector cover “1” in direction “b”, slide the
fuel hose connector cover in direction “c”, and 2
then remove the hose from the fuel rail.
• Before removing the hose, place a few rags in 1
the area under where it will be removed.
• It is prohibited to wear the cotton work gloves
or equivalent coverings.
1 c EAS30477
CHECKING THE INJECTORS

1. Check:
• Injector
Obstruction → Replace and check the fuel
pump/fuel supply system.
Deposit → Replace.
Damage → Replace.
2. Check:
• Injector resistance
a Refer to “CHECKING THE FUEL INJEC-
b TORS” on page 8-49.
7-12
THROTTLE BODIES
EAS30769
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:
• Valve clearance
• Spark plug a
• Air filter element a. Place the throttle bodies on a flat surface
• Throttle body joint with the air filter case side facing up.
• Fuel hose b. Install the caps (895-14169-00) onto the
• Air induction system hose fittings “a”.
• Exhaust system
• Crankcase breather hose
• Vacuum hose
EWA17340
WARNING
If the throttle bodies are subjected to strong
shocks or dropped during cleaning, replace
them as a set.
1. Check: a a
• Throttle body c. Hold the throttle valves in the open position.
Cracks/damage → Replace the throttle bod- EWA15940
ies as a set. WARNING

2. Clean: When cleaning the throttle bodies, be careful
• Throttle body not to injure yourself on the throttle valves or
ECA21540 other components of the throttle bodies.
NOTICE ECA20380
• Observe the following precautions; other- NOTICE
wise, the throttle bodies may not operate • Do not open the throttle valves by supply-
properly. ing electrical power to the throttle bodies.
• Do not subject the throttle bodies to exces- • Do not use tools to open the throttle valves
sive force. or to keep them in the open position.
• Clean the throttle bodies in the recom- • Do not open the throttle valves quickly.
mended cleaning solvent.
• Do not use any caustic carburetor cleaning
solution.
• Do not apply cleaning solvent directly to
any plastic parts, sensors, or seals.
• Be careful not to remove the white paint
mark that identifies the standard throttle
body.
• Do not turn the bypass air screws “a”; oth-
erwise, the throttle body synchronization
G089040
will be affected.
Recommended cleaning solvent

Yamaha Oil & Brake Cleaner
7-13
THROTTLE BODIES
d. Apply the recommended cleaning solvent 4. Reset:

to the throttle valves and the inside of the • ISC (Idle Speed Control) learning value
throttle bodies to remove any carbon de- Use the diagnostic code number “67”.
posits. Refer to “DIAGNOSTIC CODE: SENSOR
TIP OPERATION TABLE” on page 9-77.
• Do not allow any cleaning solvent to enter the 5. Reset:
opening for the injectors. • A/F control learning value
• Do not apply any cleaning solvent to the por- Use the diagnostic code number “87”.
tions of the throttle valve shafts between the Refer to “DIAGNOSTIC CODE: SENSOR
throttle bodies. OPERATION TABLE” on page 9-77.
6. Adjust:
e. Remove the carbon deposits from the in- • Throttle bodies synchronizing
side of each throttle body in a downward di- Out of specification → Replace the throttle
rection, from the air filter case side of the bodies.
throttle body to the engine side. Refer to “SYNCHRONIZING THE THROT-
ECA17590
TLE BODIES” on page 3-9.
NOTICE
• Do not use a tool, such as a wire brush, to EAS31160
remove the carbon deposits; otherwise, the REPLACING THE THROTTLE BODIES
inside of the throttle bodies may be dam- 1. Remove the throttle bodies from the vehicle.
aged. 2. Install a new throttle bodies to the vehicle.
• Do not allow carbon deposits or other for- 3. Reset:
eign materials to enter any of the passages • ISC (Idle Speed Control) learning value
in each throttle body or in the space be- Use the diagnostic code number “67”.
tween the throttle valve shaft and the throt- Refer to “DIAGNOSTIC CODE: SENSOR
tle body. OPERATION TABLE” on page 9-77.
4. Reset:
f. After removing the carbon deposits, clean • A/F control learning value
the inside of the throttle bodies with the rec- Use the diagnostic code number “87”.
ommended cleaning solvent, and then dry Refer to “DIAGNOSTIC CODE: SENSOR
the throttle bodies using compressed air. OPERATION TABLE” on page 9-77.
g. Make sure that there are no carbon depos- 5. Adjust:
its or other foreign materials in any of the • Throttle bodies synchronizing
passages “a” in each throttle body or in the Refer to “SYNCHRONIZING THE THROT-
space “b” between the throttle valve shaft TLE BODIES” on page 3-9.
and the throttle body. 6. Place the vehicle on a maintenance stand so
A B
7. Check:
b • Engine idling speed
Start the engine, warm it up, and then mea-
sure the engine idling speed.
Engine idling speed

a a 1200–1400 r/min
A. Air filter case side

B. Throttle body joint side
3. Install the throttle bodies.
7-14
THROTTLE BODIES
EAS30480
INSTALLING THE INJECTORS

ECA21550
Pressure gauge
NOTICE 90890-03153
• Always use new O-rings. Pressure gauge
YU-03153
• When installing the injectors, do not allow
any foreign material to enter or adhere to
90890-03210
the injectors, fuel rails, or O-rings.
• Be careful not to twist or pinch the O-rings YU-03210
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
excessive force, replace it.
• If installing the original fuel rail and bolts,
remove the white paint marks using a
cleaning solvent. Otherwise, paint chips on
the bolt seats could prevent the bolts from
being tightened to the specified torque.
G089041
1. Install a new seal onto the end of each injec- c. Close the valve on the injector pressure
tor. adapter.
2. Install the injectors to the fuel rails. d. Apply air pressure with the air compressor.
3. Install the fuel injector joint, making sure to in- e. Open the valve on the injector pressure
stall them in the correct direction. adapter until the specified pressure is
4. Install the injector assemblies to the throttle reached.
bodies.
Specified air pressure
Fuel rail screw (throttle body) 490 kPa (5.0 kgf/cm², 71.1 psi)
3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
T.
R.
ECA17600
5. Check the injector pressure after the injectors NOTICE

are installed. Never exceed the specified air pressure or
Refer to “CHECKING THE INJECTOR damage could occur.
PRESSURE” on page 7-15.
f. Close the valve on the injector pressure
EAS30481 adapter.
CHECKING THE INJECTOR PRESSURE g. Check that the specified air pressure is held
TIP at least one minute.
• After installing the injectors, perform the follow- Pressure drops → Check the pressure
ing steps to check the injector pressure. gauge and adapter.
• Do not allow any foreign materials to enter the Check the seals and O-rings and then rein-
fuel lines. stall.
Out of specification → Replace the fuel in-
1. Check:
jectors.
• Injector pressure
a. Connect the fuel injector pressure adapter
“1” to the injector joint “2”, and then connect
an air compressor “3” to the adapter.
b. Connect the pressure gauge “4” to the fuel
injector pressure adapter “1”.
7-15
THROTTLE BODIES
EAS30482
CHECKING THE FUEL PRESSURE

1. Remove:
• Rider seat
Refer to “GENERAL CHASSIS (1)” on 2
page 4-1.
• Air scoop
page 4-8.
• Fuel tank cover/Fuel tank side cover 3
Refer to “GENERAL CHASSIS (2)” on d. Start the engine.
page 4-8. e. Measure the fuel line pressure.
2. Check: Faulty → Replace the fuel pump.
• Fuel pressure
a. Remove the fuel tank bolts and hold up the Fuel line pressure (at idle)
fuel tank. 300–390 kPa (3.0–3.9 kgf/cm²,
b. Disconnect the fuel hose “1” from the fuel 43.5–56.6 psi)
pump.
Refer to “FUEL TANK” on page 7-1. 3. Install:
EWA17320
• Fuel tank
WARNING • Fuel tank cover/Fuel tank side cover
Cover fuel hose connections with a cloth Refer to “GENERAL CHASSIS (2)” on
when disconnecting them. Residual pres- page 4-8.
sure in the fuel lines could cause fuel to • Air scoop
spurt out when removing the hose. Refer to “GENERAL CHASSIS (2)” on
ECA17490 page 4-8.
NOTICE • Rider seat
Be sure to disconnect the fuel hose by hand. Refer to “GENERAL CHASSIS (1)” on
Do not forcefully disconnect the hose with page 4-1.
tools. EAS31159
INSTALLING THE FUEL HOSE (FUEL RAIL

SIDE)
1. Connect:
• Fuel hose (fuel rail side)
ECA17500
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
1
the correct position, otherwise the fuel hose
c. Connect the pressure gauge “2” and fuel will not be properly installed.
pressure adapter “3” to the fuel hose. TIP
• Install the fuel hose onto the fuel rail securely,
Pressure gauge
and slide the fuel hose connector cover “1” in
90890-03153
the direction shown in the illustration.
Pressure gauge
YU-03153 • To install the fuel hose onto the fuel rail joint,
Fuel pressure adapter slide the fuel hose connector cover “1” on the
90890-03176 end of the hose in the direction of the arrow
Fuel pressure adapter shown.
YM-03176 • It is prohibited to wear the cotton work gloves
or equivalent coverings.
7-16
THROTTLE BODIES
TIP
• Yamaha diagnostic tool (A/I) (90890-03264) in-
1 cludes YDT sub harness (6P) (90890-03266).
• If you already have Yamaha diagnostic tool (A/
(90890-03266) is separately required.
Refer to “DIAGNOSTIC CODE: SENSOR
OPERATION TABLE” on page 9-77.
e. Diagnostic code number “01” is selected.
f. Adjust the position of the throttle position
EAS30485
sensor angle so that 11–21 can appear in
ADJUSTING THE THROTTLE POSITION
the YDT screen.
SENSOR
ECA17540 g. After adjusting the throttle position sensor
NOTICE angle, tighten the throttle position sensor
• Handle the throttle position sensor with bolts “1”.
special care.
• Never subject the throttle position sensor Throttle position sensor bolt
to strong shocks. If the throttle position 3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
T.
R.
sensor is dropped, replace it.
1. Check:
• Throttle position sensor
Refer to “DIAGNOSTIC CODE: SENSOR
OPERATION TABLE” on page 9-77.
2. Adjust:
• Throttle position sensor angle 1
TIP 1
Before adjusting the throttle position sensor, the
throttle bodies must be removed.
a. Temporary tighten the throttle position sen-

sor 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 YDT to coupler.
Yamaha diagnostic tool USB

(US)
90890-03269
Yamaha diagnostic tool (A/I)
90890-03264
7-17
AIR INDUCTION SYSTEM
EAS20071
5
1
3
1. Air filter case

2. Cylinder head cover
4. Air induction system hose (air filter case to air
cut-off valve)
5. Air induction system hose (air cut-off valve to
reed valve cover)
7-18
Removing the air cut-off valve assembly and reed valves
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.2 lb•ft)
4
5
LT
LT
1
0.3 N•m (0.03 kgf•m, 0.22 lb•ft)
T.R
.
3
9 N•m (0.9 kgf•m, 6.6 lb•ft)

T.R
.

Air scoop/Fuel tank cover/Fuel tank side cover/ Refer to “GENERAL CHASSIS (2)” on
Air duct page 4-8.
1 Atmospheric pressure sensor coupler 1 Disconnect.
2 Air filter case duct 1
3 Atmospheric pressure sensor 1
4 Air filter case duct 1
5 Air cut-off valve coupler 1 Disconnect.
7-19
Removing the air cut-off valve assembly and reed valves
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.2 lb•ft)
LT
10
11
9 12
8
LT
10
7 11
6
12
0.3 N•m (0.03 kgf•m, 0.22 lb•ft)
T.R
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)

T.R
.

Air induction system hose (air filter case to air
6 1
cut-off valve)
Air induction system hose (air cut-off valve to
7 1
reed valve cover)
Air induction system hose (air cut-off valve to
8 1
reed valve cover)
9 Air cut-off valve 1
10 Reed valve cover 2
11 Reed valve assembly 2
12 Reed valve plate 4
7-20
EAS30488
A. From the air filter case
CHECKING THE AIR INDUCTION SYSTEM
B. To the cylinder head
Air injection 1. Check:
The air induction system burns unburned ex- • Hose
haust gases by injecting fresh air (secondary air) Loose connections → Connect properly.
into the exhaust port, reducing the emission of Cracks/damage → Replace.
hydrocarbons. When there is negative pressure 2. Check:
at the exhaust port, the reed valve opens, allow- • Reed valve
ing secondary air to flow into the exhaust port. • Reed valve stopper
The required temperature for burning the un- • Reed valve seat
burned exhaust gases is approximately 600 to Cracks/damage → Replace the reed valve
700 °C (1112 to 1292 °F). assembly.
3. Measure:
Air cut-off valve • Reed valve bending limit “a”
The air cut-off valve is controlled by the signals Out of specification → Replace the reed
from the ECU in accordance with the combus- valve assembly.
tion conditions. Ordinarily, the air cut-off valve
opens to allow the air to flow during idle and Reed valve bending limit
closes to cut-off the flow when the vehicle is be- 0.4 mm (0.02 in)
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.
G089044
4. Check:
5. Check:
• Air induction system solenoid
Refer to “CHECKING THE AIR INDUCTION
SYSTEM SOLENOID” on page 8-48.
7-21
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.
G089045
A. Exhaust side
3. Install:
• Reed valve cover
Reed valve cover bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
LOCTITE®
7-22
7-23
ELECTRICAL SYSTEM
IGNITION SYSTEM ......................................................................................... 8-1

CIRCUIT DIAGRAM .................................................................................. 8-1
ENGINE STOPPING DUE TO SIDESTAND OPERATION.......................8-3
TROUBLESHOOTING ..............................................................................8-4
ELECTRIC STARTING SYSTEM .................................................................... 8-7

CIRCUIT DIAGRAM .................................................................................. 8-7
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION .......................... 8-9
TROUBLESHOOTING ............................................................................8-10
CHARGING SYSTEM....................................................................................8-13
CIRCUIT DIAGRAM ................................................................................ 8-13
LIGHTING SYSTEM ......................................................................................8-17

CIRCUIT DIAGRAM ................................................................................ 8-17
SIGNALING SYSTEM ...................................................................................8-21

CIRCUIT DIAGRAM ................................................................................ 8-21
COOLING SYSTEM....................................................................................... 8-29

CIRCUIT DIAGRAM ................................................................................ 8-29
FUEL PUMP SYSTEM...................................................................................8-33

CIRCUIT DIAGRAM ................................................................................ 8-33
ELECTRICAL COMPONENTS...................................................................... 8-37

CHECKING THE SWITCHES .................................................................8-39
CHECKING THE FUSES ........................................................................8-40
REPLACING THE ECU (Engine Control Unit) ........................................ 8-41
CHECKING AND CHARGING THE BATTERY....................................... 8-41
CHECKING THE RELAYS ...................................................................... 8-41
CHECKING THE RELAY UNIT (DIODE) ................................................ 8-42
8
CHECKING THE IGNITION COILS......................................................... 8-43
CHECKING THE IGNITION SPARK GAP............................................... 8-44
CHECKING THE CRANKSHAFT POSITION SENSOR.......................... 8-44
CHECKING THE STARTER MOTOR OPERATION ...............................8-45
CHECKING THE STATOR COIL ............................................................ 8-45
CHECKING THE RECTIFIER/REGULATOR ..........................................8-45
CHECKING THE HORN..........................................................................8-46
CHECKING THE FUEL SENDER ........................................................... 8-46
CHECKING THE FUEL LEVEL WARNING ICON................................... 8-46
CHECKING THE RADIATOR FAN MOTORS.........................................8-47
CHECKING THE COOLANT TEMPERATURE SENSOR.......................8-47
CHECKING THE THROTTLE SERVO MOTOR ..................................... 8-47
CHECKING THE AIR INDUCTION SYSTEM SOLENOID ......................8-48
CHECKING THE CYLINDER IDENTIFICATION SENSOR ....................8-48
CHECKING THE INTAKE AIR TEMPERATURE SENSOR ....................8-49
CHECKING THE FUEL INJECTORS......................................................8-49
CHECKING THE WHEEL SWITCH ........................................................ 8-50
EAS30490
EAS20072
L/W L/B L/B L/W R/WR/W R/W R/W

B/W R/W R/W B/W R/W
R/WR/W
R/W
A C R/W R/W
R/W
R/W
R/W
R/W R/W 57
O/L
R/W O/L R/W
61
(B)
R RR
R
R/W
R/W O/L 58
5 Gy Gy
Gy R/W
O/L
R R R 61
Gy
CIRCUIT DIAGRAM
R R (B)
3 R
R/W
Br/L R R Br/L O/L

59
Br/R R/B R/B Br/R 25 O/L R/W
61
L/B L/Y 30 (B)
L/Y L/B R/G
IGNITION SYSTEM
R L/W R/W L R/L R/W

ON B 60
OFF B L/W L/Y R/W L/B L/Y Sb B/Y Sb/W Gy
L/Y
61 Gy R/W
26 Sb L/Y
Br/L L/B L/B (B)
L/Y L/B
R/W
B R/W L/Y
R/L
6 R/W
R/W L/B B
R/L
R/W R/L R/W R/W R W/BR/Y L/W L/B (B)
OFF B
38 RUN B B
START
R/L Br B
Sb 42
Br/L
Br/L L/W R/W Y/G W/G B
Br/L B/Y Br Br Y/B Y/R W/B W/R
36 B Br/Y R/L
R/W L
41
12
R
L W/B W L/Y L/Y L L L
51 W B/LW/B
R/G B/L B/L W/B
(B)
16 (B)
56 Y/R P/W P/B O/L Gy O/L Gy L/Y L Br/Y R/W
R/G Lg/R L/B O/B R/B G/B B W W L B/R
R/G R/L G/Y Br/R B B/G B B/G
R/G Y/B L/Y R/L B/W B/W B/L B B/Y W/Y
R/W (B) (B)
Br/L R/W 6
19 20
R/W Br Br Br L/B O/W Lg/L P/W P V L L/R Gy
8-1
Br/L Br Br B Gy Gy
R/W B/L Gy B Gy L/W B/Y Br G/LGy/G Br/W B/L W W/B
22 53 Gy B/L L/Y L/W Lg/B Gy/Y G/W G Gy/B W/L
(B)
B/L
B/L B/L
B/L B/L
B/L
B/L
B/L B/L B/L B/L
B/L
B/L B/L
B/L
R/W R/W
B/W L/W L/B R/W (B)
R/W B/W
L/B
B L/W
B 75
L/W L/B
B/W B/W B B
L/W L/B B/W R/W

B B B B B B
B B L/W L/B B/W R/W
B B
B B B B/W
B B
B
B B B
B B/W B/W B B/W B
L/W L/W L/B L/B B B/W B
6 B B/W
L/W L/W L/W L/W L/W L/W L/R L/R Br L/R L/R L/R B/W B/W
L/B L/B L/B L/B L/B L/B
IGNITION SYSTEM
IGNITION SYSTEM
3. Main switch
5. Main fuse
6. Joint coupler
12. Fuse box 1
16. Backup fuse
19. Fuse box 2
20. Ignition fuse
22. Signaling system fuse
25. Battery
26. Engine ground
30. Relay unit
36. Handlebar switch (right)
38. Start/engine stop switch
41. Neutral switch
42. Sidestand switch
53. Crankshaft position sensor
56. ECU (Engine Control Unit)
57. Ignition coil #1
61. Spark plug
75. IMU (Inertial Measurement Unit)
A. Wire harness
C. Sub-wire harness (IMU (Inertial Measure-
ment Unit))
*. For MT10SPN/MT10SPNC
8-2
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 un-
der the following conditions:
• The transmission is in gear (the neutral switch is open) and the sidestand is up (the sidestand switch
circuit is closed).
• The transmission is in neutral (the neutral switch is closed) and the sidestand is down (the sidestand
switch circuit is open).
2
9 5
8
6
11 10
1. Battery
2. Main fuse
3. Main switch
4. Ignition fuse
6. Ignition coil
7. Spark plug
9. Relay unit (diode)
11. Neutral switch
8-3
IGNITION SYSTEM
EAS30492
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP
• Before troubleshooting, remove the following part(s):
1. Rider seat
2. Auxiliary light
3. Air scoop (right)
1. Check the fuses.

(Main, ignition, backup fuse and
signaling system) NG→ Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 8-40.
OK↓
2. Check the battery.

Refer to “CHECKING AND • Clean the battery terminals.
NG→
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 8-41.
OK↓
3. Check the spark plugs.

Refer to “CHECKING THE SPARK NG→ Re-gap or replace the spark plug(s).
PLUGS” on page 3-5.
OK↓
4. Check the ignition spark gap.

Refer to “CHECKING THE SPARK OK→ Ignition system is OK.
PLUGS” on page 3-5.
NG↓
5. Check the ignition coils.

Refer to “CHECKING THE IGNI- NG→ Replace the ignition coil(s).
TION COILS” on page 8-43.
OK↓
6. Check the crankshaft position sen-

sor.
Refer to “CHECKING THE NG→ Replace the stator coil assembly.
CRANKSHAFT POSITION SEN-
SOR” on page 8-44.
OK↓
7. Check the cylinder identification

sensor.
Refer to “CHECKING THE CYLIN- NG→ Replace the cylinder identification sensor.
DER IDENTIFICATION SENSOR”
on page 8-48.
8-4
IGNITION SYSTEM
OK↓
8. Check the main switch.

Refer to “CHECKING THE NG→ Replace the main switch.
SWITCHES” on page 8-39.
OK↓
9. Check the start/engine stop switch.

Refer to “CHECKING THE NG→ Replace the handlebar switch (right).
OK↓
10.Check the neutral switch.

Refer to “CHECKING THE NG→ Replace the neutral switch.
OK↓
11.Check the sidestand switch.

Refer to “CHECKING THE NG→ Replace the sidestand switch.
OK↓
12.Check the relay unit (diode).

Refer to “CHECKING THE RELAY NG→ Replace the relay unit.
UNIT (DIODE)” on page 8-42.
OK↓
13.Check the entire ignition system’s

wiring. Properly connect or repair the ignition sys-
NG→
Refer to “CIRCUIT DIAGRAM” on tem’s wiring.
page 8-1.
OK↓
Replace the ECU or IMU.

Refer to “REPLACING THE ECU (En-
gine Control Unit)” on page 8-41.
8-5
IGNITION SYSTEM
8-6
EAS30493
EAS20073
R/WR/W R/W R/W R/W

R/W
R/WR/W
R/W
R/W R/W
R/W
R/W
R/W
R/L
R/W L/W
R RR
R (B)
L/W
R/W
5
R R R R/W
CIRCUIT DIAGRAM
3 R R R
28 L/W L/W L/W
L/W
B L/W
Br/L R R Br/L
Br/R R/B R/B Br/R 25 6 L/W
29 L/W L/W L/W L/W L/W R/W
L/B L/Y 30
L/Y L/B R/G
ON B R L/W R/W L R/L 31
OFF B L/W L/Y R/W L/B L/Y Sb B/Y Sb/W
L/Y
L/B 26 R/W L B/Y Sb L/Y

Br/L L/B
L/Y L/B
B/W
R/W
B R/W B/Y L/Y
R/W Y/B B/Y B/Y
R/L L/Y
6 Y/W L/Y
R/W
R/W L/B B
(Gy) R/L L
R/W R/L R/W R/W R W/BR/Y L/W L/B (B)
B/Y
OFF B
Br Gy 38 RUN B B
START
OFF
ON
R/L Br B
Sb 42
Br/L Gy Br
L/W R/W Y/G W/G B
Br/L G/W Y/B B/Y Br Br Y/B Y/R W/B W/R
(Gy) Y/B G/W B
L/Y 36 B Br/Y R/L
33 R/W L
41
12
R
ELECTRIC STARTING SYSTEM
R/G
16
B
B/W
R/W B (B) (B)
Br/L R/W B B/W
20 B B
19 B/W
L/B O/W Lg/L P/W P V L L/R Gy
8-7
B/W B
L/W B/Y Br G/LGy/G Br/W B/L W W/B
B/W L/Y L/W Lg/B Gy/Y G/W G Gy/B W/L
(B)
B
B
B/W B/W
B B
B B
B B
B B B B/W
B B
B
B B B
B B/W B/W B
B B/W
B B/W
B/W B/W
3. Main switch
5. Main fuse
6. Joint coupler
12. Fuse box 1
16. Backup fuse
19. Fuse box 2
20. Ignition fuse
25. Battery
26. Engine ground
28. Starter relay
29. Starter motor
30. Relay unit
31. Starting circuit cut-off relay
33. Clutch switch
41. Neutral switch
8-8
EAS30494
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION

If 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:
• 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.
12
11
4
6 6
10
6
6
7 a
6
8 9 10
b
a. WHEN THE TRANSMISSION IS IN NEU- 11. Starter relay

TRAL 12. Starter motor
b. WHEN THE SIDESTAND IS UP AND THE
CLUTCH LEVER IS PULLED TO THE HAN-
DLEBAR
1. Battery
2. Main fuse
3. Main switch
4. Ignition fuse
6. Relay unit (diode)
7. Clutch switch
8. Sidestand switch
9. Neutral switch
8-9
EAS30495
TROUBLESHOOTING
The starter motor fails to turn.
TIP
1. Rider seat
2. Auxiliary light
4. Thermostat
1. Check the fuses.

(Main, ignition and backup)
NG→ Replace the fuse(s).
ES” on page 8-40.
OK↓

NG→
page 8-41.
OK↓
3. Check the starter motor operation.

Starter motor is OK. Perform the electric
Refer to “CHECKING THE START-
OK→ starting system troubleshooting, starting
ER MOTOR OPERATION” on
with step (5).
page 8-45.
NG↓
4. Check the starter motor.

Refer to “CHECKING THE START- NG→ Repair or replace the starter motor.
ER MOTOR” on page 5-50.
OK↓
5. Check the relay unit (starting circuit

cut-off relay).
NG→ Replace the relay unit.
Refer to “CHECKING THE RE-
LAYS” on page 8-41.
OK↓
6. Check the relay unit (diode).

OK↓
7. Check the starter relay.

Refer to “CHECKING THE RE- NG→ Replace the starter relay.
OK↓
8-10

OK↓
9. Check the neutral switch.

OK↓
10.Check the sidestand switch.

Refer to “CHECKING THE NG→ Replace the sidestand switch.
OK↓
11.Check the clutch switch.

Refer to “CHECKING THE NG→ Replace the clutch switch.
OK↓
12.Check the start/engine stop switch.

OK↓
13.Check the entire starting system’s

wiring. Properly connect or repair the starting sys-
NG→
page 8-7.
OK↓
Replace the ECU.

8-11
8-12
CHARGING SYSTEM
EAS20074
CHARGING SYSTEM
EAS30496
CIRCUIT DIAGRAM
RR
B
B
26
R
25
5
R
R
R
R
R
R
(B)
R
B
2
B
WWW
(Gy)
W W
W W
W W
W W W
W W W
1
8-13
CHARGING SYSTEM
1. AC magneto
5. Main fuse
25. Battery
26. Engine ground
8-14
CHARGING SYSTEM
EAS30497
TROUBLESHOOTING
The battery is not being charged.
TIP
1. Rider seat
2. Air scoop stay (left)
1. Check the fuse.

(Main)
NG→ Replace the fuse.
ES” on page 8-40.
OK↓

NG→
page 8-41.
OK↓
3. Check the stator coil.

Refer to “CHECKING THE STA- NG→ Replace the stator coil assembly.
TOR COIL” on page 8-45.
OK↓
4. Check the rectifier/regulator.

Refer to “CHECKING THE RECTI-
NG→ Replace the rectifier/regulator.
FIER/REGULATOR” on page 8-
45.
OK↓
5. Check the entire charging system’s

wiring. Properly connect or repair the charging
NG→
Refer to “CIRCUIT DIAGRAM” on system’s wiring.
page 8-13.
OK↓
The charging system circuit is OK.
8-15
CHARGING SYSTEM
8-16
EAS30498
EAS20075
R/WR/W R/W R/W

R/W
R/WR/W
R/W
R/W R/W
R/W
R RR
R
R/W
5
R R R
CIRCUIT DIAGRAM
3 R R/B R R
Br/L R R Br/L
Br/R R/B R/B Br/R 25
ON R/G
OFF
LIGHTING SYSTEM
B
B B
Br/L
Br/R 26
B/W
B
6 R/W
R/W
R/W R/L R/W R/W
Br/L
Br/L
Br/L
12
R
R/G
16
B
B/W
R/W (B) (B)
Br/L R/W B B/W
B/W
20 B B
19 B/W
Br/L B/W B 76
8-17
Br L/W B/Y Br G/LGy/G Br/W B/L W W/B
22 B/W L/Y L/W Lg/B Gy/Y G/W G Gy/B W/L
23 (B)
Br
Br/R Br Y/B
L L/R
RES FREE UP 114 HI
PUSH PUSH (N) LO ON L
OFF N OFF
FREE DOWN PASS ON
SET R
W L W/B R/W
B/L
Y W/R W/G L/R Y W/B W B/W R B R
G/Y G G/B
Y Br
110 Y
W/L Y/B W/Y
B Br/Y B/W
82
6 Y/B Y/B Y/B Y/B
Y/B
B/W
Y/B
Y/B
Y 6
Y Y Y
L/R L/R Y
B B/R
101 BB Y
100 Br Br Y/B
B L/R
B 88
B L
99 B/W B/W
B B/R B L/R 96 90
Y
(B) B
B L/R B (Gy)
B B
B B B L/R
B B (B) 98 97 B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y L/W L/B G/W
B B L Y
B R/GR/G Sb/W G/L G/Y G G/B W/B W/G W G/O Y B B/W
B B Br B Y/B Y B Br B
B B B (B) B
Y L/R
B B/W B/W B
B L/R Br B B/W
B 6 L/R L/R B B/W
B L/W L/W L/W L/W L/W L/W L/R L/R Br L/R L/R L/R
B B/W B/W
LIGHTING SYSTEM
LIGHTING SYSTEM
3. Main switch
5. Main fuse
6. Joint coupler
12. Fuse box 1
16. Backup fuse
19. Fuse box 2
20. Ignition fuse
23. Headlight fuse
25. Battery
26. Engine ground
76. Meter assembly
82. Multi-function meter
88. Meter light
90. High beam indicator light
96. Headlight control unit
97. Headlight (high beam)
98. Headlight (low beam)
99. Tail/brake light
100.License plate light
101.Auxiliary light
110.Handlebar switch (left)
114.Dimmer/pass switch
8-18
LIGHTING SYSTEM
EAS30499
TROUBLESHOOTING
Any of the following fail to light: headlight, auxiliary light, high beam indicator light, tail/brake light, li-
cense plate light or meter light.
TIP
1. Rider seat
2. Headlight assembly
3. Air scoop (right and left)
4. Seat lock bracket
5. Air filter case
1. Check the fuses.

(Main, headlight, backup, ignition
and signaling system) NG→ Replace the fuse(s).
ES” on page 8-40.
OK↓

NG→
page 8-41.
OK↓

OK↓
4. Check the dimmer/pass switch.

The dimmer/pass switch is faulty. Replace
Refer to “CHECKING THE NG→
the handlebar switch (left).
OK↓
5. Check the entire lighting system’s

wiring. Properly connect or repair the lighting sys-
NG→
page 8-17.
OK↓
Replace the ECU, meter assembly,

headlight assembly, tail/brake light, li-
cense plate light or auxiliary light.
8-19
LIGHTING SYSTEM
8-20
EAS30500
EAS20076
R/WR/W R/W R/W

B/L G/W G/W B/L
R/W
R/WR/W
R/W
A B R/W R/W
R/W
R RR
R
R/W
5
CIRCUIT DIAGRAM
R R R
3 R R L/R G W
45
R W W
G G
(B) L/R L/R
Br/L R R Br/L
Br/R R/B R/B Br/R 25 Sb/W
ON 30
OFF B R/G
B R L/W R/W L R/L
B B L/W L/Y R/W L/B L/Y Sb B/Y Sb/W
Br/L
SIGNALING SYSTEM
26 Sb
B/W
B G/W Y/B Y/B G/Y
G/Y Y/W
6 R/W Lg/L Lg/B
R/W
(B) (B)
7 R/W R/L R/W R/W G/W
8 G/W G/Y
Br G/W
L/R B Br Y 43 B/L V L R W B 48 R L
OFF OFF W V V
B ON ON B B/L
(B)
Sb (B)
Br/L Y/B G/W Br Y
B
Br/L Y/W G/Y B G R/L B G/W B
(B) (B) B G
G/Y (B)
Lg/B 41
12 34 35
R
L L
R/G
16
B R/G
B R/G Y/B L/Y R/L B/W B/W B/L B B/Y W/Y
B/W R/G
R/W (B) (B)
Br/L R/W B B/W
6 B/W
B B
19 21 20 Br/B
B/W
8-21
Br Br R/W Br Br Br B/W B 76
Br G/W A G/W G/W
G/W B/L (B) 54 B/L A (B)
B/L
Br
L L/R
RES FREE UP HI
PUSH PUSH (N) LO ON L
115 OFF N OFF
FREE DOWN PASS 118 ON B/L
SET R
80 B/L B/L
W L W/B R/W Sb/W B/L B/L
B/L
Lg/B Y W/R W/G L/R Y 117 W/B W B/W R B R
L/R G/Y G G/B 81 B/L
B W/L W/Y Br/Y B/L
109 110 Y Br
W/L Y/B W/Y B/L B/L
B/L B/L B/L
B Br/Y B/W B/L B/L
B 116
L/R Y
Y G/W 82 B/L
R/G
R/G
Lg/B Y B L/W
L/B
(B)
G/L
84 Gy/B Gy/B
W/L W/L
72 W W
B/W B B
W/Y
W/L L/B
Br/Y 86 B W W B
Br/B
B L/W
Br/B 87 Y
B Br/W 71
Y Ch
Dg
G/L
B L Br/W L/R B Ch B Dg B
Br/B L/R B
B 99 G B/W B/W
L/R Br/B (Gy) L/R Br/W (B) Ch (B) Dg B/W B
Br G Br G
B B B L/R Br B L/R G B Br B G (Gy)
B B
91
(Gy) (B) (B)
B B B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y L/W L/B G/W
B B L Y 93 92
B
95 94 R/GR/G Sb/W G/L G/Y G G/B W/B W/G W G/O Y B B/W
B B B B B B R Gy/B L Y G Br/B B L/W B/W
B
B B B B R/L B
G/O W/L L B W W L/B
Y L/R
B B/W B/W B
B L/W L/B B B B/W B/W (B)
B L/W L/B B B/W
B
6 L/R
L/W L/W L/W L/W L/W L/W L/R L/R Br L/R L/R L/R B/W B/W
B B L/R
SIGNALING SYSTEM
SIGNALING SYSTEM
3. Main switch
5. Main fuse
6. Joint coupler
7. Fuse box 3
8. Brake light fuse
12. Fuse box 1
16. Backup fuse
19. Fuse box 2
20. Ignition fuse
21. ABS ECU fuse
25. Battery
26. Engine ground
30. Relay unit
34. Front brake light switch
35. Rear brake light switch
41. Neutral switch
43. Fuel sender
45. Gear position sensor
48. Shift sensor
54. Coolant temperature sensor
71. Rear wheel sensor
72. Hydraulic unit assembly (ABS ECU)
76. Meter assembly
80. Neutral indicator light
81. Shift indicator light
84. Oil pressure and coolant temperature
warning light
86. Right turn signal indicator light
87. Left turn signal indicator light
92. Rear turn signal light (right)
93. Rear turn signal light (left)
94. Front turn signal/position light (right)
95. Front turn signal/position light (left)
109.Brake light relay
115.Horn switch
116.Horn
117.Turn signal switch
118.Hazard switch
A. Wire harness
B. Sub-wire harness (Coolant temperature
sensor)
8-22
SIGNALING SYSTEM
EAS30501
TROUBLESHOOTING
• Any of the following fail to light: turn signal light, brake light or an indicator light.
• The horn fails to sound.
• The speedometer fails to operate.
TIP
1. Rider seat
2. Auxiliary light
5. Drive sprocket cover
1. Check the fuses.

(Main, ignition, signaling system,
backup, ABS ECU and brake light) NG→ Replace the fuse(s).
ES” on page 8-40.
OK↓

NG→
page 8-41.
OK↓

OK↓
4. Check the entire signaling sys-

tem’s wiring. Properly connect or repair the signaling
NG→
page 8-21.
OK↓
Check the condition of each of the sig-

naling system circuits.
Refer to “Checking the signaling sys-
tem”.
8-23
SIGNALING SYSTEM
Checking the signaling system
The horn fails to sound.
1. Check the horn switch.

Refer to “CHECKING THE NG→ Replace the handlebar switch (left).
OK↓
2. Check the horn.

Refer to “CHECKING THE HORN” NG→ Replace the horn.
on page 8-46.
OK↓

NG→
page 8-21.
OK↓
This circuit is OK.
The tail/brake light fails to come on.
1. Check the front brake light switch.

Refer to “CHECKING THE NG→ Replace the front brake light switch.
OK↓
2. Check the rear brake light switch.

Refer to “CHECKING THE NG→ Replace the rear brake light switch.
OK↓
3. Check the brake light relay.

Refer to “CHECKING THE RE- NG→ Replace the brake light relay.
OK↓

NG→
page 8-21.
OK↓
Replace the tail/brake light.
The turn signal light, turn signal indicator light or both fail to blink.
1. Check the turn signal switch.

8-24
SIGNALING SYSTEM
OK↓
2. Check the hazard switch.

OK↓

NG→
page 8-21.
OK↓
Replace the meter assembly or turn

signal light.
The neutral indicator light fails to come on.
1. Check the neutral switch.

OK↓
2. Check the relay unit (diode).

OK↓

NG→
page 8-21.
OK↓
Replace the meter assembly.
The oil pressure and coolant temperature warning light fails to come on, or the oil pressure warn-
ing icon flashes when the main switch is set to “ON”.

tem’s wiring. Properly connect or replace the wiring har-
NG→
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-21.
OK↓
2. Disconnect the oil pressure switch

lead from the oil pressure switch,
and then check whether the oil
pressure and coolant temperature NG→ Replace the meter assembly.
warning light comes on when the
lead is connected to the engine
ground.
8-25
SIGNALING SYSTEM
OK↓
Replace the oil pressure switch.
The oil pressure and coolant temperature warning light remains on after the engine is started.

NG→
page 8-21.
OK↓
2. Measure the engine oil pressure.

Refer to “MEASURING THE EN- Check the engine oil leakage, oil viscosity,
NG→
GINE OIL PRESSURE” on page 3- oil seal, oil filter, or oil pump.
30.
OK↓
Replace the oil pressure switch.
The fuel level warning icon fails to come on.
1. Check the fuel sender.

Refer to “CHECKING THE FUEL NG→ Replace the fuel pump assembly.
SENDER” on page 8-46.
OK↓

NG→
page 8-21.
OK↓
Replace the meter assembly.
The oil pressure and coolant temperature warning light fails to come on.
1. Check the coolant temperature

sensor.
Refer to “CHECKING THE COOL- NG→ Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR”
on page 8-47.
OK↓

NG→
page 8-21.
OK↓
8-26
SIGNALING SYSTEM
Replace the ECU or meter assembly.

Quick shift system does not operate.
1. Check that the MIL does not come

NG→ Repair the faulty parts.
on.
OK↓
Check the quick shift system operating

2. Check that the quick shift system is
conditions explained in the owner’s manu-
working under normal quick shift NG→
al and operate the quick shift system ac-
system operating conditions.
cordingly.
OK↓
3. Make sure that the quick shift sys-

tem is effective. Activate the quick shift system. (Set the
(Check whether the “QS ” icon NG→ quick shift system to a setting other than
is displayed at the top of the me- “OFF”.)
ter.)
OK↓
4. Are you operating while the

NG→ Operate while the “QS ” icon is lit.
“QS ” icon is lit?
OK↓
5. Is the transmission gear display

NG→ Repair the gear position sensor.
normal?
OK↓
6. Check the connection of the cou-

pler between the gear position sen- NG→ Connect the gear position sensor coupler.
sor and the ECU.
OK↓
7. Are the clutch and neutral switches

NG→ Repair the switch if it is not normal.
normal?
OK↓
8. Check the shift sensor value in the

DIAG mode.
2.5 V when the shift pedal is not be-
ing operated.
NG→ 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.
OK↓
8-27
SIGNALING SYSTEM

NG→
page 8-21.
OK↓
Replace the ECU.

The speedometer fails to operate.
1. Check the rear wheel sensor.

Refer to “MAINTENANCE OF THE
NG→ Replace the rear wheel sensor.
REAR WHEEL SENSOR AND
SENSOR ROTOR” on page 4-36.
OK↓
2. Check the entire wheel sensor wir-

Properly connect or repair the wheel sen-
ing. NG→
sor wiring.
Refer to TIP.
OK↓
Replace the hydraulic unit assembly,

ECU, meter assembly.
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)
• 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)
8-28
EAS30502
EAS20077
R/WR/W R/W R/W

B/L G/W G/W B/L
R/W R/W
R/WR/W
R/W
A B R/W R/W
R/W
R RR
R
R/W
5
CIRCUIT DIAGRAM
R R R
3 R R R
Br/L R R Br/L
ON
COOLING SYSTEM
OFF R/G
B
B
Br/L
26
B
R/W
R
4
R/B Br/L
R G/Y
R/B Br/L
R/W G/Y
12
R/G
17 16 L
R/B R/G
L/W Lg/R L/B O/B R/B G/B B W W L B/R
18 R/G Y/B L/Y R/L B/W B/W B/L B B/Y W/Y
(B) (B)
Br/L R/W
19 20
8-29
L/Y L/W Lg/B Gy/Y G/W G Gy/B W/L
G/W A G/W G/W
G/W B/L (B) 54 B/L A (B)
B/L
B/L
B/L B/L
L/W L B/L B/L
B/L
L
B B/L
B
L B/L B/L
107 L 108 B/L B/L
(B) B/L B/L
B B B/L
B B
L/W L
G/Y
B
B
B
B/W B/W
B B
B B
B B
B B B B/W
B B
B
B B B
B B/W B/W B
B B/W
B B/W
B/W B/W
COOLING SYSTEM
COOLING SYSTEM
3. Main switch
5. Main fuse
12. Fuse box 1
16. Backup fuse
17. Sub radiator fan motor fuse
18. Radiator fan motor fuse
19. Fuse box 2
20. Ignition fuse
25. Battery
26. Engine ground
107.Radiator fan motor (left)
108.Sub radiator fan motor (right)
A. Wire harness
sensor)
8-30
COOLING SYSTEM
EAS30503
TROUBLESHOOTING
TIP
1. Rider seat
2. Auxiliary light
3. Air scoop (left)
1. Check the fuses.

(Main, ignition, backup, radiator fan
motor and sub radiator fan motor) NG→ Replace the fuse(s).
ES” on page 8-40.
OK↓

NG→
page 8-41.
OK↓

OK↓
4. Check the radiator fan motor.

Refer to “CHECKING THE RADIA-
NG→ Replace the radiator fan motor.
TOR FAN MOTORS” on page 8-
47.
OK↓
5. Check the radiator fan motor relay.

Refer to “CHECKING THE RE- NG→ Replace the radiator fan motor relay.
OK↓
6. Check the coolant temperature

sensor.
Refer to “CHECKING THE COOL- NG→ Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR”
on page 8-47.
OK↓
7. Check the entire cooling system’s

wiring. Properly connect or repair the cooling sys-
NG→
page 8-29.
OK↓
8-31
COOLING SYSTEM
Replace the ECU.

8-32
EAS30513
EAS20081
R/L
R/L
R/WR/W R/W R/W R/L R/L
R/L
R/W R/L
R/L
R/WR/W
R/L
R/W
R/L
R/W R/W
R/L
R/W
R/W
R/W
R RR
R
R/W
5
CIRCUIT DIAGRAM
R R R
3 R R R
Br/L R R Br/L L/Y

Br/R R/B R/B Br/R 25 R/W R
ON 30
OFF R/G
B R L/W R/W L R/L 32 R/L
B L/W L/Y R/W L/B L/Y Sb B/Y Sb/W
Br/L
FUEL PUMP SYSTEM
26 L/Y
R/L
B/W
R/W
R/W
R/L
6 R/W
R/W
R/L
R/W R/L R/W R/W R W/BR/Y L/W R/L
OFF
38 RUN 44
START
Br/L R/L Br B
L/W R/W Y/G W/G B
Br/L B/Y Br Br Y/B Y/R W/B W/R R/L B G/W B
36 B Br/Y R/L (B)

R/W L
12 14 R
R
R/G
16
B
B/W R/G Y/B L/Y R/L B/W B/W B/L B B/Y W/Y
R/W (B) (B)
Br/L R/W B B/W
20 B B
19 B/W B
8-33
B/W B
(B)
B/W B/W
B B/W
B
B
B/W B/W B
B B/W
B B/W
B/W B/W
FUEL PUMP SYSTEM
FUEL PUMP SYSTEM
3. Main switch
5. Main fuse
6. Joint coupler
12. Fuse box 1
14. Fuel injection system fuse
16. Backup fuse
19. Fuse box 2
20. Ignition fuse
25. Battery
26. Engine ground
30. Relay unit
32. Fuel pump relay
44. Fuel pump
8-34
FUEL PUMP SYSTEM
EAS30514
TROUBLESHOOTING
If the fuel pump fails to operate.
TIP
1. Rider seat
2. Auxiliary light
4. Air filter case
1. Check the fuses.

(Main, ignition, backup and fuel in-
jection system) NG→ Replace the fuse(s).
ES” on page 8-40.
OK↓

NG→
page 8-41.
OK↓

OK↓
4. Check the start/engine stop switch.

OK↓
5. Check the relay unit (fuel pump re-

lay).
NG→ Replace the relay unit.
Refer to “CHECKING THE RE-
OK↓
6. Check the fuel pump.

Refer to “CHECKING THE FUEL NG→ Replace the fuel pump.
PUMP OPERATION” on page 7-3.
OK↓
7. Check the entire fuel pump sys-

tem’s wiring. Properly connect or repair the fuel pump
NG→
page 8-33.
OK↓
8-35
FUEL PUMP SYSTEM
Replace the ECU.

8-36
ELECTRICAL COMPONENTS
EAS20089
3 7
2 4 8
1 5 6 9
23
10
22
11
21 12
20
19 17
13
18 16 14
15
1. Clutch switch 18. Starter motor

2. Front brake light switch 19. Radiator fan motor
3. Accelerator position sensor 20. Horn
4. SCU (Suspension Control Unit) (for 21. Headlight control unit
MT10SPN/MT10SPNC) 22. Main switch
5. Intake air pressure sensor 23. Auxiliary DC jack
6. Throttle servo motor
7. Fuel injector
8. Throttle position sensor
9. Fuel pump
10. EXUP servo motor
13. Battery
15. Shift sensor
16. Stator coil
8-37
3 4 5 6
2
1 7
8
26 9
25
10
24 11
12
23
13
22 14
21
15
20 18 17 16
19
1. Front fork stepping motor (for MT10SPN/ 19. O2 sensor

MT10SPNC) 20. Oil pressure switch
2. Atmospheric pressure sensor 21. Gear position sensor
3. Intake air temperature sensor 22. Front wheel sensor
4. Ignition coil 23. Cylinder identification sensor
5. Coolant temperature sensor 24. Air induction system solenoid
6. Brake light relay 25. Relay unit
7. Radiator fan motor relay 26. Rectifier/regulator
8. Starter relay
9. Main fuse
10. Fuse box 2
11. Fuse box 1
12. Fuse box 4 (SCU fuse) (for MT10SPN/
MT10SPNC)
13. Fuse box 3
15. Rear shock absorber assembly stepping
motor (for MT10SPN/MT10SPNC)
17. Neutral switch
8-38
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 G/W G/Y Y/W Y/B
10 R Br/L Br/R R/B L/B L/Y
ON
OFF OFF
Y/B G/W
ON Y/W G/Y
(B) R Br/L
L/B L/Y
R/B Br/R
2 Br Y/B Gy G/W
11 R/L R/W L/W B
OFF Gy Br
OFF
ON G/W Y/B RUN
(Gy) START
R/L Br B
L/W R/W
3 G/B Y/W G/Y G

RES
PUSH
FREE
SET 12 L/B
4 Y B
B Y G
B
FREE B B
Y/W G/B G/Y
PUSH
5 W/R B/W W/G

UP W/R W/G B
(N) (B)
DOWN
6
HI
Y L Y
13 Br B Y G
LO OFF
PASS ON Br Y
B G
7 L/R B/L
(B)
ON L/R Y
OFF
8 W/B L/R W
L 14
N
R
9 L/R R
OFF W L W/B
B/W R B
ON

2. Clutch switch
3. Cruise control setting/power switch
4. Mode switch
5. Select switch
6. Dimmer/pass switch
7. Horn switch
8. Turn signal switch
9. Hazard switch
10. Main switch
14. Neutral switch
8-39
EAS30551
CHECKING THE FUSES Amper-

Fuses Q’ty
The following procedure applies to all of the fus- age rating
es. Main 50 A 1
ECA13680
NOTICE Headlight 10 A 1
To avoid a short circuit, always set the main Signaling system 7.5 A 1
switch to “OFF” when checking or replacing Ignition 15 A 1
a fuse.
Radiator fan motor 15 A 1
1. Remove: Sub radiator fan motor 10 A 1
• Rider seat
Fuel injection system 15 A 1
page 4-1. ABS motor 30 A 1
2. Check: ABS ECU 7.5 A 1
• Fuse
ABS solenoid 15 A 1
a. Connect the digital circuit tester to the fuse
Terminal 1 2A 1
and check the continuity.
TIP Backup 10 A 1
Set the digital circuit tester selector to “ Ω ”. Electronic throttle valve 7.5 A 1
Brake light 1.0 A 1
Digital circuit tester (CD732) Cruise control 1.0 A 1
90890-03243 SCU (for MT10SPN/ 7.5 A 1
Model 88 Multimeter with ta- MT10SPNC)
chometer
YU-A1927 Spare 30 A 1
Spare 15 A 1
b. If the digital circuit tester indicates “O.L”, re-
Spare 10 A 1
place the fuse.
Spare 7.5 A 1
3. Replace:
• Blown fuse Spare 2A 1
a. Set the main switch to “OFF”. Spare 1.0 A 1
b. Install a new fuse of the correct amperage
EWA13310
rating.
c. Set on the switches to verify if the electrical WARNING
circuit is operational. Never use a fuse with an amperage rating
d. If the fuse immediately blows again, check other than that specified. Improvising or us-
the electrical circuit. ing a fuse with the wrong amperage rating
may cause extensive damage to the electri-
cal system, cause the lighting and ignition
systems to malfunction and could possibly
cause a fire.
4. Install:
• Rider seat
page 4-1.
8-40
EAS31006
8. Check:
REPLACING THE ECU (Engine Control Unit)
• Battery terminal
1. Turn the main switch to “OFF”.
Dirt → Clean with a wire brush.
2. Replace the ECU (Engine Control Unit).
Loose connection → Connect properly.
3. Clean the throttle body assembly and reset
9. Lubricate:
the ISC (Idle Speed Control) learning value.
• Battery terminal
Refer to “CHECKING AND CLEANING THE
THROTTLE BODIES” on page 7-13.
4. Check: Dielectric grease
• Engine idling speed
Start the engine, warm it up, and then mea- 10.Install:
sure the engine idling speed. • Battery band/Rider seat
Engine idling speed page 4-1.
1200–1400 r/min
EAS30553
EAS30552
CHECKING THE RELAYS
CHECKING AND CHARGING THE BATTERY Check each switch for continuity with the digital
TIP circuit tester. If the continuity reading is incor-
Refer to “CHECKING AND CHARGING THE rect, replace the relay.
BATTERY” in “BASIC INFORMATION” (sepa-
rate volume). Digital circuit tester (CD732)
90890-03243
1. Remove: Model 88 Multimeter with ta-
• Rider seat/Battery band chometer
Refer to “GENERAL CHASSIS (1)” on YU-A1927
page 4-1.
1. Disconnect the relay from the wire harness.
2. Disconnect:
2. Connect the digital circuit tester (Ω) and bat-
• Battery lead
tery (12 V) to the relay terminal as shown.
(from the battery terminals)
ECA13700 Check the relay operation.
NOTICE Out of specification → Replace.
First, disconnect the negative battery lead,
and then the positive battery lead. Starter relay
3. Remove: 3
• Battery
page 4-1. R/L
4. Check: R/W L/W
• Battery charge
5. Charge: 1 2
• Battery
6. Install: 4
• Battery 1. Positive battery terminal
Refer to “GENERAL CHASSIS (1)” on 2. Negative battery terminal
page 4-1. 3. Positive tester probe
7. Connect: 4. Negative tester probe
• Battery lead
(to the battery terminals) Relay operation
ECA26980
NOTICE Continuity
(between “3” and “4”)
First, connect the positive battery lead, and
then the negative battery lead.
8-41
Relay unit (starting circuit cut-off relay) Radiator fan motor relay
R
R/B
R/W G/Y
R L/W R/W L R/L
L/W L/Y R/W L/B L/Y Sb B/Y Sb/W
1. Positive battery terminal 1. Positive battery terminal

2. Negative battery terminal 2. Negative battery terminal
3. Positive tester probe 3. Positive tester probe
4. Negative tester probe 4. Negative tester probe
Result Result
Continuity Continuity
(between “3” and “4”) (between “3” and “4”)
Relay unit (fuel pump relay) Brake light relay
3 2 1 4
L/R
Lg/B Y B
R L/W R/W L R/L
4
1. Positive battery terminal 1. Positive battery terminal

2. Negative battery terminal 2. Negative battery terminal
3. Positive tester probe 3. Positive tester probe
4. Negative tester probe 4. Negative tester probe
Result Result
Continuity Continuity
(between “3” and “4”) (between “3” and “4”)
EAS30795
CHECKING THE RELAY UNIT (DIODE)

1. Check:
• Relay unit (diode)
Digital circuit tester (CD732)

90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927
8-42
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 (Ω) to the
relay unit terminal as shown.
c. Check the relay unit (diode) for continuity.
Continuity d. Check the relay unit (diode) for no continui-
Positive tester probe
ty.
sky blue “1”
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 • Primary coil resistance
sky blue “1” Out of specification → Replace.
Continuity
Positive tester probe Primary coil resistance
sky blue “1” 1.19–1.61 Ω
Negative tester probe
blue/yellow “3”
a. Disconnect the ignition coil coupler from the
No continuity
ignition coil.
blue/yellow “3” b. Connect the digital circuit tester (Ω) to the
Negative tester probe ignition coil as shown.
sky blue “1”
Continuity Digital circuit tester (CD732)
Positive tester probe 90890-03243
sky blue “1” Model 88 Multimeter with ta-
Negative tester probe chometer
sky blue/white “4” YU-A1927
No continuity
Positive tester probe • Positive tester probe
sky blue/white “4” Ignition coil terminal “1”
Negative tester probe • Negative tester probe
sky blue “1” Ignition coil terminal “2”
Continuity
blue/black “5” 1
2
blue/yellow “3”
No continuity
blue/yellow “3”
blue/black “5”
G089046
c. Measure the primary coil resistance.

2. Check:
• Secondary coil resistance
R L/W R/W L R/L Secondary coil resistance

L/W L/Y R/W L/B L/Y Sb B/Y Sb/W 8.50–11.50 kΩ
8-43
a. Connect the digital circuit tester (Ω) to the

ignition coil as shown.

90890-03243
chometer
YU-A1927
G089048
• Negative tester probe
Ignition coil terminal “1” 2. Ignition coil
• Positive tester probe
c. Turn the main switch to “ON”.
Spark plug terminal “2”
d. Measure the ignition spark gap “a”.
e. Crank the engine by pushing the “ ” side of
the start/engine stop switch and gradually
1 increase the spark gap until a misfire oc-
curs.
EAS30560
CHECKING THE CRANKSHAFT POSITION

SENSOR
1. Disconnect:
• Crankshaft position sensor coupler
2 G089047 (from the wire harness)
b. Measure the secondary coil resistance. 2. Check:
EAS30556
• Crankshaft position sensor resistance
CHECKING THE IGNITION SPARK GAP Out of specification → Replace the stator coil
1. Check: assembly.
• Ignition spark gap
Out of specification → Perform the ignition Crankshaft position sensor re-
system troubleshooting, starting with step (5). sistance
Refer to “TROUBLESHOOTING” on page 8- 189–231 Ω
4.
crankshaft position sensor coupler as
Minimum ignition spark gap
6.0 mm (0.24 in) shown.
TIP Digital circuit tester (CD732)

90890-03243
If the ignition spark gap is within specification,
the ignition system circuit is operating normally.
chometer
a. Remove the ignition coil from the spark YU-A1927
plug.
b. Connect the ignition checker “1” as shown.
black “1”
Ignition checker gray “2”
90890-06754
Oppama pet–4000 spark checker
YM-34487
8-44
2. Check:
• Stator coil resistance
Out of specification → Replace the stator coil
assembly.
Stator coil resistance

0.112–0.168 Ω
B Gy
a. Connect the digital circuit tester to the stator
coil coupler as shown.
b. Measure the crankshaft position sensor re-
sistance. Digital circuit tester (CD732)
EAS30562
90890-03243
CHECKING THE STARTER MOTOR Model 88 Multimeter with ta-
OPERATION chometer
1. Check: YU-A1927
• Starter motor operation
Does not operate → Perform the electric
white “1”
starting system troubleshooting, starting with • Negative tester probe
step (4). white “2”
Refer to “TROUBLESHOOTING” on page 8-
10.
a. Connect the positive battery terminal “1” white “1”
and starter motor lead “2” with a jumper • Negative tester probe
lead “3”. white “3”
EWA13810
WARNING
• A wire that is used as a jumper lead must • Positive tester probe
have at least the same capacity of the bat- white “2”
tery lead, otherwise the jumper lead may
white “3”
burn.
• This check is likely to produce sparks,
therefore, make sure no flammable gas or
fluid is in the vicinity.
1 2 3
W W W
b. Measure the stator coil resistance.

EAS30680
G089054
CHECKING THE RECTIFIER/REGULATOR
b. Check the starter motor operation. 1. Check:
EAS30566
• Battery charging voltage
CHECKING THE STATOR COIL Out of specification → Check the stator coil
1. Disconnect: condition. If the stator coil does not have a
• Stator coil coupler problem, replace the rectifier/regulator.
(from the rectifier/regulator) Refer to “CHECKING THE STATOR COIL”
on page 8-45.
8-45
Battery charging voltage Digital circuit tester (CD732)

above 14 V at 5000 r/min 90890-03243
a. Connect the digital circuit tester to the bat- chometer
tery terminal. YU-A1927
Digital circuit tester (CD732) • Positive tester probe →

90890-03243 Fuel sender terminal “1”
Model 88 Multimeter with ta- • Negative tester probe →
chometer Fuel sender terminal “2”
YU-A1927
• Positive tester probe →

Battery positive terminal
• Negative tester probe →
Battery negative terminal
b. Start the engine and let it run at approxi-

mately 5000 r/min. 2
c. Measure the battery charging voltage. 1
EAS30569
b. Move the fuel sender float to maximum and
CHECKING THE HORN
minimum level position.
1. Check:
• Horn sound EAS33653
Faulty sound → Replace. CHECKING THE FUEL LEVEL WARNING

ICON
EAS30573
This model is equipped with a self-diagnosis de-
CHECKING THE FUEL SENDER
vice for the fuel level detection circuit.
1. Disconnect:
1. Check:
• Fuel pump coupler
• Fuel level warning icon “1”
(from the fuel pump)
(Turn the main switch to “ON”.)
2. Remove:
Warning icon comes on for a few seconds,
• Fuel tank
then goes off → Warning icon is OK.
3. Remove:
Warning icon does not come on → Replace
• Fuel pump
the meter assembly.
(from the fuel tank)
Warning icon flashes eight times, then goes
4. Check:
off for 3 seconds in a repeated cycle (mal-
• Fuel sender resistance
function detected in fuel sender) → Replace
Out of specification → Replace the fuel pump
the fuel pump assembly.
assembly.
1
Sender unit resistance (full)
9.0–12.0 Ω
Sender unit resistance (empty) Er:00
12 r
213.0–219.0 Ω 1000 r/min

fuel sender terminals as shown.
8-46
EAS30577
CHECKING THE RADIATOR FAN MOTORS

1. Check: 90890-03243
• Radiator fan motor Model 88 Multimeter with ta-
Faulty/rough movement → Replace. chometer
a. Disconnect the radiator fan motor coupler YU-A1927
from the wire harness.
b. Connect the battery (DC 12 V) as shown. b. Immerse the coolant temperature sensor
“1” in a container filled with coolant “2”.
TIP
blue “1”
• Negative tester probe Make sure the coolant temperature sensor ter-
black “2” minals do not get wet.
c. Place a thermometer “3” in the coolant.
3
2 1
1 2
G089056
c. Measure the radiator fan motor movement. d. Heat the coolant or let it cool down to the
EAS30578 specified temperatures.
CHECKING THE COOLANT TEMPERATURE e. Measure the coolant temperature sensor
SENSOR resistance.
1. Remove:
3. Install:
• Coolant temperature sensor
• Coolant temperature sensor
Refer to “CYLINDER HEAD” on page 5-31.
EWA14130
WARNING Coolant temperature sensor

• Handle the coolant temperature sensor 15 N·m (1.5 kgf·m, 11 lb·ft)
T.
R.
with special care. EAS30592

• Never subject the coolant temperature sen- CHECKING THE THROTTLE SERVO MOTOR
sor to strong shocks. If the coolant tem- 1. Remove:
perature sensor is dropped, replace it. • Air filter case
2. Check: Refer to “AIR FILTER CASE” on page 7-6.
• Coolant temperature sensor resistance 2. Check:
Out of specification → Replace. • Throttle valve operation
Throttle valves do not fully close → Replace
Coolant temperature sensor re- the throttle body assembly.
sistance a. Connect two C-size batteries to the throttle
2513–2777 Ω at 20 °C (2513– servo motor terminals “1” as shown.
2777 Ω at 68 °F) ECA17660
Coolant temperature sensor re- NOTICE

sistance Do not use a 12 V battery to operate the throt-
210–221 Ω at 100 °C (210–221 Ω tle servo motor.
at 212 °F)
TIP
a. Connect the digital circuit tester (Ω) to the Do not use old batteries to operate the throttle
coolant temperature sensor as shown. servo motor.
8-47
O G
1 1 2
2 3V
c. Measure the air induction system solenoid

1 resistance.
EAS30589
CHECKING THE CYLINDER

IDENTIFICATION SENSOR
1. Remove:
1 • Fuel tank
3V Refer to “FUEL TANK” on page 7-1.
2
• Air filter case
A. Check that the throttle valves “2” open. Refer to “AIR FILTER CASE” on page 7-6.
B. Check that the throttle valves “2” fully close. • Air filter case duct
Air cut-off valve
EAS30587
CHECKING THE AIR INDUCTION SYSTEM page 7-18.
SOLENOID 2. Check:
1. Check: • Cylinder identification sensor output voltage
• Air induction system solenoid resistance Out of specification → Replace.
Cylinder identification sensor
Solenoid resistance output voltage (ON)
18–22 Ω 4.8 V
Cylinder identification sensor
a. Remove the air induction system solenoid output voltage (OFF)
coupler from the air induction system sole- 0.8 V
noid.
b. Connect the digital circuit tester (Ω) to the a. Connect the test harness– speed sensor
air induction system solenoid terminal as (3P) “1” to the cylinder identification sensor
shown. coupler and wire harness as shown.
b. Connect the digital circuit tester (DC V) to
Digital circuit tester (CD732) the test harness– speed sensor (3P).
90890-03243
Model 88 Multimeter with ta- Digital circuit tester (CD732)
chometer 90890-03243
YU-A1927 Model 88 Multimeter with ta-
chometer
• Positive tester probe YU-A1927
orange “1” Test harness– speed sensor (3P)
• Negative tester probe 90890-03208
green “2” Test harness– speed sensor (3P)
YU-03208
8-48
• Positive tester probe a. Connect the digital circuit tester (Ω) to the
white/black (wire harness color) intake air temperature sensor terminal as
• Negative tester probe shown.
black/blue (wire harness color)
90890-03243
1 chometer
YU-A1927
b. Immerse the intake air temperature sensor

“1” in a container filled with water “2”.
TIP
Make sure that the intake air temperature sensor
terminals do not get wet.
c. Turn the main switch to “ON”. c. Place a thermometer “3” in the water.
d. Rotate the crankshaft.
e. Measure the voltage. With each full rotation
of the crankshaft, the voltage reading 3
should cycle from 0.8 V to 4.8 V to 0.8 V to 1
4.8 V.
EAS30594
CHECKING THE INTAKE AIR

TEMPERATURE SENSOR 2
1. Remove: G089057
• Intake air temperature sensor
EWA14110 d. Slowly heat the water, then let it cool down
WARNING to the specified temperature.
• Handle the intake air temperature sensor e. Measure the intake air temperature sensor
with special care. resistance.
• Never subject the intake air temperature 3. Install:
sensor to strong shocks. If the intake air • Intake air temperature sensor
temperature sensor is dropped, replace it.
EAS30681
2. Check: CHECKING THE FUEL INJECTORS

• Intake air temperature sensor resistance The following procedure applies to all of the fuel
Out of specification → Replace. injectors.
1. Remove:
Intake air temperature sensor re- • Fuel injector
sistance Refer to “THROTTLE BODIES” on page 7-9.
5400–6600 Ω at 0 °C (5400–6600 2. Check:
Ω at 32 °F) • Fuel injector resistance
Intake air temperature sensor re- Out of specification → Replace the fuel injec-
sistance tor.
290–390 Ω at 80 °C (290–390 Ω
at 176 °F) Resistance
12.0 Ω
a. Disconnect the fuel injector coupler from

the fuel injector.
b. Connect the digital circuit tester (Ω) to the
fuel injector coupler as shown.
8-49
d. Connect the digital circuit tester (DC V) to

Digital circuit tester (CD732) the handlebar switch coupler (right) as
90890-03243 shown.
chometer Digital circuit tester (CD732)
YU-A1927 90890-03243
• Positive tester probe chometer
Injector terminal “1” YU-A1927
Injector terminal “2” • Positive tester probe
white/black “4”
black/yellow “3”
e. When turning the wheel switch in direction

“a”, check that the output voltage is within
the specified values.
Output voltage
More than 5 V
c. Measure the fuel injector resistance. f. When turning the wheel switch in direction
“b”, check that the output voltage is within
EAS31673
CHECKING THE WHEEL SWITCH the specified values.

1. Check:
• Wheel switch “1” output voltage Output voltage
Less than 0.5 V
Out of specification → Replace the handlebar
switch (right).
a. Connect the digital circuit tester (DC V) to 3 2 4
the handlebar switch coupler (right) as
shown. W W/G B/W B/Y W/G W/B a
R/W B W/B R B R/Y
90890-03243
Model 88 Multimeter with ta- b
chometer
YU-A1927 1

white/green “2”
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
8-50
8-51
SELF DIAGNOSTIC
SELF-DIAGNOSTIC FUNCTION..................................................................... 9-1

GLOSSARY............................................................................................... 9-1
OUTLINE ...................................................................................................9-1
CHECKING THE WARNING LIGHT .........................................................9-2
YDT ...........................................................................................................9-3
PARTS CONNECTED TO THE ECU ........................................................9-4
PARTS CONNECTED TO THE SCU (for MT10SPN/MT10SPNC)...........9-4
PARTS CONNECTED TO THE ABS ECU................................................ 9-5
PRECAUTIONS FOR ROAD TEST .......................................................... 9-5
SYSTEM DIAGRAM ........................................................................................9-6

ECU CIRCUIT DIAGRAM..........................................................................9-6
ECU COUPLER LAYOUT ......................................................................... 9-9
FUEL INJECTION SYSTEM..........................................................................9-12

CIRCUIT DIAGRAM ................................................................................ 9-12
BASIC PROCESS FOR TROUBLESHOOTING ..................................... 9-14
[A] THE MIL COMES ON/FLASHES AND ENGINE OPERATION IS
NOT NORMAL........................................................................................ 9-15
[B] THE MIL DOES NOT COME ON, BUT THE ENGINE OPERATION
IS NOT NORMAL ...................................................................................9-15
CRUISE CONTROL SYSTEM ....................................................................... 9-16

CIRCUIT DIAGRAM ................................................................................ 9-16
CRUISE CONTROL CIRCUIT OPERATION...........................................9-18
BASIC INSTRUCTIONS FOR TROUBLESHOOTING ............................ 9-19
INSPECTION AFTER YVSL ABNORMALITY OCCURS ........................ 9-19
BASIC PROCESS FOR TROUBLESHOOTING ..................................... 9-20
[A] CHECKING THE CRUISE CONTROL SYSTEM INDICATOR
LIGHT ..................................................................................................... 9-21
[B-1] DIAGNOSIS USING THE DTC .......................................................9-21
[B-2] DIAGNOSIS USING THE MALFUNCTION HISTORY CODES...... 9-21
[B-3] MALFUNCTION HISTORY IS NOT DISPLAYED........................... 9-21
[C-1] ERASING THE DTC ....................................................................... 9-22
[C-2] FINAL CHECK ................................................................................ 9-22
ABS (Anti-lock Brake System) .................................................................... 9-24

CIRCUIT DIAGRAM ................................................................................ 9-24
ABS COMPONENTS CHART .................................................................9-26
ABS COUPLER LOCATION CHART ......................................................9-27
MAINTENANCE OF THE ABS ECU .......................................................9-28
ABS TROUBLESHOOTING OUTLINE....................................................9-28
[A] CHECKING THE ABS WARNING LIGHT..........................................9-31
9
[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON............. 9-31
[A-2] ALL INDICATOR LIGHTS FAIL TO COME ON ..............................9-31
[A-3] THE ABS WARNING LIGHT COMES ON ...................................... 9-31
[A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE ........................ 9-32
[A-5] ABS ECU AND FI ECU FAIL TO COMMUNICATE ........................ 9-32
[B-1] MALFUNCTION ARE CURRENTLY DETECTED .......................... 9-32
[B-2] DIAGNOSIS USING THE DTC .......................................................9-32
[B-3] DELETING THE DTC ..................................................................... 9-33
[C-1] FINAL CHECK ................................................................................ 9-33
ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM

(for MT10SPN/MT10SPNC) .........................................................................9-36
CIRCUIT DIAGRAM ................................................................................ 9-36
MAINTENANCE OF THE SCU (suspension control unit) .......................9-38
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE..........9-39

DTC TABLE............................................................................................. 9-39
SELF-DIAGNOSTIC FUNCTION TABLE
(FOR FUEL INJECTION SYSTEM)........................................................ 9-47
SELF-DIAGNOSTIC FUNCTION TABLE
(FOR ABS (Anti-lock Brake System)) .....................................................9-69
SELF-DIAGNOSTIC FUNCTION TABLE (FOR ELECTRONICALLY
ADJUSTABLE SUSPENSION SYSTEM) ............................................... 9-74
COMMUNICATION ERROR WITH THE METER ................................... 9-77
DIAGNOSTIC CODE: SENSOR OPERATION TABLE ........................... 9-77
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE ......................9-82
DIAGNOSTIC CODE TABLE (SCU) (for MT10SPN/MT10SPNC) ..........9-84
EVENT CODE TABLE...................................................................................9-85
30_EVENT ..................................................................................................... 9-88

70_EVENT ..................................................................................................... 9-90

C0044 ............................................................................................................9-91
C0520 (FI) ...................................................................................................... 9-92

C0520 (SCU).................................................................................................. 9-96

C1002 ............................................................................................................9-97
C1003 ............................................................................................................9-98
C1007 ..........................................................................................................9-104
TROUBLESHOOTING ..........................................................................9-104
P0030...........................................................................................................9-105
P0050...........................................................................................................9-109
P0069...........................................................................................................9-113
P00D1, P2195..............................................................................................9-115
P00D3, P2197..............................................................................................9-119
P0107, P0108 ..............................................................................................9-123

P0112, P0113 ..............................................................................................9-127

P0117, P0118 ..............................................................................................9-131

P0122, P0123, P0222, P0223 .....................................................................9-135

P0132...........................................................................................................9-139
P0152...........................................................................................................9-142
P0201...........................................................................................................9-145
P0202........................................................................................................... 9-148
P0203........................................................................................................... 9-151
P0204........................................................................................................... 9-154
P0335........................................................................................................... 9-157
P0340........................................................................................................... 9-160
P0351........................................................................................................... 9-163
P0352........................................................................................................... 9-167
P0353........................................................................................................... 9-171
P0354........................................................................................................... 9-175
P0475, P0476, P048B .................................................................................9-179

P0480........................................................................................................... 9-183
P048D, P048E .............................................................................................9-186

P0500 (FI), P1500........................................................................................ 9-189

P0500 (SCU)................................................................................................ 9-200

P0560 (FI), P0563........................................................................................9-201
P0560 (SCU)................................................................................................9-202
P0564...........................................................................................................9-203
P056C ..........................................................................................................9-209
P0601...........................................................................................................9-216
P0606...........................................................................................................9-217
P062F ..........................................................................................................9-218
P0638...........................................................................................................9-219
P0657...........................................................................................................9-223
P0916, P0917 ..............................................................................................9-227

P1400...........................................................................................................9-231
P1600...........................................................................................................9-235
P1601...........................................................................................................9-239
P1602...........................................................................................................9-243
P1806, P1807 ..............................................................................................9-247
P2122, P2123, P2127, P2128, P2138 ......................................................... 9-251

P2135........................................................................................................... 9-255
P2158 (FI) .................................................................................................... 9-258

P2158 (SCU)................................................................................................ 9-263

P2228, P2229 ..............................................................................................9-264

U0100 ..........................................................................................................9-268
U0121 ..........................................................................................................9-271
U0125 (FI) .................................................................................................... 9-274

U0125 (SCU)................................................................................................ 9-278

U0155 or Err (FI) ......................................................................................... 9-281

U0155 or Err (SCU)..................................................................................... 9-285

11_ABS .......................................................................................................9-288
12_ABS .......................................................................................................9-289
13, 26_ABS .................................................................................................9-290
14, 27_ABS .................................................................................................9-291

15_ABS .......................................................................................................9-292
16_ABS .......................................................................................................9-294
21_ABS .......................................................................................................9-296
31_ABS .......................................................................................................9-297
33_ABS .......................................................................................................9-299
34_ABS .......................................................................................................9-301
41_ABS .......................................................................................................9-302
42_ABS .......................................................................................................9-303
43, 45_ABS .................................................................................................9-304

44, 46_ABS .................................................................................................9-305

51_ABS .......................................................................................................9-306
53_ABS .......................................................................................................9-307
55_ABS .......................................................................................................9-309
56_ABS .......................................................................................................9-310
57_ABS .......................................................................................................9-311
62_ABS .......................................................................................................9-315
68_ABS .......................................................................................................9-316
89_ABS .......................................................................................................9-317
90_ABS .......................................................................................................9-320
91_ABS .......................................................................................................9-323
SELF-DIAGNOSTIC FUNCTION
EAS20437
EAS33142
GLOSSARY
Word Description
MIL
MIL is an indicator light that comes on when a control unit determines a
(Malfunction indica-
malfunction.
tor light)
DTC
DTC is a code that is saved within a control unit’s memory when the control
(Diagnostic trouble
unit determines a malfunction.
code)
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
(On-board diagnos-
system.
tics)
GST
Generic diagnostic tool that complies with OBD standards.
(Generic scan tool)
YDT
(Yamaha diagnostic Diagnostic tool developed especially for Yamaha vehicles.
tool)
EAS32858
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 un-
der 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.
9-1
EAS32859
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.
If 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.
• Reprogramming of the ECU software.
• Using the electrical accessory which may affect the ECU.
• 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.
• Removing or modifying the O2 sensor, the air induction system, the exhaust system part (catalyst, EX-
UP, etc.).
• Poor maintenance of the drive chain and tire air pressure.
• Incorrect brake pedal height, rear brake dragging.
• Excessive opening and closing of the throttle grip, frequently used of burnout, wheelie and half clutch.
• Air mixture by fuel supply badness.
3 2 1
9-2
System Lighting up warning light Lighting time
FUEL INJECTION SYSTEM MIL “2” 2.0 seconds
ABS (Anti-lock Brake Sys-
ABS warning light “1” *1
tem)
CRUISE CONTROL SYS-
MIL “2” 2.0 seconds
TEM
ELECTRONICALLY AD-
JUSTABLE SUSPENSION
Auxiliary system warning light “3” 2.0 seconds
SYSTEM (for MT10SPN/
MT10SPNC)
TIP
*1: 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.

(US)
90890-03269
90890-03264
TIP
• Yamaha diagnostic tool (A/I) (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.
• A GST can also be used to identify malfunctions.
Connecting the YDT

Remove the protective cap “1”, and then connect the YDT to the YDT coupler.
9-3
EAS32864
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 • Fuel pump
• Fuel injector #1 • Hydraulic unit assembly (ABS ECU)
• Fuel injector #2 • Air induction system solenoid
• Fuel injector #3 • Throttle servo motor
• Fuel injector #4 • Relay unit
• Ignition coil #1 • Starter relay
• Ignition coil #2 • Radiator fan motor relay
• Ignition coil #3 • Brake light relay
• Ignition coil #4 • Meter assembly
• Throttle position sensor • EXUP servo motor
• Accelerator position sensor • Cylinder identification sensor
• Intake air pressure sensor • Rear brake light switch
• Atmospheric pressure sensor • Clutch switch
• Coolant temperature sensor • Grip warmer (left and right) (OPTION)
• Gear position sensor • Headlight control unit
• Shift sensor • Handlebar switch (left and right)
• Intake air temperature sensor • IMU (Inertial Measurement Unit)
• O2 sensor 1 (left side) • SCU (Suspension Control Unit) (for MT10SPN/
MT10SPNC)
• O2 sensor 2 (right side)
EAS32865
PARTS CONNECTED TO THE SCU (for MT10SPN/MT10SPNC)

The following parts are connected to the SCU.
parts beforehand.
• Front fork stepping motor (left) (compression • Radiator fan motor
damping)
• Front fork stepping motor (right) (rebound • Sub radiator fan motor
damping)
• Rear shock absorber assembly stepping motor • Sidestand switch
(compression damping)
• Rear shock absorber assembly stepping motor • Handlebar switch (left)
(rebound damping)
• ECU (Engine Control Unit) • Grip warmer (left and right) (OPTION)
• Hydraulic unit assembly (ABS ECU) • Headlight control unit
• Meter assembly • Auxiliary light
• IMU (Inertial Measurement Unit) • Front turn signal/position light (left and right)
9-4
EAS32918
PARTS CONNECTED TO THE ABS ECU

The following parts are connected to the hydraulic unit assembly (ABS ECU).
parts beforehand.
• SCU (Suspension Control Unit) (for MT10SPN/ • Front wheel sensor
MT10SPNC)
• Meter assembly • Rear wheel sensor
• IMU (Inertial Measurement Unit) • Brake light relay
• ECU (Engine Control Unit)
EAS33137
PRECAUTIONS FOR ROAD TEST

EWA20860
WARNING
When test riding the vehicle, always comply with local traffic regulations.
9-5
SYSTEM DIAGRAM
EAS20387
SYSTEM DIAGRAM
EAS32920
ECU CIRCUIT DIAGRAM

A
29 15
2. Electronic throttle valve fuse B 41. Fuel injector #1
26
10. Fuel pump 16
3. Backup fuse relay 42. Fuel injector #2
32
13
4. Fuel injection 9. Start/engine 43. Fuel injector #3
system fuse stop switch 11. Fuel pump
14
13. Neutral 41 44. Fuel injector #4
5. Ignition fuse 12. Starter
relay indicator
light
6. Main switch 96
7. Main fuse 15. Starter

M
motor
C
8. Battery
14. Starting circuit
cut-off relay
95
19. Rectifier/regulator 1. ECU (Engine
16. Clutch Control Unit)
switch
80 18 A
9. Start/engine
stop switch 45. Throttle servo motor
17. Sidestand 18. Neutral 1
switch switch 10
34
33
B 46. Ignition
coil #1
8
20. Cruise control power switch
66
21. Cruise control setting switch “SET–” 47. Ignition
23. Front brake 83 coil #2
light switch 22. Cruise control setting switch “RES+” 9
82
24. Rear brake 16. Clutch 23. Front brake 24. Rear brake
light switch switch light switch light switch 48. Ignition
67 coil #3
6
98
25. Brake
49. Ignition
light relay
coil #4
7
26. Tail/brake light 17
25
72
92
28. Crankshaft 76
position
sensor
a b c
9-6
SYSTEM DIAGRAM
a b c
29. EXUP servo motor 60 50. Grip 51. Grip

warmer (left) warmer (right)
(OPTION) (OPTION)
30. Atmospheric 40
pressure sensor 69
31. Intake air pressure
sensor
53
68 29. EXUP servo motor

102 47
33. Intake air temperature sensor

86
34. Shift sensor 71
52. Air induction system

73 solenoid
35. Gear position sensor 103 20
89 53. Radiator fan
motor relay
36. O2 sensor 1 84 C
(left side) 19
5
28
37. O2 sensor 2 100
(right side)
4 54. Dimmer 55. Pass
switch switch
88
4
37
38. Throttle position
43 56. Headlight
sensor
38. Throttle position control unit
sensor 56
49
57. Meter assembly
45
35
39. Accelerator position 77
42 58. CAN communication
sensor circuit
61
39. Accelerator position
51
sensor
54
57
40. Hydraulic unit assembly 105

(ABS ECU)
107
9-7
SYSTEM DIAGRAM
1. ECU (Engine Control Unit) 54. Dimmer switch
2. Electronic throttle valve fuse 55. Pass switch
3. Backup fuse 56. Headlight control unit
4. Fuel injection system fuse 57. Meter assembly
5. Ignition fuse 58. CAN communication circuit
6. Main switch
7. Main fuse
8. Battery
10. Fuel pump relay
11. Fuel pump
12. Starter relay
13. Neutral indicator light
15. Starter motor
16. Clutch switch
18. Neutral switch
21. Cruise control setting switch “SET–”
22. Cruise control setting switch “RES+”
25. Brake light relay
30. Atmospheric pressure sensor
31. Intake air pressure sensor
34. Shift sensor
36. O2 sensor 1 (left side)
37. O2 sensor 2 (right side)
39. Accelerator position sensor
41. Fuel injector #1
50. Grip warmer (left) (OPTION)
51. Grip warmer (right) (OPTION)
52. Air induction system solenoid
9-8
SYSTEM DIAGRAM
EAS33369
ECU COUPLER LAYOUT
1 2 3 4 5 6 7 8 9 35 36 37 38 39 40 41
10 11 12 13 14 15 16 17 42 43 44 45 46 47 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76
18 19 20 21 22 23 24 25 48 49 50 51 52 53 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92
26 27 28 29 30 31 32 33 34 54 55 56 57 58 59 60 93 94 95 96 97 98 99 100101102103104105106107108
Wire harness Wire harness

No. Connected parts No. Connected parts
color color
1 Throttle servo motor Y/R 27 — —
2 — — Pass switch, dim-
3 — — 28 mer switch, head- Y/B
light control unit
O2 sensor 2 (right
4 P/W 29 Fuel pump relay L/Y
side)
30 — —
O2 sensor 1 (left
5 P/B 31 — —
side)
6 Ignition coil #3 O/L Fuel pump relay,
32 R/L
fuel pump
7 Ignition coil #4 Gy
33 Ground B/W
8 Ignition coil #1 O/L
34 Ground B/W
9 Ignition coil #2 Gy
Accelerator position
10 Throttle servo motor Lg/R 35 L/Y
sensor
11 — — 36 — —
12 — — Throttle position
37 L
13 Fuel injector #3 L/B sensor
14 Fuel injector #4 O/B 38 — —
15 Fuel injector #1 R/B 39 — —
16 Fuel injector #2 G/B Grip warmer (left)
17 Ground B (OPTION), grip
40 Br/Y
warmer (right) (OP-
Electronic throttle TION)
18 R/L
valve fuse
41 Ignition fuse R/W
Radiator fan motor
19 G/Y Accelerator position
relay 42 W
sensor
Air induction system
20 Br/R Throttle position
solenoid 43 W
sensor
21 — —
44 — —
22 — —
Accelerator position
23 — — 45 L
sensor
24 — — 46 — —
25 Ground B 47 EXUP servo motor B/R
26 Backup fuse R/G 48 — —
9-9
SYSTEM DIAGRAM
Wire harness Wire harness
No. Connected parts No. Connected parts
color color
Throttle position Crankshaft position
49 B/G 76 Gy
sensor sensor
50 — — CAN communica-
77 L/W
Accelerator position tion circuit
51 B
sensor 78 — —
52 — — 79 — —
53 EXUP servo motor B/G Starting circuit cut-
Accelerator position 80 off relay, clutch B/Y
54 B/L switch
sensor
55 — — 81 — —
Throttle position Cruise control set-

56 B 82 Br
sensor ting switch “RES+”
Accelerator position Cruise control set-

57 B/Y 83 G/L
sensor ting switch “SET–”
58 — — O2 sensor 1 (left
84 Gy/G
side)
59 — —
85 — —
60 EXUP servo motor W/Y
Intake air tempera-
CAN communica- 86 Br/W
61 L/B ture sensor
tion circuit
87 — —
62 — —
Cylinder identifica-
63 — — tion sensor, crank-
64 — — shaft position
sensor, EXUP servo
65 — — motor, atmospheric
Cruise control pow- pressure sensor, in-
66 O/W
er switch take air pressure
88 sensor, coolant tem- B/L
Rear brake light
67 Lg/L perature sensor, in-
switch
take air temperature
Intake air pressure sensor, shift sensor,
68 P/W
sensor O2 sensor 1 (left
Atmospheric pres- side), O2 sensor 2
69 P (right side)
sure sensor
70 — — Gear position sen-
89 W
sor
71 Shift sensor V
90 — —
Cylinder identifica-
tion sensor, EXUP 91 — —
servo motor, atmo- Cylinder identifica-
72 spheric pressure L 92 W/B
tion sensor
sensor, intake air
pressure sensor, 93 — —
shift sensor 94 — —
Gear position sen- 95 Main switch L/Y
73 L/R
sor
Starter relay, relay
74 — — 96 L/W
unit
75 — —
9-10
SYSTEM DIAGRAM
Wire harness
No. Connected parts
color
97 — —
98 Brake light relay Lg/B
99 — —
O2 sensor 2 (right
100 Gy/Y
side)
101 — —
Coolant tempera-
102 G/W
ture sensor
Gear position sen-
103 G
sor
104 — —
Hydraulic unit as-
105 Gy/B
sembly (ABS ECU)
106 — —
Hydraulic unit as-
107 W/L
sembly (ABS ECU)
108 — —
9-11
EAS32871
EAS20440
A B
R/L
R/L
L/W L/B L/B L/W R/WR/W R/W R/W R/W R/L R/L R/L R/L
B/L G/W G/W B/L R/L
B/W R/W R/W R/W R/W R/W R/L R/L R/L
R/W B/W R/L
R/WR/W
R/L
R/W
R/L
A B A C R/W R/W
R/L
R/W
R/W
R/W R/W
R/W R/W 57
O/L
R R/W O/L R/W
R 61
(B)
RR
5 R/W
R R R R/W O/L 58
R R/B R Gy Gy
Gy R/W
CIRCUIT DIAGRAM
3 O/L
45 Gy
61
L/R G W (B)
R W W
R Br/L G G R/W
Br/L R (B) L/R L/R
Br/R R/B R/B Br/R
O/L
59
L/Y
L/Y
25 R/W R O/L R/W
L/B 61
L/Y L/B R/L
30 (B)
ON B R/G
OFF R L/W R/W L R/L 31 32 R/W
B R/L 60
B L/W L/Y R/W L/B L/Y Sb B/Y Sb/W Gy
L/Y
Br/L L/B B/Y 61 Gy R/W
Br/R L/Y 26 B/Y Sb L/Y L/Y R/W B B P/B
L/B R/L Gy/G (B)
L/B B/L W L
B/W
R/W Br/R R/W
B B/Y L/Y O G
R/W R/W P/W B B B B R/W P/B 62
Y/B B/Y B/Y B/Y
R/L L/Y Gy/Y B/L W L
47 46 W L Gy/G B/L Br/R Br/R G O R/W
6 R/W Y/W L/Y
R/W (B) (B)
R/W L/B B (B) (B) (Gy)
R/W R/L R/W B B P/W P/W R/L R/B
(Gy) 63
R/W R/L R/W R/W R W/BR/Y L/W L/B (B) R/L B/L W L Gy/Y Gy/Y
B/Y W/R Y/G B L/Y R/B R/B R/L
OFF L B/L B
B Br Gy 38 RUN W/B Y/R
B/Y W B B R L
FUEL INJECTION SYSTEM
4 OFF
START W/G Y/B
44 B/L V L R W B 48 W V V R/L G/B
B ON B B/L
(B) (B) (B) 64
40 Sb 42 (B) (Gy)
Br/L Gy Br R/L Br B G/B G/B R/L
R Br/L L/W R/W Y/G W/G B B L
G/Y
Br/L G/W Y/B B/Y Br Br Y/B Y/R W/B W/R B/L P/W L (Dl) B/L
R/B R/L B G/W B 49 P/W P/W R/L L/B
(Gy) Y/B G/W
R/W G/Y B B/Y L W
L/Y 36 B Br/Y R/L B B/L L/Y (B) L
65 (Gy)
R/W L
41 B/L P L 50 B/L L/B L/B R/L
12 14 33 P P
R (Dl) R/L O/B
R R/L
L W/B W L/Y L/Y L L L
66 (Gy)
15 51 W B/LW/B
O/B O/B R/L
R/G B/L B/L W/B
R/G (B) L
16 (B)
R/G L W/Y B/L Lg/R L/B O/B R/B G/B B W W L B/R
G B/G B/R
B
(B) R/G Y/B L/Y R/L B/W B/W B/L B B/Y W/Y
B/W
R/W B W/Y (B) (B)
Br/L R/W B B/W L W/Y
6 B/W B/G B/G
B B 52
19 21 20 B/L B/R B/R
B/W B
Br/B L/B O/W Lg/L P/W P V L L/R Gy
9-12
Br/L Br Br R/W Br Br Br B/W B 76 Gy Gy
B
R/W B/L Gy B Gy L/W B/Y Br G/LGy/G Br/W B/L W W/B
22 B/W
53 Gy B/L
G/W A G/W G/W
G/W B/L (B)
23 54 B/L A (B)
Br B/L
Br/R Br Y/R Lg/R (B)
(B)
Br/W Br/W
67
Br/W B/L 55 B/L Lg/R Lg/R
79 Y/R Y/R
B/L
B/L B/L
R/W B/L B/L
B/L
B/L
B/L B/L B/L B/L B/L B/L B/L
B/L B/L B/L B/L B/L B/L
B/L B/L
82 B/L
L/Y
B/L 70
L/W L
L/B B/Y
W B W W B
B
Gy/B W W
6 Gy/B B
Y/B Y/B Y/B R/W R/W W/L W/L B
Y/B 85 G/Y 72 W W
B/W B B
B/W L/W L/B R/W (B) W B/G L B (B) Y/B
Y/B
R/W B/W
B/G B/G L/B B W
Br/B W B
74 W W
B B B L/W L/B
B L L L/W
BB Br Br Y/B 75 71
B
B
L/W L/B
B/W B/W B B
96 B/W B
L/W L/B B/W R/W

B B (Gy) B B B B
B B L/W L/B B/W R/W
B B 98 97 B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y Lg L/W L/B G/W
B B B B/W
R/GR/G Sb/W G/L G/Y G G/B W/B W/G W G/O Y L/W B/W
B B Br B Y/B Y B Br (R) R Gy/B L Y G Br/B B L/W B/W
R/G L/B B
B B (B) B R/L B
G/O W/L L B W W L/B
B L/W B/W B/W B B/W B
6 L/W L/W L/B L/B L/B B B/W B B/W (B)
L/W L/W L/W L/B L/B B/W B B/W
L/W L/W L/W L/W L/W L/W L/R L/R Br L/R L/R L/R R/G B/W B/W
L/B L/B L/B L/B L/B L/B L/B
73
3. Main switch 75. IMU (Inertial Measurement Unit)
4. Radiator fan motor relay 76. Meter assembly
5. Main fuse 79. MIL (Malfunction indicator light)
6. Joint coupler 82. Multi-function meter
12. Fuse box 1 85. Stability control indicator light
14. Fuel injection system fuse 96. Headlight control unit
15. Electronic throttle valve fuse 97. Headlight (high beam)
16. Backup fuse 98. Headlight (low beam)
19. Fuse box 2
A. Wire harness
20. Ignition fuse
21. ABS ECU fuse sensor)
22. Signaling system fuse C. Sub-wire harness (IMU (Inertial Measure-
23. Headlight fuse ment Unit))
25. Battery *. For MT10SPN/MT10SPNC
26. Engine ground
30. Relay unit
32. Fuel pump relay
33. Clutch switch
41. Neutral switch
44. Fuel pump
46. O2 sensor 1 (left side)
47. O2 sensor 2 (right side)
48. Shift sensor
49. Intake air pressure sensor
50. Atmospheric pressure sensor
61. Spark plug
62. Air induction system solenoid
70. Front wheel sensor
73. YDT coupler
9-13
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
Check the MIL (LED).
“ON”, does the MIL come on? properly?
Yes Yes
Yes [B] Perform the checking with the

The MIL goes off after 2 seconds?
diagnostic mode.
No
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.
9-14
EAS33147
[A] THE MIL COMES ON/FLASHES AND ENGINE OPERATION IS NOT NORMAL
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
• If 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.
EAS33148
[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 9-77 and “DIAGNOSTIC
CODE: ACTUATOR OPERATION TABLE” on page 9-82.
01: Throttle position sensor signal 1 (throttle angle)
13: Throttle position sensor signal 2 (throttle angle)
14: Accelerator position sensor signal 1 (throttle angle)
15: Accelerator position sensor signal 2 (throttle angle)
30: Cylinder-#1 ignition coil
36: Fuel injector #1
48: Air induction system solenoid
If a malfunction is detected in the sensors or actuators, repair or replace all faulty parts.
If no malfunction is detected in the sensors and actuators, check and repair the inner parts of the en-
gine.
9-15
EAS32875
EAS20441
R/WR/W R/W R/W

R/W R/W
R/WR/W
R/W
R/W R/W
R/W
R RR
R
R/W
5
CIRCUIT DIAGRAM
R R R
3 R R R
Br/L R R Br/L
ON
OFF R/G
B
B
Br/L
26
B/W
G/W Y/B Y/B G/Y
Y/B B/Y
G/Y Y/W
6 R/W Y/W L/Y Lg/L Lg/B
R/W
(B) (B)
(Gy)
7 R/W R/L R/W R/W R W/BR/Y L/W
8 Y/B G/W Y/W G/Y Y/B W/R Y/G B L/Y
Br G/W OFF L B/L
Br Gy Br Y RUN W/B Y/R
9 START W/G Y/B B/Y W
R/W Y/B OFF OFF OFF
Y/W ON ON ON
40 (B) (B)
Br/L Gy Br Y/B G/W Br Y
CRUISE CONTROL SYSTEM
Br/L Y/G W/G

Br/L G/W Y/B Y/W G/Y B G B/Y Br Br Y/B Y/R W/B W/R
(Gy) Y/B G/W (B) (B) B G
B/Y L W
Y/W G/Y Y/B B B/L L/Y
Lg/B Lg/L 36
12 33 34 35
R
R/G
R/G Lg/L
16 Lg/B
B
B/W
R/W (B) (B)
Br/L R/W B B/W
6 B/W
20 B B
19 B/W
9-16
Br/L Br Br R/W Br Br Br B/W B
76 77 (B)
Y/W
78
L L/R
RES FREE UP HI
PUSH PUSH (N) LO ON L 79
OFF N OFF
FREE DOWN PASS ON
SET R
Lg/B B Y G R/W
111 B/L
Lg/B W/R W/G W/B W R
G/Y G G/B Y/W G/B G/Y Y
109 O/W G/L Br

110 G/L G/Y B
B O/W Br Y/W
L/R 82
L/Y
B/L
Lg/B Y B L/W L
L/B B/Y
(B) W
B
O/W
G/L
Br
B/W
L/B
L/W
B/W B/W
(Gy)
B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y L/W L/B G/W
R/GR/G Sb/W G/L G/Y G G/B W/B W/G W G/O Y L/W B/W B B/W
(R)
R/G L/B B
B
L/W B/W B/W B/W B
L/W L/B L/B B B B/W
6 L/W L/W L/B B/W B B/W
73
3. Main switch
5. Main fuse
6. Joint coupler
7. Fuse box 3
8. Brake light fuse
9. Cruise control fuse
12. Fuse box 1
16. Backup fuse
19. Fuse box 2
20. Ignition fuse
25. Battery
26. Engine ground
33. Clutch switch
73. YDT coupler
76. Meter assembly
77. Cruise control system indicator light
78. Cruise control setting indicator light
79. MIL (Malfunction indicator light)
111.Cruise control setting/power switch
9-17
EAS32876
CRUISE CONTROL CIRCUIT OPERATION
4. Ignition 7. Cruise control 8. Cruise control

fuse fuse power switch
9.Cruise control
setting switch
11.Front brake 12.Rear brake

10.Clutch light switch light switch
5. Signaling 6. Brake switch 15.ECU (Engine
system light Control Unit)
fuse fuse
13. Accelerator
position sensor
4. Ignition
fuse
3. Main
switch
16.Multi-function
meter
2. Main
fuse
1. Battery
1. Battery
2. Main fuse
3. Main switch
4. Ignition fuse
6. Brake light fuse
7. Cruise control fuse
9. Cruise control setting switch
10. Clutch switch
14. Brake light relay
9-18
EAS32877
BASIC INSTRUCTIONS FOR TROUBLESHOOTING

TIP
4. Do the final check.
EWA17420
WARNING
• 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.
EAS33655
INSPECTION AFTER YVSL ABNORMALITY OCCURS

Speed setting indicator icon “1” is flashing while YVSL is starting up.
1. Turn off the YVSL display (Press the cruise control power switch or turn the main switch to “OFF”
and back to “ON”.)
2. Troubleshoot cruise control.
Refer to “BASIC PROCESS FOR TROUBLESHOOTING” on page 9-20.
TIP
• When a YVSL abnormality has occurred, if you press the cruise control power switch, then the cruise
control system indicator light flashes.
• If you press the cruise control power switch again, then the cruise control system indicator light turns
off. The YVSL display is not displayed.
BM 1 12:00
LIM
1
MPH
MPH
3
1 N2
SCS OFF OFF
9-19
EAS32878
BASIC PROCESS FOR TROUBLESHOOTING

When turning the main switch to No
Check the MIL (LED).
“ON”, does the MIL come on?
Yes
The MIL goes off after 2 Yes

seconds?
No
[A] Push the cruise control Fails to come on • The cruise control power switch is
power switch, and check defective.
the cruise control system Return to [A].
Flashes
• The cruise control fuse is blown.
indicator light.
• The ECU is defective.
Comes on
[B-1] Diagnosis using the DTC. [C-1] Delete the DTC. Return to [A].
[B-2] Check the malfunction

history using the malfunction Yes
mode of the YDT.
Is there any malfunction
history?
No
[B-3] Is there automatic Yes Explain the conditions for

deactivation history for the automatically deactivating the
cruise control system? cruise control system to the
customer.
No
OK
[C-2] Final check.
DTC No. is not displayed.
Finished.
9-20
EAS32879
[A] CHECKING THE CRUISE CONTROL SYSTEM INDICATOR LIGHT

Turn the main switch to “ON”, and then push the cruise control power switch.
1. The cruise control system indicator light does not come on.
• Check the cruise control power switch for continuity. Refer to “CHECKING THE SWITCHES” on
page 8-39. If there is no continuity, replace the handlebar switch (left).
• Check the fuse for continuity. Refer to “CHECKING THE FUSES” on page 8-40. If the cruise con-
trol fuse is blown, replace the fuse.
• Check for continuity between the orange/white terminal of the handlebar switch coupler (left) and
orange/white terminal of the ECU (engine control unit) coupler. If there is no continuity, the wire
harness is defective. Replace the wire harness.
2. The cruise control system indicator light flashes. [B-1]
3. The cruise control system indicator light come on. [B-2]
EAS32880
[B-1] DIAGNOSIS USING THE DTC

1. Information for the DTCs from the cruise control system is contained in the following table. Refer to
this table for troubleshooting.
DTC table
DTC No. Symptom Check point
P056C Normal signal is not sent to ECU from • Wire harness (ECU coupler and front or rear
the switch. brake light switch coupler)
• Signaling system fuse and brake light fuses
• Connection of the ECU coupler, clutch
switch coupler, front brake light switch cou-
pler, rear brake light switch coupler, brake
light relay coupler and handlebar switch
coupler (right)
• Accelerator position sensor
• Front brake light switch
• Rear brake light switch
P0564 Normal signal is not sent to ECU from • Wire harness (ECU coupler and handlebar
the switch. switch coupler (left))
• Ignition fuse and cruise control fuse
• Cruise control setting switch
EAS32881
[B-2] DIAGNOSIS USING THE MALFUNCTION HISTORY CODES

Check the malfunction history using the malfunction mode of the YDT.
• Malfunction history is displayed on the YDT. [B-1]
• Malfunction history is not displayed on the YDT. [B-3]
EAS32882
[B-3] MALFUNCTION HISTORY IS NOT DISPLAYED

Use the YDT to check whether automatic deactivation history for the cruise control system exists.
1. There is automatic deactivation history for the cruise control system.
• Explain the conditions for automatically deactivating the cruise control system to the customer.
• For information about the conditions for automatically deactivating the cruise control system.
Refer to “Automatic deactivation of the cruise control system” on page 9-22.
TIP
If you do not have a YDT, the automatic deactivation history cannot be checked. Therefore, explain the
automatic deactivation function of the cruise control system to the customer and explain that this is not
a malfunction.
9-21
Automatic deactivation of the cruise control system
The cruise control system for this model is electronically controlled and is linked with the other control
systems. The cruise control system will automatically deactivate under the following conditions:
• The cruise control system is not able to maintain the set cruising speed.
• Wheel slip or wheel spin is detected. (If the traction control system has not been turned off, the traction
control system will operate normally while the cruise control system is active)
• The start/engine stop switch is set to the “ ” position.
• The engine stalls.
• The sidestand is lowered.
When traveling with a set cruising speed, if the cruise control system is deactivated under the above
conditions, the “ ” indicator light will go off and the “SET” indicator light will flash for 4 seconds, and
then go off.
When not traveling with a set cruising speed, if the start/engine stop switch is set to the “ ” position, the
engine stalls, or the sidestand is lowered, then the “ ” indicator light will go off (the “SET” indicator light
will not flash).
If the cruise control system is automatically deactivated, please stop and confirm that your vehicle is in
good operating condition.
Before using the cruise control system again, activate it using the cruise control power switch.
TIP
In some cases, the cruise control system may not be able to maintain the set cruising speed when the
vehicle is traveling uphill or downhill.
• When the vehicle is traveling uphill, the actual traveling speed may become lower than the set cruising
speed. If this occurs, accelerate to the desired traveling speed using the throttle.
• When the vehicle is traveling downhill, the actual traveling speed may become higher than the set
cruising speed. If this occurs, the cruise control setting switch cannot be used to adjust the set cruising
speed. To reduce the traveling speed, apply the brakes. When the brakes are applied, the cruise con-
trol system will deactivate.
EAS32883
[C-1] ERASING THE DTC

1. Delete the DTC using the malfunction of the YDT, and check that the MIL goes off.
EAS32884
[C-2] FINAL CHECK

EWA17441
WARNING
When maintenance or checks have been performed on components related to the cruise control
system, be sure to perform a final check before delivering the vehicle to the customer.
1. Check the brake lever and brake pedal operation.
2. Check the rear brake light switch.
Refer to “CHECKING THE SWITCHES” on page 8-39.
3. Execute the diagnostic mode (No. 82 and 83) to check the operation of the clutch switch, front brake
light switch, rear brake light switch, and accelerator position sensor.
Refer to “DIAGNOSTIC CODE: SENSOR OPERATION TABLE” on page 9-77.
4. Execute the diagnostic mode (No. 80 and 81) to check the operation of the cruise control setting
switch.
Refer to “DIAGNOSTIC CODE: SENSOR OPERATION TABLE” on page 9-77.
5. Delete the DTCs.
Refer to “DTC TABLE” on page 9-39.
6. Check the operation of the cruise control system.
Test ride the vehicle and confirm that the cruise control system is operating normally.
9-22
9-23
EAS32890
EAS20443
L/W L/B L/B L/W R/WR/W R/W R/W

B/W R/W R/W B/W R/W
R/WR/W
R/W
A C R/W R/W
R/W
R/L
R/W L/W
R RR
R (B)
R/L
R/W
5 27
CIRCUIT DIAGRAM
R R R
3 R R R
R
Br/L R R Br/L
ON
OFF B R/G
B
B B
Br/L
26
B/W
G/W Y/B Y/B G/Y
G/Y Y/W
6 R/W Lg/L Lg/B
R/W
(B) (B)
7 R/W R/L R/W R/W
8 G/W G/Y
Br G/W
L/R B Br Y
B OFF OFF
ON ON
Br/L Y/B G/W Br Y
Br/L
Br/L Y/W G/Y B G
(B) (B) B G
R R G/Y Lg/B
12 13 34 35
R
R/G
R/G
16
R/B R/G Lg/R L/B O/B R/B G/B B W W L B/R
B
B/W
R/W (B) (B)
Br/L R/W B B/W
6 B/W
B B
19 21 20 Br/B
B/W
9-24
Br/L Br Br R/W Br Br Br B/W B
R/W Br L/W B/Y Br G/LGy/G Br/W B/L W W/B
76 (B)
R/W
Lg/B
L/R
109
B
L/R Y
Y 82
Lg/B Y B L/W R/L 70
L/B
L
(B) L
B W W B
Gy/B W W
Gy/B B
R/W R/W W/L W/L B
72 W W
B/W B B
B/W L/W L/B R/W (B)
B/W R
R/W L/B G/O B W W B
Br/B
L/W L/B
75 Y L/W
Y
71
L L/W L/B
99 B/W B/W
89 G/O B/W B
L/W L/B B/W R/W

(Gy) B B B B
L/W L/B B/W R/W
B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y L/W L/B G/W
L Y
B R/GR/G Sb/W G/L G/Y G G/B W/B W/G W G/O Y L/W B/W B B/W
(R) R Gy/B L Y G Br/B B L/W B/W
R/G L/B B
B B R/L B
G/O W/L L B W W L/B
Y L/R
L/W B/W B/W B/W B/W B
B L/W L/W L/B L/B L/B B B B/W B/W (B)
B 6 L/W L/W L/W L/B L/B B/W B B/W
B L/B
73
3. Main switch
5. Main fuse
6. Joint coupler
7. Fuse box 3
8. Brake light fuse
12. Fuse box 1
13. ABS solenoid fuse
16. Backup fuse
19. Fuse box 2
20. Ignition fuse
21. ABS ECU fuse
25. Battery
26. Engine ground
27. ABS motor fuse
73. YDT coupler
76. Meter assembly
89. ABS warning light
A. Wire harness
ment Unit))
9-25
EAS32891
ABS COMPONENTS CHART
6
5
4
3
2
7
1
9
13
12
10
11
1. Meter assembly
3. Starter relay (ABS motor fuse)
4. YDT coupler
5. Fuse box 2 (ABS ECU fuse)
6. Fuse box 1 (ABS solenoid fuse)
7. Rear brake caliper
8. Rear wheel sensor rotor
10. Front brake caliper (left)
12. Front wheel sensor rotor
13. Front brake caliper (right)
9-26
EAS32892
ABS COUPLER LOCATION CHART
1 2
L/W B/W
B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y L/W L/B G/W R/G L/B
R/GR/G Sb/W G/L G/Y G G/B W/B W/G W G/O Y
(R)
(Gy)
5
B W W B
3
4 R Gy/B L Y G Br/B B L/W B/W
B W R/L G/O W/L L B W W L/B B

W B
(B)
1. Meter assembly coupler

2. YDT coupler
3. ABS ECU coupler
4. Rear wheel sensor coupler
5. Front wheel sensor coupler
9-27
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
If the ABS ECU coupler is clogged with mud or dirt, clean with compressed air.
1 2
EAS33284
ABS TROUBLESHOOTING OUTLINE

EWA16710
WARNING
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 9-33.
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 9-38.
9-28
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.
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

TIP
4. Do the final check.
EWA17420
WARNING
• 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.
9-29
Fails to
[A] Turn the main switch to “ON”, come on [A-1] Does only the ABS Yes • The ABS warning light (LED) is
and check the ABS warning warning 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.
No
• The main switch is defective.
[A-2] Do all indicator lights Yes • The battery voltage is low. Return to [A].
fail to come on? • The main fuse is blown.
Cannot
[A-3] The ABS warning light comes communicate • The ABS ECU fuse is blown.
[A-4] Only the ABS ECU Yes
on. • 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.
Can 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.
screen for the YDT. Return to [A].
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 CHECK”.
[C-1] Perform the final checks. • The brake hoses and brake
No
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 ABS warning light circuit in
the hydraulic unit assembly is
defective.
Finished.
9-30
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.
EAS32899
[A-2] ALL INDICATOR LIGHTS FAIL TO COME ON

1. Main switch
• Check the main switch for continuity.
• If there is no continuity, replace the main switch.
2. Battery
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-41.
• 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 8-40.
• If the main fuse is blown, replace the fuse.
4. Circuit
• Check the meter assembly circuit.
Refer to “CIRCUIT DIAGRAM” on page 9-24.
• 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.
• Only the ABS ECU fails to communicate. [A-4]
• 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.)
9-31
EAS32901
[A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE

1. ABS ECU fuse
• Check the ABS ECU fuse for continuity.
• If the ABS ECU fuse is blown, replace the fuse.
2. ABS ECU coupler
• Check that the ABS ECU coupler is connected properly.
For information about connecting the ABS ECU coupler properly, refer to “INSTALLING THE HY-
DRAULIC UNIT ASSEMBLY” on page 4-66.
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 brown/black ter-
minal of the ABS ECU coupler.
Check for continuity between black terminal of the ABS ECU coupler and the ground.
If there is no continuity, the wire harness is defective. Replace the wire harness.
• Open circuit in the wire harness between the ABS ECU coupler and the 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.
EAS32902
[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)
EAS32903
[B-1] MALFUNCTION ARE CURRENTLY DETECTED

When the YDT is connected to the YDT coupler, the DTC will be displayed on the computer screen.
• A DTC is displayed. [B-2]
• A DTC is not displayed. [C-1]
EAS32904
[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.

(US)
90890-03269
90890-03264
9-32
TIP
Details about the displayed DTCs are shown in the following chart. Refer to this chart and check the ve-
hicle.
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]
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.

(US)
90890-03269
90890-03264
TIP
EAS32905
[C-1] FINAL CHECK

EWA16710
WARNING
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.
If 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 cyl-
inder reservoir.
Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-14.
2. Check the wheel sensors for proper installation.
Refer to “INSTALLING THE FRONT WHEEL (DISC BRAKE)” on page 4-27 and “INSTALLING THE
REAR WHEEL (DISC BRAKE)” on page 4-36.
3. Perform brake line routing confirmation.
Refer to “HYDRAULIC UNIT OPERATION TEST” on page 4-67.
If 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 9-33.
9-33
5. Checking the ABS warning light.
Confirm the ABS warning light go off.
If the ABS warning light does not come on or does not go off, refer to “[A] CHECKING THE ABS
WARNING LIGHT” on page 9-31.
If the ABS warning light does not turn off, the possible causes are following:
• The problem is not solved.
• Open circuit between the ABS ECU and the meter assembly.
Check for continuity between 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.
9-34
9-35
EAS32914
EAS20446
B C
L/W L/B L/B L/W B Br/W Br/W B R/WR/W R/W R/W

B/W R/W R/W B/W L/B L/W L/W L/B R/W
R/WR/W
R/W
A C A D R/W R/W
R/W
MT10SPNC)
R RR
R
R/W
5
R R R
CIRCUIT DIAGRAM
3 R R R
Br/L R R Br/L
ON
OFF B R/G
B
B
Br/L
26
B/W
B
6 R/W
R/W
R/W R/L R/W R/W
B
B
Br/L 10 11
Br/L Br/L Br/W
Br/L
12
R
R/G
R/G
16
B
B/W
R/W (B) (B)
Br/L R/W B B/W
6 B/W
B B
19 21 20 Br/B
B/W
R/W Br Br Br L/B O/W Lg/L P/W P V L L/R Gy
Br/L Br Br B/W B
R/W L/W B/Y Br G/LGy/G Br/W B/L W W/B
9-36
22
76
(B)
P/W G/R Y Br/W
P G Y/R B
L/B P/L G/B Y/G
L/W P/B G/L Y/B W W/R W/B W/G
(B)
R/W
Br/W C Br/W
B C B
G
G/B 82
G/R 103
G/L L/W 70
L/B
83 B W W B
G/R G G/B G/L
Gy/B W W
Gy/B B
R/W R/W W/L W/L B
P
W W
P/B B/W 72
104 B/W L/W L/B R/W (B) B B
P/W
P/L
B R/W B/W
L/B B W
Br/B W B
B L/W L/B
P/W P P/B P/L
75 L/W 71
W L/W L/B
W/B B/W B/W
102 W/R 105 B/W B
W/G
L/W L/B B/W R/W
B B (Gy) B B B B
W/R W W/B W/G B B L/W L/B B/W R/W
B B B B/W
R/GR/G Sb/W G/L G/Y G G/B W/B W/G W G/O Y L/W B/W
B B (R) R Gy/B L Y G Br/B B L/W B/W
R/G L/B B
B B B R/L B
Y G/O W/L L B W W L/B
Y/B B L/W B/W B/W B/W B/W B
Y/R 106 L/W L/W L/B L/B L/B B B/W B/W (B)
L/W L/W L/W L/W L/B L/B B/W B B/W
Y/G L/W L/W L/W L/W L/W L/W L/R L/R Br L/R L/R L/R
6 R/G B/W B/W
L/B
73
Y/R Y Y/B Y/G
L/W L/W C L/W

L/B L/B C L/B
ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for MT10SPN/
MT10SPN/MT10SPNC)
ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for
MT10SPN/MT10SPNC)
3. Main switch
5. Main fuse
6. Joint coupler
10. Fuse box 4
11. SCU fuse
12. Fuse box 1
16. Backup fuse
19. Fuse box 2
20. Ignition fuse
21. ABS ECU fuse
25. Battery
26. Engine ground
73. YDT coupler
76. Meter assembly
83. Auxiliary system warning light
102.SCU (Suspension Control Unit)
103.Front fork stepping motor (left) (compres-
sion damping)
104.Front fork stepping motor (right) (rebound
damping)
105.Rear shock absorber assembly stepping
motor (compression damping)
106.Rear shock absorber assembly stepping
motor (rebound damping)
A. Wire harness
ment Unit))
D. Sub-wire harness (SCU (Suspension Con-
trol Unit))
9-37
MT10SPN/MT10SPNC)
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
If the SCU couplers are clogged with mud or dirt, clean with compressed air.
1 2
EAS32916

TIP
9-38
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
EAS20551

EAS33149
DTC TABLE
Fail-safe system
Diagnos-
DTC Symptom Starting the Driving the tic code
engine vehicle
Front wheel sensor (intermittent pulses
“11_ABS” — — —
or no pulses)
Rear wheel sensor (intermittent pulses or
“12_ABS” — — —
no pulses)
“13, Front wheel sensor (abnormal pulse pe-
— — —
26_ABS” riod)
“14, Rear wheel sensor (abnormal pulse peri-
— — —
27_ABS” od)
“15_ABS” Front wheel sensor (open or short circuit) — — —
“16_ABS” Rear wheel sensor (open or short circuit) — — —
Hydraulic unit assembly (defective sole-
“21_ABS” — — —
noid drive circuit)
“30_EVEN
Overturn is detected. Unable Unable 17
T”
Hydraulic unit assembly (defective ABS
“31_ABS” — — —
solenoid power circuit)
Hydraulic unit assembly (abnormal ABS
“33_ABS” — — —
motor power supply)
Hydraulic unit assembly (short circuit in
“34_ABS” — — —
ABS motor power supply circuit)
Front wheel ABS (intermittent wheel
“41_ABS” speed pulses or incorrect depressuriza- — — —
tion)
Rear wheel ABS (intermittent wheel
“42_ABS” speed pulses or incorrect depressuriza- — — —
tion)
“43,
Front wheel sensor (missing pulses) — — —
45_ABS”
“44,
Rear wheel sensor (missing pulses) — — —
46_ABS”
Vehicle system power supply (voltage of
“51_ABS” — — —
ABS ECU power supply is high)
Vehicle system power supply (voltage of
“53_ABS” — — —
ABS ECU power supply is low)
Hydraulic unit assembly (defective ABS
“55_ABS” — — —
ECU)
Hydraulic unit assembly (abnormal inter-
“56_ABS” — — —
nal circuit)
Vehicle CAN communication line or pow-
“57_ABS” — — —
er source of vehicle system
9-39
Fail-safe system
Diagnos-
engine vehicle
Power supply voltage failure in pressure
“62_ABS” — — —
sensor
Defective hydraulic unit assembly (de-
“68_ABS” — — —
fective front pressure sensor)
“70_EVEN Engine forcibly stops when the vehicle is
Unable Unable —
T” left idling for a long period.
CAN communication (between meter as-
“89_ABS” — — —
sembly and hydraulic unit assembly)
CAN communication (between ECU and
“90_ABS” — — —
hydraulic unit assembly)
CAN communication (between IMU and
“91_ABS” — — —
hydraulic unit assembly)
Abnormal ABS (Brake fluid pressure val-
“C0044” Able Able —
ue is not normal.)
Able/Unable Able/Unable
Abnormal IMU (Normal signal is not re-
“C0520 (depending (depending
ceived from the IMU or failure signal is re- —
(FI)” on the situa- on the situa-
ceived from IMU.)
tion) tion)
Able/Unable
“C0520 Abnormal IMU (IMU sensor value is not (depending
Unable —
(SCU)” normal.) on the situa-
tion)
Abnormal SCU EEPROM (SCU internal
data is not normal.)
“C1003” Stepping motor is not driving properly. Able Able —
Abnormal SCU inside 1 (SCU does not
operate properly.)
O2 sensor 1 heater: defective heater or
“P0030” heater driver ON / OFF command and er- Able Able —
ror signal is mismatching.
O2 sensor 2 heater: defective heater or
“P0050” heater driver ON / OFF command and er- Able Able —
ror signal is mismatching.
Intake air pressure sensor or atmospher-
ic pressure sensor: when the main switch
“P0069” is turned to “ON”, the intake air pressure Able Able 02, 03
sensor voltage and atmospheric pres-
sure sensor voltage differ greatly.
[P00D1] O2 sensor 1: heater perfor-
mance is deteriorated. Normal signal is
not received from the O2 sensor while
“P00D1,
driving the O2 sensor 1 heater. Able Able —
P2195”
[P2195] O2 sensor 1: open circuit is de-
tected. Normal signal is not received
from the O2 sensor.
9-40
Fail-safe system
Diagnos-
engine vehicle
[P00D3] O2 sensor 2: heater perfor-
mance is deteriorated. Normal signal is
not received from the O2 sensor while
“P00D3,
driving the O2 sensor 2 heater. Able Able —
P2197”
[P2197] O2 sensor 2: open circuit is de-
tected. Normal signal is not received
from the O2 sensor.
[P0107] Intake air pressure sensor: short
to ground circuit is detected. Normal sig-
nal is not received from the intake air
“P0107, pressure sensor circuit.
Able Able 03
P0108” [P0108] Intake air pressure sensor: open
or short to power circuit is detected. Nor-
mal signal is not received from the intake
air pressure sensor circuit.
[P0112] Intake air temperature sensor:
short to ground circuit is detected. Nor-
mal signal is not received from the intake
“P0112, air temperature sensor circuit.
Able Able 05
P0113” [P0113] Intake air temperature sensor:
open or short to power circuit is detected.
Normal signal is not received from the in-
take air temperature sensor circuit.
[P0117] Coolant temperature sensor:
mal signal is not received from the cool-
“P0117, ant temperature sensor circuit.
Able Able 06
P0118” [P0118] Coolant temperature sensor:
Normal signal is not received from the
coolant temperature sensor circuit.
[P0122] Throttle position sensor: short to
ground circuit is detected. Normal signal
is not received from the throttle position
sensor circuit.
[P0123] Throttle position sensor: open or
short to power circuit is detected. Normal
“P0122, signal is not received from the throttle po- Able Able
P0123, sition sensor circuit. (depending (depending
01, 13
P0222, [P0222] Throttle position sensor: open or on the situa- on the situa-
P0223” short to ground circuit is detected. Nor- tion) tion)
mal signal is not received from the throt-
tle position sensor circuit.
[P0223] Throttle position sensor: short to
power circuit is detected. Normal signal
is not received from the throttle position
sensor circuit.
O2 sensor 1: short to power circuit is de-
“P0132” tected. Normal signal is not received Able Able —
from the O2 sensor 1.
9-41
Fail-safe system
Diagnos-
engine vehicle
O2 sensor 2: short to power circuit is de-
“P0152” tected. Normal signal is not received Able Able —
from the O2 sensor 2.
Able Able
Fuel injector #1: malfunction in fuel injec- (depending (depending
“P0201” tor #1. Normal signal is not received from on the num- on the num- 36
the fuel injector circuit. ber of faulty ber of faulty
cylinder) cylinder)
Able Able
cylinder) cylinder)
Able Able
cylinder) cylinder)
Able Able
cylinder) cylinder)
Crankshaft position sensor: normal sig-
“P0335” nals are not received from the crankshaft Unable Unable —
position sensor.
Cylinder identification sensor: normal
“P0340” signal is not received from the cylinder Unable Able —
identification sensor.
Cylinder-#1 ignition coil: open or short Able Able
circuit is detected in the primary lead of (depending (depending
“P0351” the cylinder-#1 ignition coil. Normal sig- on the num- on the num- 30
nal is not received from the ignition cir- ber of faulty ber of faulty
cuit. cylinder) cylinder)
9-42
Fail-safe system
Diagnos-
engine vehicle
[P0475] EXUP servo motor: performance
deterioration. EXUP servo motor posi-
tioning signal changes slowly, when
during it control.
“P0475, [P0476] EXUP servo motor: stuck EXUP
P0476, servo motor is detected. EXUP servo Able Able 53
P048B” motor positioning signal is not changed,
when during it control.
[P048B] EXUP servo motor: signal stuck.
EXUP servo motor positioning signal is
not changed, when during it control.
Radiator fan motor relay: open or short
circuit is detected. Normal signal is not
“P0480” Able Able 51
received from the radiator fan motor re-
lay.
[P048D] EXUP servo motor: open or
mal signal is not received from the EXUP
“P048D, servo motor circuit to ECU.
Able Able 53
P048E” [P048E] EXUP servo motor: short to
is not received from the EXUP servo mo-
tor circuit to ECU.
[P0500 (FI)] Rear wheel sensor: open or
short circuit is detected. Normal signal is
not received from the rear wheel sensor
or ABS unit to ECU.
[P1500] Neutral switch: open or short cir-
“P0500
cuit is detected. Normal signal is not re-
(FI), Able Able 07, 21
ceived from the rear wheel sensor to
P1500”
ECU when the gear-in.
[P1500] Clutch switch: open or short cir-
ceived from the rear wheel sensor to
ECU when the gear-in.
“P0500 Abnormal rear wheel sensor (Sensor val-
Able Able —
(SCU)” ue is not normal.)
9-43
Fail-safe system
Diagnos-
engine vehicle
[P0560 (FI)] Battery charging voltage is
abnormal. Poor charging performance
(Discharged condition). Vehicle system
power voltage is abnormal. (Regulator is
not operated properly or battery is not
“P0560
charged properly.)
(FI), Able Able —
[P0563] Battery charging voltage is ab-
P0563”
normal. Charging voltage is not within
range (Overcharged condition). Vehicle
system power voltage is abnormal. (Reg-
ulator is not operated properly or battery
is not charged properly.)
Abnormal SCU power supply voltage.
“P0560
(Regulator is not operated properly or Able Able 09
(SCU)”
battery is not charged properly.)
Cruise control setting switch “RES+”:
open or short circuit is detected. Normal
signal is not sent to ECU.
“P0564” Able Able 80, 81
Cruise control setting switch “SET–”:
open or short circuit is detected. Normal
Front brake light switch: open or short cir-
cuit is detected. Normal signal is not sent
to ECU.
“P056C” Able Able 82, 83
Rear brake light switch: open or short cir-
cuit is detected. Normal signal is not sent
to ECU.
ROM error. Internal malfunction in ECU.
(When this malfunction is detected in the
“P0601” Unable Unable —
ECU, the DTC might not appear on the
tool display.)
Processor error. Internal malfunction in Able/Unable Able/Unable
ECU. (When this malfunction is detected (depending (depending
“P0606” —
in the ECU, the DTC might not appear on on the situa- on the situa-
the tool display.) tion) tion)
EEPROM DTC: an error is detected (depending (depending
“P062F” 60
while reading or writing on EEPROM. on the situa- on the situa-
tion) tion)
Able Able
YCC-T drive system: malfunction detect- (depending (depending
“P0638” —
ed. on the situa- on the situa-
tion) tion)
Fuel system voltage: incorrect voltage
“P0657” supplied to the fuel injector, fuel pump Able Able 09, 50
and relay unit.
9-44
Fail-safe system
Diagnos-
engine vehicle
[P0916] Gear position sensor: open or
mal signal is not received from the gear
“P0916, position sensor to ECU.
Able Able —
P0917” [P0917] Gear position sensor: short to
is not received from the gear position
sensor to ECU.
Air induction system solenoid: open or
“P1400” Able Able 48
mal signal is not received from the air in-
duction system solenoid.
Lean angle sensor: open or short circuit
“P1600” is detected. Normal signal is not received Unable Unable 17
from IMU or defective IMU.
Sidestand switch: open or short circuit in
wire harness of the ECU is detected.
“P1601” Unable Unable 20
Normal signal is not received from the
sidestand switch.
Malfunction in ECU internal circuit (mal- (depending (depending
“P1602” —
function of ECU power cut-off function). on the situa- on the situa-
tion) tion)
[P1806] Shift sensor: open or short to
ground circuit is detected. Normal signal
is not received from the shift sensor to
“P1806,
ECU. Able Able 95
P1807”
[P1807] Shift sensor: short to power cir-
ceived from the shift sensor to ECU.
[P2122] Accelerator position sensor:
open or short to ground circuit is detect-
ed. Normal signal is not received from
the accelerator position sensor.
signal is not received from the accelera-
“P2122, tor position sensor.
Able Able
P2123, [P2127] Accelerator position sensor:
(depending (depending
P2127, open or short to ground circuit is detect- 14, 15
on the situa- on the situa-
P2128, ed. Normal signal is not received from
tion) tion)
P2138” the accelerator position sensor.
signal is not received from the accelera-
tor position sensor.
[P2138] Deviation error. Normal signal is
not received from the accelerator posi-
tion sensor.
9-45
Fail-safe system
Diagnos-
engine vehicle
Throttle position sensor: output voltage Able Able
deviation error. Normal signal is not re- (depending (depending
“P2135” 01, 13
ceived from the throttle position sensor on the situa- on the situa-
circuit. tion) tion)
“P2158 Front wheel sensor: normal signal is not
Able Able 16
(FI)” received from the front wheel sensor.
“P2158 Abnormal front wheel sensor. (Sensor
Able Able —
(SCU)” value is not normal.)
[P2228] Atmospheric pressure sensor:
mal signal is not received from the atmo-
“P2228, spheric pressure sensor.
Able Able 02
P2229” [P2229] Atmospheric pressure sensor:
Normal signal is not received from the at-
mospheric pressure sensor.
Abnormal CAN communication (between
“U0100” Able Able —
ECU and SCU)
Abnormal CAN communication (between
“U0121” Able Able —
ABS ECU and SCU)
Able/Unable
“U0125 Signals cannot be transmitted between (depending
Unable —
(FI)” the ECU and the IMU. on the situa-
tion)
“U0125 Abnormal CAN communication (between
Able Able —
(SCU)” IMU and SCU)
Multi-function meter: signals cannot be
“U0155 or
transmitted between the ECU and multi- Able Able —
Err (FI)”
function meter.
“U0155 or Abnormal CAN communication (between
Able Able —
Err (SCU)” meter assembly and SCU)
Displayed Abnormal SCU inside 2 (SCU does not
Able Able —
Err (NIL) operate properly.)
9-46
EAS33028
SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM)

TIP
For details of the DTC, refer to “BASIC PROCESS FOR TROUBLESHOOTING” on page 9-14.
Probable cause of Fail-safe system

DTC Item Vehicle symptom
malfunction operation
30_EVEN Overturn is detect- • The vehicle has – –
T ed. overturned.
• Installed condition
of IMU.
• Defective IMU.
• Malfunction in
ECU.
70_EVEN Engine forcibly • Allow to idle for a – –
T stops when the ve- long period of time.
hicle is left idling for • Malfunction in
a long period. ECU.
C0520 Abnormal IMU: Nor- • Defective IMU Engine cannot be Engine cannot be
mal signal is not re- coupler or ECU started (depending started (depending
ceived from IMU or coupler. on the circumstanc- on the circumstanc-
failure signal is re- • Open or short cir- es). es).
ceived from IMU. cuit in wire har- Cruise control /
ness between IMU YVSL fixed to OFF.
and ECU.
• Improperly in-
stalled IMU.
• Malfunction in
IMU.
• Malfunction in
ECU.
P0030 O2 sensor 1 heater: • Open or short cir- (When the O2 sen- Display only (If the
defective heater or cuit in wire har- sor 1 does not oper- O2 sensor 1 does
heater driver ON / ness. ate because the not operate, O2
OFF command and • Disconnected cou- exhaust tempera- feedback is not car-
error signal is mis- pler. ture is low) ried out.)
matching. • Defective O2 sen- Increased exhaust Cruise control /
sor 1 heater con- emissions. YVSL fixed to OFF.
troller (Malfunction Fuel learning cannot
in ECU). be carried out.
• Broken or discon-
nected lead in O2
sensor 1 heater.
9-47
P0050 O2 sensor 2 heater: • Open or short cir- (When the O2 sen- Display only (If the
defective heater or cuit in wire har- sor 2 does not oper- O2 sensor 2 does
heater driver ON / ness. ate because the not operate, O2
OFF command and • Disconnected cou- exhaust tempera- feedback is not car-
error signal is mis- pler. ture is low) ried out.)
matching. • Defective O2 sen- Increased exhaust Cruise control /
sor 2 heater con- emissions. YVSL fixed to OFF.
troller (Malfunction Fuel learning cannot
in ECU). be carried out.
• Broken or discon-
nected lead in O2
sensor 2 heater.
P0069 Intake air pressure • Malfunction in Engine is difficult to Intake air pressure
sensor or atmo- ECU. start. is fixed to 101.3
spheric pressure • Intake air pressure Engine idling speed [kPa].
sensor: when the sensor hose is dis- is unstable. Intake air pressure
main switch is connected, Increased exhaust difference is fixed to
turned to “ON”, the clogged, twisted, emissions. 0 [kPa].
intake air pressure or pinched. Loss of engine pow- Atmospheric pres-
sensor voltage and • Defective intake er. sure is fixed to
atmospheric pres- air pressure sen- 101.3 [kPa].
sure sensor voltage sor or atmospheric α–N is fixed.
differ greatly. pressure sensor. Fuel is not cut off
due to the intake air
pressure difference.
Atmospheric pres-
sure sensor output
correction value is
fixed to 0.
O2 feedback is not
carried out.
ISC feedback is not
carried out.
ISC learning is not
carried out.
Quick shift system is
not carried out.
Cruise control /
YVSL fixed to OFF.
9-48
P00D1 O2 sensor 1: heater • Improperly in- Increased exhaust O2 feedback is not
performance is de- stalled O2 sensor emissions. carried out.
teriorated. Normal 1. O2 learning is not
signal is not re- • Defective coupler carried out.
ceived from the O2 between O2 sen- Air induction system
sensor while driving sor 1 and ECU. solenoid is turned
the O2 sensor 1 • Open or short cir- ON all the time (air
heater. cuit in wire har- induction system air
ness between O2 cut off).
sensor 1 and ECU. Quick shift system is
• Incorrect fuel pres- not carried out.
sure. Cruise control /
• Defective O2 sen- YVSL fixed to OFF.
sor 1.
• Malfunction in
ECU.
P00D3 O2 sensor 2: heater • Improperly in- Increased exhaust O2 feedback is not
performance is de- stalled O2 sensor emissions. carried out.
teriorated. Normal 2. O2 learning is not
signal is not re- • Defective coupler carried out.
ceived from the O2 between O2 sen- Air induction system
sensor while driving sor 2 and ECU. solenoid is turned
the O2 sensor 2 • Open or short cir- ON all the time (air
heater. cuit in wire har- induction system air
ness between O2 cut off).
sensor 2 and ECU. Quick shift system is
• Incorrect fuel pres- not carried out.
sure. Cruise control /
• Defective O2 sen- YVSL fixed to OFF.
sor 2.
• Malfunction in
ECU.
9-49
P0107 [P0107] Intake air [P0107] Low voltage Engine idling speed Intake air pressure
P0108 pressure sensor: of the intake air is unstable. difference is fixed to
short to ground cir- pressure sensor cir- Engine response is 0 [kPa].
cuit is detected. cuit (0.5 V or less) poor. α–N is fixed.
Normal signal is not [P0108] High volt- Loss of engine pow- Fuel is not cut off
received from the in- age of the intake air er. due to the intake air
take air pressure pressure sensor cir- Increased exhaust pressure difference.
sensor circuit. cuit (4.8 V or more) emissions. Atmospheric pres-
[P0108] Intake air • Defective coupler sure sensor output
pressure sensor: between intake air correction value is
open or short to pressure sensor fixed to 0.
power circuit is de- and ECU. Intake air pressure
tected. Normal sig- • Open or short cir- is fixed to 101.3
nal is not received cuit in wire har- [kPa].
from the intake air ness between O2 feedback is not
pressure sensor cir- intake air pressure carried out.
cuit. sensor and ECU. ISC feedback is not
• Poor circuit conti- carried out.
nuity in wire har- ISC learning is not
ness between carried out.
intake air pressure Quick shift system is
sensor and ECU. not carried out.
• Defective intake Cruise control /
air pressure sen- YVSL fixed to OFF.
sor.
• Malfunction in
ECU.
9-50
P0112 [P0112] Intake air [P0112] Low voltage Engine is difficult to Intake air tempera-
P0113 temperature sensor: of the intake air tem- start. ture is fixed to 20
short to ground cir- perature sensor cir- Increased exhaust [°C].
cuit is detected. cuit (0.1 V or less) emissions. O2 sensor heater
Normal signal is not [P0113] High volt- Engine idling speed driving is not carried
received from the in- age of the intake air is unstable. out.
take air temperature temperature sensor O2 feedback is not
sensor circuit. circuit (4.8 V or carried out.
[P0113] Intake air more) ISC feedback is not
temperature sensor: • Defective coupler carried out.
open or short to between intake air ISC learning is not
power circuit is de- temperature sen- carried out.
tected. Normal sig- sor and ECU. Quick shift system is
nal is not received • Open or short cir- not carried out.
from the intake air cuit in wire har- Cruise control /
temperature sensor ness between YVSL fixed to OFF.
circuit. intake air tempera-
ture sensor and
ECU.
• Poor circuit conti-
nuity in wire har-
ness between
intake air tempera-
ture sensor and
ECU.
• Improperly in-
stalled intake air
temperature sen-
sor.
• Defective intake
air temperature
sensor.
• Malfunction in
ECU.
9-51
P0117 [P0117] Coolant [P0117] Low voltage Engine is difficult to Radiator fan motor
P0118 temperature sensor: of the coolant tem- start. relay is ON only
short to ground cir- perature sensor cir- Increased exhaust when the vehicle is
cuit is detected. cuit (0.1 V or less) emissions. traveling at low
Normal signal is not [P0118] High volt- Engine idling speed speeds.
received from the age of the coolant is unstable. O2 feedback is not
coolant tempera- temperature sensor carried out.
ture sensor circuit. circuit (4.9 V or ISC feedback is not
[P0118] Coolant more) carried out.
temperature sensor: • Defective coupler ISC learning is not
open or short to between coolant carried out.
power circuit is de- temperature sen- The coolant tem-
tected. Normal sig- sor and ECU. perature is fixed to
nal is not received • Open or short cir- 60 [°C].
from the coolant cuit in wire har- Quick shift system is
temperature sensor ness between not carried out.
circuit. coolant tempera- Engine brake man-
ture sensor and agement: control
ECU. value is fixed.
• Improperly in- Cruise control /
stalled coolant YVSL fixed to OFF.
temperature sen-
sor.
• Defective coolant
temperature sen-
sor.
• Malfunction in
ECU.
9-52
P0122 [P0122] Throttle po- [P0122, P0222] Low Engine idling speed Change in the throt-
P0123 sition sensor: short voltage of the throt- is high. tle opening is 0
P0222 to ground circuit is tle position sensor Engine idling speed (transient control is
P0223 detected. Normal circuit (0.25 V or is unstable. not carried out).
P2135 signal is not re- less) Engine response is D–j is fixed.
ceived from the [P0123, P0223] poor. Throttle opening is
throttle position sen- High voltage of the Loss of engine pow- fixed to 125 [°].
sor circuit. throttle position sen- er. O2 feedback is not
[P0123] Throttle po- sor circuit (4.75 V or Deceleration is carried out.
sition sensor: open more) poor. Fuel is not cut off
or short to power cir- [P2135] Difference Increased exhaust due to the throttle
cuit is detected. in output voltage 1 emissions. opening.
Normal signal is not and output voltage 2 Vehicle cannot be Output is restricted.
received from the of the throttle posi- driven. Air induction system
throttle position sen- tion sensor solenoid is turned
sor circuit. • Defective coupler ON all the time (air
[P0222] Throttle po- between throttle induction system air
sition sensor: open position sensor cut off).
or short to ground and ECU. ISC feedback is not
circuit is detected. • Open or short cir- carried out.
Normal signal is not cuit in wire har- ISC learning is not
received from the ness between carried out.
throttle position sen- throttle position O2 sensor heater
sor circuit. sensor and ECU. driving is not carried
[P0223] Throttle po- • Improperly in- out.
sition sensor: short stalled throttle po- Quick shift system is
to power circuit is sition sensor. not carried out.
detected. Normal • Defective throttle Engine brake man-
signal is not re- position sensor. agement: control
ceived from the • Malfunction in mode is fixed.
throttle position sen- ECU. Cruise control /
sor circuit. YVSL fixed to OFF.
[P2135] Throttle po-
sition sensor: output
voltage deviation er-
ror. Normal signal is
not received from
the throttle position
sensor circuit.
9-53
P0132 O2 sensor 1: short to • High voltage of the Increased exhaust O2 feedback is not
power circuit is de- O2 sensor 1 circuit emissions. carried out.
tected. Normal sig- (4.8 V or more) O2 feedback learn-
nal is not received • Improperly in- ing is not carried
from the O2 sensor stalled O2 sensor out.
1. 1. Air induction system
• Defective coupler solenoid is turned
between O2 sen- ON all the time (air
sor 1 and ECU. induction system air
• Open or short cir- cut off).
cuit in wire har- Quick shift system is
ness between O2 not carried out.
sensor 1 and ECU. Cruise control /
• Incorrect fuel pres- YVSL fixed to OFF.
sure.
• Defective O2 sen-
sor 1.
• Malfunction in
ECU.
P0152 O2 sensor 2: short to • High voltage of the Increased exhaust O2 feedback is not
power circuit is de- O2 sensor 2 circuit emissions. carried out.
tected. Normal sig- (4.8 V or more) O2 feedback learn-
nal is not received • Improperly in- ing is not carried
from the O2 sensor stalled O2 sensor out.
2. 2. Air induction system
• Defective coupler solenoid is turned
between O2 sen- ON all the time (air
sor 2 and ECU. induction system air
• Open or short cir- cut off).
cuit in wire har- Quick shift system is
ness between O2 not carried out.
sensor 2 and ECU. Cruise control /
• Incorrect fuel pres- YVSL fixed to OFF.
sure.
sor 2.
• Malfunction in
ECU.
9-54
P0201 [P0201] Fuel injec- • Defective coupler Loss of engine pow- O2 feedback is not
P0202 tor #1: malfunction between fuel injec- er. carried out.
P0203 in fuel injector #1. tor and ECU. Engine is difficult to Air induction system
P0204 Normal signal is not • Open or short cir- start. solenoid is turned
received from the cuit in wire har- Engine cannot be ON all the time (air
fuel injector circuit. ness between fuel started. induction system air
[P0202] Fuel injec- injector and ECU. Engine stops. cut off).
tor #2: malfunction • Defective fuel in- Engine idling speed ISC feedback is not
in fuel injector #2. jector. is unstable. carried out.
Normal signal is not • Malfunction in Increased exhaust ISC learning is not
received from the ECU. emissions. carried out.
fuel injector circuit. • Improperly in- Injection to the ap-
[P0203] Fuel injec- stalled fuel injec- plicable cylinder
tor #3: malfunction tor. group (cylinders #1
in fuel injector #3. and #2 or cylinders
Normal signal is not #3 and #4) is cut off.
received from the Quick shift system is
fuel injector circuit. not carried out.
[P0204] Fuel injec- Cruise control /
tor #4: malfunction YVSL fixed to OFF.
in fuel injector #4.
Normal signal is not
received from the
fuel injector circuit.
P0335 Crankshaft position • Defective coupler Engine cannot be Does not operate.
sensor: normal sig- between crank- started. ISC feedback is not
nals are not re- shaft position sen- carried out.
ceived from the sor and ECU. ISC learning is not
crankshaft position • Open or short cir- carried out.
sensor. cuit in wire har- Cruise control /
ness between YVSL fixed to OFF.
crankshaft position
sensor and ECU.
• Improperly in-
stalled crankshaft
position sensor.
• Malfunction in
generator rotor.
• Defective crank-
shaft position sen-
sor.
• Malfunction in
ECU.
9-55
P0340 Cylinder identifica- • Defective coupler Engine cannot be The vehicle is oper-
tion sensor: normal between cylinder started. ated using only the
signals are not re- identification sen- cylinder identifica-
ceived from the cyl- sor and ECU. tion information
inder identification • Open or short cir- stored during opera-
sensor. cuit in wire har- tion.
ness between ISC feedback is not
cylinder identifica- carried out.
tion sensor and ISC learning is not
ECU. carried out.
• Improperly in- Cruise control /
stalled cylinder YVSL fixed to OFF.
identification sen-
sor.
• Defective pickup
rotor.
• Defective cylinder
identification sen-
sor.
• Malfunction in
ECU.
9-56
P0351 [P0351] Cylinder-#1 • Defective coupler Engine stops. Injection to the ap-
P0352 ignition coil: open or between ignition Loss of engine pow- plicable cylinder
P0353 short circuit is de- coil and ECU. er. group (cylinders #1
P0354 tected in the primary • Open or short cir- Engine is difficult to and #4 or cylinders
lead of the cylinder- cuit in wire har- start. #2 and #3) is cut off.
#1 ignition coil. Nor- ness between Engine cannot be Air induction system
mal signal is not re- ignition coil and started. solenoid is turned
ceived from the ECU. Engine idling speed ON all the time (air
ignition circuit. • Improperly in- is unstable. induction system air
[P0352] Cylinder-#2 stalled ignition coil. Increased exhaust cut off).
ignition coil: open or • Defective ignition emissions. O2 feedback is not
short circuit is de- coil. carried out.
tected in the primary • Malfunction in ISC feedback is not
lead of the cylinder- ECU. carried out.
#2 ignition coil. Nor- ISC learning is not
mal signal is not re- carried out.
ceived from the Quick shift system is
ignition circuit. not carried out.
[P0353] Cylinder-#3 Cruise control /
ignition coil: open or YVSL fixed to OFF.
short circuit is de-
tected in the primary
lead of the cylinder-
#3 ignition coil. Nor-
mal signal is not re-
ceived from the
ignition circuit.
[P0354] Cylinder-#4
ignition coil: open or
short circuit is de-
tected in the primary
lead of the cylinder-
#4 ignition coil. Nor-
mal signal is not re-
ceived from the
ignition circuit.
9-57
P0475 EXUP servo motor: • Defective coupler Loss of engine pow- EXUP learning val-
performance deteri- between EXUP er. ues are fixed.
oration. EXUP servo servo motor and O2 feedback is not
motor positioning ECU. carried out.
signal changes • Open or short cir- Cruise control /
slowly, when during cuit in wire har- YVSL fixed to OFF.
it control. ness between
EXUP servo motor
and ECU.
• Improperly in-
stalled EXUP ser-
vo motor and
cables.
• Defective EXUP
servo motor.
• Stuck EXUP servo
motor (mechanism
or motor).
• Malfunction in
ECU.
P0476 EXUP servo motor: • Defective coupler Loss of engine pow- EXUP learning val-
stuck EXUP servo between EXUP er. ues are fixed.
motor is detected. servo motor and O2 feedback is not
EXUP servo motor ECU. carried out.
positioning signal is • Open or short cir- Cruise control /
not changed, when cuit in wire har- YVSL fixed to OFF.
during it control. ness between
EXUP servo motor
and ECU.
• Improperly in-
stalled EXUP ser-
vo motor and
cables.
• Defective EXUP
servo motor.
motor (mechanism
or motor).
• Malfunction in
ECU.
P0480 Radiator fan motor • Open or short cir- Engine is difficult to Radiator fan motor
relay: open or short cuit in wire har- start. relay is OFF all the
circuit is detected. ness. Loss of engine pow- time.
Normal signal is not • Disconnected cou- er. O2 feedback is not
received from the pler. Engine overheats. carried out.
radiator fan motor • Defective radiator Increased exhaust ISC feedback is not
relay. fan motor relay. emissions. carried out.
• Defective radiator ISC learning is not
fan motor relay carried out.
controller (Mal- Cruise control /
function in ECU). YVSL fixed to OFF.
9-58
P048B EXUP servo motor: • Defective coupler Loss of engine pow- EXUP learning val-
signal stuck. EXUP between EXUP er. ues are fixed.
servo motor posi- servo motor and O2 feedback is not
tioning signal is not ECU. carried out.
changed, when • Open or short cir- Cruise control /
during it control. cuit in wire har- YVSL fixed to OFF.
ness between
EXUP servo motor
and ECU.
• Improperly in-
stalled EXUP ser-
vo motor and
cables.
• Defective EXUP
servo motor.
motor (mechanism
or motor).
• Malfunction in
ECU.
P048D [P048D] EXUP ser- [P048D] Low volt- Loss of engine pow- EXUP learning val-
P048E vo motor: open or age of EXUP servo er. ues are fixed.
short to ground cir- motor circuit (0.2 V O2 feedback is not
cuit is detected. or less) carried out.
Normal signal is not [P048E] High volt- Cruise control /
received from the age of EXUP servo YVSL fixed to OFF.
EXUP servo motor motor circuit (4.8V
circuit to ECU. or more)
[P048E] EXUP ser- • Defective coupler
vo motor: short to between EXUP
power circuit is de- position sensor
tected. Normal sig- and ECU.
nal is not received • Open or short cir-
from the EXUP ser- cuit in wire har-
vo motor circuit to ness between
ECU. EXUP position
sensor and ECU.
• Defective EXUP
position sensor.
• Malfunction in
ECU.
9-59
P0500 Rear wheel sensor: • Open or short cir- Vehicle speed is not Vehicle speed dis-
open or short circuit cuit in wire har- displayed on the played on the meter
is detected. Normal ness between rear meter. = 0 [km/h]
signal is not re- wheel sensor and Engine idling speed O2 feedback is not
ceived from the rear ABS unit. is unstable. carried out.
wheel sensor or • Open or short cir- Traction control Fuel cut-off control
ABS unit to ECU. cuit in wire har- does not work. when the rear wheel
ness between sensor or neutral
ABS unit and ECU. switch malfunctions
• Defective rear is carried out.
wheel sensor. ISC feedback is not
• Malfunction in carried out.
ECU. ISC learning is not
carried out.
Traction control
does not work.
Quick shift system is
not carried out.
Cruise control /
YVSL fixed to OFF.
P0560 Battery charging • Battery discharg- Engine is difficult to O2 feedback is not
voltage is abnormal. ing (disconnected start. carried out.
Poor charging per- lead in charging Increased exhaust
formance. (Dis- system). emissions.
charged condition) • Battery discharg- Battery perfor-
Vehicle system ing (defective rec- mance has deterio-
power voltage is ab- tifier/regulator). rated or battery is
normal. (Regulator defective.
is not operated
properly or battery is
not charged proper-
ly.)
P0563 Battery charging • Battery overcharg- Engine is difficult to O2 feedback is not
voltage is abnormal. ing (defective rec- start. carried out.
Charging voltage is tifier/regulator). Increased exhaust
not within range • Battery overcharg- emissions.
(Overcharged con- ing (disconnected Battery perfor-
dition) Vehicle sys- lead in rectifier/ mance has deterio-
tem power voltage regulator wire har- rated or battery is
is abnormal. (Regu- ness). defective.
lator is not operated
properly or battery is
not charged proper-
ly.)
9-60
P0564 Cruise control set- • Open or short cir- Cruise control / Cruise control /
ting switch “RES+”: cuit in wire har- YVSL cannot be YVSL fixed to OFF.
open or short circuit ness between used.
is detected. Normal cruise control set-
signal is not sent to ting switch and
ECU. ECU.
Cruise control set- • Defective cruise
ting switch “SET–”: control setting
open or short circuit switch.
is detected. Normal • Malfunction in
ECU.
P056C Front brake light • Open or short cir- Cruise control / Cruise control /
switch: open or cuit in wire har- YVSL cannot be YVSL fixed to OFF.
short circuit is de- ness between used.
tected. Normal sig- front brake light
nal is not sent to switch and ECU.
ECU. • Open or short cir-
Rear brake light cuit in wire har-
switch: open or ness between rear
short circuit is de- brake light switch
tected. Normal sig- and ECU.
nal is not sent to • Defective front
ECU. brake light switch
or rear brake light
switch.
• Malfunction in
ECU.
P0601 Internal malfunction • Malfunction in Engine cannot be Engine cannot be
in ECU. (When this ECU (ROM error). started. started.
malfunction is de- Cruise control /
tected in the ECU, YVSL fixed to OFF.
the DTC might not
appear on the tool
display.)
9-61
P0606 Internal malfunction • Malfunction in Engine cannot be Engine cannot be
in ECU. (When this ECU (Processor started. started.
malfunction is de- error). Engine response is Ignition and injec-
tected in the ECU, poor. tion are not carried
the DTC might not Loss of engine pow- out.
appear on the tool er. Judgment for other
display.) DTCs are not car-
ried out.
Load control is not
carried out. (Relay
unit, headlight relay,
and other relays are
all turned OFF.)
The CO adjustment
mode and diagnos-
tic mode cannot be
activated.
Output is restricted.
Cruise control /
YVSL fixed to OFF.
P062F EEPROM DTC: an • CO adjustment Increased exhaust CO adjustment val-
error is detected value is not prop- emissions. ue for the faulty cyl-
while reading or erly written. Engine cannot be inder = 0 (default
writing on EE- • ISC learning value started or is difficult value)
PROM. is not properly writ- to start. ISC learning values
ten. Engine idling speed = Default values.
• O2 feedback learn- is unstable. OBD memory value
ing value is not OBD memory value is initialized.
properly written. is not correct. Initialization of O2
• OBD memory val- feedback learning
ue is not properly value.
written. Cruise control /
• Malfunction in YVSL fixed to OFF.
ECU.
P0638 YCC-T drive sys- • Defective coupler Engine response is O2 feedback is not
tem: malfunction de- between throttle poor. carried out.
tected. servo motor and Loss of engine pow- YCC-T evacuation
ECU. er. is activated.
• Open or short cir- Engine idling speed Output is restricted.
cuit in wire har- is unstable. ISC feedback is not
ness between carried out.
throttle servo mo- ISC learning is not
tor and ECU. carried out.
• Defective throttle Quick shift system is
servo motor. not carried out.
• Throttle servo mo- Cruise control /
tor is stuck (mech- YVSL fixed to OFF.
anism or motor).
• Malfunction in
ECU.
• Blown electric
throttle valve fuse.
9-62
P0657 Fuel system volt- • Open or short cir- Engine is difficult to Monitor voltage = 12
age: incorrect volt- cuit in wire har- start. [V]
age supplied to the ness between Increased exhaust O2 feedback is not
fuel injector, fuel relay unit and emissions. carried out.
pump and relay unit. ECU. Cruise control /
• Open circuit in wire YVSL fixed to OFF.
harness between
battery and ECU.
• Defective relay
unit.
• Malfunction in
ECU.
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
short to ground cir- sensor circuit (0.2 V Engine response is previous value.
cuit is detected. or less) poor. Quick shift system is
Normal signal is not [P0917] High volt- not carried out.
received from the age of the gear posi- Engine brake man-
gear position sensor tion sensor circuit agement: control
to ECU. (4.8 V or more) mode is fixed.
[P0917] Gear posi- • Defective coupler Engine brake man-
tion sensor: short to between gear po- agement: control
power circuit is de- sition sensor and value is fixed.
tected. Normal sig- ECU. Cruise control /
nal is not received • Open or short cir- YVSL fixed to OFF.
from the gear posi- cuit in wire har-
tion sensor to ECU. ness between
gear position sen-
sor and ECU.
• Poor circuit conti-
nuity in wire har-
ness between
gear position sen-
sor and ECU.
• Improperly in-
stalled gear posi-
tion sensor.
• Defective gear po-
sition sensor.
• Malfunction in
ECU.
P1400 Air induction system • Open or short cir- Increased exhaust Electric current in air
solenoid: open or cuit in wire har- emissions. induction system
short to ground cir- ness. solenoid is prohibit-
cuit is detected. • Disconnected cou- ed (air induction
Normal signal is not pler. system air in).
received from the air • Defective air in- O2 feedback is not
induction system duction system so- carried out.
solenoid. lenoid. Cruise control /
• Defective air in- YVSL fixed to OFF.
duction system so-
lenoid controller.
(malfunction in
ECU)
9-63
P1500 Neutral switch: open • Open or short cir- Vehicle speed is not Vehicle speed dis-
or short circuit is de- cuit in wire har- displayed on the played on the meter
tected. Normal sig- ness between rear meter. = 0 [km/h]
nal is not received wheel sensor and Indication of the O2 feedback is not
from the rear wheel ABS unit. neutral indicator carried out.
sensor to ECU • Open or short cir- light is in-correct. Fuel cut-off control
when the gear-in. cuit in wire har- Engine idling speed when the rear wheel
Clutch switch: open ness between is unstable. sensor or neutral
or short circuit is de- ABS unit and ECU. Traction control switch malfunctions
tected. Normal sig- • Open or short cir- does not work. is carried out.
nal is not received cuit in wire har- ISC feedback is not
from the rear wheel ness between carried out.
sensor to ECU neutral switch and ISC learning is not
when the gear-in. ECU. carried out.
• Open or short cir- Traction control
cuit in wire har- does not work.
ness between Cruise control /
clutch switch and YVSL fixed to OFF.
ECU.
• Defective rear
wheel sensor.
• Defective neutral
switch.
• Defective clutch
switch.
• Improper adjust-
ment of clutch le-
ver.
• Malfunction in
ECU.
P1600 Lean angle sensor: • Open or short cir- Engine cannot be Engine cannot be
open or short circuit cuit in wire har- started. started.
is detected. Normal ness. Cruise control /
signal is not re- • Malfunction in YVSL fixed to OFF.
ceived from IMU or IMU.
defective IMU. • Malfunction in
ECU.
9-64
P1601 Sidestand switch: • Defective coupler Engine cannot be Engine is forcefully
open or short circuit between relay unit started. stopped (the injector
in wire harness of and ECU. output is stopped).
the ECU is detect- • Open or short cir- Cruise control /
ed. Normal signal is cuit in wire har- YVSL fixed to OFF.
not received from ness between
the sidestand relay unit and
switch. ECU.
• Defective coupler
between sidestand
switch and relay
unit.
• Open or short cir-
cuit in wire har-
ness between
sidestand switch
and relay unit.
• Defective side-
stand switch.
• Malfunction in
ECU.
P1602 Malfunction in ECU • Open or short cir- Engine idling speed O2 feedback learn-
internal circuit (mal- cuit in wire har- is unstable. ing is not carried
function of ECU ness between Engine idling speed out.
power cut-off func- ECU and battery. is high. O2 feedback learn-
tion). • Open or short cir- Increased exhaust ing value is not writ-
cuit in wire har- emissions. ten.
ness between Engine is difficult to Cruise control /
ECU and main start. YVSL fixed to OFF.
switch.
• Blown backup
fuse.
• Malfunction in
ECU.
P1806 [P1806] Shift sen- • Defective coupler Unable to carry out Quick shift system is
P1807 sor: open or short to between shift sen- quick shift system. not carried out.
ground circuit is de- sor and ECU. (If this abnormality
tected. Normal sig- • Open or short cir- occurs during actual
nal is not received cuit in wire har- shifting, the opera-
from the shift sensor ness between shift tion will be carried
to ECU. sensor and ECU. out until the process
[P1807] Shift sen- • Improperly in- is completed.)
sor: short to power stalled shift sen-
circuit is detected. sor.
Normal signal is not • Defective shift
received from the sensor.
shift sensor to ECU. • Malfunction in
ECU.
9-65
P2122 [P2122] Accelerator [P2122, P2127] Low Engine response is No change in accel-
P2123 position sensor: voltage of the accel- poor. erator opening
P2127 open or short to erator position sen- Loss of engine pow- (transient control is
P2128 ground circuit is de- sor circuit (0.25 V or er. not carried out).
P2138 tected. Normal sig- less) Engine idling speed Accelerator open-
nal is not received [P2123, P2128] is unstable. ing is fixed to 0[°].
from the accelerator High voltage of the O2 feedback is not
position sensor cir- accelerator position carried out.
cuit. sensor circuit (4.75 YCC-T evacuation
[P2123] Accelerator V or more) is activated.
position sensor: [P2138] Difference Fuel cut is prohibit-
short to power cir- in output voltage 1 ed by accelerator
cuit is detected. and output voltage 2 opening.
Normal signal is not of the accelerator Output is restricted.
received from the position sensor ISC feedback is not
accelerator position • Defective coupler carried out.
sensor circuit. between accelera- ISC learning is not
[P2127] Accelerator tor position sensor carried out.
position sensor: and ECU. Quick shift system is
open or short to • Open or short cir- not carried out.
ground circuit is de- cuit in wire har- Cruise control /
tected. Normal sig- ness between YVSL fixed to OFF.
nal is not received accelerator posi-
from the accelerator tion sensor and
position sensor cir- ECU.
cuit. • Improperly in-
[P2128] Accelerator stalled accelerator
position sensor: position sensor.
short to power cir- • Defective acceler-
cuit is detected. ator position sen-
Normal signal is not sor.
received from the • Malfunction in
accelerator position ECU.
sensor circuit.
[P2138] Deviation
error. Normal signal
is not received from
the accelerator posi-
tion sensor circuit.
P2158 Front wheel sensor: • Open or short cir- Traction control Traction control
normal signal is not cuit in wire har- does not work. does not work.
received from the ness between Traction control sys- Cruise control /
front wheel sensor. front wheel sensor tem indicator on the YVSL fixed to OFF.
and ECU. meter comes ON.
• Defective front Traction control sys-
wheel sensor. tem switch is dis-
• Malfunction in abled. (Traction
ECU. control system indi-
cator on the meter
comes OFF.)
9-66
P2195 O2 sensor 1: open • Signal voltage is Increased exhaust O2 feedback is not
circuit is detected. 0.18–0.49 V. emissions. carried out.
Normal signal is not • Improperly in- O2 feedback learn-
received from the O2 stalled O2 sensor ing is not carried
sensor 1. 1. out.
• Defective coupler Air induction system
between O2 sen- solenoid is turned
sor 1 and ECU. ON all the time (air
• Open or short cir- induction system air
cuit in wire har- cut off).
ness between O2 Quick shift system is
sensor 1 and ECU. not carried out.
• Incorrect fuel pres- Cruise control /
sure. YVSL fixed to OFF.
sor 1.
• Malfunction in
ECU.
P2197 O2 sensor 2: open • Signal voltage is Increased exhaust O2 feedback is not
circuit is detected. 0.18–0.49 V. emissions. carried out.
Normal signal is not • Improperly in- O2 feedback learn-
received from the O2 stalled O2 sensor ing is not carried
sensor 2. 2. out.
• Defective coupler Air induction system
between O2 sen- solenoid is turned
sor 2 and ECU. ON all the time (air
• Open or short cir- induction system air
cuit in wire har- cut off).
ness between O2 Quick shift system is
sensor 2 and ECU. not carried out.
• Incorrect fuel pres- Cruise control /
sure. YVSL fixed to OFF.
sor 2.
• Malfunction in
ECU.
9-67
P2228 [P2228] Atmospher- [P2228] Low voltage Engine is difficult to α–N is fixed.
P2229 ic pressure sensor: of the atmospheric start. Intake air pressure
short to ground cir- pressure sensor cir- Increased exhaust difference is fixed to
cuit is detected. cuit (0.5 V or less) emissions. 0 [kPa].
Normal signal is not [P2229] High volt- Insufficient power at Atmospheric pres-
received from the age of the atmo- high altitudes. sure is fixed to
atmospheric pres- spheric pressure Engine idling speed 101.3 [kPa].
sure sensor. sensor circuit (4.8 V is unstable. Atmospheric pres-
[P2229] Atmospher- or more) sure sensor output
ic pressure sensor: • Defective coupler correction value is
open or short to between atmo- fixed to 0.
power circuit is de- spheric pressure Fuel is not cut off
tected. Normal sig- sensor and ECU. due to the intake air
nal is not received • Open or short cir- pressure difference.
from the atmospher- cuit in wire har- O2 feedback is not
ic pressure sensor. ness between carried out.
atmospheric pres- ISC feedback is not
sure sensor and carried out.
ECU. ISC learning is not
• Improperly in- carried out.
stalled atmospher- Quick shift system is
ic pressure not carried out.
sensor. Cruise control /
• Defective atmo- YVSL fixed to OFF.
spheric pressure
sensor.
• Malfunction in
ECU.
U0125 Signals cannot be • Defective IMU Engine cannot be Engine cannot be
transmitted between coupler or ECU started. started.
the ECU and the coupler. Cruise control /
IMU. • Open or short cir- YVSL fixed to OFF.
cuit in wire har-
ness between IMU
and ECU.
• Malfunction in
IMU.
• Malfunction in
ECU.
9-68
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 9-29.
DTC Item Symptom Check point

11 Front wheel sensor (inter- Front wheel sensor signal • Foreign material ad-
mittent pulses or no puls- is not received properly. hered around the front
es) (Pulses are not received wheel sensor
or are received intermit- • Incorrect installation of
tently while the vehicle is the front wheel
traveling.) • Defective sensor rotor or
incorrect installation of
the rotor
• Defective front wheel
sensor or incorrect in-
stallation of the sensor
12 Rear wheel sensor (inter- Rear wheel sensor signal • Foreign material ad-
mittent pulses or no puls- is not received properly. hered around the rear
es) (Pulses are not received wheel sensor
or are received intermit- • Incorrect installation of
tently while the vehicle is the rear wheel
traveling.) • Defective sensor rotor or
the rotor
• Defective rear wheel
13* Front wheel sensor (ab- Front wheel sensor signal • Foreign material ad-
26* normal pulse period) is not received properly. hered around the front
(The pulse period is ab- wheel sensor
normal while the vehicle is • Incorrect installation of
traveling.) the front wheel
• Defective sensor rotor or
the rotor
14* Rear wheel sensor (abnor- Rear wheel sensor signal • Foreign material ad-
27* mal pulse period) is not received properly. hered around the rear
(The pulse period is ab- wheel sensor
normal while the vehicle is • Incorrect installation of
traveling.) the rear wheel
the rotor
9-69
15 Front wheel sensor (open Open or short circuit is de- • Defective coupler be-
or short circuit) tected in the front wheel tween the front wheel
sensor. sensor and the hydraulic
unit assembly
• Open or short circuit in
the wire harness be-
tween the front wheel
sensor and the hydraulic
unit assembly
sensor or hydraulic unit
assembly
16 Rear wheel sensor (open Open or short circuit is de- • Defective coupler be-
or short circuit) tected in the rear wheel tween the rear wheel
sensor. sensor and the hydraulic
unit assembly
tween the rear wheel
sensor and the hydraulic
unit assembly
sensor or hydraulic unit
assembly
21 Hydraulic unit assembly Solenoid drive circuit in • Defective hydraulic unit
(defective solenoid drive the hydraulic unit assem- assembly
circuit) bly is open or short-circuit-
ed.
31 Hydraulic unit assembly Power is not supplied to • Blown ABS solenoid fuse
(defective ABS solenoid the solenoid circuit in the • Defective coupler be-
power circuit) hydraulic unit assembly. tween the battery and the
hydraulic unit assembly
tween the battery and the
• Defective hydraulic unit
assembly
33 Hydraulic unit assembly Power is not supplied to • Blown ABS motor fuse
(abnormal ABS motor the motor circuit in the hy- • Defective coupler be-
power supply) draulic unit assembly. tween the battery and the
assembly
34 Hydraulic unit assembly Short circuit is detected in • Defective hydraulic unit
(short circuit in ABS motor the motor power supply assembly
power supply circuit) circuit in the hydraulic unit
assembly.
9-70
41 Front wheel ABS (intermit- • Pulses from the front • Incorrect installation of
tent wheel speed pulses or wheel sensor are re- the front wheel sensor
incorrect depressuriza- ceived intermittently • Incorrect rotation of the
tion) while the vehicle is trav- front wheel
eling. • Front brake dragging
• Front wheel will not re- • Defective hydraulic unit
cover from the locking assembly
tendency even though
the signal is transmitted
from the ABS ECU to re-
duce the hydraulic pres-
sure.
42 Rear wheel ABS (intermit- • Pulses from the rear • Incorrect installation of
tent wheel speed pulses or wheel sensor are re- the rear wheel sensor
incorrect depressuriza- ceived intermittently • Incorrect rotation of the
tion) while the vehicle is trav- rear wheel
eling. • Rear brake dragging
• Rear wheel will not re- • Defective hydraulic unit
cover from the locking assembly
tendency even though
the signal is transmitted
from the ABS ECU to re-
duce the hydraulic pres-
sure.
43* Front wheel sensor (miss- Front wheel sensor signal • Foreign material ad-
45* ing pulses) is not received properly. hered around the front
(Missing pulses are de- wheel sensor
tected in the signal while • Incorrect installation of
the vehicle is traveling.) the front wheel
the rotor
44* Rear wheel sensor (miss- Rear wheel sensor signal • Foreign material ad-
46* ing pulses) is not received properly. hered around the rear
(Missing pulses are de- wheel sensor
tected in the signal while • Incorrect installation of
the vehicle is traveling.) the rear wheel
the rotor
51 Vehicle system power Power voltage supplied to • Defective battery
supply (voltage of ABS the ABS ECU in the hy- • Disconnected battery
ECU power supply is high) draulic unit assembly is terminal
too high. • Defective charging sys-
tem
9-71
53 Vehicle system power Power voltage supplied to • Defective battery
supply (voltage of ABS the ABS ECU in the hy- • Defective coupler be-
ECU power supply is low) draulic unit assembly is tween the battery and the
too low. hydraulic unit assembly
• Defective charging sys-
tem
55 Hydraulic unit assembly Abnormal data is detected • Defective hydraulic unit
(defective ABS ECU) in the hydraulic unit as- assembly
sembly.
56 Hydraulic unit assembly Abnormality detected in of • Defective hydraulic unit
(abnormal internal circuit) hydraulic unit assembly. assembly
57 Vehicle CAN communica- Short-circuit in CAN com- • Short-circuit in CAN
tion line or power source of munication line or the volt- communication line
vehicle system age that supplies the • Defective battery
hydraulic unit assembly is • Defective coupler be-
too low. tween battery and hy-
draulic unit assembly
• Wire harness between
battery and hydraulic unit
is interrupted or has
short-circuited
• Defective charging sys-
tem
62 Power supply voltage fail- Abnormality detected in • Defective hydraulic unit
ure in pressure sensor pressure sensor power assembly
supply circuit of hydraulic
unit assembly.
68 Defective hydraulic unit Abnormality detected in In case of electrical inter-
assembly (defective front pressure sensor circuit at locking brake
pressure sensor) front caliper side of hy- • Defective front brake line
draulic unit assembly. • Defective hydraulic unit
assembly
89 CAN communication (be- Transmitted data from the • Defective coupler be-
tween meter assembly meter cannot be normally tween meter assembly
and hydraulic unit assem- received. and hydraulic unit as-
bly) sembly
• Harness is broken or
short-circuit between
meter assembly and hy-
draulic unit assembly
• Defective meter assem-
bly
assembly
9-72
tween ECU and hydraulic FI ECU cannot be normal- tween FI ECU and hy-
unit assembly) ly received. draulic unit assembly
short-circuit between FI
ECU and hydraulic unit
assembly
• Defective FI ECU
assembly
tween IMU and hydraulic IMU cannot be normally tween IMU and hydraulic
unit assembly) received. unit assembly
short-circuit between
IMU and hydraulic unit
assembly
• Defective IMU
assembly
* The DTC number varies according to the vehicle conditions.
9-73
EAS33288
SELF-DIAGNOSTIC FUNCTION TABLE (FOR ELECTRONICALLY ADJUSTABLE SUSPENSION

SYSTEM)
(for MT10SPN/MT10SPNC)
TIP
For details of the DTC, refer to “BASIC INSTRUCTIONS FOR TROUBLESHOOTING” on page 9-38.

C0044 Abnormal ABS • Defective front • ERS adjustments —
(Brake fluid pres- and rear brake cannot be per-
sure value is not lines. formed.
normal.) • Defective hydrau- • The damping pre-
lic unit assembly. set value is fixed at
the prescribed po-
sition (automatic
setting modes).
C0520 Abnormal IMU (IMU • Defective IMU • ERS adjustments —
sensor value is not coupler or ECU cannot be per-
normal.) coupler. formed.
• Open or short cir- • The damping pre-
cuit in wire har- set value is fixed at
ness between IMU the prescribed po-
and ECU. sition (automatic
• Improperly in- setting modes).
stalled IMU.
• Malfunction in
IMU.
• Malfunction in
ECU.
C1002 Abnormal SCU EE- • SCU abnormal • ERS adjustments —
PROM (SCU inter- data writing error. cannot be per-
nal data is not • Malfunction in formed.
normal.) SCU.
C1003 Stepping motor is • Defective connec- • ERS adjustments —
not driving properly. tion of stepping cannot be per-
motor and SCU formed.
couplers. • The damping pre-
• Defective connec- set value is fixed
tion of sub-wire on the defective
harness coupler. side (front fork or
• Short circuit in RCU) at the cur-
wire harness or rent value (auto-
wire harness con- matic setting
tinuity. modes).
• Defective stepping
motor.
• Malfunction in
SCU.
C1007 Abnormal SCU in- • Malfunction in • ERS adjustments —
side 1 (SCU does SCU. cannot be per-
not operate proper- formed.
ly.)
9-74
P0500 Abnormal rear • Open or short cir- • ERS adjustments —
wheel sensor (Sen- cuit in wire har- cannot be per-
sor value is not nor- ness between rear formed.
mal.) wheel sensor and • The damping pre-
ABS unit. set value is fixed at
• Open or short cir- the prescribed po-
cuit in wire har- sition (automatic
ness between setting modes).
ABS unit and
ECU.
• Defective rear
wheel sensor.
• Malfunction in
ECU.
P0560 Abnormal SCU • Battery overcharg- • ERS adjustments —
power supply volt- ing (defective rec- cannot be per-
age (Regulator is tifier/regulator). formed.
not operated prop- • Battery overcharg-
erly or battery is not ing (broken or dis-
charged properly.) connected lead in
rectifier/regulator
wire harness).
• Battery over-dis-
charging (broken
or disconnected
lead in charging
system).
• Battery over-dis-
charging (defec-
tive rectifier/
regulator).
P2158 Abnormal front • Open or short cir- • ERS adjustments —
wheel sensor. (Sen- cuit in wire har- cannot be per-
sor value is not nor- ness between formed.
mal.) front wheel sen- • The damping pre-
sor and ECU. set value is fixed at
• Defective front the prescribed po-
wheel sensor. sition (automatic
• Malfunction in setting modes).
ECU.
U0100 Abnormal CAN • Defective connec- • ERS adjustments —
communication (be- tion of wire har- cannot be per-
tween ECU and ness, ECU, and formed.
SCU) SCU couplers. • The damping pre-
• Wire harness con- set value is fixed at
tinuity. the prescribed po-
• Malfunction in sition (automatic
SCU. setting modes).
• Malfunction in
ECU.
9-75
tween ABS ECU ness, ABS ECU, formed.
and SCU) and SCU cou- • The damping pre-
plers. set value is fixed at
• Wire harness con- the prescribed po-
tinuity. sition (automatic
SCU.
• Malfunction in
ABS ECU.
tween IMU and ness, IMU, and formed.
SCU) SCU couplers. • The damping pre-
• Wire harness con- set value is fixed at
tinuity. the prescribed po-
• Malfunction in sition (automatic
SCU. setting modes).
• Malfunction in
IMU.
tween meter as- ness, meter formed.
sembly and SCU) assembly, and • The damping pre-
SCU couplers. set value is fixed at
• Wire harness con- the prescribed po-
tinuity. sition (automatic
SCU.
• Malfunction in me-
ter assembly.
Displayed Abnormal SCU in- • Malfunction in • ERS adjustments —
Err (NIL) side 2 (SCU does SCU. cannot be per-
not operate proper- formed.
ly.) • The “Err” and ERS
icons are dis-
played on the me-
ter display.
9-76
EAS33030
COMMUNICATION ERROR WITH THE METER

U0155 [U0155 (FI)] Multi- Communication be- Defective meter dis- Map switching:
(YDT) function meter: sig- tween the ECU and play. Fixed state.
Err (multi- nals cannot be the meter is not pos- Traction control Traction control
function transmitted between sible does not work. does not work.
meter dis- the ECU and the • Defective meter Meter switch input:
play) multi-function me- coupler and ECU Fixed to OFF.
ter. coupler Quick shift system is
[U0155 (SCU)] Ab- • Open or short cir- not carried out.
normal CAN com- cuit in the wire har- Engine brake man-
munication ness between the agement: control
(between meter as- meter and the mode is fixed.
sembly and SCU) ECU Cruise control /
• Defective meter YVSL fixed to OFF.
• Defective ECU
EAS33031
DIAGNOSTIC CODE: SENSOR OPERATION TABLE

Diagnostic
Item Tool display Procedure
code No.
01 Throttle position sensor 0–125
signal 1
• Fully closed position 11–21 Check the fully closed
throttle valve.
• Fully opened position 96–107 Check the fully opened
throttle valve.
02 Atmospheric pressure Displays the atmospheric Compare the actually
pressure. measured atmospheric
0–126 kPa pressure with the tool dis-
Atmospheric pressure at played value.
the current altitude and
weather conditions is indi-
cated.
At sea level (0m): Approx.
101 kPa
Above sea level (3000 m):
Approx. 70 kPa
03 Intake air pressure Displays the intake air Operate the throttle while
pressure. pushing the “ ” side of the
0–126 kPa start/engine stop switch. (If
When engine is stopped: the displaying value
Atmospheric pressure at changes, the performance
the current altitude is indi- is OK.)
cated.
At sea level (0m): Approx.
101 kPa
Above sea level (3000 m):
Approx. 70 kPa
9-77
Diagnostic
code No.
05 Intake air temperature Displays the intake air Compare the actually
temperature. measured air temperature
-30–120 °C with the tool displayed val-
When engine is cold: ue.
Displays temperature clos-
er to air temperature.
When engine is hot:
Air temperature + approx.
20 °C
06 Coolant temperature Displays the coolant tem- Compare the actually
perature. measured coolant tem-
-30–120 °C perature with the tool dis-
When engine is cold: Dis- played value.
plays temperature closer
to air temperature.
When engine is hot: Dis-
plays current coolant tem-
perature.
07 Rear wheel vehicle speed Rear wheel speed pulse Check that the number in-
pulses 0–999 creases when the rear
wheel is rotated. The num-
ber is cumulative and does
not reset each time the
wheel is stopped.
09 Fuel system voltage Displays the fuel system Compare the actually
(battery voltage) voltage. measured battery voltage
0–18.7 V with the tool displayed val-
Standard voltage: ue. (If the actually mea-
Approx 12.0 V sured battery voltage is
low, recharge the battery.)
13 Throttle position sensor 0–125
signal 2
• Fully closed position 9–23 Check the fully closed
throttle valve.
• Fully opened position 93–109 Check the fully opened
throttle valve.
14 Accelerator position sen- 0–125
sor signal 1
• Fully closed position 14–18 Check with throttle grip ful-
ly closed position.
• Fully opened position 82–92 Check with throttle grip ful-
ly opened position.
• Turn the throttle grip past 7–12
the closed position in the
deceleration direction.
9-78
Diagnostic
code No.
15 Accelerator position sen- 0–125
sor signal 2
• Fully closed position 14–18 Check with throttle grip ful-
ly closed position.
• Fully opened position 82–92 Check with throttle grip ful-
ly opened position.
• Turn the throttle grip past 7–12
the closed position in the
deceleration direction.
16 Front wheel speed pulses Front wheel speed pulse Check that the number in-
0–999 creases when the front
wheel is rotated. The num-
ber is cumulative and does
not reset each time the
wheel is stopped.
17 Bank angle display Displays the bank angle in Check that 0–5° is dis-
increments of 5° played when the vehicle is
• 0–5° (vehicle is vertical) vertical and that the dis-
• Less than 30° (when the played value increases as
sidestand is used) the vehicle continues to in-
cline.
20 Sidestand switch Extend and retract the
• Sidestand retracted ON sidestand.
• Sidestand extended OFF

21 Neutral switch and clutch Check the neutral switch
switch and clutch switch condi-
• Transmission is in neu- ON tion.
tral
• Transmission is in gear OFF
and the clutch lever re-
leased
• 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
9-79
Diagnostic
code No.
60 EEPROM DTC display —
• No history 00
• No malfunctions detect-
ed (If the DTC P062F is
indicated, the ECU is de-
fective.)
• History exists 01–04 (CO adjustment val-
ue)
• (If more than one cylinder
is defective, the display
alternates every two sec-
onds to show all the de-
tected cylinder numbers.
When all cylinder num-
bers are shown, the dis-
play repeats the same
process.)
Except 00–04 (EEPROM
data error for correspond-
ing learning/memory val-
ues)
67 ISC (Idle Speed Control) 00 To erase the ISC (Idle
learning condition display ISC (Idle Speed Control) Speed Control) learning
ISC (Idle Speed Control) learning data has been data, push the “Operation”
learning data erasure erased. button 3 times within 5
01 seconds.
It is not necessary to erase
the ISC (Idle Speed Con-
trol) learning data.
02
It is necessary to erase the
ISC (Idle Speed Control)
learning data.
70 Programmed unit Ver. 0–254 [-] Check the programmed
number unit Ver. number
80 Cruise control setting Push and release the
switch “RES+” “RES+” side of the cruise
• Switch is pushed ON control setting switch.
• Switch is released OFF

81 Cruise control setting Push and release the
switch “SET-” “SET-” side of the cruise
• Switch is pushed ON control setting switch.
• Switch is released OFF
9-80
Diagnostic
code No.
82 Cruise control cancel cir- Operate the clutch lever,
cuit brake lever and brake ped-
• Clutch lever is squeezed ON al.
• Clutch lever is released OFF

• Brake lever is squeezed ON
• Brake lever is released OFF
• Brake pedal is pushed ON
• Brake pedal is released OFF
83 Front brake light switch Operate the brake lever
and rear brake light switch and brake pedal.
• Brake lever is squeezed ON
• Brake lever is released OFF
• Brake pedal is pushed ON
• Brake pedal is released OFF
87 O2 feedback learning data 00 To erase the O2 feedback
erasure O2 feedback learning data learning data, push the
has been erased. “Operation” button 3 times
01 within 5 seconds.
O2 feedback learning data
has not been erased.
95 Shift sensor Check the sensor condi-
• Shift sensor output volt- 0.2–4.8 V tion by operating the shift
age display pedal.
• With no shift weighting Approx. 2.5 V
input
• Shift up weighting Changes to the low side
voltage
• Shift down weighting Changes to the high side
voltage
9-81
EAS33032
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE

Diagnostic
Item Actuation Procedure
code No.
30 Cylinder-#1 ignition coil Actuates the cylinder-#1 Check that a spark is gen-
ignition coil five times at erated five times.
one-second intervals. • Connect an ignition
The “check” indicator on checker.
the YDT screen comes on • Check the sparking per-
each time the ignition coil formance on the spark
is actuated. plug.
is actuated. plug.
is actuated. plug.
is actuated. plug.
36 Fuel injector #1 Actuates the fuel injector Disconnect the fuel pump
#1 five times at one-sec- coupler before doing this
ond intervals. procedure.
The “check” indicator on Check that fuel injector #1
the YDT screen comes on is actuated five times by
each time the fuel injector listening for the operating
is actuated. sound.
is actuated. sound.
is actuated. sound.
9-82
Diagnostic
Item Actuation Procedure
code No.
is actuated. sound.
48 Air induction system sole- Actuates the air induction Check that the air induc-
noid system solenoid five times tion system solenoid is ac-
at one-second intervals. tuated five times by
The “check” indicator on listening for the operating
the YDT screen comes on sound.
each time the air induction
system solenoid is actuat-
ed.
50 Relay unit Actuates the relay unit five Check that the relay unit is
times at one-second inter- actuated five times by lis-
vals. tening for the operating
The “check” indicator on sound.
the YDT screen comes on
each time the relay is actu-
ated.
51 Radiator fan motor relay Actuates the radiator fan Check that the radiator fan
motor relay five times at motor relay is actuated
five-seconds intervals. five times by listening for
The “check” indicator on the operating sound.
each time the relay is actu-
ated.
52 Headlight relay Actuates the headlight re- Check that the headlight
lay five times at five-sec- relay comes on five times
onds intervals. by listening for the operat-
The “check” indicator on ing sound.
each time the headlight re-
lay is actuated.
53 EXUP servo motor After the EXUP is fully Check the operating
closed, it stops at the sound.
opening base position (in-
termediate position).
This operation takes ap-
proximately 3 seconds
during which the “check”
indicator is displayed on
the YDT.
57 Grip warmer (OPTION) Energize (warm up) the Check that the grip warm-
grip warmers for 2 min- er temperature by hand.
utes.
9-83
EAS33289
DIAGNOSTIC CODE TABLE (SCU) (for MT10SPN/MT10SPNC)

Diagnostic
code No.
09 Monitor voltage Displays the SCU power Check the displayed SCU
voltage. power supply voltage.
0–18.7 V
Standard voltage: Approx.
12.0 V
9-84
EVENT CODE TABLE
EAS20707
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 Same as for DTC num- Perform the inspection
sure sensor detected in the in- ber P0107 and P0108 items listed for DTC num-
take air pressure ber P0107 and P0108.
sensor
193 Throttle position Brief abnormality Same as for DTC num- Perform the inspection
sensor detected in the ber P0122, P0123, items listed for DTC num-
throttle position P0222 and P0223 ber P0122, P0123,
sensor P0222 and P0223.
194 EXUP servo Brief abnormality Same as for DTC num- Perform the inspection
motor circuit detected in EXUP ber P048D and P048E items listed for DTC num-
servo motor circuit ber P048D and P048E.
195 Sidestand Brief abnormality Same as for DTC num- Perform the inspection
switch detected in the ECU ber P1601 items listed for DTC num-
(blue/yellow) input ber P1601.
line
196 Coolant tem- Brief abnormality Same as for DTC num- Perform the inspection
perature sensor detected a in the ber P0117 and P0118 items listed for DTC num-
coolant tempera- ber P0117 and P0118.
ture sensor
197 Intake air tem- Brief abnormality Same as for DTC num- Perform the inspection
perature sensor detected in the in- ber P0112 and P0113 items listed for DTC num-
take air temperature ber P0112 and P0113.
sensor
198 Atmospheric Brief abnormality Same as for DTC num- Perform the inspection
pressure sensor detected in atmo- ber P2228 and P2229 items listed for DTC num-
spheric pressure ber P2228 and P2229.
sensor
207 Accelerator po- Brief abnormality Same as for DTC num- Perform the inspection
sition sensor detected in the ac- ber P2122, P2123, items listed for DTC num-
celerator position P2127 and P2128 ber P2122, P2123,
sensor P2127 and P2128.
220 Gear position Brief abnormality Same as for DTC num- Perform the inspection
sensor detected in the gear ber P0916 and P0917 items listed for DTC num-
position sensor ber P0916 and P0917.
240 O2 sensor During O2 feed- • Open or short circuit • If a DTC is occurring,
(Stuck at the up- back, the adjust- in the wire harness respond to that first.
per limit for ad- ment is maintained between the sensor * Rarely, Code 240 oc-
justment) at the upper limit and ECU curs even when the sys-
• Drop in fuel pressure tem is functioning
• Clogged fuel injector properly.
• Fault in sensor
• Malfunction in ECU
• Malfunction in the
fuel injection system
9-85
EVENT CODE TABLE
241 O2 sensor During O2 feed- • Open or short circuit • If a DTC is occurring,
(Stuck at the back, the adjust- in the wire harness respond to that first.
lower limit for ment is maintained between the sensor * Rarely, Code 241 oc-
adjustment) at the lower limit and ECU curs even when the sys-
• Drop in fuel pressure tem is functioning
• Clogged fuel injector properly.
• Fault in sensor
fuel injection system
242 ISC During idling, the Idling engine speed is • Implement diagnosis
(Stuck at the up- adjustment is main- slow mode D67, and check
per limit for ad- tained at the upper • Clogged throttle body the ISC maintenance
justment) limit • Poorly adjusted request.
clutch cable • If a DTC is occurring,
• Malfunction in the respond to that first.
fuel injection system * Rarely, Code 242 oc-
• Dirty or worn spark curs even when the sys-
plug tem is functioning
• Malfunction in the properly.
battery
243 ISC During idling, the Idling engine speed is • If a DTC is occurring,
(Stuck at the adjustment is main- fast respond to that first.
lower limit for tained at the lower • Poorly adjusted * Rarely, Code 243 oc-
adjustment) limit clutch cable curs even when the sys-
• Malfunction in the tem is functioning
fuel injection system properly.
• Dirty or worn spark
plug
battery
244 Poor starting/in- Poor starting/inabili- • No gasoline • If a DTC is occurring,
ability to start ty to start detected • Malfunction in the respond to that first.
fuel injection system * Rarely, Code 244 oc-
• Dirty or worn spark curs even when the sys-
plug tem is functioning
• Malfunction in the properly.
battery
245 Engine stop Engine stop detect- • No gasoline • If a DTC is occurring,
ed • Poorly adjusted respond to that first.
clutch cable * Rarely, Code 245 oc-
• Malfunction in the curs even when the sys-
fuel injection system tem is functioning
• Dirty or worn spark properly.
plug
battery
9-86
EVENT CODE TABLE
246 Cruise control Automatic turning While setting the Cruise control system
OFF detected in the cruise control system: turns OFF automatically,
cruise control sys- • Unable to maintain but it is not system fail-
tem. the set cruising ure.
speed when driving
up steep slope.
• Wheel slip is detect-
ed.
• Engine stalls
• Sidestand is extend-
ed.
• Engine stop switch is
set to the OFF.
251 Shift sensor Brief abnormality Same as for DTC num- Perform the inspection
detected in the shift ber P1806 and P1807 items listed for DTC num-
sensor ber P1806 and P1807.
9-87
30_EVENT
EAS20552
30_EVENT
EAS33033
TROUBLESHOOTING
Item
Overturn is detected.
Fail-safe system
• Unable to start engine
• Unable to drive vehicle
Procedure
1. The vehicle has overturned.
• Raise the overturned vehicle vertically and check again.
• 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
3. Defective IMU.
• Execute the diagnostic mode. (Code 17)
• 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.
b. Turn the main switch to “ON”, then to “OFF”, and then back to “ON”.
9-88
30_EVENT
Is the MIL on?

YES
→ Go to step 4.
NO
4. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
9-89
70_EVENT
EAS20554
70_EVENT
EAS33034
TROUBLESHOOTING
Item
Engine forcibly stops when the vehicle is left idling for a long period.
Procedure
TIP
If 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
NO
→ Go to step 2.
9-90
C0044
EAS20559
C0044
EAS33039
TROUBLESHOOTING
Item
Abnormal ABS (Brake fluid pressure value is not normal.)
Fail-safe system
• Able to start engine
• Able to drive vehicle
Procedure
1. Abnormal ABS (Brake fluid pressure value is not normal.)
• Check the items of DTCs 62 and 68 for the ABS.
Refer to “[B-2] DIAGNOSIS USING THE DTC” on page 9-32.
• Turn the main switch to “OFF” and back to “ON”, and then check the DTC using the malfunction
mode of the YDT.
Is it in the “Recovered” condition?

YES
NO
→ Refer to the item corresponding to the DTC.
9-91
C0520 (FI)
EAS20689
C0520 (FI)
EAS33319
TROUBLESHOOTING
Item
Abnormal IMU (Normal signal is not received from the IMU or failure signal is received from IMU.)
Fail-safe system
• Able/Unable to start engine (depending on the situation)
• Able/Unable to drive vehicle (depending on the situation)
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 DTC using the malfunction mode of the YDT.

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 2.
2. Connection of ECU coupler.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
3. Wire harness continuity.
• Disconnect the ECU coupler “1”, joint coupler “2”, IMU coupler “3” and signaling system fuse “4”.
• Open circuit check
9-92
C0520 (FI)
blue/white–blue/white
Between ECU coupler and joint coupler
blue/black–blue/black
Between joint coupler and IMU coupler
Between IMU coupler and signaling system
red/white–brown
fuse holder
Between IMU coupler and ECU coupler black/white–black/white
4 1
3 B/W L/W L/B R/W
Y/R P/W P/B O/L Gy O/L Gy
Lg/R L/B O/B R/B G/B B
R/L G/Y Br/R B
R/G Y/B L/Y R/L B/W B/W
1
2 L/B O/W Lg/L P/W P V L L/R Gy
L/W L/W L/W L/W L/W L/W L/R L/R Br L/R L/R L/R L/W B/Y Br G/LGy/G Br/W B/L W W/B
L/B L/B L/B L/B L/B L/B L/Y L/W Lg/B Gy/Y G/W G Gy/B W/L
*. MT10SPN/MT10SPNC
Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.

YES
NO
• Short circuit check
TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-4.
Ground short circuit check “A”
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
9-93
C0520 (FI)
Lines short circuit check “B”
blue/white–any other coupler terminal
ECU coupler
blue/black–any other coupler terminal
Joint coupler “2”
IMU coupler blue/black–any other coupler terminal
red/white–any other coupler terminal
A B
1 1
L/B O/W Lg/L P/W P V L L/R Gy L/B O/W Lg/L P/W P V L L/R Gy
L/W B/Y Br G/LGy/G Br/W B/L W W/B L/W B/Y Br G/LGy/G Br/W B/L W W/B
L/Y L/W Lg/B Gy/Y G/W G Gy/B W/L L/Y L/W Lg/B Gy/Y G/W G Gy/B W/L
3 B/W L/W L/B R/W
3
B/W L/W L/B R/W
2
L/W L/W L/W L/W L/W L/W L/R L/R Br L/R L/R L/R
*. MT10SPN/MT10SPNC
Is resistance ∞ Ω?
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
9-94
C0520 (FI)
Is check result OK?

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
5. Defective IMU.
• Replace the IMU.
• Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

YES
NO
→ Go to step 6.
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.
9-95
C0520 (SCU)
EAS20664
C0520 (SCU)
EAS33290
TROUBLESHOOTING
Item
Abnormal IMU (IMU sensor value is not normal.)
Fail-safe system
Procedure
1. Abnormal IMU (IMU sensor value is not normal.)
• Check the item of DTC C0520 for the ECU.
Refer to “SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM)” on page 9-
47.
mode of the YDT.

YES
NO
→ Refer to the item corresponding to DTC.
9-96
C1002
EAS20562
C1002
EAS33042
TROUBLESHOOTING
Item
Abnormal SCU EEPROM (SCU internal data is not normal.)
Fail-safe system
Procedure
1. Confirmation after correction of abnormality.
• Turn the main switch to “OFF” and back to “ON”.
• Check the DTC using the malfunction mode of the YDT.

YES
NO
→ Go to step 2.
2. Malfunction in SCU.
• Replace the SCU.
mode of the YDT.
• Make sure confirm the “Recovered” condition, and complete the service.
9-97
C1003
EAS20563
C1003
EAS33043
TROUBLESHOOTING
Item
Stepping motor is not driving properly.
Fail-safe system
Procedure
1. Connection of stepping motor coupler.
Front fork stepping motor (left)
Front fork stepping motor (right)
Rear shock absorber assembly stepping motor (×2)
pins).

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 DTC using the malfunction
mode of the YDT.

YES
NO
→ Go to step 2.
2. Connection of SCU coupler.
pins).

YES
→ Go to step 3.
NO
mode of the YDT.

YES
NO
→ Go to step 3.
9-98
C1003
3. Connection of stepping motor sub-wire harness coupler.
pins).

YES
→ Go to step 4.
NO
mode of the YDT.

YES
NO
→ Go to step 4.
green–green
Between SCU coupler “1” and front fork step- green/black–green/black
ping motor (left) (compression damping) “2” green/red–green/red
green/blue–green/blue
1 2
P/W G/R Y Br/W
P G Y/R B
G/R G G/B G/L
L/B P/L G/B Y/G
pink–pink
Between SCU coupler “1” and front fork step- pink/black–pink/black
ping motor (right) (rebound damping) “2” pink/white–pink/white
pink/blue–pink/blue
1 2
P/W G/R Y Br/W
P G Y/R B
P/W P P/B P/L
L/B P/L G/B Y/G
9-99
C1003
white–white
Between SCU coupler “1” and rear shock ab-
white/black–white/black
sorber assembly stepping motor (compression
white/red–white/red
damping) “2”
white/green–white/green
1 2
P/W G/R Y Br/W
P G Y/R B
W/R W W/B W/G
L/B P/L G/B Y/G
yellow–yellow
Between SCU coupler “1” and rear shock ab-
yellow/black–yellow/black
sorber assembly stepping motor (rebound
yellow/red–yellow/red
damping) “2”
yellow/green–yellow/green
1 2
P/W G/R Y Br/W
P G Y/R B
Y/R Y Y/B Y/G
L/B P/L G/B Y/G
Is resistance 0 Ω?
YES
NO
a. Replace the wire harness and/or sub-wire harness.
mode of the YDT.

YES
NO
TIP
Disconnect the SCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SCU (for MT10SPN/MT10SPNC)” on page 9-4.
9-100
C1003
green–black
Between front fork stepping motor (left) “1” and green/black–black
power 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
white–black
Between rear shock absorber assembly step-
white/black–black
ping motor (compression damping) “4” and
white/red–black
power ground “2”
white/green–black
yellow–black
yellow/black–black
ping motor (rebound damping) “5” and power
yellow/red–black
ground “2”
yellow/green–black
green–brown/white
Between front fork stepping motor (left) “1” and green/black–brown/white
power 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
white/black–brown/white
ping motor (compression damping) “4” and
white/red–brown/white
power battery “6”
white/green–brown/white
yellow–brown/white
yellow/black–brown/white
ping motor (rebound damping) “5” and power
yellow/red–brown/white
battery “6”
yellow/green–brown/white
3 1 5 2 6
P/W G/R Y Br/W

P G Y/R B
L/B P/L G/B Y/G
YES
→ Go to step 5.
NO
mode of the YDT.
9-101
C1003

YES
NO
→ Go to step 5.
5. Malfunction in stepping motor.
a. Connect the digital circuit tester (Ω) to the stepping motor.
• Positive tester probe “1”
• Negative tester probe “2”
A B
1 3
1 2 3 4 2 4
A. Stepping motor coupler

B. Connection wiring diagram
b. Measure the resistance of the stepping motor between “1” and “2”.
14.8–18.2 Ω (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 MT10SPN/MT10SPNC)” on page 4-86 and “REAR SHOCK
ABSORBER ASSEMBLY” on page 4-100.
b. Turn the main switch to “ON”. Check the DTC using the malfunction mode of the YDT.

YES
NO
→ Go to step c.
c. Connect the digital circuit tester (Ω) to the stepping motor.
• Positive tester probe “3”
• Negative tester probe “4”
d. Measure the resistance of the stepping motor between “3” and “4”.
14.8–18.2 Ω (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 MT10SPN/MT10SPNC)” on page 4-86 and “REAR SHOCK
ABSORBER ASSEMBLY” on page 4-100.
b. Turn the main switch to “ON”. Check the DTC using the malfunction mode of the YDT.
9-102
C1003

YES
NO
→ Go to step 6.
mode of the YDT.

YES
NO
9-103
C1007
EAS20566
C1007
EAS33046
TROUBLESHOOTING
Item
Abnormal SCU inside 1 (SCU does not operate properly.)
Fail-safe system
Procedure
mode of the YDT.
• Make sure confirm the“Recovered”condition, and complete the service.
9-104
P0030
EAS20397
P0030
EAS33134
TROUBLESHOOTING
Item
O2 sensor 1 heater: defective heater or heater driver ON / OFF command and error signal is mismatch-
ing.
Fail-safe system
Procedure
TIP
If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first.
• P0112, P0113, P0122, P0123, P0222, P0223, P2135
1. Connection of O2 sensor 1 coupler.
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Start the engine, and then check the DTC.

YES
NO
→ Go to step 2.
TIP
For this check, also set the start/engine stop switch to “ON”.
pins).

YES
→ Go to step 3.
NO
9-105
P0030

YES
NO

YES
NO
→ Go to step 3.
TIP
• Disconnect the O2 sensor 1 coupler “1”, ECU coupler “2” and ignition fuse “3”.
Between O2 sensor 1 coupler and ECU coupler pink/black–pink/black
Between O2 sensor 1 coupler and ignition fuse
red/white–red/white
holder
3 1 2
R/W P/B Lg/R L/B O/B R/B G/B B
Gy/G B/L R/L G/Y Br/R B
Is resistance 0 Ω?
YES
NO

YES
NO

YES
NO
9-106
P0030
TIP
TIP
red/white–ground
Between O2 sensor 1 coupler “1” and ground
pink/black–ground

O2 sensor 1 coupler red/white–any other coupler terminal
pink/black–any other coupler terminal
ECU coupler “2” pink/black–any other coupler terminal
A B
1 1 2
R/W P/B R/W P/B

Gy/G B/L Gy/G B/L
R/L G/Y Br/R B
YES
→ Go to step 4.
NO

YES
NO

YES
NO
→ Go to step 4.
TIP
4. Defective O2 sensor 1.
• Replace the O2 sensor 1.
9-107
P0030

YES
NO

YES
NO
→ Go to step 5.
TIP
9-108
P0050
EAS20398
P0050
EAS33135
TROUBLESHOOTING
Item
O2 sensor 2 heater: defective heater or heater driver ON / OFF command and error signal is mismatch-
ing.
Fail-safe system
Procedure
TIP
• P0112, P0113, P0122, P0123, P0222, P0223, P2135
pins).

YES
→ Go to step 2.
NO

YES
NO

YES
NO
→ Go to step 2.
TIP
pins).

YES
→ Go to step 3.
NO
9-109
P0050

YES
NO

YES
NO
→ Go to step 3.
TIP
Between O2 sensor 2 coupler and ECU coupler pink/white–pink/white
holder
3 1 2
R/W P/W Lg/R L/B O/B R/B G/B B
Gy/Y B/L R/L G/Y Br/R B
Is resistance 0 Ω?
YES
NO

YES
NO

YES
NO
9-110
P0050
TIP
TIP
red/white–ground
pink/white–ground

O2 sensor 2 coupler red/white–any other coupler terminal
pink/white–any other coupler terminal
ECU coupler “2” pink/white–any other coupler terminal
A B
1 1 2
R/W P/W R/W P/W

Gy/Y B/L Gy/Y B/L
R/L G/Y Br/R B
YES
→ Go to step 4.
NO

YES
NO

YES
NO
→ Go to step 4.
TIP
• Replace the O2 sensor 2.
9-111
P0050

YES
NO

YES
NO
→ Go to step 5.
TIP
9-112
P0069
EAS20390
P0069
EAS33136
TROUBLESHOOTING
Item
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
Procedure
TIP
• P0107, P0108, P0335, P2228, P2229
1. Defective intake air pressure sensor.
• 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.

YES
NO
→ Go to step 2.
2. Defective atmospheric pressure sensor.
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
a. Replace the atmospheric pressure sensor.
Refer to “AIR INDUCTION SYSTEM” on page 7-18.
9-113
P0069

YES
NO
→ Go to step 3.
9-114
P00D1, P2195
EAS20660
P00D1, P2195
EAS33115
TROUBLESHOOTING
Item
• [P00D1] O2 sensor 1: heater performance is deteriorated. Normal signal is not received from the O2
sensor while driving the O2 sensor 1 heater.
• [P2195] O2 sensor 1: open circuit is detected. Normal signal is not received from the O2 sensor.
Fail-safe system
Procedure
TIP
• P0030
1. Installed condition of O2 sensor 1.
• Check for looseness or pinching.
Is check result OK?

YES
→ Go to step 2.
NO
a. Reinstall or replace the sensor.
b. Start the engine and let it idle for approximately 1 minute.
c. Check the DTC using the malfunction mode of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-115
P00D1, P2195
pins).

YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
gray/green–gray/green
Between O2 sensor 1 coupler and ECU coupler pink/black–pink/black
black/blue–black/blue
holder
2 2
3 Y/R P/W P/B O/L Gy O/L Gy
Lg/R L/B O/B R/B G/B B L/B O/W Lg/L P/W P V L L/R Gy
R/L G/Y Br/R B L/W B/Y Br G/LGy/G Br/W B/L W W/B
R/G Y/B L/Y R/L B/W B/W L/Y L/W Lg/B Gy/Y G/W G Gy/B W/L
1
R/W P/B
Gy/G B/L
Is resistance 0 Ω?
YES
NO

YES
NO
9-116
P00D1, P2195
TIP
gray/green–ground
pink/black–ground
black/blue–ground
red/white–ground

gray/green–any other coupler terminal
pink/black–any other coupler terminal
O2 sensor 1 coupler
black/blue–any other coupler terminal
ECU coupler “2” pink/black–any other coupler terminal
A B
1
2
R/W P/B
1 Gy/G B/L
R/W P/B Lg/R L/B O/B R/B G/B B
Gy/G B/L R/L G/Y Br/R B

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
5. Check fuel pressure.
• Check the fuel pressure.
Refer to “CHECKING THE FUEL PRESSURE” on page 7-16.
9-117
P00D1, P2195
Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the fuel pump.
Refer to “REMOVING THE FUEL PUMP” on page 7-3.

YES
NO
→ Go to step 6.
a. Replace the O2 sensor 1.

YES
NO
→ Go to step 7.
9-118
P00D3, P2197
EAS20661
P00D3, P2197
EAS33338
TROUBLESHOOTING
Item
• [P00D3] O2 sensor 2: heater performance is deteriorated. Normal signal is not received from the O2
sensor while driving the O2 sensor 2 heater.
• [P2197] O2 sensor 2: open circuit is detected. Normal signal is not received from the O2 sensor.
Fail-safe system
Procedure
TIP
• P0050
Is check result OK?

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-119
P00D3, P2197
pins).

YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
gray/yellow–gray/yellow
Between O2 sensor 2 coupler and ECU coupler pink/white–pink/white
holder
2 2
Lg/R L/B O/B R/B G/B B L/B O/W Lg/L P/W P V L L/R Gy
R/L G/Y Br/R B L/W B/Y Br G/LGy/G Br/W B/L W W/B
R/G Y/B L/Y R/L B/W B/W L/Y L/W Lg/B Gy/Y G/W G Gy/B W/L
1
R/W P/W
Gy/Y B/L
Is resistance 0 Ω?
YES
NO

YES
NO
9-120
P00D3, P2197
TIP
gray/yellow–ground
pink/white–ground
black/blue–ground
red/white–ground

gray/yellow–any other coupler terminal
pink/white–any other coupler terminal
O2 sensor 2 coupler
ECU coupler “2” pink/white–any other coupler terminal
A B
1
2
R/W P/W
1 Gy/Y B/L
R/W P/W Lg/R L/B O/B R/B G/B B
Gy/Y B/L R/L G/Y Br/R B

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
5. Check fuel pressure.
• Check the fuel pressure.
Refer to “CHECKING THE FUEL PRESSURE” on page 7-16.
9-121
P00D3, P2197
Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the fuel pump.
Refer to “REMOVING THE FUEL PUMP” on page 7-3.

YES
NO
→ Go to step 6.

YES
NO
→ Go to step 7.
9-122
P0107, P0108
EAS20567
P0107, P0108
EAS33047
TROUBLESHOOTING
Item
• [P0107] Intake air pressure sensor: short to ground circuit is detected. Normal signal is not received
from the intake air pressure sensor circuit.
• [P0108] Intake air pressure sensor: open or short to power circuit is detected. Normal signal is not re-
ceived from the intake air pressure sensor circuit.
Fail-safe system
Procedure
1. Connection of intake air pressure sensor coupler.
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-123
P0107, P0108
• Disconnect the intake air pressure sensor coupler “1” and ECU coupler “2”.
[P0108] blue–blue
Between intake air pressure sensor coupler and
[P0107, P0108] pink/white–pink/white
ECU coupler
[P0108] black/blue–black/blue
2
1
B/L P/W L L/W B/Y Br G/LGy/G Br/W B/L W W/B
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
Between intake air pressure sensor coupler “1” [P0108] blue–ground
and ground [P0107, P0108] pink/white–ground

[P0108] blue–any other coupler terminal
[P0107, P0108] pink/white–any other coupler
Intake air pressure sensor coupler
terminal
[P0108] black/blue–any other coupler terminal
[P0108] blue–any other coupler terminal
[P0107, P0108] pink/white–any other coupler
ECU coupler “2”
terminal
9-124
P0107, P0108
A B
1 1 2
B/L P/W L B/L P/W L
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
4. Installed condition of intake air pressure sensor.
Is check result OK?

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
5. Defective intake air pressure sensor.
dicated.
Approx. 101 kPa (757.6 mmHg, 29.8 inHg), ap-
At sea level
prox. 3.64 V
1000 m (3300 ft) above sea level
prox. 3.30 V
prox. 3.00 V
prox. 2.70 V
9-125
P0107, P0108
• 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.

YES
NO
→ Go to step 6.
9-126
P0112, P0113
EAS20568
P0112, P0113
EAS33048
TROUBLESHOOTING
Item
• [P0112] Intake air temperature sensor: short to ground circuit is detected. Normal signal is not re-
ceived from the intake air temperature sensor circuit.
• [P0113] Intake air temperature sensor: short to power circuit is detected. Normal signal is not received
from the intake air temperature sensor circuit.
Fail-safe system
Procedure
TIP
Perform this procedure when the engine is cold.
1. Connection of intake air temperature sensor coupler.
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-127
P0112, P0113
• Disconnect the intake air temperature sensor coupler “1” and ECU coupler “2”.
Between intake air temperature sensor coupler [P0112, P0113] brown/white–brown/white
and ECU coupler [P0113] black/blue–black/blue
2
1
Br/W B/L
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
Between intake air temperature sensor coupler
[P0112, P0113] brown/white–ground
“1” and ground

[P0112, P0113] brown/white–any other coupler
Intake air temperature sensor coupler terminal
[P0112, P0113] brown/white–any other coupler
ECU coupler “2” terminal
9-128
P0112, P0113
A B
1 1 2
Br/W B/L Br/W B/L
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
4. Installed condition of intake air temperature sensor.
Is check result OK?

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
5. Defective intake air temperature sensor.
• 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 8-49.
9-129
P0112, P0113
Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the intake air temperature sensor.

YES
NO
→ Go to step 6.
9-130
P0117, P0118
EAS20569
P0117, P0118
EAS33049
TROUBLESHOOTING
Item
• [P0117] Coolant temperature sensor: short to ground circuit is detected. Normal signal is not received
from the coolant temperature sensor circuit.
• [P0118] Coolant temperature sensor: short to power circuit is detected. Normal signal is not received
from the coolant temperature sensor circuit.
Fail-safe system
Procedure
TIP
Perform this procedure when the engine is cold.
1. Connection of coolant temperature sensor coupler.
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
2. Connection of wire harness coupler and sub-wire harness coupler.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-131
P0117, P0118
pins).

YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
• 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”.
Between coolant temperature sensor coupler
[P0117, P0118] green/white–green/white
and sub-wire harness coupler (wire harness
side)
Between wire harness coupler (sub-wire har- [P0117, P0118] green/white–green/white
ness side) and ECU coupler [P0118] black/blue–black/blue
4
1 2 3
G/W B/L B/L G/W
G/W B/L L/W B/Y Br G/LGy/G Br/W B/L W W/B
Is resistance 0 Ω?
YES
→ Go to step “Short circuit check”.
NO

YES
NO
→ Go to step “Short circuit check”.
9-132
P0117, P0118
TIP
Between coolant temperature sensor coupler
[P0117, P0118] green/white–ground
“1” and ground
Between wire harness coupler (sub-wire har-
[P0117, P0118] green/white–ground
ness side) “3” and ground

[P0117, P0118] green/white–any other coupler
Coolant temperature sensor coupler terminal
Wire harness coupler (sub-wire harness side) terminal
A B
4
1 3 1 3
G/W B/L B/L G/W G/W B/L B/L G/W
YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
5. Installed condition of coolant temperature sensor.
9-133
P0117, P0118
Is check result OK?

YES
→ Go to step 6.
NO

YES
NO
→ Go to step 6.
6. Defective coolant temperature sensor.
• 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 8-47.
Is check result OK?

YES
→ Go to step 7.
NO
a. Replace the coolant temperature sensor.

YES
NO
→ Go to step 7.
9-134
P0122, P0123, P0222, P0223
EAS20813
P0122, P0123, P0222, P0223

EAS33050
TROUBLESHOOTING
Item
• [P0122] Throttle position sensor: short to ground circuit is detected. Normal signal is not received from
the throttle position sensor circuit.
• [P0123] Throttle position sensor: open or short to power circuit is detected. Normal signal is not re-
ceived from the throttle position sensor circuit.
• [P0222] Throttle position sensor: open or short to ground circuit is detected. Normal signal is not re-
ceived from the throttle position sensor circuit.
• [P0223] Throttle position sensor: short to power circuit is detected. Normal signal is not received from
the throttle position sensor circuit.
Fail-safe system
• Able to start engine (depending on the situation)
• Able to drive vehicle (depending on the situation)
Procedure
1. Connection of throttle position sensor coupler.
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-135
P0122, P0123, P0222, P0223
• Disconnect the throttle position sensor coupler “1” and ECU coupler “2”.
[P0122, P0123, P0222, P0223] white–white
Between throttle position sensor coupler and [P0123, P0223] black/green–black/green
ECU coupler [P0122, P0222] blue–blue
[P0122, P0123, P0222, P0223] black–black
1 2 L/Y L Br/Y R/W

W W L B/R
W B/G L B B/G B B/G
B/L B B/Y W/Y
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
[P0122, P0123, P0222, P0223] white–ground
Between throttle position sensor coupler “1” and
[P0122, P0222] blue–ground
ground
[P0122, P0123, P0222, P0223] black–ground
9-136
P0122, P0123, P0222, P0223
[P0122, P0123, P0222, P0223] white–any other
coupler terminal
[P0123, P0223] black/green–any other coupler
Throttle position sensor coupler terminal
[P0122, P0222] blue–any other coupler terminal
[P0122, P0123, P0222, P0223] black–any other
coupler terminal
[P0122, P0123, P0222, P0223] white–any other
coupler terminal
[P0123, P0223] black/green–any other coupler
[P0122, P0123, P0222, P0223] black–any other
coupler terminal
A B
1 1 2
L/Y L Br/Y R/W
W B/G L B W B/G L B
W W L B/R
B/G B B/G
B/L B B/Y W/Y
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
4. Installed condition of throttle position sensor.
Refer to “ADJUSTING THE THROTTLE POSITION SENSOR” on page 7-17.
Is check result OK?

YES
→ Go to step 5.
NO
a. Reinstall or adjust the sensor.
9-137
P0122, P0123, P0222, P0223

YES
NO
→ Go to step 5.
5. Defective throttle position sensor.
• Check throttle position sensor signal 1.
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
a. Replace the throttle position sensor.

YES
NO
→ Go to step 6.
Is check result OK?

YES
→ Go to step 7.
NO

YES
NO
→ Go to step 7.
9-138
P0132
EAS20571
P0132
EAS33051
TROUBLESHOOTING
Item
O2 sensor 1: short to power circuit is detected. Normal signal is not received from the O2 sensor 1.
Fail-safe system
Procedure
Is check result OK?

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
pins).
9-139
P0132

YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
• Disconnect the O2 sensor 1 coupler “1” and ECU coupler “2”.
Between O2 sensor 1 coupler and ECU coupler
gray/green–gray/green
1 2
R/W P/B
Gy/G B/L
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
9-140
P0132
Between O2 sensor 1 coupler “1” and ground gray/green–ground

O2 sensor 1 coupler
ECU coupler “2”
A B
1 1 2
R/W P/B
Gy/G B/L R/W P/B
Gy/G B/L L/B O/W Lg/L P/W P V L L/R Gy
YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.

YES
NO
→ Go to step 6.
9-141
P0152
EAS20572
P0152
EAS33052
TROUBLESHOOTING
Item
O2 sensor 2: short to power circuit is detected. Normal signal is not received from the O2 sensor 2.
Fail-safe system
Procedure
Is check result OK?

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
pins).
9-142
P0152

YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
• Disconnect the O2 sensor 2 coupler “1” and ECU coupler “2”.
Between O2 sensor 2 coupler and ECU coupler
gray/yellow–gray/yellow
1 2
R/W P/W
Gy/Y B/L
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
9-143
P0152
Between O2 sensor 2 coupler “1” and ground gray/yellow–ground

O2 sensor 2 coupler
ECU coupler “2”
A B
1 1 2
R/W P/W
Gy/Y B/L R/W P/W
Gy/Y B/L L/B O/W Lg/L P/W P V L L/R Gy
YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.

YES
NO
→ Go to step 6.
9-144
P0201
EAS20574
P0201
EAS33054
TROUBLESHOOTING
Item
Fuel injector #1: malfunction in fuel injector #1. Normal signal is not received from the fuel injector cir-
cuit.
Fail-safe system
• Able to start engine (depending on the number of faulty cylinder)
• Able to drive vehicle (depending on the number of faulty cylinder)
Procedure
1. Connection of fuel injector #1 coupler.
pins).

YES
→ Go to step 2.
NO
b. Execute the diagnostic mode. (Code 36)
Is it hear operating sound?

YES
→ Go to step 6.
NO
→ Go to step 2.
2. Defective fuel injector #1.
• Measure the fuel injector resistance.
Refer to “CHECKING THE FUEL INJECTORS” on page 8-49.
Is check result OK?

YES
→ Go to step 3.
NO
a. Replace the fuel injector #1.

YES
→ Go to step 6.
NO
→ Go to step 3.
pins).
9-145
P0201

YES
→ Go to step 4.
NO

YES
→ Go to step 6.
NO
→ Go to step 4.
• Disconnect the fuel injector #1 coupler “1”, ECU coupler “2” and relay unit coupler “3”
Between fuel injector #1 coupler and ECU cou-
red/black–red/black
pler
Between fuel injector #1 coupler and relay unit
red/blue–red/blue
coupler
1
R/L R/B
3
R L/W R/W L R/L
2 L/W L/Y R/W L/B L/Y Sb B/Y Sb/W
R/L G/Y Br/R B
Is resistance 0 Ω?
YES
NO

YES
→ Go to step 6.
NO
TIP
9-146
P0201
red/black–ground
Between fuel injector #1 coupler “1” and ground
red/blue–ground

red/black–any other coupler terminal
Fuel injector #1 coupler
red/blue–any other coupler terminal
ECU coupler “2” red/black–any other coupler terminal
Relay unit coupler “3” red/blue–any other coupler terminal
A B
1 1 2
R/L R/B R/L R/B Y/R P/W P/B O/L Gy O/L Gy
R/L G/Y Br/R B
3
R L/W R/W L R/L
YES
→ Go to step 5.
NO

YES
→ Go to step 6.
NO
→ Go to step 5.
• 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.
9-147
P0202
EAS20575
P0202
EAS33055
TROUBLESHOOTING
Item
cuit.
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO

YES
→ Go to step 6.
NO
→ Go to step 2.
Is check result OK?

YES
→ Go to step 3.
NO

YES
→ Go to step 6.
NO
→ Go to step 3.
pins).
9-148
P0202

YES
→ Go to step 4.
NO

YES
→ Go to step 6.
NO
→ Go to step 4.
green/black–green/black
pler
red/blue–red/blue
coupler
1
R/L G/B
3
R L/W R/W L R/L
R/L G/Y Br/R B
Is resistance 0 Ω?
YES
NO

YES
→ Go to step 6.
NO
TIP
9-149
P0202
green/black–ground
red/blue–ground

green/black–any other coupler terminal
ECU coupler “2” green/black–any other coupler terminal
A B
1 1 2
R/L G/B R/L G/B Y/R P/W P/B O/L Gy O/L Gy
R/L G/Y Br/R B
3
R L/W R/W L R/L
YES
→ Go to step 5.
NO

YES
→ Go to step 6.
NO
→ Go to step 5.
9-150
P0203
EAS20576
P0203
EAS33056
TROUBLESHOOTING
Item
cuit.
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO

YES
→ Go to step 6.
NO
→ Go to step 2.
Is check result OK?

YES
→ Go to step 3.
NO

YES
→ Go to step 6.
NO
→ Go to step 3.
pins).
9-151
P0203

YES
→ Go to step 4.
NO

YES
→ Go to step 6.
NO
→ Go to step 4.
pler
red/blue–red/blue
coupler
1
R/L L/B
3
R L/W R/W L R/L
R/L G/Y Br/R B
Is resistance 0 Ω?
YES
NO

YES
→ Go to step 6.
NO
TIP
9-152
P0203
blue/black–ground
red/blue–ground

ECU coupler “2” blue/black–any other coupler terminal
A B
1 1 2
R/L L/B R/L L/B Y/R P/W P/B O/L Gy O/L Gy
R/L G/Y Br/R B
3
R L/W R/W L R/L
YES
→ Go to step 5.
NO

YES
→ Go to step 6.
NO
→ Go to step 5.
9-153
P0204
EAS20577
P0204
EAS33057
TROUBLESHOOTING
Item
cuit.
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO

YES
→ Go to step 6.
NO
→ Go to step 2.
Is check result OK?

YES
→ Go to step 3.
NO

YES
→ Go to step 6.
NO
→ Go to step 3.
pins).
9-154
P0204

YES
→ Go to step 4.
NO

YES
→ Go to step 6.
NO
→ Go to step 4.
orange/black–orange/black
pler
red/blue–red/blue
coupler
1
R/L O/B
3
R L/W R/W L R/L
R/L G/Y Br/R B
Is resistance 0 Ω?
YES
NO

YES
→ Go to step 6.
NO
TIP
9-155
P0204
orange/black–ground
red/blue–ground

orange/black–any other coupler terminal
ECU coupler “2” orange/black–any other coupler terminal
A B
1 1 2
R/L O/B R/L O/B Y/R P/W P/B O/L Gy O/L Gy
R/L G/Y Br/R B
3
R L/W R/W L R/L
YES
→ Go to step 5.
NO

YES
→ Go to step 6.
NO
→ Go to step 5.
9-156
P0335
EAS20578
P0335
EAS33058
TROUBLESHOOTING
Item
Crankshaft position sensor: normal signals are not received from the crankshaft position sensor.
Fail-safe system
Procedure
1. Connection of crankshaft position sensor coupler.
pins).

YES
→ Go to step 2.
NO
b. Crank the engine, and then check the DTC using the malfunction mode of the YDT.

YES
NO
→ Go to step 2.
2. Connection of wire harness ECU coupler.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
• Disconnect the crankshaft position sensor coupler “1” and ECU coupler “2”.
Between crankshaft position sensor coupler black/blue–black/blue
and ECU coupler gray–gray
9-157
P0335
1 2
B/L Gy
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
Between crankshaft position sensor coupler “1”
gray–ground
and ground

Crankshaft position sensor coupler
gray–any other coupler terminal
ECU coupler “2”
A B
1 1 2
B/L Gy B/L Gy
9-158
P0335
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
4. Installed condition of crankshaft position sensor.
Refer to “GENERATOR” on page 5-42.
• 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

YES
NO
→ Go to step 5.
5. Defective crankshaft position sensor.
• Check the crankshaft position sensor.
Refer to “CHECKING THE CRANKSHAFT POSITION SENSOR” on page 8-44.
Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the stator coil assembly.
Refer to “GENERATOR” on page 5-42.

YES
NO
→ Go to step 6.
9-159
P0340
EAS20579
P0340
EAS32839
TROUBLESHOOTING
Item
• Cylinder identification sensor: normal signal is not received from the cylinder identification sensor.
Fail-safe system
Procedure
TIP
• P0335
1. Connection of cylinder identification sensor coupler.
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-160
P0340
• Disconnect the cylinder identification sensor coupler “1” and ECU coupler “2”.
white/black–white/black
Between cylinder identification sensor coupler
blue–blue
and ECU coupler
1 2
L W/B
B/L
Is resistance 0 Ω?
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
4. Installed condition of cylinder identification sensor.
Is check result OK?

YES
→ Go to step 5.
NO
a. Reinstall or replace the cylinder identification sensor.

YES
NO
→ Go to step 5.
5. Defective cylinder identification sensor.
• Replace the cylinder identification sensor.
• Crank the engine, and then check the DTC using the malfunction mode of the YDT.
9-161
P0340

YES
NO
→ Go to step 6.
9-162
P0351
EAS20580
P0351
EAS33060
TROUBLESHOOTING
Item
Cylinder-#1 ignition coil: open or short circuit is detected in the primary lead of the cylinder-#1 ignition
coil. Normal signal is not received from the ignition circuit.
Fail-safe system
Procedure
1. Connection of cylinder-#1 ignition coil coupler.
pins).

YES
→ Go to step 2.
NO
b. Start the engine and let it idle for approximately 5 seconds.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-163
P0351
• Disconnect the cylinder-#1 ignition coil coupler “1”, ECU coupler “2” and handlebar switch (right)
coupler “3”.
Between cylinder-#1 ignition coil coupler and
orange/blue–orange/blue
ECU coupler
handlebar switch (right) coupler “3”
2 3
1
B Br/Y R/L
O/L R/W R/W L
R/L G/Y Br/R B
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
Between cylinder-#1 ignition coil coupler “1” and orange/blue–ground
ground red/white–ground

orange/blue–any other coupler terminal
Cylinder-#1 ignition coil coupler
ECU coupler “2” orange/blue–any other coupler terminal
Handlebar switch (right) coupler “3” red/white–any other coupler terminal
9-164
P0351
A B
1 1
O/L R/W O/L R/W 2 3
B Br/Y R/L
R/W L
R/L G/Y Br/R B
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
4. Installed condition of cylinder-#1 ignition coil.
Is check result OK?

YES
→ Go to step 5.
NO
a. Reinstall or replace the ignition coil.

YES
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 8-43.
Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the cylinder-#1 ignition coil.
9-165
P0351

YES
NO
→ Go to step 6.
• Confirm that spark plug does not sparking.
9-166
P0352
EAS20581
P0352
EAS33061
TROUBLESHOOTING
Item
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-167
P0352
coupler “3”.
gray–gray
ECU coupler
handlebar switch (right) coupler
2 3
1
B Br/Y R/L
Gy R/W R/W L
R/L G/Y Br/R B
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
Between cylinder-#2 ignition coil coupler “1” and gray–ground

ECU coupler “2” gray–any other coupler terminal
9-168
P0352
A B
1 1
Gy R/W Gy R/W 2 3
B Br/Y R/L
R/W L
R/L G/Y Br/R B
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
Is check result OK?

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
Is check result OK?

YES
→ Go to step 6.
NO
9-169
P0352

YES
NO
→ Go to step 6.
9-170
P0353
EAS20582
P0353
EAS33062
TROUBLESHOOTING
Item
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3
NO

YES
NO
→ Go to step 3.
9-171
P0353
coupler “3”.
orange/blue–orange/blue
ECU coupler
2 3
1
B Br/Y R/L
O/L R/W R/W L
R/L G/Y Br/R B
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
Between cylinder-#3 ignition coil coupler “1” and orange/blue–ground

orange/blue–any other coupler terminal
ECU coupler “2” orange/blue–any other coupler terminal
9-172
P0353
A B
1 1
O/L R/W O/L R/W 2 3
B Br/Y R/L
R/W L
R/L G/Y Br/R B
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
Is check result OK?

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
Is check result OK?

YES
→ Go to step 6.
NO
9-173
P0353

YES
NO
→ Go to step 6.
9-174
P0354
EAS20583
P0354
EAS33063
TROUBLESHOOTING
Item
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-175
P0354
coupler “3”.
gray–gray
ECU coupler
2 3
1
B Br/Y R/L
Gy R/W R/W L
R/L G/Y Br/R B
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
Between cylinder-#4 ignition coil coupler “1” and gray–ground

ECU coupler “2” gray–any other coupler terminal
9-176
P0354
A B
1 1
Gy R/W Gy R/W 2 3
B Br/Y R/L
R/W L
R/L G/Y Br/R B
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
Is check result OK?

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
Is check result OK?

YES
→ Go to step 6.
NO
9-177
P0354

YES
NO
→ Go to step 6.
9-178
P0475, P0476, P048B
EAS20672
P0475, P0476, P048B

EAS32841
TROUBLESHOOTING
Item
• [P0475] EXUP servo motor: performance deterioration. EXUP servo motor positioning signal changes
slowly, when during it control.
• [P0476] EXUP servo motor: stuck EXUP servo motor is detected. EXUP servo motor positioning sig-
nal is not changed, when during it control.
• [P048B] EXUP servo motor: signal stuck. EXUP servo motor positioning signal is not changed, when
during it control.
Fail-safe system
Procedure
TIP
• P048D, P048E
1. Connection of EXUP servo motor coupler.
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
9-179
P0475, P0476, P048B

YES
NO
→ Go to step 3.
• Disconnect the EXUP servo motor coupler “1” and ECU coupler “2”.
Between EXUP servo motor coupler and ECU black/green–black/green
coupler black/red–black/red
2 1
L/Y L Br/Y R/W
W W L B/R L W/Y B/L
B/G B B/G G B/G B/R
B/L B B/Y W/Y
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
Between EXUP servo motor coupler “1” and black/green–ground
ground black/red–ground

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
9-180
P0475, P0476, P048B
A B
1 1 2
L/Y L Br/Y R/W
L W/Y B/L L W/Y B/L
G B/G B/R W W L B/R
G B/G B/R
B/G B B/G
B/L B B/Y W/Y
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
4. Defective EXUP servo motor.
• Disconnect the cables and execute the diagnostic code. (Code 53)
• Check the operating sound of the motor.
Is check result OK?

YES
→ Go to step 5.
NO
a. Replace the EXUP servo motor.

YES
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
a. Replace the cables.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the
YDT.
9-181
P0475, P0476, P048B

YES
NO
→ Go to step 6.
NO
a. Replace the exhaust chamber.

YES
NO
→ Go to step 6.
9-182
P0480
EAS20585
P0480
EAS33065
TROUBLESHOOTING
Item
Radiator fan motor relay: open or short circuit is detected. Normal signal is not received from the radi-
ator fan motor relay.
Fail-safe system
Procedure
1. Connection of radiator fan motor relay coupler.
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-183
P0480
• Disconnect the radiator fan motor relay “1”, ECU coupler “2” and ignition fuse “3”.
Between radiator fan motor relay and ignition
fuse holder
Between radiator fan motor relay and ECU cou-
green/yellow–green/yellow
pler
3 1 R
R/B
R/W G/Y
2
R/L G/Y Br/R B
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
green/yellow–ground
Between radiator fan motor relay “1” and ground
red/white–ground

green/yellow–any other coupler terminal
Radiator fan motor relay
ECU coupler “2” green/yellow–any other coupler terminal
9-184
P0480
A B
1 1 2
R
R
R/B Y/R P/W P/B O/L Gy O/L Gy
R/B
R/W G/Y Lg/R L/B O/B R/B G/B B
R/W G/Y
R/L G/Y Br/R B
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
4. Defective radiator fan motor relay.
• Replace the radiator fan motor relay.

YES
NO
→ Go to step 5.
9-185
P048D, P048E
EAS20586
P048D, P048E
EAS33066
TROUBLESHOOTING
Item
• [P048D] EXUP servo motor: open or short to ground circuit is detected. Normal signal is not received
from the EXUP servo motor circuit to ECU.
• [P048E] EXUP servo motor: short to power circuit is detected. Normal signal is not received from the
EXUP servo motor circuit to ECU.
Fail-safe system
Procedure
TIP
If “P048D/P048E” and “P0476” are both indicated, take the actions specified for “P048D/P048E” first.
1. Connection of EXUP servo motor coupler.
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-186
P048D, P048E
• Disconnect the EXUP servo motor coupler “1” and ECU coupler “2”.
blue–blue
Between EXUP servo motor coupler and ECU
white/yellow–white/yellow
coupler
2 1 2
L/Y L Br/Y R/W
L W/Y B/L
W W L B/R G B/G B/R L/B O/W Lg/L P/W P V L L/R Gy
B/G B B/G L/W B/Y Br G/LGy/G Br/W B/L W W/B
B/L B B/Y W/Y L/Y L/W Lg/B Gy/Y G/W G Gy/B W/L
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
Between EXUP servo motor coupler “1” and white/yellow–ground
ground blue–ground

white/yellow–any other coupler terminal
EXUP servo motor coupler blue–any other coupler terminal
white/yellow–any other coupler terminal
ECU coupler “2” blue–any other coupler terminal
9-187
P048D, P048E
A B
1 1 2 2
L/Y L Br/Y R/W
L W/Y B/L L W/Y B/L
G B/G B/R W W L B/R
G B/G B/R L/B O/W Lg/L P/W P V L L/R Gy
B/G B B/G
B/L B B/Y W/Y
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
4. Defective EXUP servo motor.
• Replace the EXUP servo motor.

YES
NO
→ Go to step 5.
9-188
P0500 (FI), P1500
EAS20674
P0500 (FI), P1500

EAS33303
TROUBLESHOOTING
Item
• [P0500 (FI)] Rear wheel sensor: open or short circuit is detected. Normal signal is not received from
the rear wheel sensor or ABS unit to ECU.
• [P1500] Neutral switch: open or short circuit is detected. Normal signal is not received from the rear
wheel sensor to ECU when the gear-in
• [P1500] Clutch switch: open or short circuit is detected. Normal signal is not received from the rear
wheel sensor to ECU when the gear-in.
Fail-safe system
Procedure
TIP
• In case P0500 is detected, or both P0500 and P1500 are detected, proceed from step 1.
• If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first.
• P0335
1. Locate the malfunction.
• DTCs P0500 or P0500 and P1500 detected.
a. Execute the diagnostic mode. (Code 07)
b. Rotate the rear wheel by hand and check that the indicated value increases.
Is that value increased?

YES
NO
→ Go to step 2.
TIP
Perform the procedure from step 2 to step 7 and step 20.
• DTC P1500 detected.
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 13 and step 20.
9-189
P0500 (FI), P1500
When the transmission is in gear with the clutch lever squeezed and the
ON
sidestand retracted
Is check result OK?

YES
NO
→ Go to step 14.
TIP
Perform the procedure from step 14 to step 20.
2. Connection of rear wheel sensor coupler.

pins).

YES
→ Go to step 3.
NO
c. Rotate the rear wheel by hand and check that the indicated value increases.

YES
NO
→ Go to step 3.
3. Connection of ABS ECU coupler.
pins).

YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
9-190
P0500 (FI), P1500
pins).

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
• Disconnect the rear wheel sensor coupler “1”, ABS ECU coupler “2” and ECU coupler “3”.
Between rear wheel sensor coupler and ABS black–black
ECU coupler white–white
Between ABS ECU coupler and ECU coupler white/blue–white/blue
2 3
1
B W R Gy/B L Y G Br/B B L/W B/W L/B O/W Lg/L P/W P V L L/R Gy
R/L G/O W/L L B W W L/B B
Is resistance 0 Ω?
YES
NO

YES
NO
9-191
P0500 (FI), P1500
TIP
black–ground
Between ABS ECU coupler “2” and ground white–ground
white/blue–ground

black–any other coupler terminal
Rear wheel sensor coupler “1”
white–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
2 3
1 2
R Gy/B L Y G Br/B B L/W B/W
R/L G/O W/L L B W W L/B B B W R Gy/B L Y G Br/B B L/W B/W L/B O/W Lg/L P/W P V L L/R Gy
YES
→ Go to step 6.
NO

YES
NO
→ Go to step 6.
• Replace the ECU.
• Rotate the rear wheel by hand and check that the indicated value increases.

YES
NO
→ Go to step 7.
9-192
P0500 (FI), P1500
7. Malfunction in hydraulic unit assembly (ABS ECU).
• Replace the hydraulic unit assembly (ABS ECU).
Refer to “ABS (Anti-lock Brake System)” on page 4-63.
• Go to step 20, and complete the service.
8. Connection of neutral switch coupler.
pins).

YES
→ Go to step 9.
NO

Is it correct indication?
YES
NO
→ Go to step 9.
pins).

YES
→ Go to step 10.
NO

YES
NO
→ Go to step 10.
9-193
P0500 (FI), P1500
10.Wire harness continuity.
• Disconnect the relay unit coupler “1”, ECU coupler “2” and neutral switch coupler “3”.
Between relay unit coupler and ECU coupler black/yellow–black/yellow
Between relay unit coupler and neutral switch
sky blue–sky blue
coupler
2
3 1
R L/W R/W L R/L L/B O/W Lg/L P/W P V L L/R Gy
L/W L/Y R/W L/B L/Y Sb B/Y Sb/W L/W B/Y Br G/LGy/G Br/W B/L W W/B
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
black/yellow–ground
Between relay unit coupler “1” and ground
sky blue–ground

black/yellow–any other coupler terminal
Relay unit coupler
sky blue–any other coupler terminal
ECU coupler “2” black/yellow–any other coupler terminal
9-194
P0500 (FI), P1500
A B
2
1 1
R L/W R/W L R/L
R L/W R/W L R/L
L/W L/Y R/W L/B L/Y Sb B/Y Sb/W L/B O/W Lg/L P/W P V L L/R Gy
YES
→ Go to step 11.
NO

YES
NO
→ Go to step 11.
11.Defective neutral switch.
• Check the neutral switch.
• Refer to “CHECKING THE SWITCHES” on page 8-39.
Is check result OK?

YES
→ Go to step 12.
NO
a. Replace the neutral switch.
Refer to “CRANKCASE” on page 5-68.

YES
NO
→ Go to step 12.
12.Faulty shift drum (neutral detection area).
• Check the shift drum.
Refer to “CHECKING THE SHIFT DRUM ASSEMBLY” on page 5-98.
9-195
P0500 (FI), P1500
Is check result OK?

YES
→ Go to step 13.
NO
a. Replace the shift drum.
Refer to “TRANSMISSION” on page 5-93.

YES
→Go to step 20, and complete the service.
NO
→ Go to step 13.
13.Malfunction in ECU.
14.Clutch lever adjustment.
• Refer to “ADJUSTING THE CLUTCH LEVER FREE PLAY” on page 3-13.
When the clutch lever is released with the transmission in gear and when
OFF
the sidestand is retracted
When the clutch lever is squeezed with the transmission in gear and when
ON
YES
NO
→ Go to step 15.
15.Connection of clutch switch coupler.
pins).

YES
→ Go to step 16.
NO
OFF
ON
9-196
P0500 (FI), P1500
YES
NO
→ Go to step 16.
16.Connection of ECU coupler.
pins).

YES
→ Go to step 17.
NO
OFF
ON
YES
NO
→ Go to step 17.
17.Wire harness continuity.
• Disconnect the ECU coupler “2”, relay unit coupler “1” and clutch switch coupler “3”.
Between ECU coupler and relay unit coupler black/yellow–black/yellow
Between clutch switch coupler and relay unit black/yellow–black/yellow
coupler blue/yellow–blue/yellow
2
1
L/W L/Y R/W L/B L/Y Sb B/Y Sb/W L/W B/Y Br G/LGy/G Br/W B/L W W/B
3 L/Y L/W Lg/B Gy/Y G/W G Gy/B W/L
Y/B B/Y
Y/W L/Y
9-197
P0500 (FI), P1500
Is resistance 0 Ω?
YES
NO
OFF
ON
YES
NO
TIP
black/yellow–ground
blue/yellow–ground

Relay unit coupler
blue/yellow–any other coupler terminal
ECU coupler “2” black/yellow–any other coupler terminal
Clutch switch coupler “3”
A B
2
1 1 3
R L/W R/W L R/L
L/W L/Y R/W L/B L/Y Sb B/Y Sb/W R L/W R/W L R/L L/B O/W Lg/L P/W P V L L/R Gy Y/B B/Y
L/W L/Y R/W L/B L/Y Sb B/Y Sb/W L/W B/Y Br G/LGy/G Br/W B/L W W/B Y/W L/Y
YES
→ Go to step 18.
NO
9-198
P0500 (FI), P1500
OFF
ON
YES
NO
→ Go to step 18.
18.Defective clutch switch.
• Check the clutch switch.
Is check result OK?

YES
→ Go to step 20.
NO
a. Replace the clutch switch.
OFF
ON
YES
NO
→ Go to step 19.
20.Delete 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).
then delete the DTC. Delete this DTC even if it has a condition of “Detected”.
9-199
P0500 (SCU)
EAS20588
P0500 (SCU)
EAS33068
TROUBLESHOOTING
Item
Abnormal rear wheel sensor (Sensor value is not normal.)
Fail-safe system
Procedure
1. Abnormal rear wheel sensor (Sensor value is not normal.)
• Check the item of DTC P0500 for the ECU.
47.
mode of the YDT.

YES
NO
9-200
P0560 (FI), P0563
EAS20675
P0560 (FI), P0563

EAS33304
TROUBLESHOOTING
Item
• [P0560 (FI)] Battery charging voltage is abnormal. Poor charging performance (Discharged condi-
tion). Vehicle system power voltage is abnormal. (Regulator is not operated properly or battery is not
charged properly.)
• [P0563] Battery charging voltage is abnormal. Charging voltage is not within range (Overcharged con-
dition). Vehicle system power voltage is abnormal. (Regulator is not operated properly or battery is not
charged properly.)
Fail-safe system
Procedure
TIP
• P0335
1. Malfunction in charging system.
• Check the charging system.
Refer to “CHARGING SYSTEM” on page 8-13.
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 DTC using the malfunction mode of the YDT.

YES
NO
→ Repeat step 1.
9-201
P0560 (SCU)
EAS20593
P0560 (SCU)
EAS33073
TROUBLESHOOTING
Item
Abnormal SCU power supply voltage. (Regulator is not operated properly or battery is not charged
properly.)
Fail-safe system
Procedure
1. Malfunction in charging system.
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 DTC using the malfunction mode of the YDT.

YES
NO
→ Repeat the maintenance job.
9-202
P0564
EAS20594
P0564
EAS33074
TROUBLESHOOTING
Item
• Cruise control setting switch “RES+”: open or short circuit is detected. Normal signal is not sent to
ECU.
• Cruise control setting switch “SET–”: open or short circuit is detected. Normal signal is not sent to
ECU.
Fail-safe system
Procedure
1. Connection of ECU coupler, handlebar switch (left) coupler and main switch coupler.
pins).

YES
→Go to step 2.
NO
b. Turn the main switch to “ON”, and then push the “RES+” side and “SET–”side of the cruise con-
trol setting switch.

YES
NO
→Go to step 2.
When the cruise control setting switch “RES+” is pushed ON
When the cruise control setting switch is released OFF
Is check result OK?

YES
→Go to step b.
NO
→Go to step 3.
TIP
Perform the procedure from step 3 to step 5, and from step 9 to step 10.
When the cruise control setting switch “SET–” is pushed ON
When the cruise control setting switch is released OFF
9-203
P0564
c. Confirm that it is defective.
d. Go to step 6.
TIP
3. Check the fuse.

• Check the ignition fuse and cruise control fuse.
Is check result OK?

YES
→Go to step 4.
NO
a. Replace the fuse.
c. Push and release the “RES+” side of the cruise control setting switch, and then check the DTC
using the malfunction mode of the YDT.

YES
NO
→Go to step 4.
4. Wire harness continuity
• Disconnect the ignition fuse “1”, cruise control fuse “2”, handlebar switch (left) coupler “3” and ECU
coupler “4”.
Between ignition fuse holder and cruise control
fuse holder
Between cruise control fuse holder and handle-
yellow/white–yellow/white
bar switch coupler (left)
Between handlebar switch coupler (left) and
brown–brown
ECU coupler
1 2
4
3 L/B
L/W B/Y
O/W Lg/L P/W P
Br G/LGy/G Br/W
V L L/R
B/L W
Gy
W/B
G/L G/Y B
O/W Br Y/W
Is resistance 0 Ω?
YES
→Go to “Short circuit check”.
NO
9-204
P0564

YES
NO
TIP
Between handlebar switch coupler (left) “3” and brown–ground
ground yellow/white–ground

brown–any other coupler terminal
Handlebar switch coupler (left)
yellow/white–any other coupler terminal
ECU coupler “4” brown–any other coupler terminal
A B
3 3 4
G/L G/Y B
G/L G/Y B
O/W Br Y/W
O/W Br Y/W L/B O/W Lg/L P/W P V L L/R Gy
YES
→Go to step 5.
NO

YES
NO
→Go to step 5.
5. Defective cruise control setting switch.
• Replace the handlebar switch (left).
• Turn the main switch to “ON”.
• Push the “RES+” side and “SET–” side of the cruise control setting switch, and then check the DTC
9-205
P0564

YES
NO
→Go to step 9.
6. Check the fuse.
• Check the main fuse, ignition fuse and cruise control fuse.
Is check result OK?

YES
→Go to step 7.
NO
c. Push and release the “SET–” side of the cruise control setting switch, and then check the DTC

YES
NO
→Go to step 7.
• Disconnect the main fuse “1”, main switch coupler “2”, ignition fuse “3”, cruise control fuse “4”, han-
dlebar switch (left) coupler “5” and ECU coupler “6”.
Between main fuse holder and main switch cou-
red–red
pler
Between main switch coupler and ignition fuse
brown/blue–brown/blue
holder
Between ignition fuse holder and cruise control
fuse holder
Between cruise control fuse holder and handle-
yellow/white–yellow/white
bar switch (left) coupler
Between handlebar switch (left) coupler and
green/blue–green/blue
ECU coupler
2 6
Br/L
Br/R
R
R/B
5 L/B
L/W B/Y
O/W Lg/L P/W P
Br G/LGy/G Br/W
V L L/R
B/L W
Gy
W/B
G/L G/Y B
O/W Br Y/W
3 4
9-206
P0564
Is resistance 0 Ω?
YES
NO
c. Push and “SET–” side of the cruise control setting switch, and then check the DTC using the
malfunction mode of the YDT.

YES
NO
TIP
red–ground
Between main switch coupler “2” and ground
brown/blue–ground
Between handlebar switch (left) coupler “5” and green/blue–ground
ground yellow/white–ground

red–any other coupler terminal
Main switch coupler
brown/blue–any other coupler terminal
green/blue–any other coupler terminal
Handlebar switch (left) coupler red–any other coupler terminal
brown/blue–any other coupler terminal
ECU coupler “6” green/blue–any other coupler terminal
A B
5 5 6
G/L G/Y B 2
2 O/W Br Y/W
G/L G/Y B
O/W Br Y/W L/B O/W Lg/L P/W P V L L/R Gy
Br/L R L/W B/Y Br G/LGy/G Br/W B/L W W/B
Br/L R Br/R R/B L/Y L/W Lg/B Gy/Y G/W G Gy/B W/L
Br/R R/B
YES
→Go to step 8.
NO
c. Push and “SET–” side of the cruise control setting switch, and then check the DTC using the
malfunction mode of the YDT.
9-207
P0564

YES
NO
→Go to step 8.
8. Defective cruise control setting switch.
• Replace the handlebar switch (left).
• Push the “RES+” side and “SET–” side of the cruise control setting switch, and then check the DTC

YES
NO
→Go to step 9.
9-208
P056C
EAS20595
P056C
EAS33075
TROUBLESHOOTING
Item
• Front brake light switch: open or short circuit is detected. Normal signal is not sent to ECU.
• Rear brake light switch: open or short circuit is detected. Normal signal is not sent to ECU.
Fail-safe system
Procedure
a. Execute the diagnostic mode. (Code 82, 83)
When the front brake is applied ON
When the front brake is not applied OFF
Is check result OK?

YES
→Go to step b.
NO
→Go to step 2.
TIP
Perform the procedure from step 2 to step 5, and from step 10 to step 11.
b. Execute the diagnostic mode. (Code 82, 83)
When the rear brake is applied ON
When the rear brake is not applied OFF
c. Confirm that it is defective.

d. Go to step 6.
TIP
2. Connection of ECU coupler, front brake light switch coupler, brake light relay coupler and main
switch coupler.
pins).

YES
→Go to step 3.
NO
c. Operate the brake lever, and then check the DTC using the malfunction mode of the YDT.
9-209
P056C

YES
NO
→Go to step 3.
3. Check the fuse.
• Check the signaling system fuse and brake light fuse.
Is check result OK?

YES
→Go to step 4.
NO

YES
NO
→Go to step 4.
• Disconnect the signaling system fuse “1”, joint coupler “2” brake light fuse “3”, front brake light switch
coupler “4”, rear brake light switch coupler “5”, brake light relay coupler “6” and ECU coupler “7”.
Between signaling system fuse holder and joint
brown–brown
coupler
Between joint coupler and brake light fuse hold- brown–brown
er
Between brake light fuse holder and front brake green/white–green/white
light switch coupler
Between front brake light switch coupler and
rear brake light switch coupler
Between rear brake light switch coupler and
light green/black–light green/black
brake light relay coupler
Between brake light relay coupler and ground black–ground
Between brake light relay coupler and ECU cou-
pler
9-210
P056C
1 3 4
G/W Y/B
G/Y Y/W
7
2
R/W Br Br Br 5 L/R
L/W B/Y
L/Y L/W
Br G/LGy/G
Lg/B Gy/Y
Br/W
G/W G
B/L W
Gy/B
W/B
W/L
Y/B G/Y
Lg/L Lg/B Lg/B Y B
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
Between joint coupler “2” and ground brown–ground
Between front brake light switch coupler “4” and green/white–ground
ground green/yellow–ground
Between brake light relay coupler “6” and
light green/black–ground
ground

green/white–any other coupler terminal
Front brake light switch coupler
Rear brake light switch coupler “5”
light green/black–any other coupler terminal
Brake light relay coupler light green/black–any other coupler terminal
ECU coupler “7” light green/black–any other coupler terminal
9-211
P056C
A B
4
4
G/W Y/B
G/Y Y/W
7
G/W Y/B 6
G/Y Y/W L/R
6
Lg/B Y B
5 L/R L/W B/Y
L/Y L/W
Br G/LGy/G
Lg/B Gy/Y
Br/W
G/W G
B/L W
Gy/B
W/B
W/L
R/W Br Br Br Lg/B Y B
Y/B G/Y
Lg/L Lg/B
YES
→Go to step 5.
NO

YES
NO
→Go to step 5.
5. Defective front brake light switch.
• Replace the front brake light switch.
• Operate the brake lever, and then check the DTC using the malfunction mode of the YDT.

YES
NO
→Go to step 10.
6. Connection of wire harness ECU coupler, rear brake light switch coupler, brake light relay coupler
and main switch coupler.
pins).

YES
→Go to step 7.
NO
c. Operate the brake pedal, and then check the DTC using the malfunction mode of the YDT.
9-212
P056C

YES
NO
→Go to step 7.
7. Check the fuse.
• Check the signaling system fuse and brake light fuse.
Is check result OK?

YES
→Go to step 8.
NO

YES
NO
→Go to step 8.
• Disconnect the signaling system fuse “1”, joint coupler “2”, brake light fuse “3”, front brake light
switch coupler “4”, rear brake light switch coupler “5”, brake light relay coupler “6” and ECU coupler
“7”.
Between signaling system fuse holder and joint
brown–brown
coupler
Between joint coupler and brake light fuse hold-
brown–brown
er
Between brake light fuse holder and front brake
green/white–green/white
light switch coupler
Between front brake light switch coupler and
rear brake light switch coupler
Between rear brake light switch coupler and
brake light relay coupler
Between brake light relay coupler and ground black–ground
Between brake light relay coupler and ECU cou-
pler
9-213
P056C
1 3 4
G/W Y/B
G/Y Y/W
7
2
R/W Br Br Br 5 L/R
L/W B/Y
L/Y L/W
Br G/LGy/G
Lg/B Gy/Y
Br/W
G/W G
B/L W
Gy/B
W/B
W/L
Y/B G/Y
Lg/L Lg/B Lg/B Y B
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
Between joint coupler “2” and ground brown–ground
Between front brake light switch coupler “4” and green/white–ground
ground green/yellow–ground
Between brake light relay coupler “6” and
light green/black–ground
ground

green/white–any other coupler terminal
Front brake light switch coupler
Rear brake light switch coupler “5”
light green/black–any other coupler terminal
Brake light relay coupler light green/black–any other coupler terminal
ECU coupler “7” light green/black–any other coupler terminal
9-214
P056C
A B
4
4
G/W Y/B
G/Y Y/W
7
G/W Y/B 6
G/Y Y/W L/R
6
Lg/B Y B
5 L/R L/W B/Y
L/Y L/W
Br G/LGy/G
Lg/B Gy/Y
Br/W
G/W G
B/L W
Gy/B
W/B
W/L
R/W Br Br Br Lg/B Y B
Y/B G/Y
Lg/L Lg/B
YES
→Go to step 9.
NO

YES
NO
→Go to step 9.
9. Defective rear brake light switch.
• Replace the rear brake light switch.
Refer to “REAR BRAKE” on page 4-51.
Is check result OK?

YES
→Go to step 10.
NO
a. Turn the main switch to “ON”.
b. Operate the brake pedal, and then check the DTC using the malfunction mode of the YDT.

YES
NO
→Go to step 10.
9-215
P0601
EAS20676
P0601
EAS33305
TROUBLESHOOTING
Item
ROM error. Internal malfunction in ECU. (When this malfunction is detected in the ECU, the DTC might
not appear on the tool display.)
Fail-safe system
Procedure
• Check that the MIL does not come on.
9-216
P0606
EAS20677
P0606
EAS33306
TROUBLESHOOTING
Item
Processor error. Internal malfunction in ECU. (When this malfunction is detected in the ECU, the DTC
might not appear on the tool display.)
Fail-safe system
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.

YES
NO
→ Go to step 2.
• Check that the MIL does not come on.
9-217
P062F
EAS20598
P062F
EAS33078
TROUBLESHOOTING
Item
EEPROM DTC: an error is detected while reading or writing on EEPROM.
Fail-safe system
Procedure
• Execute the diagnostic mode (Code 60)
9-218
P0638
EAS20599
P0638
EAS33079
TROUBLESHOOTING
Item
YCC-T drive system: malfunction detected.
Fail-safe system
Procedure
1. Connection of throttle servo motor coupler.
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-219
P0638
3. Check the electronic throttle valve fuse.
Is check result OK?

YES
→ Go to step 4.
NO
a. Replace the electronic throttle valve fuse.

YES
NO
→ Go to step 4.
• Disconnect the throttle servo motor coupler “1”, ECU coupler “2” and electronic throttle valve fuse
“3”.
Between throttle servo motor coupler and ECU yellow/red–yellow/red
coupler light green/red–light green/red
Between ECU coupler and electronic throttle
red/blue–red/blue
valve fuse holder
1 2
Y/R Lg/R Lg/R L/B O/B R/B G/B B
R/L G/Y Br/R B
3 R/G Y/B L/Y R/L B/W B/W
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
9-220
P0638
yellow/red–ground
Between ECU coupler “2” and ground light green/red–ground
red/blue–ground

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
A B
2 1
Y/R P/W P/B O/L Gy O/L Gy Y/R Lg/R
R/L G/Y Br/R B
2
R/L G/Y Br/R B
YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
5. Defective throttle body assembly.
• Check the throttle body assembly.
Refer to “CHECKING THE THROTTLE SERVO MOTOR” on page 8-47.
Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the throttle body assembly.
Refer to “REPLACING THE THROTTLE BODIES” on page 7-14.

YES
NO
→ Go to step 6.
9-221
P0638
9-222
P0657
EAS20601
P0657
EAS33081
TROUBLESHOOTING
Item
Fuel system voltage: incorrect voltage supplied to the fuel injector, fuel pump and relay unit.
Fail-safe system
Procedure
TIP
• P0335
1. Connection of relay unit coupler.
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
2. Connection of handlebar switch (right) coupler.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-223
P0657
pins).

YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
• Disconnect the fuel injection system fuse “1”, relay unit coupler “2”, ignition fuse “3”, joint coupler “4”,
handlebar switch (right) coupler “5” and ECU coupler “6”.
Between fuel injection system fuse holder and
red–red
relay unit coupler
Between ignition fuse holder and joint coupler red/white–red/white
Between joint coupler and handlebar switch
red/blue–red/blue
(right) coupler
Between handlebar switch (right) coupler and
relay unit coupler
red/blue–red/blue
Between relay unit coupler and ECU coupler
blue/yellow–blue/yellow
1 2
R L/W R/W L R/L
6
R/L G/Y Br/R B
4 5 B Br/Y R/L
R/W L
R/W R/L R/W R/W
Is resistance 0 Ω?
YES
NO
9-224
P0657

YES
NO
TIP
red–ground
red/white–ground
red/blue–ground
Between joint coupler “4” and ground red/white–ground
Between handlebar switch (right) coupler “5”
red/blue–ground
and ground

Relay unit coupler
Handlebar switch (right) coupler
ECU coupler “6”
A B
2 6
2 5 R L/W R/W L R/L Y/R P/W P/B O/L Gy O/L Gy
R L/W R/W L R/L L/W L/Y R/W L/B L/Y Sb B/Y Sb/W Lg/R L/B O/B R/B G/B B
B Br/Y R/L
R/W L R/L G/Y Br/R B
5
4 B Br/Y R/L
R/W L
R/W R/L R/W R/W
YES
→ Go to step 5.
NO
9-225
P0657

YES
NO
→ Go to step 5.
5. Defective relay unit.
• Check the operating sound of the relay.
Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the relay unit.

YES
NO
→ Go to step 6.
6. Defective relay unit.
Is the Fuel system voltage less than 3V?

YES
a. Replace the relay unit.

YES
NO
→ Go to step 7.
NO
→ Go to step 7.
9-226
P0916, P0917
EAS20611
P0916, P0917
EAS33091
TROUBLESHOOTING
Item
• [P0916] Gear position sensor: open or short to ground circuit is detected. Normal signal is not received
from the gear position sensor to ECU.
• [P0917] Gear position sensor: short to power circuit is detected. Normal signal is not received from the
gear position sensor to ECU.
Fail-safe system
Procedure
1. Connection of gear position sensor coupler.
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-227
P0916, P0917
• Disconnect the gear position sensor coupler “1” and ECU coupler “2”.
white–white
Between gear position sensor coupler and ECU
green–green
coupler
blue/red–blue/red
2
L/R G W L/W B/Y Br G/LGy/G Br/W B/L W W/B
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
Between gear position sensor coupler “1” and green–ground
ground blue/red–ground

Gear position sensor coupler green–any other coupler terminal
blue/red–any other coupler terminal
ECU coupler “2” green–any other coupler terminal
blue/red–any other coupler terminal
9-228
P0916, P0917
A B
1 2
1
L/R G W
L/R G W L/B O/W Lg/L P/W P V L L/R Gy
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
4. Installed condition of gear position sensor.
Is check result OK?

YES
→ Go to step 5.
NO

YES
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.
9-229
P0916, P0917

YES
NO
→ Go to step 6.
9-230
P1400
EAS20612
P1400
EAS33092
TROUBLESHOOTING
Item
Air induction system solenoid: open or short to ground circuit is detected. Normal signal is not received
from the air induction system solenoid.
Fail-safe system
Procedure
1. Connection of air induction system solenoid coupler.
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Start the engine and check the status of the DTC.

YES
NO
→ Go to step 2.
TIP
Check that the start/engine stop switch is turned to “ON” then.
pins).

YES
→ Go to step 3.
NO
9-231
P1400

YES
NO

YES
NO
→ Go to step 3.
TIP
• Disconnect the air induction system solenoid coupler “1”, ECU coupler “2” and ignition fuse “3”.
Between air induction system solenoid coupler
brown/red–brown/red
and ECU coupler
Between air induction system solenoid coupler
and ignition fuse holder
2 1
Br/R R/W
R/L G/Y Br/R B
Is resistance 0 Ω?
YES
NO

YES
NO

YES
NO
9-232
P1400
TIP
TIP
Between air induction system solenoid coupler brown/red–ground
“1” and ground red/white–ground

brown/red–any other coupler terminal
Air induction system solenoid coupler
ECU coupler “2” brown/red–any other coupler terminal
A B
1 1 2
Br/R R/W Br/R R/W
R/L G/Y Br/R B
YES
→ Go to step 4.
NO

YES
NO

YES
NO
→ Go to step 4.
TIP
9-233
P1400
4. Defective air induction system solenoid.
• Check the air induction system solenoid.
Refer to “CHECKING THE AIR INDUCTION SYSTEM SOLENOID” on page 8-48.

YES
NO

YES
NO
→ Go to step 5.
TIP
9-234
P1600
EAS20613
P1600
EAS33093
TROUBLESHOOTING
Item
Lean angle sensor: open or short circuit is detected. Normal signal is not received from IMU or defective
IMU.
Fail-safe system
Procedure
TIP
• U0125
pins).

YES
→ Go to step 2.
NO
b. Turn the main switch to “ON”, then to “OFF”, and back to “ON”.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-235
P1600
Between ECU coupler and IMU coupler black/white–black/white
Between signaling system fuse holder and IMU
brown–red/white
coupler
4 1
3 B/W L/W L/B R/W
R/L G/Y Br/R B
1
*. MT10SPN/MT10SPNC
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
Disconnect the ECU and IMU related connectors before checking.
9-236
P1600
blue/white–ground
blue/black–ground
blue/white–ground
red/white–ground

ECU coupler
black/black–any other coupler terminal
black/black–any other coupler terminal
A B
1 1
3 B/W L/W L/B R/W
3
B/W L/W L/B R/W
2
*. MT10SPN/MT10SPNC
YES
→ Go to step 4.
NO
9-237
P1600

YES
NO
→ Go to step 4.
Is check result OK?

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
5. Defective IMU.
• Turn the main switch to “ON”, then to “OFF”, and back to “ON”.
• Check the DTC using the malfunction mode of the YDT.

YES
NO
→ Go to step 6.
9-238
P1601
EAS20614
P1601
EAS33094
TROUBLESHOOTING
Item
Sidestand switch: open or short circuit in wire harness of the ECU is detected. Normal signal is not re-
ceived from the sidestand switch.
Fail-safe system
Procedure
1. Connection of sidestand switch coupler.
pins).

YES
→ Go to step 2.
NO
b. Turn the main switch to “ON”, and then extend and retract the sidestand.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
3. Connection of relay unit coupler.
pins).
9-239
P1601

YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
4. Connection of main switch coupler.
pins).

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
• Disconnect the relay unit coupler “1”, ECU coupler “2”, sidestand switch coupler “3” and main switch
“4”.
Between relay unit coupler and main switch
blue/yellow–blue/black
coupler
Between main switch coupler and ECU coupler blue/yellow–blue/yellow
Between relay unit coupler and sidestand
switch coupler
2
3 1 4
L/B B L/Y L/B L/W B/Y Br G/LGy/G Br/W B/L W W/B
9-240
P1601
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
blue/black–ground
Between main switch coupler “4” and ground blue/yellow–ground

Relay unit coupler
ECU coupler “2” blue/yellow–any other coupler terminal
Sidestand switch coupler “3” blue/black–any other coupler terminal
Main switch coupler “4” blue/yellow–any other coupler terminal
A B
1 1 3
R L/W R/W L R/L R L/W R/W L R/L L/B B
L/W L/Y R/W L/B L/Y Sb B/Y Sb/W L/W L/Y R/W L/B L/Y Sb B/Y Sb/W
2
4 4
L/Y L/B L/B O/W Lg/L P/W P V L L/R Gy L/Y L/B
9-241
P1601
YES
→ Go to step 6.
NO

YES
NO
→ Go to step 6.
6. Defective sidestand switch.
• Shift the transmission into gear.
Sidestand retracted ON
Sidestand extended OFF
Is check result OK?

YES
→ Go to step 7.
NO
a. Replace the sidestand switch.

YES
NO
→ Go to step 7.
9-242
P1602
EAS20615
P1602
EAS33095
TROUBLESHOOTING
Item
Malfunction in ECU internal circuit (malfunction of ECU power cut-off function).
Fail-safe system
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.

YES
NO
→ Go to step 2.
2. Connection of starter relay coupler.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
3. Connection of main switch coupler.
pins).
9-243
P1602

YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
4. Check the fuse.
• Check the backup fuse.
Is check result OK?

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
• Disconnect the battery “1”, backup fuse “2”, ECU coupler “3”, main switch coupler “4” and ignition
fuse “5”.
Between battery and backup fuse holder red–red
Between backup fuse holder and ECU coupler red/green–red/green
Between main switch coupler and ignition fuse
brown/blue–brown/blue
holder
Between ignition fuse holder and ECU coupler red/white–red/white
9-244
P1602
1
3
2 Lg/R
R/L G/Y Br/R
L/B O/B R/B G/B B
B
4
5
Br/L R
Br/R R/B
3
L/Y L Br/Y R/W
W W L B/R
B/G B B/G
B/L B B/Y W/Y
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
Between battery “1” and ground red–ground
red/green–ground
red/white–ground
Between main switch coupler “4” and ground brown/blue–ground

red/green–any other coupler terminal
ECU coupler
Main switch coupler brown/blue–any other coupler terminal
9-245
P1602
A B
1 3 3 3
Y/R P/W P/B O/L Gy O/L Gy Y/R P/W P/B O/L Gy O/L Gy L/Y L Br/Y R/W
Lg/R L/B O/B R/B G/B B Lg/R L/B O/B R/B G/B B W W L B/R
R/L G/Y Br/R B R/L G/Y Br/R B B/G B B/G
R/G Y/B L/Y R/L B/W B/W R/G Y/B L/Y R/L B/W B/W B/L B B/Y W/Y
4 3
L/Y L Br/Y R/W 4
Br/L R W W L B/R Br/L R
Br/R R/B B/G B B/G Br/R R/B
B/L B B/Y W/Y
YES
→ Go to step 6.
NO

YES
NO
→ Go to step 6.
9-246
P1806, P1807
EAS20623
P1806, P1807
EAS33103
TROUBLESHOOTING
Item
• [P1806] Shift sensor: open or short to ground circuit is detected. Normal signal is not received from the
shift sensor to ECU.
• [P1807] Shift sensor: short to power circuit is detected. Normal signal is not received from the shift
sensor to ECU.
Fail-safe system
Procedure
1. Connection of shift sensor coupler.
pins).

YES
→ Go to step 2.
NO
b. Turn the main switch to “ON”, and then check the condition of the auxiliary system warning.
Is the auxiliary system warning off?

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-247
P1806, P1807
• Disconnect the shift sensor coupler “1” and ECU coupler “2”.
Between shift sensor coupler and ECU coupler violet–violet
blue–blue
2
1
B/L V L L/W B/Y Br G/LGy/G Br/W B/L W W/B
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
violet–ground
Between shift sensor coupler “1” and ground
blue–ground

Shift sensor coupler violet–any other coupler terminal
blue–any other coupler terminal
ECU coupler “2” violet–any other coupler terminal
blue–any other coupler terminal
9-248
P1806, P1807
A B
1 1 2
B/L V L B/L V L
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
4. Installed condition of shift sensor.
Refer to “CHAIN DRIVE” on page 4-113.
Is check result OK?

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
5. Defective shift sensor.
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
9-249
P1806, P1807
Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the shift sensor.
Refer to “CHAIN DRIVE” on page 4-113.

YES
NO
→ Go to step 6.
7. Delete the DTC.
9-250
P2122, P2123, P2127, P2128, P2138
EAS20632
P2122, P2123, P2127, P2128, P2138

EAS33112
TROUBLESHOOTING
Item
• [P2122] Accelerator position sensor: open or short to ground circuit is detected. Normal signal is not
received from the accelerator position sensor.
• [P2123] Accelerator position sensor: short to power circuit is detected. Normal signal is not received
from the accelerator position sensor.
• [P2127] Accelerator position sensor: open or short to ground circuit is detected. Normal signal is not
received from the accelerator position sensor.
• [P2128] Accelerator position sensor: short to power circuit is detected. Normal signal is not received
from the accelerator position sensor.
• [P2138] Deviation error. Normal signal is not received from the accelerator position sensor.
Fail-safe system
Procedure
TIP
If a DTC other than P2138 (P2122, P2123, P2127, or P2128) is indicated, perform troubleshooting first.
1. Connection of accelerator position sensor coupler.
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
9-251
P2122, P2123, P2127, P2128, P2138

YES
NO
→ Go to step 3.
• Disconnect the accelerator position sensor coupler “1” and ECU coupler “2”.
[P2122, P2123, P2127, P2128, P2138] white–
white
[P2122, P2123, P2127, P2128, P2138] black–
Between accelerator position sensor coupler black
and ECU coupler [P2122, P2127] blue/yellow–blue/yellow
[P2122, P2127] blue–blue
[P2123, P2128] black/blue–black/blue
[P2123, P2128] black/yellow–black/yellow
1 2
L/Y L Br/Y R/W
B L/Y
W W L B/R
L B/L
B/G B B/G
B/Y W
B/L B B/Y W/Y
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
9-252
P2122, P2123, P2127, P2128, P2138
[P2122, P2123, P2127, P2128, P2138] white–
ground
Between accelerator position sensor coupler “1” [P2122, P2123, P2127, P2128, P2138] black–
and ground ground
[P2122, P2127] blue/yellow–ground
[P2122, P2127] blue–ground

[P2122, P2123, P2127, P2128, P2138] white–
any other coupler terminal
[P2122, P2123, P2127, P2128, P2138] black–
[P2122, P2127] blue/yellow–any other coupler
Accelerator position sensor coupler terminal
[P2123, P2128] black/blue–any other coupler
terminal
[P2123, P2128] black/yellow–any other coupler
terminal
[P2122, P2123, P2127, P2128, P2138] white–
[P2122, P2123, P2127, P2128, P2138] black–
[P2122, P2127] blue/yellow–any other coupler
[P2123, P2128] black/blue–any other coupler
terminal
[P2123, P2128] black/yellow–any other coupler
terminal
A B
1 1 2
B L/Y L/Y L Br/Y R/W
B L/Y
L B/L W W L B/R
L B/L
B/Y W B/Y W B/G B B/G
B/L B B/Y W/Y
YES
→ Go to step 4.
NO
9-253
P2122, P2123, P2127, P2128, P2138

YES
NO
→ Go to step 4.
4. Defective accelerator position sensor.
• Execute the diagnostic mode. (Code 14) (Accelerator position sensor signal 1.)
When the throttle valves are fully open 82–92
Turn the throttle grip past the closed position in the deceleration direction. 7–12
• Execute the diagnostic mode. (Code 15) (Accelerator position sensor signal 2.)
When the throttle valves are fully open 82–92
Turn the throttle grip past the closed position in the deceleration direction. 7–12
Is check result OK?

YES
→ Go to step 5.
NO
a. Replace the handlebar switch (right).

YES
NO
→ Go to step 5.
9-254
P2135
EAS20812
P2135
EAS33652
TROUBLESHOOTING
Item
Throttle position sensor: output voltage deviation error. Normal signal is not received from the throttle
position sensor circuit.
Fail-safe system
Procedure
TIP
• P0122, P0123, P0222, P0223, P0638
1. Check the starting and racing the engine possibility.
• Turn the main switch to “ON”, and then start the engine and racing the engine.
Unable to starting the engine and racing the engine.

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
2. Connection of throttle position sensor coupler.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-255
P2135
pins).

YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
4. Installed condition of throttle position sensor.
Is check result OK?

YES
→ Go to step 5.
NO
a. Reinstall or adjust the sensor.

YES
NO
→ Go to step 5.
Is check result OK?

YES
→ Go to step 6.
NO
9-256
P2135

YES
NO
→ Go to step 6.
Is check result OK?

YES
→ Go to step 7.
NO

YES
NO
→ Go to step 7.
9-257
P2158 (FI)
EAS20633
P2158 (FI)
EAS33113
TROUBLESHOOTING
Item
Front wheel sensor: normal signal is not received from the front wheel sensor.
Fail-safe system
Procedure
• Check the ABS warning light.
Is the ABS warning light on?

YES
→ Refer to “BASIC INSTRUCTIONS FOR TROUBLESHOOTING” on page 9-29.
NO
→ Go to step 2.
2. Execute the diagnostic mode.
• Rotate the front wheel by hand and check that the indicated value increases.

YES
NO
→ Go to step 3.
3. Connection of front wheel sensor coupler.
pins).

YES
→ Go to step 4.
NO
c. Rotate the front wheel by hand and check that the indicated value increases.

YES
NO
→ Go to step 4.
pins).
9-258
P2158 (FI)

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
pins).

YES
→ Go to step 6.
NO

YES
NO
→ Go to step 6.
• Disconnect the front wheel sensor coupler “1”, ABS ECU coupler “2” and ECU coupler “3”.
Between front wheel sensor coupler and ABS black–black
ECU coupler white–white
Between ABS ECU coupler and ECU coupler gray/black–gray/black
3
2
1
R Gy/B L Y G Br/B B L/W B/W L/B O/W Lg/L P/W P V L L/R Gy
B W L/W B/Y Br G/LGy/G Br/W B/L W W/B
9-259
P2158 (FI)
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
Disconnect the ECU and ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-4 and “PARTS CONNECTED TO THE ABS
ECU” on page 9-5.
black–ground
Between ABS ECU coupler “2” and ground white–ground
gray/black–ground

Front wheel sensor coupler “1”
ABS ECU coupler white–any other coupler terminal
gray/black–any other coupler terminal
ECU coupler “3” gray/black–any other coupler terminal
9-260
P2158 (FI)
A B
1
2 B W
2

YES
→ Go to step 7.
NO

YES
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-
26.
Is check result OK?

YES
→ Go to step 8.
NO
a. Reinstall or replace the front wheel sensor.
Refer to “FRONT WHEEL” on page 4-21.
9-261
P2158 (FI)

YES
NO
→ Go to step 8.
• Rotate the front wheel by hand and check that the indicated value increases.

YES
NO
→ Go to step 9.
• Replace the hydraulic unit assembly (ABS ECU).
• Go to step 10, and complete the service.
• 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).
• Delete this DTC even if it has a condition of “Detected”.
9-262
P2158 (SCU)
EAS20634
P2158 (SCU)
EAS33114
TROUBLESHOOTING
Item
Abnormal front wheel sensor. (Sensor value is not normal.)
Fail-safe system
Procedure
1. Abnormal front wheel sensor. (Sensor value is not normal.)
• Check the item of DTC P2158 for the ECU.
47.
mode of the YDT.

YES
NO
9-263
P2228, P2229
EAS20641
P2228, P2229
EAS33121
TROUBLESHOOTING
Item
• [P2228] Atmospheric pressure sensor: short to ground circuit is detected. Normal signal is not re-
ceived from the atmospheric pressure sensor.
• [P2229] Atmospheric pressure sensor: open or short to power circuit is detected. Normal signal is not
received from the atmospheric pressure sensor.
Fail-safe system
Procedure
1. Connection of atmospheric pressure sensor coupler.
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-264
P2228, P2229
• Disconnect the atmospheric pressure sensor coupler “1” and ECU coupler “2”.
[P2228, P2229] pink–pink
Between atmospheric pressure sensor coupler
[P2228] blue–blue
and ECU coupler
2
1
B/L P L L/W B/Y Br G/LGy/G Br/W B/L W W/B
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
Between atmospheric pressure sensor coupler [P2228, P2229] pink–ground
“1” and ground [P2228] blue–ground

[P2228, P2229] pink–any other coupler terminal
Atmospheric pressure sensor coupler [P2228] blue–any other coupler terminal
[P2228, P2229] pink–any other coupler terminal
ECU coupler “2” [P2228] blue–any other coupler terminal
9-265
P2228, P2229
A B
1 1 2
B/L P L B/L P L
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
4. Installed condition of atmospheric pressure sensor.
Is check result OK?

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
5. Defective atmospheric pressure sensor.
dicated.
At sea level
prox. 3.64 V
prox. 3.30 V
prox. 3.00 V
prox. 2.70 V
9-266
P2228, P2229
Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the atmospheric pressure sensor.

YES
NO
→ Go to step 6.
9-267
U0100
EAS20644
U0100
EAS33124
TROUBLESHOOTING
Item
Abnormal CAN communication (between ECU and SCU)
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO
mode of the YDT.

YES
NO
→ Go to step 2.
• Disconnect the SCU coupler “1”, joint coupler “2” and ECU coupler “3”.
Between SCU coupler and joint coupler
Between the joint coupler and ECU coupler
9-268
U0100
1
P/W G/R Y Br/W
P G Y/R B
L/B P/L G/B Y/G
3
2 L/W B/Y Br G/LGy/G Br/W B/L W W/B
*. MT10SPN/MT10SPNC
Is resistance 0 Ω?
YES
NO
mode of the YDT.

YES
NO
TIP
Disconnect the ECU and SCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-4 and “PARTS CONNECTED TO THE SCU
blue/white–ground
Between SCU coupler “1” and ground
blue/black–ground
blue/white–ground
blue/black–ground

SCU coupler
ECU coupler
9-269
U0100
A B
1 1
P/W G/R Y Br/W
P G Y/R B P/W G/R Y Br/W
L/B P/L G/B Y/G P G Y/R B
L/W P/B G/L Y/B W W/R W/B W/G L/B P/L G/B Y/G
3 3
2
*. MT10SPN/MT10SPNC
YES
→ Go to step 3.
NO
mode of the YDT.

YES
NO
→ Go to step 3.
9-270
U0121
EAS20646
U0121
EAS33126
TROUBLESHOOTING
Item
Abnormal CAN communication (between ABS ECU and SCU)
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO
mode of the YDT.

YES
NO
→ Go to step 2.
• Disconnect the SCU coupler “1”, joint coupler “2” and ABS ECU coupler “3”.
Between the joint coupler and ABS ECU cou- blue/white–blue/white
pler blue/black–blue/black
9-271
U0121
1
P/W G/R Y Br/W
P G Y/R B
L/B P/L G/B Y/G
3
2
*. MT10SPN/MT10SPNC
Is resistance 0 Ω?
YES
→ Go to “Short circuit check”
NO
mode of the YDT.

YES
NO
TIP
Disconnect the SCU and ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SCU (for MT10SPN/MT10SPNC)” on page 9-4 and “PARTS
CONNECTED TO THE ABS ECU” on page 9-5.
blue/white–ground
blue/black–ground
blue/white–ground
Between ABS ECU coupler “3” and ground
blue/black–ground

SCU coupler
ABS ECU coupler
9-272
U0121
A B
1 1
P/W G/R Y Br/W
3 3
R Gy/B L Y G Br/B B L/W B/W R Gy/B L Y G Br/B B L/W B/W
R/L G/O W/L L B W W L/B B R/L G/O W/L L B W W L/B B
2
*. MT10SPN/MT10SPNC
YES
→ Go to step 3.
NO
mode of the YDT.

YES
NO
→ Go to step 3.
• Replace the hydraulic unit assembly (ABS ECU), and complete the service.
9-273
U0125 (FI)
EAS20647
U0125 (FI)
EAS33127
TROUBLESHOOTING
Item
Signals cannot be transmitted between the ECU and the IMU.
Fail-safe system
Procedure
TIP
• P1600
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-274
U0125 (FI)
Between IMU coupler and signaling system
red/white–brown
fuse holder
Between IMU coupler and ECU coupler black/white–black/white
4 1
3 B/W L/W L/B R/W
R/L G/Y Br/R B
1
*. MT10SPN/MT10SPNC
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
Disconnect the ECU and IMU related connectors before checking.
blue/white–ground
blue/black–ground
blue/white–ground
red/white–ground
9-275
U0125 (FI)
ECU coupler
A B
1 1
3 B/W L/W L/B R/W
3
B/W L/W L/B R/W
2
*. MT10SPN/MT10SPNC
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
9-276
U0125 (FI)
4. Malfunction in IMU.

YES
NO
→ Go to step 5.
9-277
U0125 (SCU)
EAS20648
U0125 (SCU)
EAS33128
TROUBLESHOOTING
Item
Abnormal CAN communication (between IMU and SCU)
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO
mode of the YDT.

YES
NO
→ Go to step 2.
• Disconnect the SCU coupler “1”, joint coupler “2” and IMU coupler “3”.
Between the joint coupler and IMU coupler
9-278
U0125 (SCU)
1
P/W G/R Y Br/W 3
P G Y/R B
L/B P/L G/B Y/G
2
*. MT10SPN/MT10SPNC
Is resistance 0 Ω?
YES
NO
mode of the YDT.

YES
NO
TIP
Disconnect the SCU and IMU related connectors before checking.
blue/white–ground
blue/black–ground
blue/white–ground
Between IMU coupler “3” and ground
blue/black–ground

SCU coupler
IMU coupler
9-279
U0125 (SCU)
A B
1 1
P/W G/R Y Br/W
3 3
2
*. MT10SPN/MT10SPNC
YES
→ Go to step 3.
NO
mode of the YDT.

YES
NO
→ Go to step 3.
3. Replace the IMU.
• Replace the IMU, and complete the service.
9-280
U0155 or Err (FI)
EAS20649
U0155 or Err (FI)

EAS33129
TROUBLESHOOTING
Item
Multi-function meter: signals cannot be transmitted between the ECU and the multi-function meter.
Fail-safe system
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.
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-281
U0155 or Err (FI)
• Disconnect the meter assembly coupler “1”, joint coupler “2” and ECU coupler “3”.
Between meter assembly coupler and joint cou- blue/white–blue/white
Between joint coupler and ECU coupler
1
B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y Lg L/W L/B G/W
3
2 L/W B/Y Br G/LGy/G Br/W B/L W W/B
*. MT10SPN/MT10SPNC
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
Between meter assembly coupler “1” and blue/white–ground
ground blue/black–ground
blue/white–ground
blue/black–ground
9-282
U0155 or Err (FI)
Meter assembly coupler
ECU coupler
A B
1 1
B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y Lg L/W L/B G/W B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y Lg L/W L/B G/W
R/GR/G Sb/W G/L G/Y G G/B W/B W/G W G/O Y R/GR/G Sb/W G/L G/Y G G/B W/B W/G W G/O Y
3
3
L/B O/W Lg/L P/W P V L L/R Gy L/W B/Y Br G/LGy/G Br/W B/L W W/B
L/W B/Y Br G/LGy/G Br/W B/L W W/B L/Y L/W Lg/B Gy/Y G/W G Gy/B W/L
2
*. MT10SPN/MT10SPNC
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
4. Defective meter assembly.
• Replace the meter assembly.

YES
NO
→ Go to step 5.
9-283
U0155 or Err (FI)
9-284
U0155 or Err (SCU)
EAS20650
U0155 or Err (SCU)

EAS33130
TROUBLESHOOTING
Item
Abnormal CAN communication (between meter assembly and SCU)
Fail-safe system
Procedure
1. Connection of meter assembly coupler.
pins).

YES
→ Go to step 2.
NO
mode of the YDT.

YES
NO
→ Go to step 2.
• Disconnect the SCU coupler “1”, joint coupler “2” and meter assembly coupler “3”.
Between the joint coupler and meter assembly blue/white–blue/white
coupler blue/black–blue/black
9-285
U0155 or Err (SCU)
1 3
P/W G/R Y Br/W
P G Y/R B
L/B P/L G/B Y/G
2
*. MT10SPN/MT10SPNC
Is resistance 0 Ω?
YES
NO
mode of the YDT.

YES
NO
TIP
Disconnect the SCU related connectors before checking.
blue/white–ground
blue/black–ground

SCU coupler
9-286
U0155 or Err (SCU)
A B
1 1
P/W G/R Y Br/W
3 3
2
*. MT10SPN/MT10SPNC
YES
→ Go to step 3.
NO
mode of the YDT.

YES
NO
→ Go to step 3.
3. Defective meter assembly.
• Replace the meter assembly, and complete the service.
9-287
11_ABS
EAS20685
11_ABS
EAS33314
TROUBLESHOOTING
Item
Front wheel sensor (intermittent pulses or no pulses)
Procedure
TIP
If 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 4-24.
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.
26.
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.
26.
Is check result OK?

YES
→ Replace the hydraulic unit assembly (ABS ECU).
NO
→ Repair or replace the wheel sensor.
9-288
12_ABS
EAS20686
12_ABS
EAS33315
TROUBLESHOOTING
Item
Rear wheel sensor (intermittent pulses or no pulses)
Procedure
1. Foreign material adhered around the rear wheel sensor
Is check result OK?

YES
→ Go to step 2.
NO
2. Incorrect installation of the rear wheel
Refer to “CHECKING THE REAR WHEEL” on page 4-34.
Is check result OK?

YES
→ Go to step 3.
NO
→ Replace the wheel axle, tire, rear wheel, wheel bearings or oil seals.
Refer to “MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR” on page 4-
36.
Is check result OK?

YES
→ Go to step 4.
NO
4. Defective rear wheel sensor or incorrect installation of the sensor
36.
Is check result OK?

YES
NO
9-289
13, 26_ABS
EAS20687
13, 26_ABS
EAS33316
TROUBLESHOOTING
Item
Front wheel sensor (abnormal pulse period)
Procedure
TIP
• 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.
• Vehicle possibly ridden on uneven roads.
Is check result OK?

YES
→ Go to step 2.
NO
Is check result OK?

YES
→ Go to step 3.
NO
26.
Is check result OK?

YES
→ Go to step 4.
NO
26.
Is check result OK?

YES
NO
9-290
14, 27_ABS
EAS20688
14, 27_ABS
EAS33317
TROUBLESHOOTING
Item
Rear wheel sensor (abnormal pulse period)
Procedure
TIP
• If 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.
Is check result OK?

YES
→ Go to step 2.
NO
Is check result OK?

YES
→ Go to step 3.
NO
36.
Is check result OK?

YES
→ Go to step 4.
NO
36.
Is check result OK?

YES
NO
9-291
15_ABS
EAS20662
15_ABS
EAS33040
TROUBLESHOOTING
Item
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.
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.
• Disconnect the ABS ECU coupler “1” and front wheel sensor coupler “2”.
Between ABS ECU coupler and front wheel white–white
sensor coupler black–black
1
2
B W
Is resistance 0 Ω?
YES
NO
→ Replace the wire harness.
TIP
Disconnect the ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-5.
9-292
15_ABS
white–ground
black–ground

ABS ECU coupler
A B
1 1
YES
→ Go to step 3.
NO
3. Defective front wheel sensor or hydraulic unit assembly
• If the above items were performed and no malfunctions were found, the wheel sensor or hydraulic
unit assembly is defective.
• Replace the wheel sensor or hydraulic unit assembly.
Refer to “FRONT WHEEL” on page 4-21 and “ABS (Anti-lock Brake System)” on page 4-63.
9-293
16_ABS
EAS20663
16_ABS
EAS33285
TROUBLESHOOTING
Item
Rear wheel sensor (open or short circuit)
Procedure
1. Defective coupler between the rear wheel sensor and the hydraulic unit assembly
TIP
Is check result OK?

YES
→ Go to step 2.
NO
• Disconnect the ABS ECU coupler “1” and rear wheel sensor coupler “2”.
Between ABS ECU coupler and rear wheel sen- white–white
sor coupler black–black
1
2
B W
Is resistance 0 Ω?
YES
NO
TIP
9-294
16_ABS
white–ground
black–ground

ABS ECU coupler
A B
1 1
YES
→ Go to step 3.
NO
3. Defective rear wheel sensor or hydraulic unit assembly
• If the above items were performed and no malfunctions were found, the wheel sensor or hydraulic
unit assembly is defective.
• Replace the wheel sensor or hydraulic unit assembly.
Refer to “REAR WHEEL” on page 4-30 and “ABS (Anti-lock Brake System)” on page 4-63.
9-295
21_ABS
EAS20690
21_ABS
EAS33320
TROUBLESHOOTING
Item
Hydraulic unit assembly (defective solenoid drive circuit)
Procedure
1. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
9-296
31_ABS
EAS20691
31_ABS
EAS33321
TROUBLESHOOTING
Hydraulic unit assembly (defective ABS solenoid power circuit)
Procedure
1. Blown ABS solenoid fuse
• Check the ABS solenoid fuse.
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
TIP
Is check result OK?

YES
→ Go to step 3.
NO
• Disconnect the ABS solenoid fuse “1” and ABS ECU coupler “2”.
Between ABS solenoid fuse holder and ABS
red–red
ECU coupler
1 2
Is resistance 0 Ω?
YES
NO
9-297
31_ABS
TIP
Between ABS ECU coupler “2” and ground red–ground

ABS ECU coupler red–any other coupler terminal
A B
2 2
YES
→ Go to step 4.
NO
9-298
33_ABS
EAS20692
33_ABS
EAS33322
TROUBLESHOOTING
Item
Hydraulic unit assembly (abnormal ABS motor power supply)
Procedure
1. Blown ABS motor fuse
• Check the ABS motor fuse.
Is check result OK?

YES
→ Go to step 2.
NO
→ Replace the fuse and check the wire harness.
TIP
Is check result OK?

YES
→ Go to step 3.
NO
• Disconnect the starter relay coupler (ABS motor fuse) “1” and ABS ECU coupler “2”.
Between starter relay coupler (ABS motor fuse)
red/blue–red/blue
and ABS ECU coupler
1 2
R/L R Gy/B L Y G Br/B B L/W B/W
R/W L/W R/L G/O W/L L B W W L/B B
Is resistance 0 Ω?
YES
NO
9-299
33_ABS
TIP
Between ABS ECU coupler “1” and ground red/blue–ground

ABS ECU coupler red/blue–any other coupler terminal
A B
1 1
YES
→ Go to step 4.
NO
9-300
34_ABS
EAS20693
34_ABS
EAS33323
TROUBLESHOOTING
Item
Hydraulic unit assembly (short circuit in ABS motor power supply circuit)
Procedure
9-301
41_ABS
EAS20694
41_ABS
EAS33331
TROUBLESHOOTING
Item
Front wheel ABS (intermittent wheel speed pulses or incorrect depressurization)
Procedure
1. Incorrect installation of the front wheel sensor
26.
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 front wheel and make sure that it rotates smoothly.
Refer to “CHECKING THE FRONT WHEEL” on page 4-24 and “CHECKING THE FRONT BRAKE
Is check result OK?

YES
→ Go to step 3.
NO
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 4-45.
Is check result OK?

YES
→ Go to step 4.
NO
9-302
42_ABS
EAS20695
42_ABS
EAS33324
TROUBLESHOOTING
Item
Rear wheel ABS (intermittent wheel speed pulses or incorrect depressurization)
Procedure
1. Incorrect installation of the rear wheel sensor
36.
Is check result OK?

YES
→ Go to step 2.
NO
2. Incorrect rotation of the rear wheel
• Check that there is no brake disc drag on the rear wheel and make sure that it rotates smoothly.
Refer to “CHECKING THE REAR WHEEL” on page 4-34 and “CHECKING THE REAR BRAKE
DISC” on page 4-57.
Is check result OK?

YES
→ Go to step 3.
NO
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 4-57.
Is check result OK?

YES
→ Go to step 4.
NO
9-303
43, 45_ABS
EAS20696
43, 45_ABS
EAS33330
TROUBLESHOOTING
Item
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.
Is check result OK?

YES
→ Go to step 2.
NO
Is check result OK?

YES
→ Go to step 3.
NO
→ Replace the wheel axle, tire, front wheel, wheel bearings or oil seals.
26.
Is check result OK?

YES
→ Go to step 4.
NO
26.
Is check result OK?

YES
NO
9-304
44, 46_ABS
EAS20697
44, 46_ABS
EAS33325
TROUBLESHOOTING
Item
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.
Is check result OK?

YES
→ Go to step 2.
NO
Is check result OK?

YES
→ Go to step 3.
NO
36.
Is check result OK?

YES
→ Go to step 4.
NO
36.
Is check result OK?

YES
NO
9-305
51_ABS
EAS20698
51_ABS
EAS33326
TROUBLESHOOTING
Item
Vehicle system power supply (voltage of ABS ECU power supply is high)
Procedure
1. Defective battery
• Recharge or replace the battery, and check again.
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
Is check result OK?

YES
NO
→ Confirm the cause of the problem and repair it, and check again.
9-306
53_ABS
EAS20699
53_ABS
EAS33327
TROUBLESHOOTING
Item
Vehicle system power supply (voltage of ABS ECU power supply is low)
Procedure
TIP
Is check result OK?

YES
→ Go to step 3.
NO
• Disconnect the ABS ECU fuse “1” and ABS ECU coupler “2”.
Between ABS ECU fuse holder and ABS ECU
brown/black–brown/black
coupler
2
Is resistance 0 Ω?
YES
NO
TIP
9-307
53_ABS
Between ABS ECU coupler “2” and ground brown/black–ground

ABS ECU coupler brown/black–any other coupler terminal
A B
2 2
YES
→ Go to step 4.
NO
Is check result OK?

YES
NO
9-308
55_ABS
EAS20700
55_ABS
EAS33328
TROUBLESHOOTING
Item
Hydraulic unit assembly (defective ABS ECU)
Procedure
9-309
56_ABS
EAS20701
56_ABS
EAS33329
TROUBLESHOOTING
Item
Hydraulic unit assembly (abnormal internal circuit)
Procedure
9-310
57_ABS
EAS20666
57_ABS
EAS33292
TROUBLESHOOTING
Item
Vehicle CAN communication line or power source of vehicle system
Procedure
• Disconnect the ECU coupler “1”, joint coupler “2” and ABS ECU coupler “3”.
Between the joint coupler and ABS ECU cou- blue/white–blue/white
1
3
2
*. MT10SPN/MT10SPNC
Is resistance 0 Ω?
YES
NO
TIP
ECU” on page 9-5.
9-311
57_ABS
blue/white–ground
blue/black–ground
blue/white–ground
blue/black–ground

ECU coupler
ABS ECU coupler
A B
1 1
3 3
2
*. MT10SPN/MT10SPNC
YES
→ Go to step 2.
NO
TIP
9-312
57_ABS
Is check result OK?

YES
→ Go to step 4.
NO
• Disconnect the ABS ECU fuse “1”, ABS solenoid fuse “2” and ABS ECU coupler “3”.
Between ABS ECU fuse holder and ABS ECU
brown/black–brown/black
coupler
Between ABS solenoid fuse holder and ABS
red–red
ECU coupler
2 3
Is resistance 0 Ω?
YES
NO
TIP
brown/black–ground
red–ground

brown/black–any other coupler terminal
ABS ECU coupler
9-313
57_ABS
A B
3 3
YES
→ Go to step 5.
NO
YES
NO
9-314
62_ABS
EAS20702
62_ABS
EAS33333
TROUBLESHOOTING
Item
Power supply voltage failure in pressure sensor
Procedure
9-315
68_ABS
EAS20705
68_ABS
EAS33336
TROUBLESHOOTING
Item
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.
9-316
89_ABS
EAS20669
89_ABS
EAS33299
TROUBLESHOOTING
Item
CAN communication (between meter assembly and hydraulic unit assembly)
Procedure
1. Defective coupler between the meter assembly and the hydraulic unit assembly
TIP
Is check result OK?

YES
→ Go to step 2.
NO
• Disconnect the meter assembly coupler “1”, joint coupler “2” and ABS ECU coupler “3”.
Between meter assembly coupler and joint cou- blue/white–blue/white
Between joint coupler and ABS ECU coupler
1
3
R/L B
2 G/O W/L L B W W L/B
*. MT10SPN/MT10SPNC
Is resistance 0 Ω?
YES
NO
9-317
89_ABS
TIP
blue/white–ground
blue/black–ground

ABS ECU coupler
A B
1 1
3 3
2
*. MT10SPN/MT10SPNC
YES
→ Go to step 3.
NO
3. Defective meter assembly
• Replace the meter assembly, and check again.
9-318
89_ABS
9-319
90_ABS
EAS20670
90_ABS
EAS33300
TROUBLESHOOTING
Item
CAN communication (between ECU and hydraulic unit assembly)
Procedure
1. Defective coupler between the ECU and the hydraulic unit assembly
TIP
Is check result OK?

YES
→ Go to step 2.
NO
• Disconnect the ECU coupler “1”, joint coupler “2” and ABS ECU coupler “3”.
1
3
2
*. MT10SPN/MT10SPNC
9-320
90_ABS
Is resistance 0 Ω?
YES
NO
TIP
ECU” on page 9-5.
blue/white–ground
blue/black–ground
blue/white–ground
blue/black–ground

ECU coupler
ABS ECU coupler
A B
1 1
3 3
2
*. MT10SPN/MT10SPNC
YES
→ Go to step 3.
NO
9-321
90_ABS
3. Defective ECU
• Replace the ECU, and check again.
9-322
91_ABS
EAS20671
91_ABS
EAS33301
TROUBLESHOOTING
Item
CAN communication (between IMU and hydraulic unit assembly)
Procedure
1. Defective coupler between the IMU and the hydraulic unit assembly
TIP
Is check result OK?

YES
→ Go to step 2.
NO
• Disconnect the IMU coupler “1”, joint coupler “2” and ABS ECU coupler “3”.
Between IMU coupler and joint coupler
3
2 R/L G/O W/L L B W W L/B B
*. MT10SPN/MT10SPNC
Is resistance 0 Ω?
YES
NO
9-323
91_ABS
TIP
blue/white–ground
Between IMU coupler “1” and ground
blue/black–ground
blue/white–ground
blue/black–ground

IMU coupler
ABS ECU coupler
A B
1 1
3
3
2
*. MT10SPN/MT10SPNC
YES
→ Go to step 3.
NO
3. Defective IMU
• Replace the IMU, and check again.
9-324
EAS20091
54. Coolant temperature sensor 103.Front fork stepping motor (left)
WIRING DIAGRAM 55. Intake air temperature sensor (compression damping) (for
56. ECU (Engine Control Unit) MT10SPN/MT10SPNC)
MT10N/MT10NC/MT10SPN/
57. Ignition coil #1 104.Front fork stepping motor
MT10SPNC 2022 58. Ignition coil #2 (right) (rebound damping) (for
1. AC magneto 59. Ignition coil #3 MT10SPN/MT10SPNC)
2. Rectifier/regulator 60. Ignition coil #4 105.Rear shock absorber assem-
3. Main switch 61. Spark plug bly stepping motor (compres-
4. Radiator fan motor relay 62. Air induction system solenoid sion damping) (for MT10SPN/
5. Main fuse 63. Fuel injector #1 MT10SPNC)
6. Joint coupler 64. Fuel injector #2 106.Rear shock absorber assem-
7. Fuse box 3 65. Fuel injector #3 bly stepping motor (rebound
8. Brake light fuse 66. Fuel injector #4 damping) (for MT10SPN/
9. Cruise control fuse 67. Throttle servo motor MT10SPNC)
10. Fuse box 4 (for MT10SPN/ 68. Grip warmer (right) (OPTION) 107.Radiator fan motor (left)
MT10SPNC) 69. Grip warmer (left) (OPTION) 108.Sub radiator fan motor (right)
11. SCU fuse (for MT10SPN/ 70. Front wheel sensor 109.Brake light relay
MT10SPNC) 71. Rear wheel sensor 110.Handlebar switch (left)
12. Fuse box 1 72. Hydraulic unit assembly (ABS 111.Cruise control setting/power
13. ABS solenoid fuse ECU) switch
14. Fuel injection system fuse 73. YDT coupler 112.Mode switch
15. Electronic throttle valve fuse 74. Throttle position sensor 113.Select switch
16. Backup fuse 75. IMU (Inertial Measurement 114.Dimmer/pass switch
17. Sub radiator fan motor fuse Unit) 115.Horn switch
18. Radiator fan motor fuse 76. Meter assembly 116.Horn
19. Fuse box 2 77. Cruise control system indicator 117.Turn signal switch
20. Ignition fuse light 118.Hazard switch
21. ABS ECU fuse 78. Cruise control setting indicator A. Wire harness
22. Signaling system fuse light B. Sub-wire harness (Coolant
23. Headlight fuse 79. MIL (Malfunction indicator light) temperature sensor)
24. Terminal fuse 1 80. Neutral indicator light C. Sub-wire harness (IMU (Inertial
25. Battery 81. Shift indicator light Measurement Unit))
26. Engine ground 82. Multi-function meter D. Sub-wire harness (SCU (Sus-
27. ABS motor fuse 83. Auxiliary system warning light pension Control Unit)) (for
28. Starter relay 84. Oil pressure and coolant tem- MT10SPN/MT10SPNC)
29. Starter motor perature warning light *. For MT10SPN/MT10SPNC
30. Relay unit 85. Stability control indicator light
31. Starting circuit cut-off relay 86. Right turn signal indicator light
32. Fuel pump relay 87. Left turn signal indicator light
33. Clutch switch 88. Meter light
34. Front brake light switch 89. ABS warning light
35. Rear brake light switch 90. High beam indicator light
36. Handlebar switch (right) 91. Oil pressure switch
37. Wheel switch 92. Rear turn signal light (right)
38. Start/engine stop switch 93. Rear turn signal light (left)
39. Auxiliary DC jack 94. Front turn signal/position light
40. Accelerator position sensor (right)
41. Neutral switch 95. Front turn signal/position light
42. Sidestand switch (left)
43. Fuel sender 96. Headlight control unit
44. Fuel pump 97. Headlight (high beam)
45. Gear position sensor 98. Headlight (low beam)
46. O2 sensor 1 (left side) 99. Tail/brake light
47. O2 sensor 2 (right side) 100.License plate light
48. Shift sensor 101.Auxiliary light
49. Intake air pressure sensor 102.SCU (Suspension Control
50. Atmospheric pressure sensor Unit) (for MT10SPN/
51. Cylinder identification sensor MT10SPNC)
EAS30613
Y/B Yellow/Black
COLOR CODE Y/G Yellow/Green
B Black Y/L Yellow/Blue
Br Brown Y/R Yellow/Red
Ch Chocolate Y/W Yellow/White
Dg Dark green
G Green
Gy Gray
L Blue
Lg Light green
P Pink
R Red
Sb Sky blue
V Violet
W 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/Y Gray/Yellow
L/B Blue/Black
L/R Blue/Red
L/W Blue/White
L/Y Blue/Yellow
Lg/B Light green/Black
Lg/L Light green/Blue
Lg/R Light green/Red
O/B Orange/Black
O/L Orange/Blue
O/W Orange/White
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
W/G White/Green
W/L White/Blue
W/R White/Red
W/Y White/Yellow
Wiring_diagram_US.fm 10 ページ２０２２年１月２６日水曜日午後４時５６分
MT10N/MT10NC/MT10SPN/MT10SPNC 2022
WIRING DIAGRAM
A B C
R/L
R/L
L/W L/B L/B L/W B Br/W Br/W B R/WR/W R/W R/W R/W R/W R/W R/L R/L R/L R/L
B/L G/W G/W B/L R/L
B/W R/W L/W L/B R/W R/W R/W R/W R/W R/L R/L R/L
R/W B/W L/B L/W R/L
R/WR/W
R/L
R/W
R/L
A B A C A D R/W R/W
R/L
L/B L/B R/W
L/Y L/Y R/W
R/W R/W
WWW B R
R/W R/W 57
1 (Gy) (B)
R R/L
R/W
O/L
61 O/L R/W
W W R R/W L/W (B)
W W
W W 2 R RR
(B)
5 R/L
L/W
R/W
W W W R
R R R 27 R/W O/L
Gy Gy
58
B
3 R R/B RR
R/W O/L
61 Gy R/W
W W W
28 L/W L/W L/W L/R G W
45 Gy (B)
Br/L R R Br/L R L/W W W
R G G
L/W R/W
Br/R R/B R/B Br/R B (B) L/R L/R
O/L
59
L/Y L/B L/B L/Y 25 29 6 L/W L/W L/W L/W L/W
L/W
R/W Sb/W R
L/Y
61 O/L R/W
ON 30 R/L
(B)
OFF
B
B
R L/W R/W L R/L 31 32 R/G
R/L
R/W
60
B B B L/W L/Y R/W L/B L/Y Sb B/Y Sb/W Gy
Br/L L/B L/Y
Br/R L/Y
26 R/W L B/Y Sb L/Y L/Y
B/Y 61 Gy R/W
R/W B B P/B
L/B R/L Gy/G (B)
L/B B/L W L
B/W
B G/W Y/B W W/G B/W R/W
R/W
B/Y L/Y R/W P/W B B B B R/W P/B 62 O G Br/R R/W
R/W Y/B B/Y Y/B G/Y B/Y B/Y 47 46 Br/R Br/R G O R/W
6 R/L
R/W
R/W Y/W L/Y
G/Y Y/W
Lg/L Lg/B
R/W B W/B L/Y Gy/Y B/L W L
(B)
W L
(B)
Gy/G B/L
(B) R/W L/B B (B) (B)

R/W (Gy)
(B) (B) W/G W/B W R/W R/L L R/W B B P/W P/W 63 R/L R/B (Gy)
R 7 8 R/W R/L R/W R/W
Y/B B/Y G/W Y/W G/Y Y/B R W/BR/Y L/W
W/R Y/G B L/Y
L/B (B) G/W R/L B/L W L Gy/Y Gy/Y
R/B R/B R/L
L/R
Br G/W
Br Gy Br Y
B/Y W/G W/B 38 OFF
RUN W/B Y/R L B/L B
43 44 48
4 9 B
OFF OFF OFF
R B R/Y START W/G Y/B B/Y W B B B/L V L R W B R
W
L
V V R/L G/B
R/W Y/B
Y/W
B ON ON ON (B)
B Br 40 (B) (B) 42 (B) B B/L
64
R/B Br/L 10 11 Gy Br Y/B G/W Br Y
37 R/L Br B (B)
Sb
B
(B)
G/B G/B R/L
(Gy)
R G/Y Br/L Br/L Br/W L/W R/W Y/G W/G B B L
R/B Br/L G/W Y/B
(Gy) Y/B G/W
Y/W G/Y
(B)
B G
(B) B G
B/Y Br Br Y/B Y/R W/B W/R R/L B G/W B B/L P/W L (Dl) 49 B/L
P/W P/W R/L L/B
R/W G/Y
36
B/W B Br/Y
39
Br/Y
B
B B/Y
B
L W
B/L L/Y (B) 65
R R
33
Y/W L/Y
34
G/Y Y/B
35
Lg/B Lg/L B Br/Y R/L
41 50
L
B/L L/B L/B R/L
(Gy)
12 14 13
R/W L B/L P L
P P
Br/Y B
R (Dl) R/L O/B
R R/L
66
15 L W/B W L/Y
51
L/Y
W
L
B/LW/B
L L
O/B O/B R/L
(Gy)
R/G B/L B/L W/B
R/G (B) L Lg/L
17 16
(B) Lg/B
L
R/B R/G L W/Y B/L
L/W Lg/R L/B O/B R/B G/B B W W L B/R
G B/G B/R
18 B
B R/G
R/G
(B)
R/L G/Y Br/R
R/G Y/B L/Y
B
R/L B/W B/W B/L
B/G
B B/Y
B B/G
W/Y
B/W B B/W R/G
R/W B (B) (B)
Br/L R/W 6 B B/W
B/W L
52
W/Y W/Y
19 21 20
B/W G B/G B/G
B B B
B/L B/R B/R
B/W B
Br/B L/B O/W Lg/L P/W P V L L/R Gy
Br/L Br
Br
Br
R/W Br
R/W Br Br Br B/W B 76 B/L Gy B Gy 53
B Gy Gy
22 B/W Gy B/L
Br
77 G/W B/L (B) 54
G/W A G/W G/W
23 Br
B/L A
B/L
(B)
P/W G/R Y Br/W Br/R Br Y/W Y/B Br
78 Y/R Lg/R (B) 67
P G Y/R B Br/Y L L/R Br/W B/L (B) 55 Br/W
B/L
Br/W
Lg/R Lg/R
L/B P/L G/B Y/G 24 RES
PUSH
112 FREE
PUSH
UP
(N)
114 HI
LO 115 ON L OFF
79 Y/R Y/R
L/W P/B G/L Y/B W W/R W/B W/G FREE DOWN PASS OFF N 118 ON B/L
68 Br/Y B
(B)
SET
113
R
80 B/L B/L (Gy)
L/W L
Lg/B
Lg/B 111 B Y G W/R W/G
L/R Y
B/L 117 W/B W L W/B R/W Sb/W B/L B/L Br/Y B
Br/W C Br/W L
L/R G/Y G G/B Y/W G/B G/Y Y W/R W/G (B) W B/W R B R
81 B/L Br/Y Br/Y
B Br/Y
B C B B 109 110 O/W G/L Br G/Y B G/B G Y
Y Br
B W/L W/Y Br/Y B/L B
L 107 L 108 G/L G/Y B
B/W G G/B W/L Y/B W/Y B/L B/L B/L
B/L
B/L B/L B/L B/L
B/L B/L B/L B/L B/L
69
Br/Y B
(B)
B O/W Br Y/W (B) 116 B Br/Y B/W B/L B/L
G
G/B B B
L/R Y
Y G/W 82 B/L (B)
G/R 103 B B
R/G
R/G B/L
L/Y
70
G/L Lg/B Y B L/W L R/L
L/W L L/B B/Y G
L
(B)
G/L 83 B
W L
B W W B
G/R G G/B G/L W
W/B
W/G 84 O/W W
6 Y/B Y/B Y/B Y/B G/B
R/W R/W
G/L
Br
Gy/B
W/L
Gy/B
W/L
W
B B
P
P/B Y/B
G/Y
G 85 G/Y 72 W W
P/W 104 B/W
B/W L/W L/B R/W (B) W B/G L B (B) Y/B
B B
P/L
B
Y/B
Y 6 W/L
W/Y
86 R/W B/W
L/B G/O
R
B Y Y Y Br/Y B/G B/G B W W B
B
B
L/R L/R Y 74 W W
Br/B
P/W P P/B P/L B

101 B/R Br/B 87 75
B B L/W L/B B
71
B
B
B
100 L/R Y
BB Br Br Y/B
Y Br/W
Ch
L L Y L/W
W
B
B L
Dg 88 L/W L/B
102 W/B
W/R 105
B
B
B
B B/R B L/R
99 96
Br/B L/R B Br/W L/R B Ch B Dg B G/L
90 89
B
B/W B/W B B
(B) G
W/G
(B) B
L/R Br/B (Gy) L/R Br/W Ch (B) Dg Y G/O B/W B
6 B B B
Br G Br G L/W L/B B/W R/W
B L/R B B L/R Br B L/R G B G (Gy) B B
B B B Br B B B B B
W/R W W/B W/G B B B L/R
(B) 98 97 (Gy) (B) (B) 91 L/W L/B B/W R/W
B B L Y
B
95 94 93 92 R/GR/G Sb/W G/L G/Y G G/B W/B W/G W G/O Y
L/W B/W (R)
B B/W
B B Br B Y/B Y B Br B B B B R Gy/B L Y G Br/B B L/W B/W
R/G L/B B
B B B (B) B R/L B
Y G/O W/L L B W W L/B
Y L/R
Y/B B/W B/W B/W B B
Y/R 106 B
B L/R Br L/W L/W L/B L/B
L/W
L/B B B B/W B B/W
B/W B
Y/G B
B
B 6 L/R
L/R L/R L/W L/W L/W L/W L/B L/B B/W
R/G
B B/W
B/W B/W
(B)
B B L/W L/W L/W L/W L/W L/W L/R L/R Br L/R L/R L/R L/R L/B
73
Y/R Y Y/B Y/G
L/W L/W C L/W

L/B L/B C L/B
Wiring_diagram_US.fm 11 ページ２０２２年１月２６日水曜日午後４時５６分
MT10N/MT10NC/MT10SPN/MT10SPNC 2022
WIRING DIAGRAM
A B C
A B A C A D
57
1 (Gy) (B)
61
(B)
2 (B)
5 58
27
3 61
28 45 (B)
(B)
59
25 29 6 61
ON 30 (B)
OFF
31 32 60
26 61
(B)
62
47 46
6 (B) (B)
(B) (B) (B)
7 (Gy)
(B) (B)
63 (Gy)
8 (B)
38 OFF
RUN 43 44 48
4 9 OFF OFF OFF
START
ON ON ON (B)
40 (B) (B) 42 (B) 64
10 11 37 (B)
(B) (Gy)
(Gy) (B) (B)

(Dl) 49
36 39 (B) 65
33 34 35 41 50
(Gy)
12 14 13 (Dl)
66
15 51
(Gy)
(B)
17 16 (B)
56
18 (B)
(B) (B)
6 52
19 21 20
76 53
22
77 (B) 54 A
23 A (B)
78 (B) 67
(B) 55
24 RES
PUSH
112 FREE
PUSH
UP
(N)
114 HI
LO 115 ON L OFF
79
FREE DOWN PASS OFF N 118 ON
68
(B)
SET
113
R
80 (Gy)
111 117
C
(B) 81
C 109 110
107 108 69
(B) (B) 116
82 (B)
103 70
(B) 83
84
6
85 72
104 6
(B) (B)
86
74
101 100 87 75 71
88
102 105 99 96 90 89
(B)
(Gy) (B) (B) 6
(Gy)
91 B B B B
(B) 98 97 (Gy) (B) (B)
95 94 93 92
(R)
(B)
106 (B)
6
73
C
C

2022 Yamaha MT10-SP Workshop Manual

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2022

IMPORTANT MANUAL INFORMATION

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

A NOTICE indicates special precautions that must be taken to avoid

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

HOW TO USE THIS MANUAL

SYMBOL DEFINITION SYMBOL DEFINITION

Serviceable with engine mounted Gear oil

Filling fluid Molybdenum disulfide oil

Lubricant Brake fluid

Special tool B Wheel bearing grease

Tightening torque LS Lithium-soap-based grease

Wear limit, clearance M Molybdenum disulfide grease

Engine speed S Silicone grease

Electrical data Apply locking agent (LOCTITE®).

Engine oil New Replace the part with a new one.

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

BASIC SERVICE INFORMATION.................................................................1-17

SPECIAL TOOLS .......................................................................................... 1-18

VEHICLE IDENTIFICATION NUMBER

ABS - Anti-lock Brake System GEAR

ECU - Engine Control Unit 7 6

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

1. SCU trouble warning “ ” (MT10SPN/

Coolant temperature warning Information display

1. Display in STREET MODE

TIP Fuel reserve tripmeter:

TRIP-2 The odometer shows the total distance traveled

Fuel consumption trip meter:

1. Display in STREET MODE 1 2

Average fuel consumption:

1. Display in STREET MODE

Grip warmer indicator (if equipped)

To activate the grip warmer MODE-A: suitable for track riding

screen (PWR, TCS, SCS and ERS

EBM) cannot be adjusted independently from

Lap timer EAS31708

(indicated by the LAP mark). Use the Dimmer/ Display Mode

QS LIF 1 EBM 1 12:00

MODE-A PWR 1 TCS 3 SCS 1 A-1 OFF

MENU access and operation TIP

TRACK MODE Traction control system

LIF MPH YRC Setting 10 : 00

LIF can be set to 1, 2, 3, or OFF. Setting level 3 A 1 1 1 ON ON 1 1 1 A-1

most strongly reduces wheel lift, and setting lev- B 2 2 2 2 2 2 A-2

el 1 provides the least system intervention. OFF C 3 3 3 3 A-3

turns LIF off. D 4 4 M-1

5 OFF OFF OFF OFF M-2

YRC PWR TCS SCS QS QS LIF EBM BC ERS

YRC PWR TCS SCS QS QS LIF EBM BC ERS

MPH YRC Setting 10 : 00

4. Acceleration support level SETTING

Manual presets (M-1/M-2/M-3) adjustable set-

Fr COM: front compression damping M-1 8 18 22 22 4

Rr COM: rear compression damping M-3

Rr REB: rear rebound damping

1. In the YRC setting module, select the ERS

2. Long push the wheel switch to reset the item.

MPH Maintenance GPS 10 : 00

OIL 0 mile 1. Photo sensor