~YAMAHA

SERVICE MANUAL

BASIC INFORMATION

LlrT-11616-MC-B0 Y0A-28197-10
IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics.
This manual contains only basic instructions that must be observed during servicing. Refer to the ap-
plicable service manual for detailed information on checking, adjustment, and replacement.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Designs and specifications are subject to change without notice.

IMPORTANT MANUAL INFORMATION

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

A WARNING result in death or serious injury.

A NOTICE indicates special preca utions that must be taken to avoid

damage to the vehicle or other property.

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

BASIC INFORMATION
SERVICE MANUAL
©2017 by Yamaha Motor Corporation, U.S.A.
First edition, January 2017
All rights reserved.
Any reproduction or unauthorized! use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
P/N LIT-11616-MC-B0
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

l
~ Serviceable with engine mounted
®
Molybdenum disulfide oil

l
~ Filling fluid
~
Gear oil

1
B Lubricant
~
Brake fluid

~ Special tool
~ Wtneel bearing grease

~ Tightening torque
~ Lithium-soap-based grease

~ Wear limit, clearance

-«M»I Molybdenum disulfide grease

[g Engine speed
~ Silicone grease

l.
[i]] Electrical data
A Apply locking agent (LOCTITE®).

l Engine oil
l~N Replace the part with a new one.
®
 CONTENTS

IMPORTANT INFORMATION ............................................................................ 1

PREPARATION FOR REMOVAL AND DISASSEMBLY .............................. 1
REPLACEMENT PARTS ....................... ................... ................................ .... 1
GASKETS, OIL SEALS AND O·RINGS ....................................................... 1
LOCK WASHERS/PiLATES AND COTTER PINS ........................................ 1
BEARINGS AND OIL SEALS ....................................................................... 2
CIRCLIPS ..................................................................................................... 2
REASSEMBLY OF PARTS USING LOCKING AGENT (LOCTITE®) .......... 2
RUBBER PARTS .......................................................................................... 2

BASIC SERVICE INFORMATION ..................................•................................... 3

QUICK FASTENERS .................................................................................... 3
ELECTRICAL SYSTEM................................................................................ 4
GENERAL T IGHTENING TORQUE SPECIFICATIONS .............................. 8
ADJUSTING THE WHEEL STATIC BALANCE ............................................ 9
CHECKING THE SWITCHES .................................................................... 10
CHECKING THE BULBS AND BULB SOCKETS ...................................... 10
CHECKING AN D CHARGING THE BATTERY .......................................... 12

TROUBLESHOOTING....................................................................................... 16
GENERAL INFORMATION ................................................................ ........ 16
TROUBLESHOOTING OF ENGINE (fault code not detected) ................... 16
TROUBLESHOOTING OF CLUTCH .......................................................... 27
TROUBLESHOOTING OF TRANSMISSION ............................................. 30
TROUBLESHOOTING OF COOLING SYSTEM ........................................ 31
TROUBLESHOOTING OF BRAKE ............................................................ 32
TROUBLESHOOTING AT ABS WARNING LIGHT.................................... 33
TROUBLESHOOTING OF SUSPENSION ................................................. 34
TROUBLESHOOTING OF STEERING/HANDLING .................................. 36
TROUBLESHOOTING OF CHARGING SYSTEM ..................................... 37
TROUBLESHOOTING OF LIGHTING SYSTEM........................................ 37
TROUBLESHOOTING OF SIGNALING SYSTEM ..................................... 37
 IMPORTANT INFORMATION

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

GASKETS, OIL SEALS AND 0-RINGS

1. When overhauling the engine, replace all
gaskets, seals and 0 -rings. All gasket surfac-
es, oil seal lips and 0-rings must be cleaned.
2. During reassembly, property oil all mating
parts and bearings and lubricate the oil seal
2. Use only the proper tools and cleaning equip-
lips with grease.
ment.
Refer to "SPECIAL TOOLS" in the applicable

~
service manual.
3. When disassembling, always keep mated 2- ---i~ '---.
parts together. This includes gears, cylinders,
j
pistons and other parts that have been "mat- 1-
ed'' through nom,al wear. Mated parts must
always be reused or replaced as an assem- 4
bly.

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

LOCK WASHERS/PLATES AND COTTER

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

REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.

1
 IMPORTANT INFORMATION

BEARINGS AND OIL SEALS REASSEMBLY OF PARTS USING LOCKING

Install bearings "1" and oil seals "2" so that the AGENT (LOCTITE®)
manufacturer marks or numbers are visible. Before reassembling screws, bolts, and nuts, or
When installing oil seals, lubricate the oil seal other parts, using locking agent (LOCTITE®),
lips with a light coat of lithium-soap-based remove all the old locking agent, and then apply
grease. Oil bearings liberally when installing, if new locking agent and reassemble the parts. Al-
appropriate. so, a specified amount of time is required for tlhe
ECA13300
locking agent to cure.
NOTICE
-------------
Do not spin the bearing with compressed air RUBBER PARTS
because this will damage the bearing surfac- Check rubber parts for deterioration during in-
es. spection. Some of the rubber parts are sensitive
to gasoline, flammable oil, grease, etc. Do not al-
low any items other than the specified one to
contact the parts.

CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al-
ways replace piston pin clips after one use.
When installing a circlip "1 ", make sure the
sharp-edged corner "2" is positioned opposite
the thrust "3" that the circlip receives.

2
 BASIC SERVICE INFORMATION

BASIC SERVICE INFORMATION

QUICK FASTENERS

Rivet type
1. Remove:
• Quick fastener
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
To remove the quick fastener, push its pin with a
screwdriver, then pull the fastener out.

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

2. Install:
• Quick fastener
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
To install the quick fastener, push its pin so that
it protrudes from the fastener head, then insert
the fastener into the part to be secured and push
the pin "a" in with a screwdriver. Make sure that
the pin is flush with the fastener's head. 2. Install:
• Quick fastener
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
To install the quick fastener, insert the fastener
into the part to be secured and tighten the screw.

3
 BASIC SERVICE INFORMATION

Screw type 2
1. Remove:
• Quick fastener
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
1J
"~
To remove the quick fastener, loosen the screw
with a screwdriver, then pull the fastener out.

ELECTRICAL SYSTEM

Electrical parts handling

ECA16000

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

2. Install:
• Quick fastener ECA16761

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ NOTICE _ _ _ _ _ _ _ _ _ _ __

To install the quick fastener, insert the fastener When disconnecting the battery leads from
into the part to be secured and tighten the screw the battery, b e sure to disconnect the nega-
"a". tive battery lead first, then the positive bat-
tery lead. If the positive battery lead is
disconnected first and a tool or similar item
contacts the vehicle, a spark could be gener-
ated, which is extremely dangerous.

4
 BASIC SERVICE INFORMATION

TIP_ _ _ _ _ _ _ _ _ _ _ __
NOTICE
If a battery lead is difficult to disconnect due to ---:-"7""'.~-,,-------
Turn the main switch to " OFF" before dis-
rust on the battery terminal, remove the rust us-
connecting or connect.ing an electrical com-
ing hot water.
ponent.

ECA1.ml0
ECA16600
NOTICE
---~~---:-------
Be sure to connect the battery leads to the
NOTICE
,--::-::-- ; - - - : - - - - - - - - , - - - -
Handle electrical components with special
co:r rect battery terminals. Reversing the bat•
tery lead connect.ions could damage the care, and do not subject them to strong
shocks.
electrical components.

ECA16G30
ECA1Q71
NOTICE
NOTICE ,------,--------
---:-:---:----:--------- Electrical components are very sensitive to
When connecting the battery leads to the
and can be damaged by static electricity.
battery, be sure to connect the positive bat-
Therefore, never touch the terminals and be
tery lead first, then the negative battery lead.
sure to keep the contacts clean.
If the negative battery lead is connected first
and a tool or similar item contacts the vehi•
cle while the positive battery lead is being
connected, a spark could be generated
which is extremely dangerous. '

5
 BASIC SERVICE INFORMATION

TIP ••
When r ·otrng tho ecu by 1ur ·., 1he main NOTICE -------,-------:-----:-:--~
s.'A\kh to "OFF', be sure ,o via t epproxmatsly 5
FOf waterproot couplers, never s«t l he
oondt. belore turr· 1ho mt-1in S"litcfi k to
t vr probo& directly ln'tq 1ho ~O'-l~ r . Whon

-ON•. pertormlng any chedcs u sing a waterproo4

couplor, uto tho spocified tN-1 hamoss or ·
sultable c ommerclalJy avallsble test har-
noss,

Checlcing the elecb'lcal 9Ystem

TIP
Belo,e ched<ttg the elecltlcsl sys1em, make
Checlclng Ulle conne,cttons
sure ai 0 betiery 1t'olU9J cs at lea.st t 2 V
Check the leads. cot.1p\ers, and oonnectors tor
sr.&ns rust, mOlstu,e. etc.
Dt&COnnect·
• Laed
• C<xspler
• Cctlnector

NOTICE ----------:------:-:~
• Wh n disconnoc;1in9a~ou~ r, r lease th
coupler Ioele, he>ed bOth secdon:9 Of 1he COU·
pier MC ly, .-nd then dls~oooc1 ttlO ~ou•
C, •
pier.
NOTICE-------:---:----:-:---- • Thero- many types of couplor loc:lls;
Never insert 1he teater probes nto the oou- therefore. be sure to cbedc the type o cou-
plet terminal slots. Alwevs insert 1he probes pler loo boforo disoonnocung tho coupler.
from the opp011ite end ..a" of lhe ooupler, ~k•
149 care not to lo osen o t datnage the INdL
 BASIC SERVICE INFORMATION

• Aal<e SIR cJ I COMeC1ioAS aro ghl

NOTICE
------------
WhM dlsoonfted ng a connector. do not pull
the lead&. Hold bo1h section& of 1he oonnec,-
tor HCUtely. and then dlSCOM&et the OOA-
nector.

4 . Cbecic.
• Cont uity
,~ lfle dlgllal c IC 11 tester (C0732))

Digital ,c-irct.1il t•ste, fCD732)

9081MM)02. 3
2. CtEc · Model 88 M'-'llin'ICCcr wi•h la,•
chometet
•L ,d
YU-A1927
• Coupler
• C-Orln ot TIP
s1ure ➔ Ory i. ~th a ai blo'A'er • 1r thor- ~ no co ir ~ty cl ~n lh • , rf I
~ I, IJin" -4 C I i'ICCI nd di~or ce1
• When check1ng wire hames9, pe,to,m
eral t'Tl88. slop•· (1) 1o (4).
• A.s a quick remedy, U9e a 00fl1act rev mlizer
i!V' Jblc 01 no~ purt stor

3. CQrln
• Leed
• Coopler
• Catnecto1
TIP
• When oonnec g a oo~feror connector. push
bo( , · e1ions or th cxx._,plcr or CCf'lnoctor 10-
gether 1a1t they a,e oo!'W1e01ed seoorely_

7
 BASIC SERVICE INFORMATION

GENERAL TIGHTENING TORQUE

SPECIFICATIONS
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread pitch.
Refer to the applicable service manual for tight-
ening torque specifications of special compo-
nents or assemblies. To avoid warpage, tighten
multi-fastener assemblies in a crisscross pattern
and progressive stages until the specified tight·
ening torque is reached. Unless otherwise spec-
5. Check: ified, tightening torque specifications require
• Resistance clean, dry threads. Components should be at
room temperature.
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
The resistance values shown were obtained at
the standard measuring temperature of 20 °C
(68 °F). If the measuring temperature is not 20
°C (68 °F), the specified measuring conditions A. Distance between flats
will be shown. B. Outside thread diameter

Intake air temperature sensor re- General tightening

B torques
sistance A (nut)
(bolt)
5.40--6.60 kn at 0 0 c (32 °F) N•m kgf•m lb•ft
290-390 Q at 80 °C (176 °F)
10mm 6mm 6 0.6 4.4
12mm 8mm 15 1.5 11
14mm 10mm 30 3 22
17mm 12 mm 55 5.5 41
19mm 14mm 85 8.5 63
22mm 16mm 130 13 95.9

8
 BASIC SERVICE INFORMATION

ADJUSTING THE WHEEL STATIC BALANCE TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ Start with the lightest weight.
• After replacing the tire, wheel or both, the
wheel static balance should be adjusted.
• Adjust the wheel static balance with the brake
disc installed.

1. Remove:
• Balancing weight(s)
2. Find:
• Wheel's heavy spot
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Place the wheel on a suitable balancing stand.
b. Tum the wheel go 0 so that the heavy spot is
a . Spin the wheel. positioned as shown.
b. When the wheel stops, put an "Xi" mark at
the bottom of the wheel.

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

tion, install a heavier weight.
c. Turn the wheel go 0 so that the "Xi" mark is d. Repeat steps (b) and (c) until the wheel i s
balanced.
positioned as shown.
d. Release the wheel . 4. Check:
e . When the wheel stops, put an "X2" mark at • Wheel static balance
the bottom of the wheel. a. Tum the wheel and make sure it stays at
each position shown.
X

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

until all the marks come to rest at the same b. If the wheel does not remain stationary at all
spot. of the positions, rebalance it.
g. The spot where all the marks come to rest is
the wheel's heavy spot "X".
3. Adjust:
• Wheel static balance
a . Install a balancing weight "1 " onto the rim
exactly opposit e the heavy spot "X".

9
 BASIC SERVICE INFORMATION

CHECKING THE SWITCHES

Check each switch for continuity with the digital b
circuit tester. If the continuity reading is incor-
rect, check the wiring connections and if neces-
sary, replace the switch.
ECA143'71

NOTICE
-------------
Never insert the tester probes into the cou-
pler terminal slots. Always insert the probes
from the opposite end "a" of the coupler, tak•
ing care not to loosen or damage the leads.
CHECKING THE BULBS AND BULB
SOCKETS
Digital circuit tester (CD732) Check each bulb and bulb socket for damage or
90890-03243 wear, proper connections, and also for continuity
Model 88 Multimeter with ta• between the terminals.
chometer Damage/wear ➔ Repair or replace the bulb,
VU-A1927 bulb socket or both.
Improperly connected ➔ Properly connect.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
No continuity ➔ Repair or replace the bulb, bulb
• Before checking for continuity, set the digital socket or both.
circuit tester to the "n" range.
• When checking for continuity, switch back and Types of bulbs
forth between the switch positions a few times. The bulbs used on this vehicle are shown in the
following illustration.
• Bulbs "a" and "b" are used for the headlights
and usually use a bulb holder that must be de-
tached before removing the bulb. The majority
of these types of bulbs can be removed from
their respective socket by turning them coun-
terclockwise.
• Bulbs "c" are used for turn signal lights and can
be removed from the socket by pushing and
turning the bulb counterclockwise.
• Bulbs "d" and "e" are used for license plate and
The terminal connections for switches (e.g., auxiliary lights and can be removed from their
main switch, engine stop switch) are indicated in respective sockets by carefully pulling them
an illustration as shown in the following exam-
out.
ple.
The switch positions "a" are shown in the far left
column and the switch lead colors "b" are shown
in the top row in the switch illustrati'on.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
" 0----0 " indicates a continuity of electricity be-
tween switch terminals (i.e., a closed circuit at
the respective switch position).
The example illustration below shows that:
There is continuity between red/white, brown/
blue and brown/red when the switch is set to
"ON".
There is continuity between red/white and
brown/red when the switch is set to "PE".

10
 BASIC SERVICE INFORMATION

Digital circuit tester (CD732)

a b 90890-03243
Model 88 Multimeter with ta-
chometer
VU-A1927

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Before checking for continuity, set the digital cir-
cuit tester to the "Q " range.

a. Connect the positive tester probe to termi-

nal "1" and the negative tester probe toter-
minal "2", and check the continuity.
b. Connect the positive tester probe to termi-
nal "1" and the negative tester probe to ter-
minal "3", and check the continuity.
e~ . c. If either o f the readings indicate no continu-
I
ity, replace the bulb.

Checking the condition of the bulbs

The following procedure applies to all of the
bulbs.
1. Remove:
• Bulb
EWA tl333'l

A WARNING
Since the headlight bulb gets extremely hot,
keep flammable products and your hands Checking the condition of the bulb sockets
away from the bulb until it has cooled down. The following procedure applies to all of the bulb
ECA14381
sockets.
NOTICE 1. Check:
-------------
• Be sure to hold the socket firmly when re- • Bulb socket (for continuity)
moving the bulb. Never pull the lead, other- (with the digital circuit tester)
wise it may be pulled out of the terminal in No continuity ➔ Replace.
the coupler.
• Avoid touching the glass part of a headlight Digital circuit tester (CD732)
bulb to keep it free from oil, otherwise the 90890-03243
Model 88 Multimeter with ta-
transparency of the glass, the life of the
chometer
bulb, and the luminous flux will be adverse- VU-A1927
ly affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
with alcohol or lacquer thinner.
Check each bulb socket for continuity in the
2. Check: same manner as described in the bulb section;
• Bulb (for continuity) however, note the following.
(with the digital circuit tester)
No continuity ➔ Replace. a. Install a good bulb into the bulb socket.
b. Connect the digital circuit tester probes to
the respective leads of the bulb socket.

11
 BASIC SERVICE INFORMATION

c. Check the bulb socket for con1inuity. If any siderably. Therefore, take special care
of the readings indicate no continuity, re- when charging the battery.
place the bulb socket.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
CHECKING AND CHARGING THE BATTERY Since VALA (Valve Regulated Lead Acid) bat-
EWA1!3:200
teries are sealed, it is not possible to check the
A WARNING charge state of the battery by measuring the
Batteries generate explosive hydrogen gas specific gravity of the electrolyte. Therefore, tlhe
and contain electrolyte which is made of poi- charge of the battery has to be checked by mea-
so:nous and highly caustic sulfuric acid. suring the vo ltage at the battery terminals.
Therefore, always follow these preventive
measures: 1. Check:
• Wear protective eye gear when handling or • Battery charge
working near batteries. a. Connect a digital circuit tester to the battery
• Charge batteries in a well-ventilated area. terminals.
• Keep batteries away from fire, sparks or
• Positive tester probe ➔
open flames (e.g., welding equipment, positive battery terminal
lighted cigarettes). • Negative te ster probe ➔
• DO NOT SMOKE when charging or han• negative battery terminal
d ling batteries.
• KEEP BATTERIES AND ELECTROLYTE TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
OUT OF REACH OF CHILDREN.
• The charge state of a VALA (Valve Regulated
• Avoid bodily contact with electrolyte as it
Lead Acid) b attery can be checked by measur-
can cause severe burns or permanent eye
ing its open -circuit voltage (i.e., the voltage
injury.
when the positive battery terminal is discon-
FIRST AID IN CASE OF BODILY CONTACT:
nected).
EXTERNAL
• No charging is necessary when the open-cir-
• Skin - Wash with water.
cuit voltage equals or exceeds 12.8 V.
• Eyes - Flush with water for 15 minutes and
get immediate medical attention. b. Check the charge of the battery, as shown
INT ERNAL in the charts and the following example.
• Drink large quantities of water or milk fol-
Example
lowed with milk of magnesia, beaten egg or
Open-circuit voltage = 12.0 V
v,egetable oil. Get immediate medical atten-
Charging time = 6.5 hours
tion. Charge of the battery = 20-30%
VRLA type battery
ECA13661
A
NOTICE
-------------
• This is a VRLA (Valve Regulated Lead Acid)
13.0

12.5
battery. Never remove the sealing caps be•
cause the balance between cells will not be
maintained and battery performance will
11.5
deteriorate.
• Charging time, charging amperage and
charging voltage for a VALA (Valve Regu- 5 6.5 10 B
lated Lead Acid) battery are different from
D
those of conventional batteries. The VRLA A. Open-circuit voltage (V)
(Valve Regulated Lead Acid) battery should B. Charging time (hours)
be charged according to the appropriate C. Relationship between the open-circuit volt-
charging method. If the battery is over- age and the charging time at 20 °c (68 °F)
D. These values vary with the temperature, the
charged, the electrolyte level will drop con-
condition of the battery plates, and the elec-
trolyte level.

12
 BASIC SERVICE INFORMATION

.-1.1tvd ~ ~<:id) bahry s.1.lbilil. , abO\ft

,.A 30 mlnuies after charglng has been com-
u - plet d. ~ orv, v, • 30 mlnut att.i,
C cbarg ng la completed before measuring
1ho opon<irouit votms,o.

A C
If.
0
_ _ __ _ __,__ I ___,t _ __ B IT
Ill. ,CJ I ~ r, 1(,

A. Opcr1-e1tu1t volt.lgo (\! ,I ,~

I!>

B CNrQlf'Q CO'lcl tor or the battery (%) l;J

C Amb10flt to~C";) ~ 20 C (. 'F) •t

II
H)
n '11 :u w
2. Chafge! B
l+e
• Battery
(tefet to the appropltale cha19ng ~hOd) A. 0-,>l!fl-O c t voltage (V)
• I 8 . Timr. (m l.tc!!i)
A WARNl ~G C Cl'aftjlng
Do not qu.ck charvo a batt ry, o Ambxw 1 "'P~hrr 20 ·c r,e -F)
E. Check ttie opef\-drclJlt vollag~.
NOTICE
-----------~-
• De> not use a hjgtwate, battery charger
Ct\arging method using a "8r lable--cewtent
(voltage) charQ!lf
$lnoo tt forces a h igh--ampof ilSJ •c1Kront A. M •• ~r· 0 ·Cl•C,. • VOii g prior lo
Int<> the battery quLCICly al'ICI can cause bat- ctiargirg
Ulf'Y ov rhcatiing and battery p ta damage. TIP
• 11 lt Is l mpoealble lo tegulate ll'le chatglng
Va~ sho d be measured 30 minutes a r
cumrnt on ho battery dlarvor1 bo c;Moful lh ngl . • • lopped
not to overchatge Ille battety.
• When chargln9u batt.-y, bo$Uroto r-,ove b. Coonect a cha,ve and ammeter 401he ba1-
It Item the vehj cle. (Ir charging has to ~ y , nc, fl etl:ug '9
done wilh 1ho battery mountod on tho VGbi• TIF>_ _ _ _ _ _ _ _ _ _ _ _ _ __
de, dlaeoMKt the nega1i~ battery ll!ad Se1 l . <:l'lar9r1g \IO ;,ge- to 16-17 V. 11 1h siet-
from tho battery lorminal.) ting is Ner. ct.arging ,-.ill be in&J~icient I too
• To reduce lbe chance or spa~, do not h~ IP\ l1 ,Y W ti& O\• 1·CI rg .
pltJ9 in tho battory cha'9or until tho battery
charge, leads •~ c.onneded to lhe battecy. c. Make sure Iha lhe current tS higher than
• Before removing the battety charver INd (! !l ntlard c ryl"-'.) 01 •r nl v,rltt . o
d i~ r,om the batt«y terml!Mls, be sure to battey.
tum off Cha battwy cha1"99r,
• Make su,e tl'le baltety ebarget lead clif)s are s1ardard char g
In full c:onl act with the battery term nal a nd Wtr001 \\' t1 n on I . I 1\1, s t lh ell. tglf'9
that theyi are not shorted. A oort0ded bal·
1
voltage adjust al a 20-24 V ard mon or the
1...-y eharger lead d ip may genera,, heat In amp • 9 . 1o1 l-5 mln1..1 ~ 10 d'l .d< . bftlh ry
'tibe contact area and a weak clip 9f)ting tnay
cause &parts, • Standard oo.a g current 1s reached
• II ~ batte-ty becomes bot tC> 'tibe tOUCft at Ball•ry ,s good
any 1ime d uring 1he charging proce&&, dis- • St, ncJard "I Ct.Jtt nl ~ 'I01 , ., CM<I
c-onneel the battery charger and t the bal· Re piece the ba.1tery.
twy cool beiofe reconnecting Hot
battetles can eitplod&! d.. Ad1"8t. 1he ~tage so lhat 1he currant 18 at
• .As shown the following IIU&tra11on.. lhe . 8l1md, rd cha19-'lg I .W!'
open-circuit \loltage of a VRLA (Valve R~-

13
 BASIC SERVICE INFORMATION

e . Set the time according to the charging time Open type battery
suitable for the open-circuit voltage. 1. Check:
I. If charging requires more thani 5 hours, it is • Electrolyte level
advisable to check the charging current af- The electrolyte level should be between the
ter a lapse of 5 hours. If there is any change minimum level mark "a" and the maximum
in the amperage, readjust the voltage to ob- level mark "b".
tain the standard charging current. Below the minimum level mark ➔ Add dis-
g . Measure the battery open-circuit voltage af- tilled water to the proper level.
ECA1351Q
ter leaving the battery unused for more than
NOTICE
30 minutes.
-------------
Add only distilled water. Tap water contains
12.8 V or more --- Charging is com plete.
minerals which are harmful to the battery.
12.7 V or less --- Recharging is required .
Under 12.0 V --- Replace the battery.

Charging method using a con stant volt- ~ t E , n- _ ....,__ b

8 - -"'-'Efll.tVE!. - - +-- a
age charger
a. Measure the open-circuit voltage prior to
charging.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Vo ltage should be measured 30 minutes after
the engine is stopped.
2. Check:
b. Connect a charger and ammeter to the bat- • Specific gravity
tery and start charging. Less than 1.28 ➔ Recharge the battery.
c . Make sure that the current is higher than
the standard charging current written on the Specific gravity
battery. 1.28
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
If the current is lower than the standard charging 3. Charge:
current written on the battery, this type of battery • Battery
charger cannot charge the VRLA (Valve Regu- Battery charging amperage and time
lated Lead Acid) battery. A variable voltage Refer to "ELECTRICAL SPECIFICATIONS"
charger is recommended. in the applicable service manual.

d . Charge the battery until the battery's EWAt3300

charging voltage is 15 V. A WARNING

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ Do not quick charge a battery.
Set the charging time at 20 hours (maximum). ECA136®

NOTICE
e . Measure the battery open-circuit voltage af-
ter leaving the battery unused for more than
-------------
• Loosen the battery sealing caps.
30 minutes. • Make sure the battery breather hose and
battery vent are free of obstructions.
12.8 V or more --- Charging is com plete. • To ensure maximum performance, always
12.7 V or less --- Recharging is required .
charge a new battery before using it.
Under 12.0 V --- Replace the battery.
• Do not use a high-rate battery charger.
They force a high-amperage current into
the battery quickly and can cause battery
overheating and battery plate damage.
• If it is impossible to regulate the charging
current on the battery charger, be carefu l
not to overcharge the battery.

14
 BASIC SERVICE INFORMATION

• When charging a battery, be sure to remove

it from the vehicle. (H charging has to be
done with the battery mounted ,on the vehi•
cle, disconnect the negative lead from the
battery terminal.)
• To reduce the chance of sparks, do not
plug in the battery charger until the battery
charger leads are connected to the battery.
• Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.
• Make sure the battery charger lead clips are
in full contact with the battery terminal and
that they are not shorted. A corroded bat-
tery charger lead clip may generate heat in
the contact area and a weak clip spring may
cause sparks.
• If the battery becomes hot to the touch at
any time during the charging process, dis-
connect the battery charger and let the bat-
tery cool before reconnecting it. Hot batter-
ies can explode!
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Replace the battery whenever:
• battery voltage does not rise to specification or
b ubbles fail to rise during charging,
• sulphation of one or more battery cells occurs
(as indicated by the battery plates turning white
or material accumulating in the bottom of the
battery cell),
• specific gravity readings after a long, slow
charge indicate that one battery cell's charge is
lower than the rest,
• warpage or buckling of the battery plates or in-
sulators is evident.
4. Check:
• Battery breather hose and batte•ry vent
Obstruction ➔ Clean.
Damage ➔ Replace.

15
 TROUBLESHOOTING

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

TROUBLESHOOTING OF ENGINE (fault code not detected)

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
If a fault code is detected, refer to the "ECU SELF-DIAGNOSTIC FUNCTION" under "FUEL INJEC-
TION SYSTEM" (ELECTRICAL SYSTEM) in the Service manual.

Engine does not crank.

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

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

16
 TROUBLESHOOTING

Symptom Possible cause Actions

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

17
 TROUBLESHOOTING

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

18
 TROUBLESHOOTING

Symptom Possible cause Actions

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

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

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

19
 TROUBLESHOOTING

Symptom Possible cause Actions

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

20
 TROUBLESHOOTING

Incorrect idling speed (carburetor models)

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

21
 TROUBLESHOOTING

Symptom Possible cause Actions

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

22
 TROUBLESHOOTING

Incorrect mid-high speed (carburetor models)

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

23
 TROUBLESHOOTING

Symptom Possible cause Actions

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

24
 TROUBLESHOOTING

Excessive noise from engine

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

25
 TROUBLESHOOTING

Symptom Possible cause Actions

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

26
 TROUBLESHOOTING

TROUBLESHOOTING OF CLUTCH

Ma nual clutch

Symptom Possible cause Actions

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

27
 TROUBLESHOOTING

Symptom Possible ca use Actions

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

28
 TROUBLESHOOTING

V-belt automatic transmission

Symptom Possible cause Actions

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

29
 TROUBLESHOOTING

Symptom Possible cause Actions

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

TROUBLESHOOTING OF TRANSMISSION

Symptom Possible cause Actions

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

30
 TROUBLESHOOTING

TRO UBLESHOOTING OF COOLING SYSTEM

Symptom Possible cause Actions

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

31
 TROUBLESHOOTING

Symptom Possible cause Actions

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

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

32
 TROUBLESHOOTING

Symptom Possible cause Actions

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

TROUBLESHOOTING AT ABS WARNING LIGHT

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

33
 TROUBLESHOOTING

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

34
 TROUBLESHOOTING

Symptom Possible cause Actions

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

35
 TROUBLESHOOTING

TROUBLESHOOTING OF STEERING/HANDLING
Symptom Possible cause Actions
Handlebar wobble Loose lower ring nut Tighten the lower ring nut to the
specified torque.
Worn bearing or bearing race Replace the bearing and bear-
ing race as a set.
Warped front fork Repair or replace the front fork.
Bent front wheel axle Replace the front wheel axle.
Incorrect tire pressure Adj ust to the specified tire pres-
sure.
Worn, deformed, or incorrect tire Replace the tire.
Heavy steering Lower ring nut is tightened too Tighten the lower ring nut to th e
1ight. specified torque.
Bent lower bracket Replace the lower bracket.
Broken bearing or bearing race Replace the bearing and bear-
ing race as a set.
Incorrect tire pressure Adjust to the specified tire pres-
sure.
Front wheel vibration Incorrect wheel balance Adjust the wheel balance.
Deformed wheel (cast wheel, Replace the wheel.
pressed wheel)
Loose spoke (spoke wheel) Tighten the spoke and adjust
the runout.
Damaged or worn wheel bearing Replace the wheel bearing.
Worn, deformed, or incorrect tire Replace the tire.
Loose wheel axle or wheel axle Tighten the wheel axle or wheel
nut axle nut to the specified torque.
Loose wheel axle pinch bolt Tighten the wheel axle pinch
bolt to the specified torque.
Incorrect front fork oil level Adjust to the specified front fork
oil level.
Rear wheel vibration Incorrect wheel balance Adjust the wheel balance.
Deformed wheel (cast wheel, Replace the wheel.
pressed wheel)
Loose spoke (spoke wheel) Tighten the spoke and adjust
the runout.
Damaged or worn wheel bearing Replace the wheel bearing.
Worn, deformed, or incorrect tire Replace the tire.
Loose wheel axle nut Tighten the wheel axle nut to
the specified torque.
Loose swingarm pivot shaft Tighten the swingarm pivot
shaft to the specified torque.
Bent or damaged swingarm Replace the swingarm bearing.
Damaged or worn swingarm Replace the swingarm bearing
bearing or bushing or bushing.

36
 TROUBLESHOOTING

TROUBLESHOOTING OF CHARGING SYSTEM

Symptom Possible cause
I Actions
Battery is not charged Refer to ''TROUBLESHOOTING" under "CHARGING SYSTEM"
(ELECTRICAL SYSTEM) in the Service manual.

TROUBLESHOOTING OF LIGHTING SYSTEM

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

TROUBLESHOOTING OF SIGNALING SYSTEM

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

37
OYAMAHA
 ~YAMAHA 2021
SERVICE MANUAL

MT-09
MT-09SP

MT09M
MT09MC
MT09SPM
MT09SPMC
LIT-11616-34-61 B7N-28197-10
EAS,0000

IMPORTANT
This manual was produced by 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 manual.
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-
nifi cant 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.

EAS3Cl001
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 ithat 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.

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

MT09M/MT09MC/MT09SPM/MT09SPMC
SERVICE MANUAL
©2021 by Yamaha Motor Corporation, U.S.A.
First edition, December 2020
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
PIN LIT-11616-34-61
..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

CLUTCH CLUTCH

CLUr cH f&ii:)11110 M: CI.UTCH

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h w;:,no t<,No,Jo••llho.01,1,.-11_, ...,
t. !Y~;t1",c,·:tio<1,•:1t~ ,.,.,~-~-.

::;:~1:.:=::;~~t~c1S00◄,.,~w.-
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0,1 ,I >:t:d"uiS:.. _. n;~1, 1' 1> ►,:S:~,
, . .1,<, .. , ......

'-F:cllC'• !:
• ~,...... •1·
'.,..,.,~ CHE::11me 11-1s OOJ"'()4A.Al'U
•:1;#11>:,(;l~ai· i · lrtl,:k-1.t'>):ro«-:1.~ICl.*~".l)d ell'~
•0'1,w oo1,:c1.i•
il,.d,"'"''·

....
G088877
EA""""'5

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

l
~ Serviceable with engine mounted
~
Gear oil

~ Filling fluid
1 Molybdenum disulfide oil
~
1
B Lubricant
~
Brake fluid

~ Special tool
~ Wtneel bearing grease

~ Tightening torque ~ Lithium-soap-based grease

~ Wear limit, clearance ~ Molybdenum disulfide grease

[g Engine speed
~ Silicone grease

.!.
[iill Electrical data
A Apply locking agent (LOCTITE®).

1
®
Engine oil
l~il~I Replace the part with a new one.
TABLE OF CONTENTS
GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND

ADJUSTMENTS

CHASSIS

ENGINE

COOLING SYSTEM

FUEL SYSTEM

ELECTRICAL SYSTEM

SELF DIAGNOSTIC
 GENERAL INFORMATION

IDENTIFICATION ............................................................................................ 1·1

VEHICLE IDENTIFICATION NUMBER ..................................................... 1·1

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

FEATURES ...................................................................................................... 1•2

GLOSSARY ............................................................................................... 1-2
DISPLAY ................................................................................................... 1-2

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

ELECTRICAL SYSTEM ............................................................................. 1-9

SPECIAL TOOLS .......................................................................................... 1-10

 IDENTIFICATION

EA""""'7

IDENTIFICATION

"'"""""
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number "1" is stamped
into the right side of the steering head pipe.

EAS3Clel00
MODEL LABEL
The model label "1" is affixed to the frame under
the seat. This information will be needed to order
spare parts.

1-1
 FEATURES

EA""""'8
E\VA18210
FEATURES
A WARNING
EAS3170S Stop the vehicle before making any setting
GLOSSARY changes. Changing settings while riding can
ABS - Anti-lock Brake System distract the operator and increase the risk of
ABS ECU - Anti-lock Brake System Electronic an accident.
Control Unit
BC - Brake Control Speedometer
ECU - Engine Control Unit The speedometer shows the vehicle's traveling
LIF - Lift Control System speed.
OS - Quick Shift TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
SCS - Slide Control System The display c-an be switched between kilometers
TCS - Traction Control System and miles.
EAS317'0'7 Tachometer
DISPLAY The tachometer shows the engine speed, as
The following items can be found on the display: measured by the rotational velocity of the crank-
1 2 shaft, in revolutions per minute (r/min).
ECA190&0
1· 3 NOTICE
-------------
Do not operate the engine in the tachometer
4
red zone.
10 Vehicle information displays
I I
9 8 7 6
~ I -11
{ I ~

-15 14 13 12
1. Tachometer
2. Speedometer
3. Quick shift Indicator "OS"
4. Transmission gear display
5. Vehicle information displays 1. Vehicle information displays
6. Settings MENU icon "Q "
The two vehicle information displays can be indi-
7. Grip warmer indicator (option)
vidually set to show the following items:
8. Brake control icon "BC"
• ODO: odometer
9. Clock
• F-TRIP: fuel reserve tripmeter
10. MODE display
• TRIP1: tripmeter
11. Lap timer
• TRIP2: tripmeter
12. Oil pressure warning •~ "
• F.AVE: ave-rage fuel economy
13. Coolant temperature warning " .f. "
• F.CRNT: instantaneous fuel economy
14. Auxiliary system warning "\)-a •
• A.TEMP: air temperature
15. Error mode warning "Err" (replaces clock
when activated) • C.TEMP: coolant temperature
• Fuel meter
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ • FUELCON: amount of fuel consumed
This model uses a thin-film-transistor liquid-crys- • TRIPTIME: running time
tal display (TFT LCD) for good contrast and Operate the vehicle information display as fol-
readability in various lighting conditions. Howev- lows:
er, due to the nature of this technology, it is nor-
mal for a small number of pixels to be inactive.

1-2
 FEATURES

Rotate the wheel switch to move the cursor over MODE display
a display.
Push the wheel switch inward and the selected
display will highlight gray.
Rotate the wheel switch to choose a different
display item.
Push the wheel switch inward to confirm the new
display item.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• ODO will lock at 999999 and cannot be reset.
• TRIP1 and TRIP2 will reset to O and begin
This display shows the currently selected "D-
counting again after 9999.9 has been reached.
MODE" and ''TCS-MODE" settings. The mode
• When the fuel tank reserve level has been
that is enlarged and displayed on the right can
reached, F-TRIP appears automatically and
be adjusted using the MODE up/down switches.
begins recording distance traveled from that
Use the "MODE" switch to toggle left-right be-
point.
tween "TCS-MODE" and "D-MODE".
• After refueling and traveling some distance, F-
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
TRIP will automatically disappear.
• See "Unit'' to change the fuel consumption • When the malfunction indicator light "C •, tlhe
units. auxiliary system warning"~ ", or the coolant
• The air temperature is displayed from -9 °C
temperature warning " ,t " are on, "D-MODE"
(16 °F) to 50 °C (122 °F) in 1 °C (1 °F) incre-
and "TCS-MODE" cannot be adjusted.
ments.
• The previously selected modes will be dis-
• The air temperature displayed may vary from
played when the vehicle power is turned on.
the actual ambient temperature.
• In LAP TIME mode, the vehicle information dis- To turn off the traction control system, select
play is replaced by the lap information. "TCS-MODE" with the "MODE" switch, then
• TRIP1, TRIP2, F-TRIP, F.AVE, FUELCON and push and hold the MODE up switch until "OFIF''
TRIPTIME items can be individually reset. is displayed. To turn TCS back on, press the
• If the vehicle coolant temperature is below 40 MODE down switch (''TCS-MODE" will return to
°C (104 °F) the coolant temperature display will its previous setting).
read "Lo" TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• If the vehicle coolant temperature is above 124 • When ''TCS-MODE" has been set to "OFP',
°C (255 °F) the coolant temperature display will the TCS, SCS and LIF systems are all turned
read "Hi" off together.
To reset information display items • The ''TCS-MODE OFP' and ''TCSMODE M"
1. Rotate the wheel switch to select one of the settings can only be selected while the vehicle
two vehicle information displays.. is stopped.
2. Press the wheel switch inward to highlight the Clock
information display. The clock uses a 12-hour time system.
3. Rotate the wheel switch to select the desired Quick shift indicator "QS"
information display item.
When able to shift, the respective QS .A or T
4. Press and hold the wheel switch inward until
turns green.
the highlighted display item is reset.
When unable to shift, QS £::,. "v is white.
Transmission gear display
This shows which gear the transmission is in. If the QS function is turned OFF, QS £::,. "v itself
This model has 6 gears and a neutral position. is not displayed.
The neutral position is indicated by the neutral The QS functions can be turned on or off in the
indicator light "N " and by the transmission gear setting MENU.
display "N ".

1-3
 FEATURES

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ Lap timer

The upshift and downshift functions are inde- This stopwatch function can be activated
pendent and can be activated separately. through the setting MENU.
For more information on the QS system. Once activated, the vehicle information display
is replaced with:
Setting menu icon " O "
Choose this icon and push the wheel switch to ~1000 rlmin
3
6 7 9
change the settings MENU screen.

1 BGS...
1

Griip warmer indicator (Option) •

The grip warmers can be used when the engine
MPH
is running. There are 10 temperature levels. o . ...--.c.
When activated, the indicator will display the 1 UP02 00:12.34
2 ...,...,. 00:30.23
temperature level from 1 (lowest) to 10 (highest).
To activate the grip warmer, use the wheel
10: QQ lli1 0
switch to highlight the grip warmer display with
the cursor. 1. Lap count
Press the wheel switch inward to select the grip 2. Current lap time
warmer function. 3. LatesVPrevious lap time
O nce selected, rotate the wheel switch up and To start the ti'mer, push the dimmer/pass switch
down to adjust the temperature level. down towards "PASS".
Press the wheel switch inward to confirm the Each press of the dimmer/pass switch will in-
temperature level and exit the grip warmer func- crease the lap count by 1 and reset the current
tion. lap timer.
ECA17932
To pause the lap timer, press the wheel switch
NOTICE
-------------
• Be sure to wear gloves when using the grip
inward.
To unpause the timer, push the dimmer/pass
w armers. switch down towards "PASS" and the timer will
• Do not use the grip warmers in warm resume without counting a new lap.
weather. To exit the lap time mode, turn it off in the set-
• If the handlebar grip or throttle grip be- tings MENU.
comes worn or damaged, stop using the
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
9 rip warmers and replace the grips.
• The engine must be running to start the lap tim-
The function of the wheel switch can be locked er.
into grip warmer mode by pressing and holding • The headlights will flash when the dimmer/
the wheel switch inward while the grip warmer pass switch is pressed.
ind icator is highlighted by the cursor. • Whenever the lap timer is paused, it can be re-
In this mode, the temperature levels can be in- sumed using the dimmer/pass switch.
stantly adjusted by rotating the wheel switch up/
down. Brake control icon "BC"
To exit this mode and return the wheel switch to This icon is replaced by the auxiliary system
warning and coolant temperature warning ind i-
its normal functionality, press and hold the wheel
switch inward. cators when they are activated.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ Error mode warning "Err"
When an internal error occurs (e.g., communica-
The current grip warmer setting is saved when
tion with a system controller has been cut off),
the vehicle is turned off.
the error mode warning will appear as follows.
"Err" and "1® "indicator light indicates an ECU
error.
"Err" only indicates an ABS ECU error.

1-4
 FEATURES

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ Module Description

Depending on the nature of the error, the display
Exit MENU and re-
may not function property and TCS settings may "Exit''
tum the main display
be impossible to change. Additionallly, ABS may
not function properly. Use extra care when brak- Switch lap time
ing and have a Yamaha dealer check the vehicle mode on/off and ad-
"Display Setting"
just the tachometer
immediately.
color
Auxiliary system warning " ~ " Adjust TCS/SCS/LI F
"Manual TCS Set-
This icon appears if a problem is detected in a settings for the
ting"
non-engine-related system. "TCS-MODE M"
Coolant temperature warning " ,1, " Adjust BC/OS set-
"Vehicle Setting"
This icon appears if the coolant temperature tings
reaches 116 °C (241 ° F) or higher. Stop the ve- Turn the shift indica-
hicle and tum off the engine. Allow the engine to "Shift Indicator" tor on/off and adjust
cool. tachometer settings
ECA10'l22
View and reset main-
NOTICE "Maintenance"
-------------
Do not continue to operate the e ngine if it is
tenance intervals
Set fuel consumption
overheating.
"Unit'' and measurement
Oil pressure warning " <t::7: " units
This icon appears when the engine oil pressure Adjust screen bright-
"Brightness"
is low. When the vehicle is first turned on, engine ness
oil pressure has yet to build, so this icon will "Clock" Adjust the clock
come on and stay on until the engine has been
Return all settings to
started. "All Reset''
factory default
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
If a malfunction is detected, the oil pressure Settings MENU access and operation
warning icon will flash repeatedly. How to use tine settings MENU:
Rotate the wheel switch up or down to highlight
NOTICE items or increase/decrease values and briefly
-------------
Do not continue to operate the e ngine if the press the wheel switch inward to confim, the se-
oil pressure is low. lection.
Press and hold the wheel switch until the screen
Settings MENU returns to the main display to exit the MENU at
any time.
MENU TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
'- Exit • Certain settings menu screens have an up-
Display Setting ward pointing triangle mark item. Select the tri-
Manual TCS Setting angle mark to save settings changes and exit
Vehicle Setting the current screen.
Shift Indicator • Should vehicle motion be detected, the screen
10-00 0 MPH will automa1ically exit the settings MENU and
return to the main display.
The settings MENU screen contains the follow- • To ensure that the desired settings changes
ing settings modules. Select a module to make are saved, be sure to exit each menu via the tri-
related settings changes. angle mark (if displayed). Exiting the settings
menu by pressing and holding the wheel
switch may not save settings changes.

1-5
 FEATURES

"Display Setting" SGS

SGS can be set to OFF, 1, 2, and 3.
OFF turns the slide control system off, setting
Display Setting
level 1 provides the least amount of system in-
tervention, and setting level 3 provides the
MM ■h,i,M M·i#M greatest amount of system intervention.
Mtf#tt1¥il·i■ ■·i4M LIF
LIF can be set to OFF, 1, 2, and 3.
Setting level 1 provides the least amount of sys-
10:QQ O MPH
tem intervention and setting 3 most strongly re-
duces the rate of wheel lift.
This module allows you to switch the lap time OFF turns LIF off.
mode and tachometer color mode ON/OFF. "Vehicle Setting"
When the lap time mode is selected, the twin ve-
hicle information displays on the main screen
Vehlefe Setting
will display a lap timer and a lap counter. To exit
the lap time mode, the turn lap timer OFF in the BC Setting

display setting module. QS Setting

To change the tachometer to color mode, select
ON.
"Manual TCS Setting" ...
10:QQ O MPH

Manual TCS Setting

The vehicle setting module allows you to adjlllst
setting for the BC and QS systems.
BQ

... BC Setting
10:QQ O MPH

This module allows you to customize the "TCS-

MODE M" which is accessible on the main dis-
play using the MODE switches. ...
TCS 1000 0 MPH

This model uses a variable traction control sys-

tem. For each setting level, the further the vehi- The brake control system has two settings, BC1
cle is leaned over, the greater the amount of and BC2. Select BC1 when only standard ABS
traction control (system intervention) is applied. is desired. Select BC2 to have the brake control
There are 3 setting levels available for the "TCS- system further regulate brake pressure while
MODE M". cornering to suppress lateral wheel slip.
Setting level 1 applies the least amount of over- TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ __
all system intervention, while setting level 3 ap- For skilled riders and when riding at the track,
plies the greatest amount of overall traction
due to varying conditions, the BC2 brake system
corntrol. may engage sooner than expected relative to
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ __ your desired cornering speed or intended cor-
• TCS can only be turned on or off via the main nering line.
screen using the MODE switches.
• SGS and LIF can be turned off independently
of TCS for "TCSMODE M".
• When "TCS-MODE" has been set to "OFF" on
the main screen: TCS, SCS and LIF are all
turned off together.

1-6
 FEATURES

QS "IND Stop" - the r/min at which the indicator

stops flashing can be chosen.
Once selected, rotate the wheel switch up/down
QS 8"tllng
to increase or decrease the r/min value by incre-
ments of 200 r/min.
■·it+ "IND Stop" is settable between 6200-13000 r/
■·fr■ min.
"Maintenance"
10:QQ O MPH
Maintenance

The quick shift system indicators are divided into ltl+IM

OS t::,, and 087 sections. Ml:1i4/i'dii 111·1·¥
OS t::,, and 087 are not linked and can be inde- ll:1i§/i'dfl l l i•t#M
1 1

pendently turned on or off.

OS can be set to ON or OFF.
10:QQ O MPH
OFF turns the respective upshift or downshift
fu111ction off, and the clutch lever must then be
used when shifting in that direction. This module allows you to record the distance
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ traveled between engine oil changes (use the
If the QSS setting cannot be changed: turn the OIL item), and for two other items of your choice
engine off with the gear position set to neutral, (use INTERVAL 1 and INTERVAL2).
then change the setting. To reset a maintenance trip meter, select it and
then press and hold the wheel switch.
"S!hift Indicator" TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Maintenance item names cannot be changed.
Shift Indicator
"Unit"

Unit
km or mlle
km/L or U100km
°C or °F
10•00 0 MPH

This module allows a custom shift indicator to be ...

set. When the engine r/min (rotations per min- 1 0c00 0 MPH
ute) are in the specified range, the gear indicator
will flash.
This module has 3 options:
"IND Mode" - the shift indicator can be turned
ON/OFF
"IND Start'' - the r/min at which the indicator
starts flashing can be chosen.
Unit

km or mile
km/Lor U100km
°C or °F
....
l!ilm

Once selected, rotate the wheel switch up/down

to increase or decrease the r/min value by incre-
...
10c00 0 MPH
ments of 200 r/min.
"IND Start'' is settable between 6000-12800 r/
min.

1-7
 FEATURES

This module allows you to switch the display be- "All Reset"
tween metric and imperial measurement units.
When using kilometers, the fuel consumption
All Rosel
units can be changed between "km/L" or "U
10Okm". When using miles, MPG will be avail-
able.
Temperature units can be switched between
Celsius and Fahrenheit.
"Brightness"
1000 0MPH

Brlghtn9&o
This module resets all settings items (except the

~w
~\)
odometer and clock) to their default or factory
presets.
Select YES to reset all items. After selecting
YES, all items will be reset and the screen will
automatically return to the top MENU screen.
10-00 0 MPH

This module allows you to adjust the general

brightness level of the display screen.
Select the desired brightness level by rotating
the wheel switch, and then short press the wheel
switch to fix the setting and return to the top
MENU screen.
"Clock"

Clock

10,QQ O MPH

This module allows you to set the c lock.

When the clock module is selected, the hours
will be highlighted.
Set the hours by rotating the wheel switch. Push
the switch to confirm and highlight the minutes.
After confirming the minutes, you w ill be re-
turned to the top MENU screen.

1-8
 BASIC SERVICE INFORMATION

..BASIC
.,.,.,,.
SERVICE INFORMATION
........
ELECTRICAL SYSTEM

Electrical parts handling

E~ ll

NOTICE
------------
• Do not perfonn 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 on1ly 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.

1-9
 SPECIAL TOOLS

EA"""'12

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 techniq ues. 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 number starting with "YM-", "YU-", or "ACC-".
• For others, use part number starting with "90890-".

Reference
Tool name/Tool No. Illustration
pages
Yamaha diagnostic tool USB (U S) 3-4, 4-54, 4-55,
90890-03269 7-11, 9-3, 9-36,
9-37

Yamaha diagnostic tool (A/1) 3-4, 4-54, 4-55,

90890-03264 7-11, 9-3, 9-36,
9-37

T hickness gauge 3-6, 4-17, 4-24,

90890-03268 5-27, 5-50
Feeler gauge set
YU-26900-9

Valve lapper (01 4) 3-7

90890-04101
Valve lapper (014)
YM -A8998

Vacuum gauge 3-9

90890-03094
90890-03094
Vacuum mate
YU-44456

VU-44456

1-10
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Carburetor angle driver 2 3-9
90890-03173

Steering nut wrench 3-19, 4-76

90890-01403
Exhaust flange nut wrench
YU-A9472

Oil filter wrench 3-28

90890-01426
Oil filter wrench
YU-38411

Oil pressure gauge joint 18 mm 3-29

90890-04176
YU-04176

Oil pressure gauge set 3-29

90890-03120

Fork spring compressor 4-66, 4-71

90890-01441
Fork spring compressor
YM-01441

Rod holder 4-66, 4-71

90890-01434
Damper rod holder double ended
YM-01434

Damper rod holder (027) 4-67, 4-68

90890-01582
Damper rod holder
YM-01582

Fork seal driver 4-69, 4-69, 4-70

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

1-11
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Rod puller 4-70, 4-71
90890-01 437
90890-01437
Universal damping rod bleeding tool set
YM-A8703

YM·A8703

Rod puller attachment (M10 long)

000 4-70, 4-71
90890-01578
90890-01578
Universal damping rod bleeding tool set
YM -A8703

YM·A8703

Ring nut wrench

000 4-76
90890-01268
Spanner wrench
YU-01268

Drive chain cut & rivet tool 4-87, 4-89

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

Compression gauge 5-7

90890-03081
Engine compression tester
YU-33223

YU-33223

Compression gauge extension 122mm 5-7

90890-04136
Compression gauge extension 122mm
YM -04136

1-12
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Pivot shaft wrench 5-14, 5-14, 5-15
90890-01518
Frame spanner socket
YM-01518

Pivot shaft wrench adapter 5-14, 5-14, 5-15

90890-01476

Camshaft wrench 5-19, 5-22

90890-04162
Camshaft wrench
YM-04162

Valve spring compressor <::, 5-31, 5-35

90890-04200 ~"~- :,"t-"'-,::,
Valve spring compressor
YM-04019 ..
,,

Valve spring compressor attachment 5-31, 5-35

(023)
90890-04179
Valve spring compressor adapter (023)
YM-04179

Valve guide remover (04.5) 5-32

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

Valve guide installer (04.5) 5-32

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

Valve guide reamer (04.5) 5-32

90890-04118
Valve guide reamer (4.5 mm)
YM-04118

Sheave holder 5-38, 5-38,

90890-01903 5-39, 5-39
Primary clutch holder
YS-01880-A

1-13
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Flywheel puller 5-38
90890-01362
H eavy duty puller
YU-33270-B

Yamaha bond No. 1215 5-40, 5-65

90890-85505
T hree bond No. 1215®

Digital circuit tester (CD732) 5-43, 8-55,

90890-03243 8-56, 8-58,
Model 88 Multimeter with tachometer 8-59, 8-59,
YU-A1927 8-60, 8-61 ,
8-61, 8-62,
8-62, 8-63,
8-64, 8-65,
8-65, 8-65, 8-66
C lutch holder 5-49, 5-53
90890-04199
Universal clutch holder
YM-91042

Piston pin puller set 90890-01304 5-70

90890-01304
Piston pin puller
YU-01304

VU-01304

Connecting rod big end bearing installer 5-72, 5-75

09.1
90890-04193

~
Connecting rod big end bearing installer
YM -04193

Piston installing tool 5-77

90890-04161
Piston installing tool
YM-04161

1-14
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Radiator cap tester 6-5, 6-5
90890-01325
Mityvac cooling system tester kit
YU-24460-A

VU-24460-A

Radiator cap tester adapter 6-5, 6-5

90890-01352
Pressure tester adapter
YU-33984

VU-33984

Mechanical seal installer 6-14

90890-04078
Water pump seal installer
YM-33221-A

Middle driven shaft bearing driver 6-14

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

Pressure gauge 7-10, 7-11

90890-03153
Pressure gauge
YU-03153

Fuel injector pressure adapter 7-10

90890-03210
Fuel injector pressure adapter
YU-03210

Fuel pressure adapter 7-11

90890-03176
Fuel pressure adapter
YM-03176

1-15
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Ignition checker 8-59

~
90890-06754
Oppama pet-4000 spark checke r
YM -34487

1-16
 SPECIAL TOOLS

1-17
 SPECIFICATIONS

GENERAL SPECIFICATIONS ........................................................................ 2-1

ENGINE SPECIFICATIONS ............................................................................ 2-2

CHASSIS SPECIFICATIONS .........................................•................................ 2-6

ELECTRICAL SPECIFICATIONS ..................................•.............................. 2-10

TIGHTENING TORQUES ...............................................•.............................. 2-12

ENGINE TIGHTENING TORQUES ......................................................... 2-12
CHASSIS TIGHTENING TORQUES ....................................................... 2-12
El
CABLE ROUTING ......................................................................................... 2-15
 GENERAL SPECIFICATIONS

EA"""'13

GENERAL SPECIFICATIONS

Model
Model B7N4 (MT09M)
B7N5 (MT09MC)
BAM4 (MT09SPM)
BAM5 (MT09SPMC)

Dimensions
Overall length 2090 mm (82.3 in)
Overall width 795 mm (31 .3 in)
Overall height 1190 mm (46.9 in)
Wheelbase 1430 mm (56.3 in)
Ground clearance 140 mm (5.51 in)
Minimum turning radius 3.4 m (11.16 ft)

Weight
Curb weight 189 kg (417 lb) (MT09M, MT09MC)
190 kg (419 lb) (MT09SPM, MT09SPMC)

Loading
Maximum load 166 kg (366 lb)
Riding capacity 2 person

2-1
 ENGINE SPECIFICATIONS

EA"""'14

ENGINE SPECIFICATIONS

Engine
Combustion cycle 4-stroke
Cooling system Liquid cooled
Valve train DOHC
Displacement 890cm3
Cylinder arrangement lnline
Number of cylinders 3-cylinder
Bore x stroke 78.0 x 62.1 mm (3.07 x 2.44 in)
Compression ratio 11 .5: 1
Compression pressure 1365-1758 kPa/600 r/min (13.7-17.6 kgf/cm2/
600 r/min, 194.3-250.1 psi/600 r/min)

Fuel
Recommended fuel Premium unleaded gasoline (E10 acceptable)
Fuel tank capacity 14 L (3.7 US gal, 3.1 Imp.gal)
Fuel reserve amount 2.8 L (0.74 US gal, 0.62 Imp.gal)

Engine oil
Recommended brand YAMALUBE
SAE viscosity grades 10W-40, 10W-50, 15W-40, 20W-40 or 20W-50
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Lubrication system Wet sump
Engine oil quantity
Oil change 2.80 L (2.96 US qt, 2.46 Imp.qt)
With oil filter removal 3.20 L (3.38 US qt, 2.82 Imp.qt)
Quantity (disassembled) 3.50 L (3.70 US qt, 3.08 Imp.qt)

Oil filter
Oil filter type Cartridge

Oil pump
Oil pressure 300.0 kPa/5000 r/min at 100 °C (3.00 kgf/cm2/
5000 r/min at 100 °C, 43.5 psi/5000 r/min at 212
OF)
Co oling system
Coolant quantity
Radiator (including all routes) 1.72 L (1.82 !US qt, 1.51 Imp.qt)
Coolant reservoir (up to the maximum level
mark) 0.28 L (0.30 US qt, 0.25 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 80.0-84.0 °C (176.00-183.20 °F)
Valve full open temperature 95.0 °C (203.00 °F)

2-2
 ENGINE SPECIFICATIONS

Spark plug(s)
Manufacturer/model NGK/LMAR9A-9
Spark plug gap 0.8--0.9 mm (0.031--0.035 in)

Cylinder head
Warpage limit 0.10 mm (0.0039 in)

Camshaft
Camshaft cap inside diameter 24.500-24.521 mm (0.9646-0.9654 in)
Camshaft journal diameter 24.459-24.472 mm (0.9630--0.9635 in)
Camshaft-journal-to-camshaft-cap clearance
limit 0.080 mm (0.0032 in)
Camshaft lobe dimensions
Lobe height limit (Intake) 35.590 mm (1.4012 in)
Lobe height limit (Exhaust) 35.620 mm (1.4024 in)
Camshaft runout limit 0.030 mm (0.0012 in)

Va lve, valve seat, valve guide

Valve clearance (cold)
Intake 0.11--0.20 mm (0.0043--0.0079 in)
Exhaust 0.28--0.32 mm (0.0110--0.0126 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) 4.445 mm (0.1750 in)
Valve stem diameter limit (exhaust) 4.430 mm (0.1744 in)
Valve guide inside diameter (intake) 4.500-4.512 mm (0.1772--0.1776 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)

Va lve spring
Free length limit (intake) 37.34 mm (1.47 in)
Free length limit (exhaust) 35.89 mm (1 .41 in)

Cylinder
Bore 78.000-78.010 mm (3.0709-3.0713 in)
Wear limit 78.060 mm (3.0732 in)

Piston
Diameter 77.975-77.990 mm (3.0699-3.0705 in)
Measuring point (from piston skirt bottom) 9.0 mm (0.35 in)
Piston-to-cylinder clearance 0.010--0.035 mm (0.0004--0.0014 in)
P iston pin bore inside diameter limit 17.043 mm (0.6710 in)
Piston pin outside diameter limit 16.970 mm (0.6681 in)

2-3
 ENGINE SPECIFICATIONS

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 0.027--0.051 mm (0.0011--0.0020 in)
Bearing color code
Code 1 Blue
Code2 Black
Code3 Brown
Code 4 Green

Crankshaft
Runout limit 0.030 mm (0.0012 in)
Journal oil clearance 0.013--0.037 mm (0.0005-0.0015 in)
Bearing color code
Model identification color Two stripes of the same color
Code0 White
Code 1 Blue
Code2 Black
Code3 Brown
Code 4 Green

Ba lancer
Balancer shaft runout limit 0.030 mm (0.0012 in)
B earing color code
Code 1 Blue
Code2 Black
Code3 Brown
Code 4 Green
Codes Yellow
Balancer shaft journal to balancer shaft
bearing clearance 0.023--0.047 mm (0.0009--0.0019 in)

Clutch
Clutch type Wet, multiple-disc
Clutch lever tree play 10.0-15.0 mm (0.39--0.59 in)
Assembly width 42.7-43.5 mm (1 .68-1.71 in)
Friction plate 1 thickness 2.92-3.08 mm (0.115-0.121 in)
Plate quantity 6 pcs
Wear limit 2.82 mm (0.1111 in)
Friction plate 2 thickness 2.92- 3.08 mm (0.115-0.121 in)
Plate quantity 3 pcs
Wear limit 2.82 mm (0.1111 in)
Clutch plate 1 thickness 2.18-2.42 mm (0.086--0.095 in)

2-4
 ENGINE SPECIFICATIONS

Plate quantity 1 pcs

Warpage limit 0.10 mm (0.004 in)
Clutch plate 2 thickness 1.90-2.10 mm (0.075-0.083 in)
Plate quantity 7pcs
Warpage limit 0.10 mm (0.004 in)
Clutch spring free length limit 42.53 mm (1 .67 in)

Driivetrain
Primary reduction ratio 1.681 (79/47)
T ransmission type Constant mesh 6-speed
Gear ratio
1st 2.571 (36/14)
2nd 1.947 (37/19)
3rd 1.619 (34/21)
4th 1.381 (29/21)
5th 1.190 (25/21)
6th 1.037 (28/27)
Main axle runout limit 0.08 mm (0.0032 in)
Drive axle runout limit 0.08 mm (0.0032 in)
Secondary reduction ratio 2.813 (45/16)

Shifting mechanism
Installed shift rod length 236.4-238.4 mm (9.31 -9.39 in)

Air filter
Air filter element Oil-coated paper element

Fuel injector
Resistance 12.on
Idling condition
Engine idling speed 1200-1400 r/min
02 feedback control Active
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% 0.0-2.0%
Fuel line pressure (at idle) 300-390 kPa (3.0-3.9 kgf/cm2, 43.5-56.6 psi)

2-5
 CHASSIS SPECIFICATIONS

..CHASSIS
.,..,,.
SPECIFICATIONS

Chassis
Caster angle 25.0 °
Trail 108 mm (4.3 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 MT5.50
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)

Front tire
Type Tubeless
Size 120/70ZR17M/C (58W)
Manufacturer/model BRIDGESTONE/BATTLAX HYPERSPORT
S22F

Rear tire
Type Tubeless
Size 180/55ZR17M/C (73W)
Manufacturer/model BRIDGESTONE/BATTLAX HYPERSPORT
S22R

Tire air pressure (measured on cold tires)

Up to 90 kg (198 lb) load
Front 250 kPa (2.50 kgf/cm2 , 36 psi)
Rear 290 kPa (2.90 kgf/cm2 , 42 psi)
90 kg (198 lb) load - maximum load
Front 250 kPa (2.50 kgf/cm2 , 36 psi)
Rear 290 kPa (2.90 kgf/cm2, 42 psi)

Fro nt brake
Type Hydraulic dual disc brake
Brake disc thickness limit 4.0 mm (0.16 in)
Brake disc runout limit (as measured on
wheel) 0.10 mm (0.0039 in)
Brake pad lining thickness limit 0.5 mm (0.02 in)
Master cylinder inside diameter 15.87 mm (0.62 in)
Caliper cylinder inside diameter (Left) 30.23 mm, 27.00 mm (1.19 in, 1.06 in)
Caliper cylinder inside diameter (Right) 30.23 mm, 27.00 mm (1.19 in, 1.06 in)
Specified brake fluid DOT4

2-6
 CHASSIS SPECIFICATIONS

Rear brake
Type Hydraulic single disc 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)
Master cylinder inside diameter 12.7 mm (0.50 in)
Caliper cylinder inside diameter 38.18 mm (1 .50 in)
Specified brake fluid DOT4

Front suspension
Shock absorber Hydraulic damper
Fork spring free length limit 268.9 mm (10.59 in)
Inner tube bending limit 0.2 mm (0.01 in)
Recommended oil Yamaha Suspension Oil 01
Quantity (left) 468.0 cm3 (15.82 US oz, 16.51 Imp.oz) (MT09M,
MT09MC)
473.0 cm3 (15.99 US oz, 16.68 Imp.oz)
(MT09SPM, MT09SPMC)
Quantity (right) 472.0 cm3 (15.96 US oz, 16.65 Imp.oz) (MT09M,
MT09MC)
473.0 cm3 (15.99 US oz, 16.68 Imp.oz)
(MT09SPM, MT09SPMC)
Level (left) 107 mm (4.2 in) (MT09M, MT09MC)
110 mm (4.3 in) (MT09SPM, MT09SPMC)
Level (right) 107 mm (4.2 in) (MT09M, MT09MC)
110 mm (4.3 in) (MT09SPM, MT09SPMC)
Spring preload
Adjustment value (Soft) 19.0 mm (0.75 in)
Adjustment value (STD) 15.0 mm (0.59 in)
Adjustment value (Hard) 4.0 mm (0.16 in)
Rebound damping
Unit for adjustment Click
Adjustment value from the start position
(Soft) 11 (MT09M, IMT09MC)
26 (MT09SPM , MT09SPMC)
Adjustment value from the start position
(STD) 15 (MT09SPM, MT09SPMC)
6 (MT09M, MT09MC)
Adjustment value from the start position
(Hard) 1
Compression damping
Unit for compression damping adjustment Click (MT09M, MT09MC)
Adjustment value from the start position
(Soft) 11 (MT09M, MT09MC)
Adjustment value from the start position
(STD) 6 (MT09M, MT09MC)
Adjustment value from the start position
(Hard) 1 (MT09M, MT09MC)

2-7
 CHASSIS SPECIFICATIONS

Fast compression damping

Unit for adjustment Turn (MT09SPM, MT09SPMC)
Adjustment value from the start position
(Soft) 5 1/2 (MT09SPM, MT09SPMC)
Adjustment value from the start position
(STD) 3 1/4 (MT09SPM, MT09SPMC)
Adjustment value from the start position
(Hard) 0 (MT09SPM, MT09SPMC)
Slow compression damping
Unit for adjustment Click (MT09SPM, MT09SPMC)
Adjustment value from the start position
(Soft) 18 (MT09SPM, MT09SPMC)
Adjustment value from the start position
(STD) 12 (MT09SPM, MT09SPMC)
Adjustment value from the start position
(Hard) 1 (MT09SPM, MT09SPMC)

Rear suspension
Shock absorber Gas-hydraulic damper
Spring preload
Unit for adjustment Cam position (MT09M, MT09MC)
Adjustment value (Soft) 1 (MT09M, MT09MC)
Adjustment value (STD) 4 (MT09M, MT09MC)
Adjustment value (Hard) 7 (MT09M, MT09MC)
Adjustment value (Soft) 154.0 mm (6.06 in) (MT09SPM, MT09SPMC)
Adjustment value (STD) 154.0 mm (6.06 in) (MT09SPM, MT09SPMC)
Adjustment value (Hard) 146.0 mm (5.75 in) (MT09SPM, MT09SPMC)
Rebound damping
Unit for adjustment Click (MT09SPM, MT09SPMC)
Tum (MT09M, MT09MC)
Adjustment value from the start position
(Soft) 21/2 (MT09M, MT09MC)
30 (MT09SPM, MT09SPMC)
Adjustment value from the start position
(STD) 1 (MT09M, MT09MC)
18 (MT09SPM, MT09SPMC)
Adjustment value from the start position
(Hard) 0
Compression damping
Unit for adjustment Click (MT09SPM, MT09SPMC)
Adjustment value from the start position
(Soft) 20 (MT09SPM, MT09SPMC)
Adjustment value from the start position
(STD) 10 (MT09SPM, MT09SPMC)
Adjustment value from the start position
(Hard) 0 (MT09SPM, MT09SPMC)

2-8
 CHASSIS SPECIFICATIONS

Drive chain
Size 525
Chain type Sealed type
Number of links 110
Drive chain slack (Sidestand) 36.0--41.0 mm (1.42- 1.61 in)
Drive chain slack (Maintenance stand) 36.0--41.0 mm (1.42- 1.61 in)
Drive chain slack limit (Sidestand) 46.0 mm (1.81 in)
15-link length limit 239.3 mm (9.42 in)

2-9
 ELECTRICAL SPECIFICATIONS

...,.,.,,.
ELECTRICAL SPECIFICATIONS

Voltage
System voltage 12 V

Ignition system
l•gnition timing (B.T.D.C.) 3.0-7.0 °/1300 r/min

Engine control unit

Model TBDF6U (MT09M)
TBDF6W (MT09MC)
TBDF6X (MT09SPM)
TBDF6Y (MT09SPMC)

Ignition coil
Primary coil resistance 1.19- 1.61n
Secondary coil resistance 8.50-11.50 kQ

Charging system
Charging system AC magneto
Standard output 14.0 V, 29.6 A at 5000 r/min
Stator coil resistance 0.152-0.228 n
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 tum signal light LED
Auxiliary light LED
License plate light 5.0W
Meter lighting LED

2-10
 ELECTRICAL SPECIFICATIONS

Indicator light
Neutral indicator light LED
Stability control indicator light LED
Oil pressure and Coolant temperature warning
light LED
High beam indicator light LED
Turn signal indicator light LED
Fuel level warning light LED
Engine trouble warning light LED
Cruise control "SET' indicator light LED (MT09SPM, MT09SPMC)
Cruise control "ON" indicator light LED (MT09SPM, MT09SPMC)
Auxiliary system warning light LED
ABS warning light LED

Starter motor
Brush overall length limit 6.5 mm (0.26 in)
Mica undercut (depth) 0.70 mm (0.03 in)

Fuel sender unit

Sender unit resistance (full) 9.0-11.00
Sender unit resistance (empty) 213.0-219.o n
Fuel injection sensor
Crankshaft position sensor resistance 228--3420
Intake air temperature sensor resistance n n
5400-6600 at o 0 c (5400-6600 at 32 °F)
Intake air temperature sensor resistance 28~91 oat 80 °c (28~91 oat 176 °F)
Intake air pressure sensor output voltage 3.5~.67 V at 101.3 kPa (3.5~.67 V at 1.01
kgf/cm 2, 3.5~.67 Vat 14.7 psi)
Coolant temperature sensor resistance n n
2513--2777 at 20 °C (2513--2777 at 68 °F)
Coolant temperature sensor resistance n
210-221 oat 100 °c (210-221 at 212 °F)

Fu se(s)
Main fuse 50.0A
Headlight fuse 7.5A
Brake light fuse 2.0 A (MT09SPM, MT09SPMC)
Signaling system fuse 7.5A
Ignition fuse 10.0A
Radiator fan motor fuse 15.0 A
ABS ECU fuse 7.5A
Fuel injection system fuse 7.5A
ABS motor fuse 30.0A
ABS solenoid fuse 15.0 A
Terminal fuse 1 2.0A
Backup fuse 7.5A
Cruise control fuse 2.0 A (MT09SPM, MT09SPMC)
Electronic throttle valve fuse 7.5 A
Ignition fuse 2 7.5A
Backup fuse 2 15.0 A

2-11
 TIGHTENING TORQUES

...,.,.,,,
TIGHTENING TORQUES
...,..,,.
ENGINE TIGHTENING TORQUES
Thread
Item Q'ty Tightening torque Remarks
size
Exhaust pipe nut MS 6 20 N-m (2.0 kgf-m, 15 lb-ft)
Spark plug M10 3 13 N-m (1 .3 kgf-m, 9.6 lb-ft)
Cylinder head cover bolt M6 4 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) ---c1@
Generator cover bolt M6 2 12 N-m (1 .2 kgf-m, 8.9 lb-ft) -fii
Generator cover bolt M6 8 12 N-m (1 .2 kgf-m, 8.9 lb-ft)
Stake.
Clutch boss nut M20 1 125 N -m (12.5 kgf-m, 92 lb-ft)
-fii
Clutch spring bolt M6 3 10 N-m (1 .0 kgf-m, 7.4 lb-ft)
Clutch cover bolt M6 11 12 N-m (1 .2 kgf-m, 8.9 lb-ft)
Oil filter cartridge M20 1 17 N-m (1 .7 kgl-m, 13 lb•ft)
Oil filter cartridge union bolt M20 1 70 N -m (7.0 kgf-m, 52 lb-ft) ---c1@
Water pump drain bolt M6 1 10 N-m (1 .0 kgf-m, 7.4 lb-ft)
Engine oil drain bolt M14 1 43 N -m (4.3 kgf-m, 32 lb-ft)
...,..,,,
CHASSIS TIGHTENING TORQUES
Thread
Item Q'ty Tightening torque Remarks
size
Front wheel axle M18 1 72 N-m (7.2 kgf-m, 53 lb-ft)
Front wheel axle pinch bolt
Rear wheel sprocket nut
Rear wheel axle nut
Rear brake caliper bolt (front)
MS
M10
M24
M12
1
5
1
1
23 N-m (2.3 kgl -m, 17 lb-ft)
80 N -m (8.0 kgf-m, 59 lb-ft)
105 N -m (10.5 kgf-m, 77 lb-ft)
27 N-m (2.7 kgf-m, 20 lb-ft)
....
~
~
Rear brake caliper bolt (rear) MS 1 22 N-m (2.2 kgf-m, 16 lb-ft) and
-fii
Brake caliper bleed screw MS 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 MS 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 MS 1 7 N -m (0.7 kgf-m, 5.2 lb-ft)
Lower bracket pinch bolt MS 4 23 N -m (2.3 kgf-m, 17 lb-ft)
Upper bracket pinch bolt MS 2 26 N-m (2.6 kgf-m, 19 lb-ft)
Lower ring nut M30 1 See TIP.
Stake.
Drive sprocket nut M22 1 160 N-m (16 kgf-m, 118 lb-ft)
-fii

2-12
 TIGHTENING TORQUES

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Lower ring nut
1. Tighten the ring nut to approximately 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).

2-13
 TIGHTENING TORQUES

2-14
 CABLE ROUTING

...,..,.,
CABLE ROUTING
Handlebar (front view) (for MT09M/MT09MC)

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2-15
 CABLE ROUTING

1. Meter assembly L. Insert the handlebar switch lead (right) into

2. Handlebar the hole of the meter assembly bracket.
3. Handlebar switch (left) M. Route the handlebar switch lead (left) (to
horn) on the rear side of the clutch cable.
4. Clutch cable Insert the handlebar switch lead (left) (to
5. Headlight control unit coupler (headlight horn) into the hole of the meter assembly
assembly side) bracket.
6. Grip warmer coupler (left) (OPTION) N. Route the handlebar switch lead (left) (to
7. Meter assembly bracket horn) on the inside of the damper.
8. Auxiliary light coupler (auxiliary light side) O. Do not ride the damper over the meter
9. Auxiliary light coupler (wire harness side) assembly bracket.
P. Route the handlebar switch lead (right) on the
10. Handlebar switch coupler (right)
inside of the damper.
11. Handlebar switch lead (left) (to horn)
Q . Pass the handlebar switch lead (right) behind
12.Horn the wire harness within the range of the fig-
13. Brake hose ure.
14. Headlight bracket R. After connecting the front brake light switch
15. Wire harness coupler (red) to the handlebar switch coupler
(right), fix it into the hook part of the meter
16. Handlebar switch lead (right) assembly bracket.
17. Accelerator position sensor coupler S. After connecting the handlebar switch cou-
18. Wire harness (to headlight control unit) pler (right) (white) to the handlebar switch
19. Grip warmer coupler (right) (OPTION) coupler (right), fix it into the hook part of the
meter assembly bracket.
20. Auxiliary DC jack coupler
21. Headlight control unit coupler (wire harness
side)
22. Headlight control unit
23. Handlebar switch (right)
24. Meter assembly coupler
25. Handlebar switch lead (left)
26. Front brake light switch coupler (red)
27. Handlebar switch coupler (right) (white)

A. Clamp the handlebar switch lead (right) to the

rounded part of the handlebar. Face the lock-
ing part of the plastic band forward. Face the
end of the plastic band downward.
B. Clamp the handlebar switch lead (left) to the
rounded part of the handlebar. Face the lock-
ing part of the plastic band forward. Face the
end of the plastic band downward.
C. Insert an auxiliary light coupler into the hole
of the meter assembly bracket.
D. Insert the handlebar switch coupler (right)
into the hole of the meter assembly bracket.
E. Route the handlebar switch lead (left) (to
horn) on the rear side of the wire harness.
F. Insert the clamp into the hole of the meter
assembly bracket.
G. Face the terminal of the horn inside.
H. Insert the clamp into the hole of the headlight
bracket.
I. Route the handlebar switch lead (right) on the
rear side of the wire harness (to accelerator
position sensor).
J . Insert an accelerator position sensor coupler
into the hole of the meter assembly bracket.
K. Route the wire harness (to head light control
unit) on the front side of the handlebar switch
lead (right).

2-16
 CABLE ROUTING

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2-17
 CABLE ROUTING

1. Meter assembly H. Face the terminal of the horn inside.

2. Handlebar I. Route the handlebar switch lead (right) on the
3. Handlebar switch (left) front side of the wire harness (to front brake
light switch).
4. Clutch switch
J. Insert an accelerator position sensor coupler
5. Clutch cable into the hole of the meter assembly bracket.
6. Headlight control unit coupler (headlight K. Insert the front brake light switch coupler into
assembly side) the hole of the meter assembly bracket.
7. Clutch switch lead L. Route the wire harness (to headlight contro I
8. Grip warmer coupler (left) (OPTION) unit) on the front side of the front brake light
9. Meter assembly bracket switch lead.
10. Auxiliary light coupler (auxiliary light side) M. Pass the front brake light switch lead into the
11. Auxiliary light coupler (wire harness side) hole of the meter assembly bracket.
N. Route the clutch switch lead on the inside of
12. Clutch switch coupler the damper.
13. Handlebar switch coupler (right)
0 . Route the handlebar switch lead (left) (to
14. Handlebar switch lead (left) (to horn) horn) lead on the inside of the damper.
15.Hom P. Do not ride the damper over the meter
16. Brake hose assembly bracket.
17. Headlight bracket Q . Route the front brake light switch lead on th e
18. Wire harness inside of the damper.
19. Handlebar switch lead (right) R. Pass the handlebar switch lead (right) behind
the wire h arness within the range of the fig-
20. Accelerator position sensor coupler ure.
2 1. Front brake light switch coupler
22. Front brake light switch lead
23. Grip warmer coupler (right) (OPTION)
24. Wire harness (to headlight control unit)
25. Auxiliary DC jack coupler
26. Headlight control unit coupler (wire harness
side)
27. Headlight control unit
28. Front brake light switch
29. Handlebar switch (right)
30. Meter assembly coupler
3 1. Handlebar switch lead (left)
32. Handlebar switch coupler (right) (white)

A . Clamp the right lead of the hand lebar switch

and front brake light switch lead to the
rounded part of the handlebar. Face the lock-
ing part of the plastic band forward. Face the
end of the plastic band downward. No spe-
cific order for routing.
B. Clamp the left lead of the handlebar switch
and clutch switch lead to the rounded part of
the handlebar. Face the locking part of the
plastic band forward. Face the e,nd of the
plastic band downward. No spec ific order for
routing.
C. Route the clutch switch lead on t he rear side
of the wire harness (to handlebar switch cou-
pler (right)).
D. Insert an auxiliary light coupler into the hole
of the meter assembly bracket.
E. Insert the clutch switch coupler into the hole
of the meter assembly bracket.
F. Route the handlebar switch lead (left) (to
horn) on the rear side of the wire harness.
G. Insert the clamp into the hole of the meter
assembly bracket.

2-18
 CABLE ROUTING

Steering head (left and right

. view)

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2-19
 CABLE ROUTING

1. Coupler cover
2. Handlebar switch lead (left)
3. Handlebar switch lead (left) (to horn)
4. Clamp
5. Meter assembly bracket
6. Upper bracket
7. Clutch cable
8. Brake hose
9. Wire harness (to meter)
A. Insert the clamp into the hole of the coupler
cover.
B. Insert the clamp into the hole of the meter
assembly bracket.

2-20
 CABLE ROUTING

Fra me (right side view)

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2-21
 CABLE ROUTING

1. Battery box E. Route the oil pressure switch lead on the

2. Rectifier/regulator inside of the radiator inlet hose.
3. Rectifier/regulator cover F. Fasten the oil pressure switch lead with the
holder.
4. Wire harness (to rectifier/regulator)
G. Right side of the vehicle
5. Purge cut valve solenoid coupler (for
MT09MC/MT09SPMC) H. Left side of the vehicle
6. Clutch cable I. Set the neutral switch coupler installation
direction within the range as shown in the fig-
7. Stator coil lead ure.
8. Radiator hose (cylinder head to radiator) J. Roule the clutch cable on the front side of the
9. Front turn signal/position light (ri ght) starter motor lead.
10. Front tum signal/position light coupler (right) K. Front side of the vehicle
11. Coolant reservoir hose L. Pass each lead through the hole in the fron1
12. Oil pressure switch coupler side panel (right) and secure it with a plastic
13. Plastic band locking tie. Face the locking part of the plastic
locking tie rearward. Face the end of the plas-
14. Oil pressure switch lead tic locking tie rearward and cut off the excess.
15. Radiator inlet hose M. Pass each lead wire through the notch on the
16. Oil pressure switch front side panel (right) and arrange as shown
17. Starter motor in the figure.
18. Starter motor lead N. Route the front turn signal/position light cou-
pler (right) on the rear side of the wire har-
19. Canister (for MT09MC/MT09SPMC) ness (to oil pressure switch sub-lead) and
20. Canister purge hose (purge cul valve sole- frame (radiator mounting boss).
noid to canister) (for MT09MC/MT09SPMC) 0 . Fasten the gray tape portion of the front turn
21 . Fuel tank breather hose (fuel tank to canister) signal/position light lead (right) and wire har-
(for MT09MC/MT09SPMC) ness (to o il pressure switch sub-lead) with the
22. Rear brake light switch lead clamp. The opening of the clamp should face
the front .
23. Rear wheel sensor lead
P. Fasten the gray tape portion of the wire har-
24. Wire harness ness (to o il pressure switch sub-lead) with the
25. Neutral switch coupler clamp.
26. Neutral switch Q . Pass the plastic locking tie through the hole i n
27. Coolant temperature sensor coupler the front side panel (right) and fix the wire
28. Clutch cable holder harness (to oil pressure switch sub-lead).
Face the locking part of the plastic locking tie
29. Pull lever rearward. Face the end of the plastic locking
30. Wire harness (to oil pressure switch sub- tie rearward and cut off the excess.
lead) R. Route the oil pressure switch lead on the out-
31 . Front turn signal/position light lead (right) side of the radiator inlet hose.
32. Wire harness (to front tum signal/position S. Face the locking part of the plastic band
light (right)) inward. Face the end of the plastic locking tie
33. Radiator cover (right) rearward.
34. Front side panel (right) T. Insert the clamp into the hole of the battery
box. The opening of the clamp should face
35. Plastic locking tie the right.
36. Front tum signal/position light coupler (right) U. Fasten the gray tape portion of the wire har-
37. Frame ness (to rectifier/regulator) with the clamp.
38. Clamp The opening of the clamp should face the
right.
39. Wire harness (to front tum signal/position
light (right) and oil pressure switch sub-lead) V. Route the wire harness (to front turn signal/
position light and oil pressure switch) on the
A . When installing the rectifier/regulator cover, upper side of the radiator hose (cylinder head
the rectifier/regulator lead should not bite into to radiator).
the cover.
B. To fuel pump
C. Route the clutch cable on the fro nt side of the
stator coil lead and canister. (for MT09MC/
MT09SPMC)
D. Fix the plastic band, after aligning with the
lower end of the paint mark on the radiator
inlet hose.

2-22
 CABLE ROUTING

Frame (front left side view)

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2-23
 CABLE ROUTING

1. Intake air temperature sensor coupler H. Pass the- plastic locking tie through the holes
2. Intake air temperature sensor (2 place-s) on the front side panel (left) to fix
the 0 2 sensor lead. Face the locking part ofi
3. Air filter case assembly the plastic loc king tie rearward. Face the end
4. Radiator outlet hose of the plastic locking tie rearward and cut off
5. 0 2 sensor coupler the excess.
6. Front tum signal/position light coupler (left) I. Insert the clamp into the hole in the cable
7. Wire harness (to 0 2 sensor) guide.
8. Wire harness (to front tum signal/position
J. Fix the ECU with the claw of air filter case
assembly properly.
light (left))
9. Front turn signal/position light lead (left)
10. Clutch cable
11. Handlebar switch lead (left)
12. ECU coupler 1
13. Wire harness (to ECU coupler 1)
14. Wire harness (to ECU coupler 2)
15. Wire harness (to ECU coupler 3)
16. Wire harness
17. ECU coupler 3
18. ECU (Engine Control Unit)
19. ECU coupler 2
20. Plastic locking tie
21. Radiator cover (left)
22. Front side panel (left)
23. Front turn signal/position light (left)
24. Radiator
25. Cable guide
26. 0 2 sensor lead

A. Connect the intake air temperature sensor to

its coupler and install the intake air tempera-
ture sensor to the hook of the air filter assem-
bly. Do not ride the intake air temperature
sensor lead over the bracket.
B. Route each lead through the notch section of
the front side panel (left). Route each lead
wire as shown in the figure.
C. Pass the wire harness (to ECU coupler)
through the recess of the air filter assembly.
D. Fix the wire harness (to 0 2 sensor) and wire
harness (to front turn signal/position light
(left)) by passing the plastic locking tie
through the holes (2 places) in the front side
panel (left). Face the locking part of the plas-
tic locking tie rearward. Face the end of the
plastic locking tie rearward and cut off the
excess.
E. Fix the wire harness (to front turn signal/posi-
tion light (left)) with the plastic locking tie and
connect the front tum signal/position light
coupler (left).
F. Insert the 0 2 sensor coupler into the hole in
the front side panel (left).
G. Pass the clutch cable through the recess of
the cable guide.

2-24
 CABLE ROUTING

Frame (rear left side view)

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2-25
 CABLE ROUTING

1. Shift sensor lead 0 . Face the locking part of the plastic locking tie
2. Wire harness inward. Face the end of the plastic locking tie
downward and cut off the excess.
3. Clamp
P. Lower side of the vehicle
4. Starter motor lead
Q. For MT09M/MT09MC
5. Gear position sensor coupler
R. For MT09SPM/MT09SPMC
6. Gear position sensor
S. Route the wire harness (to gear position sen-
7. Shift sensor sor) on the left side of the rear shock
8. Sidestand switch absorber hose and starter motor lead.
9. Sidestand switch lead T. Left outside of the vehicle
10. Fuel tank drain hose
11. 0 2 sensor
12. Holder
13. Canister breather hose (for MT09MC/
MT09SPMC)
14. Fuel tank breather hose (for MT09M/
MT09SPM) or canister breather hose (for
MT09MC/MT09SPMC)
15. Shift rod joint
16. Locknut
17. Shift arm
H;l. Shift rod joint and dust cover
19. Wire harness (to gear position sensor)
20. Radiator outlet hose
21. 0 2 sensor lead
22. Rear shock absorber hose

A. To fuel pump.
B. Fix the 0 2 sensor lead to the rounded part on
the radiator outlet hose with a plastic locking
tie.
C. Arrange the sidestand switch lead, canister
breather hose (for MT09MC/MT09SPMC),
fuel tank breather hose (for MT09M/
MT09SPM) and fuel tank drain hose from
inside of the vehicle in order.
D. The opening of the clamp should face the
right.
E. Arrange the shift sensor lead to the front side.
F. Left side of the vehicle
G. Front of the vehicle
H. Pass the shift sensor lead in front of the shift
rod joint and shift arm.
I. Bend the shift sensor lead upward at the bot-
tom of the sensor side.
J . Fix the shift sensor and its lead to the top part
of the locknut on the shift sensor with the
clamp.
K. Arrange the sidestand switch lead to the
inside of the vehicle.
L. Face the paint mark on the fuel tank drain
hose to the outside and pass it through the
holder.
M. Route the wire harness (to gear position sen-
sor) on the left side of the starter motor lead.
N. Route the 0 2 sensor lead on the inside of the
radiator outlet hose.

2-26
 CABLE ROUTING

Canister (left side view) (for MT09MCIMT09SPMC)

2-27
 CABLE ROUTING

1. Canister purge hose (purge cut valve sole- P. Route the fuel tank drain hose on the rear
noid to canister) side of the stator coil lead, sidestand switch
2. Starter motor lead lead and shift sensor lead. Route the fuel
tank drain hose on the left side of the canister
3. Sidestand switch lead purge hose (purge cut valve solenoid to can-
4. Canister breather hose ister).
5. Fuel tank drain hose Q . Route the clutch cable between the cylinder
6. Plastic locking tie head and the bracket.
7. Stator coil lead
8. Shift sensor lead
9. Clutch cable
10. Wire harness
11. Bracket
12. Wire harness (to purge cut valve solenoid)
13. Purge cut valve solenoid coupler
14. Purge cut valve solenoid
15. Frame
16. Cylinder head

A. Connect each lead wire to the respective

couplers of the wire harness inside the boot.
B. Route the shift sensor lead on the outside of
the fuel tank drain hose and canister breather
hose.
C. The plastic locking tie position is aligned with
the end of the gray tape (shift sensor side
and sidestand switch side).
D. Gray tape of shift sensor lead a111d side stand
switch lead.
E. Route the stator coil lead, shift sensor lead
and sidestand switch lead on the left side of
the clutch cable and canister purge hose
(purge cut valve solenoid to canister).
F. Face the end of the plastic locking tie leftward
and cut off the excess.
G. Insert the plastic locking tie into the hole of
the bracket.
H. Arrange the sidestand switch lead to the right
side of the vehicle.
I. Arrange the shift sensor lead to the left side
of the vehicle.
J. Left side of the vehicle
K. Route the stator coil lead to the front of the
vehicle and fix the gray tape part with a plas-
tic locking tie.
L. Fix the plastic locking tie is located 2o-30
mm (0.79-t .18 in) away from the plastic lock-
ing tie "6C". Face the locking part of the plas-
tic locking tie forward. Face the end of the
plastic locking tie rightward and do not cut off
the excess.
M . Right s ide of the vehicle
N. Front side of the vehicle
0. Route the wire harness (to purge cut valve
solenoid) on the rear side of the stator coil
lead, sidestand switch lead and s hift sensor
lead.

2-28
 CABLE ROUTING

Frame (left side view) (for MT09M/MT09SPM)

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2-29
 CABLE ROUTING

1. Starter motor lead

2. Plastic locking tie
3. Clutch cable
4. Wire harness
5. Sidestand switch lead
6. Shift sensor lead
7. Stator coil lead
8. Bracket
9. Frame
10. Cylinder head
11. Fuel tank drain hose

A. The plastic locking tie position is aligned with

the end of the gray tape (shift sensor side
and sidestand switch side).
B. Gray tape of shift sensor lead a111d side stand
switch lead.
C. Right side of the vehicle
D. Route the stator coil lead to the front of the
vehicle and fix the gray tape part with a plas-
tic locking tie.
E. Fix the plastic locking tie is locat ed 20-30
mm (0.79-1.18 in) away from the plastic lock-
ing tie "6C". Face the locking part of the plas-
tic locking tie forward. Face the e nd of the
plastic locking tie rightward and do not cut off
the excess.
F. Front side of the vehicle
G . Arrange the sidestand switch lead to the right
side of the vehicle.
H. Arrange the shift sensor lead to the left side
of the vehicle.
I. Face the end of the plastic loc king tie leftward
and cut off the excess.
J. Left side of the vehicle
K. Insert the plastic locking tie into the hole of
the bracket.
L. Route the clu1ch cable between the cylinder
head and the bracket.
M. Route the shift sensor lead on the outside of
the fuel tank drain hose.

2-30
 CABLE ROUTING

Main switch (rear view) (for MT09M/MT09MC)

2-31
 CABLE ROUTING

1. Bracket
2. Handlebar switch coupler 2 (left)
3. Handlebar switch coupler 1 (left)
4. Radiator fan motor coupler
5. Brake hose
6. Radiator fan motor lead
7. Wire harness (to front tum signal/position
light (right) and oil pressure switch)
8. Front wheel sensor coupler
9. Wire harness (to handlebar switch (left))
10. Wire harness
11. Intake air temperature sensor coupler
12. Intake air temperature sensor
13. Radiator fan motor coupler (radiator side)
14. Coupler cover
15. Protector
16. Hook-and-loop fastener (loop side) (white)
17. Hook-and-loop fastener (loop side) (black)
18. End portion of sponge protector
19. Hook-and-loop fastener (hook side) (black)
20. Main switch coupler

A. Route the radiator fan motor lead between

the brake hoses and frame.
B. Route the wire harness (to front turn signal/
position light (right) and oil pressure switch)
between the brake hoses and frame.
C. Route the handlebar switch lead (left) on the
rear side of the wire harness.
D. Insert the clamp into the hole of the coupler
cover.
E. Insert the radiator fan motor coupler into the
hole of the coupler cover.
F. Cover the protector with the main switch
cover.
G . Make sure that the main switch couplers
does not protrude from the end portion of
sponge protector.
H. Align the mating surfaces on the hook-and-
loop fastener end (hook side) and hook-and-
loop fastener end (loop side) (white) and
wrap the wire.
I. Insert the handlebar switch coupler 2 (left)
into the hole of the coupler cover.

2-32
 CABLE ROUTING

M. .
am switch (rear view) (for MT09SPM/M SPMC)

2-33
 CABLE ROUTING

1. Bracket
2. Handlebar switch coupler 2 (left)
3. Handlebar switch coupler 1 (left) (blue)
4. Handlebar switch coupler 3 (left)
5. Radiator fan motor coupler
6. Brake hose
7. Radiator fan motor lead
8. Wire harness (to front tum signaVposition
light (right) and oil pressure switch)
9. Front wheel sensor coupler
10. Wire harness (to handlebar switch (left))
11. Wire harness
12. Intake air temperature sensor coupler
13. Intake air temperature sensor
14. Radiator fan motor coupler (radiator side)
15. Coupler cover
16. Protector
17. Hook-and-loop fastener (loop side) (white)
18. Hook-and-loop fastener (loop side) (black)
19. End portion of sponge protector
20. Hook-and-loop fastener (hook side) (black)
21. Main switch coupler

A. Route the radiator fan motor lead between

the brake hoses and frame.
B. Route the wire harness (to front turn signaV
position light (right) and oil pressure switch)
between the brake hoses and frame.
C. Route the handlebar switch lead (left) on the
rear side of the wire harness.
D. Insert the clamp into the hole of the coupler
cover.
E. Insert the radiator fan motor coupler into the
hole of the coupler cover.
F. Cover the protector with the main switch
cover.
G. Make sure that the main switch couplers
does not protrude from the end portion of
sponge protector.
H. Align the mating surfaces on the hook-and-
loop fastener end (hook side) and hook-and-
loop fastener end (loop side) (white) and
wrap the wire.
I. Insert the handlebar switch coupler 2 (left)
into the hole of the coupler cover.

2-34
 CABLE ROUTING

Main switch (left side view)

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3 2

2-35
 CABLE ROUTING

1. Wire harness
2. Front wheel sensor coupler
3. Front wheel sensor lead
4. Wire harness (to 0 2 sensor)
5. Bracket
6. Frame
A. Insert the clamp into the hole of the bracket.
B. Insert the clamp into the rib of the frame.
C . Insert the clamp with touched the protrusion
on the frame.
D. Insert the clamp between the protrusions on
the frame.

2-36
 CABLE ROUTING

Frame (top view)

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2-37
 CABLE ROUTING

1. Throttle body E. Pass the wire harness (to radiator fan motor
2. Throttle servo motor coupler relay) into the coupler cover and push it
between the wire harness (to ABS ECU) and
3. Fuel tank breather hose wire harness (main line).
4. Wire harness (to coolant temperature sensor) F. Insert the joint coupler into the rib of the bat-
5. Crankshaft position sensor coupler tery box.
6. Fuel pump coupler G . Route the rear brake light switch lead
7. Relay unit between the wire harness and joint coupler.
(between clamp and rear brake light switch)
8. Rear wheel sensor coupler
H. Route the wire harness (to fuel pump) on the
9. Battery box front side of the rear brake light switch lead.
10. Battery I. Route the wire harness (to ignition coil #3) to
11 . Coupler cover the left side of the cylinder head breather
12. Radiator fan motor relay hose.
13. ABS ECU coupler J. Insert the clamp into the hole of the throttle
14. Joint coupler body.
15. Rear brake light switch coupler K. Face the end of the plastic locking tie back-
ward.
16. Rear brake light switch lead
L. Insert the clamp into the hole of the battery
17. Fuel tank drain hose box.
18. Sidestand switch coupler M. Fix the plastic locking tie with the white tape
19. Shift sensor coupler part on the wire harness.
20. Wire harness (to ECU) N. Fix the rear brake light switch lead with the
21 . Stator coil coupler gray tape part.
22. Wire harness 0 . Insert the clamp into the hole of the frame.
23. Injector #1 coupler P. Route the body ground 3 is located above the
body grounds 1, 2, 4, and 5, and their
24. Ignition coil #1 coupler crimped parts of the terminals do not overlap
25. Intake air pressure sensor 2 and face them upper side.
26. Ignition coil #2 coupler Q . Install the crimped parts of the terminals of
27. Injector #2 coupler body ground 1, 2, 4, and 5 to face the uppe.r
side.
28. Intake air pressure sensor 1
29. Ignition coil #3 coupler R. Route the starter motor lead on the inside of
the clamp.
30. Injector #3 coupler
S. Insert the radiator fan motor relay all the way
31 . Throttle position sensor coupler into the bottom of the coupler cover until it
32. Wire harness (to rectifier/regulator) stops the stopper of the rib on the battery
33. Clamp box.
34. Frame
35. Body ground 3
36. Ground bolt
37. Body ground 1, 2, 4, 5
38. Wire harness (to throttle body)
39. Starter motor lead
A. Slide the coupler cover until the coupler is
covered and face the open s ide of the coupler
cover to underside of the vehicle.
B. Route the fuel tank breather hose on the left
side of the wire harness (to throttle servo
motor) and wire harness (to coolant tempera-
ture sensor). Route the fuel tank breather
hose on the right side of the wire harness (to
stator coil), wire harness (to shift sensor),
wire harness (to sidestand switch ) and stator
coil lead.
C. Insert the relay unit until it touches the rib on
the battery box.
D. Insert the rear wheel sensor coupler into the
hole of the battery box.

2-38
 CABLE ROUTING

Rear fender (top view)

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2-39
 CABLE ROUTING

1. Positive battery terminal P. For MT09M/MT09MC

2. Fuse box Q . Make a slack to the license plate light lead in
3. Box front of the seat bracket.
4. License plate light coupler
5. Tail/brake light coupler
6. Rear turn signal light (left) (black)
7. Rear turn signal light (right) (white)
8. VDT coupler
9. S1arter relay coupler
10. Starter relay
11. Negative battery terminal
12. Tail/brake light lead
13. Damper
14. Rear fender bracket
15. Cover
16. Band
17. Rear turn signal light lead (right)
18. Rear turn signal light lead (left)
19. License plate light lead
20. Plastic locking tie
21. Bonder
22. Brake light relay (for MT09SPM/MT09SPMC)
23. Seat bracket

A . Insert the clamp into the hole of the box.

B. Insert the tail/brake light coupler into the hole
of the box.
C. Do not ride the end of the bonder over the rib
on the box.
D. The plastic locking tie is assembled between
the rib and guide. Fasten the white tape por-
lion of the license plate light lead with the
plastic locking tie.
E. Insert the rear tum signal light coupler (left)
into the hole of the box.
F. Insert the rear turn signal light coupler (right)
into the hole of the box.
G . Insert the VDT coupler until it stops the rib
stopper on the box.
H. Insert the starter relay until it stops the rib
stopper on the battery box.
I. Route the tail/brake light lead to the wire
guide beneath the cover.
J. Do not bite the lead with damper.
K. Face the locking part of the plast ic locking tie
downward. The clamp end should be faced to
the right along the bottom of the box.
L. Route the license plate light lead to the inside
of the rear turn signal light leads and pass it
through the wire guide on the box.
M. Route the rear turn signal light lead to the
wire guide on the box. The order of lead
arrangement does not matter. After assem-
bling the plastic locking tie "19", the lead may
come off the wire guide.
N. Insert the brake light relay until it stops the rib
stopper on the battery box.
0 . For MT09SPM/MT09SPMC

2-40
 CABLE ROUTING

ABS ECU (top view)

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9
1

lgr~

2-41
 CABLE ROUTING

1. Crankshaft position sensor coup ler

2. Rear brake light switch lead
3. Rear wheel sensor lead
4. Rear wheel sensor coupler
5. Wire harness (to joint coupler)
6. Wire harness (to ABS ECU)
7. Wire harness (to radiator fan motor relay)
8. Radiator fan motor relay
9. Wire harness
10. Clamp
11. Battery box
12. Starter motor lead

A. Pass the crankshaft position sensor lead

beneath the wire harness (to stator coil
assembly) and connect the cran kshaft posi-
tion sensor coupler on the right s ide of the
vehicle.
B. Route the rear brake light switch lead on the
rear side of the wire harness (to rectifier/reg-
ulator).
C. Route the rear wheel sensor lead on the rear
side of the wire harness (to rectifier/regula-
tor).
D. Route the rear wheel sensor lead on the top
side of the wire harness.
E. Route the wire harness (to radiator fan motor
relay) on the rear side of the wire harness (to
ABS ECU) and wire harness (to joint cou-
pler).
F. Route the rear brake light switch lead on the
top side of the wire harness.
G . Route the wire harness (to radiator fan motor
relay) on the front side of the clamp.
H . Route the wire harness (to radiator fan motor
relay) on the lower side of the wire harness.
Route the wire harness (to radiator fan motor
relay) on the top side of the starter motor
lead.
I. Top of the vehicle

2-42
 CABLE ROUTING

IMU (top view)

2-43
 CABLE ROUTING

1. IMU (Inertial Measurement Unit)

2. Positive battery lead
3. Starter relay
4. Wire harness (to starter relay)
5. Bracket
6. Starter motor lead
7. Battery box
8. IMU coupler
9. Wire harness
10. Negative battery lead
A. Do not contact the starter motor lead with the
bracket.
B. Route the starter motor lead on the lower
side of the bracket.
C. Insert the clamp into the hole of the battery
box.
D. When inserting the clamp into the battery
box, pass the starter motor lead through the
left side of the rib on the battery box. After
inserting the clamp into the battery box, the
starter motor lead may come off the rib on the
battery box.

2-44
 CABLE ROUTING

Front brake hose {left side view)

2-45
 CABLE ROUTING

1. Front brake caliper assembly (left)

2. Brake hose (front brake caliper (left) to front
brake caliper (right))
3. Front wheel sensor lead
4. Brake hose (hydraulic unit to front brake cali-
per (left))
5. Brake hose (front brake master cylinder to
hydraulic unit)
6. Clamp
7 _ Reflector bracket
8. Front fork

A. Install the brake hose (front brake caliper

(left) to front brake caliper (right)) with its
white paint mark facing outward.
B. Install the holder with contacted the front fork
leg.
C. Make the front wheel sensor lead to follow
the brake hose (hydraulic unit to front brake
caliper (left)) without slacking.
D. Route the front wheel sensor lead on the
front side of the brake hose, and clamp the
white tape portion. The opening of the clamp
should face the front. Make sure the clamp is
engaged by 3 or more notches.
E. 45°
F. Left side of the vehicle
G. Front side of the vehicle
H. Insert the grommet of the front wheel sensor
lead.
I. Route the front wheel sensor lead on the
front side of the brake hose, and clamp the
white tape portion. Fasten the protector of the
brake hose with the clamp. The opening of
the clamp should face the front. Make sure
the clamp is engaged by 3 or more notches.
J. Fasten the white tape portion of the front
wheel sensor lead with the clamp.

2-46
 CABLE ROUTING

Front brake h ose (right side view)

2-47
 CABLE ROUTING

1. Brake hose (hydraulic unit to front brake cali-

per (left))
2. Brake hose (front brake master cylinder to
hydraulic unit)
3. Meter assembly bracket
4. Front fork
5. Front brake caliper assembly (right)
6. Front fender
7. Clamp
8. Bracket
9. Frame
10. Brake hose joint
11. Front wheel sensor lead
12. Brake hose (front brake caliper (left) to front
brake caliper (right))
A . Fit the metal fitting for the front brake hose to
the recess of the brake hose joint.
B. Install the brake hose between the stoppers
on the brake hose joint.
C. Insert the clamp into the hole of the bracket
of meter assembly.
D. Make sure the clamp is engaged by 2 or
more notches. Engage the claws so that they
face toward the right of the vehicle.
E. Insert the grommet of the front wheel sensor
lead.
F. Fit the clamp between the ribs on the front
fender.
G . Make sure the clamp is engaged by 2 or
more notches. Engage the claws so that they
face toward the rear of the vehicle.
H. Insert the clamp into the hole of the front
fender.
I. After holding the protrusion (17 mm (0.67 in)
on the brake hose joint with an appropriate
tool, tighten the brake hose union bolts to the
specified torque.

2-48
 CABLE ROUTING

Rear brake hose (right side view)

~-----

2-49
 CABLE ROUTING

1. Rear wheel sensor

2. Rear brake hose (hydraulic unit to rear brake
caliper)
3. Clamp
4. Rear brake hose (rear brake master cylinder
to hydraulic unit)
5. Rear fender
6. Frame
7. Brake fluid reservoir hose
8. Rear brake light switch lead
9. Swingarm
10. Rear wheel sensor lead
A. Fasten the white tape portion of the rear
wheel sensor lead with the clamp.
B. Fasten the grommet of the rear wheel sensor
lead with the clamp.
C. Fasten the gray tape portion of the rear brake
light switch lead with the clamp.
D. Installing position of the rear brake hose (rear
brake master cylinder to hydraulic unit). (70
mm (2.76 in))
E. 45°
F. Route the rear wheel sensor lead on the out-
side of the rear brake hose (hydraulic unit to
rear brake caliper).
G . Outside of the vehicle
H . Fasten the protector of the rear brake hose
with the clamp.
I. The opening of the clamp should face the top.
Make sure the clamp is engaged by 3 or
more notches.
J. Route the rear wheel sensor lead on the out-
side of the rear brake hose (hydraulic unit to
rear brake caliper).
K. The opening of the clamp should lace the
down.
L. The opening of the clamp should face the
outside. Make sure the clamp is engaged by
3 or more notches.
M. The opening of the clamp should face the
rear. Make sure the clamp is engaged by 3 or
more notches.
N. Route the rear brake light switch lead on the
outside of the rear brake hose (rear brake
master cylinder to hydraulic unit).
0 . Fasten the protector of the brake fluid reser-
voir hose with clamp. The opening of the
clamp should face the front.
P. Fasten the brake fluid reservoir hose and rear
brake hose (rear brake master cylinder to
hydraulic unit) with clamp. The opening of the
clamp should face the down.

2-50
 CABLE ROUTING

ABS ECU (Electronic Control Unit) (top and left side view)

2-51
 CABLE ROUTING

1. Front brake hose (front brake master cylinder

to hydraulic unit)
2. Front brake hose (hydraulic unit to front brake
caliper (left))
3. Brake hose joint
4. Hydraulic unit brake pipe (rear brake master
cylinder to hydraulic unit)
5. Hydraulic unit brake pipe (hydraulic unit to
front brake calipers)
6. Battery box
7. Hydraulic unit brake pipe (hydraulic unit to
rear brake caliper)
8. Hydraulic unit brake pipe (rear brake master
cylinder to hydraulic unit)
9. Rear brake hose (hydraulic unit to rear brake
caliper)
10. Rear brake hose (rear brake master cylinder
to hydraulic unit)
11. Bracket
A. 79°
B. ago
C. 770
D. 78°
E. Front of the vehicle

2-52
 CABLE ROUTING

Fuel tank (left side

. view) {for 09MC/MT09SPMC)

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2-53
 CABLE ROUTING

1. Fuel tank
2. Frame
3. Fuel pump
4. Fuel tank breather hose
5. Fuel tank drain hose
6. Fuel hose
7. White paint mark
8. Projection
9. Yellow paint mark

A. To engine
B. Insert the fuel tank drain hose up to the sec-
tion where the fuel tank pipe increases in
diameter. Install it so that the pa int mark
faces the front.
C. Align the clip with the paint mark on the fuel
tank drain hose and install it. Make sure not
to install the hose clip on the raised portion of
the hose fitting.
D. Face the tip of the clip backward from the
central axis of the fuel tank breather hose.
E. Face the tip of the clip forward from the cen-
tral axis of the fuel tank drain hose.
F. Install the fuel tank drain hose on the projec-
tion side of the fuel tank.
G . Insert the fuel tank breather hose up to the
section where the fuel tank pipe increases in
diameter. Install it so that the pa int mark
faces the rear.
H. Align the clip with the paint mark on the fuel
tank breather hose and install it. Make sure
not to install the hose clip on the raised por-
tion of the hose fitting.

2-54
 CABLE ROUTING

. view) (f r MT09M/MT09SPM)
Fuel tank (Ieft side

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2-55
 CABLE ROUTING

1. Fuel tank
2. Frame
3. Fuel pump
4. Fuel tank breather hose
5. Fuel tank drain hose
6. Fuel hose
7. White paint mark
8. Yellow paint mark
9. Projection

A. To engine
B. Insert the fuel tank drain hose up to the sec-
tion where the fuel tank pipe increases in
diameter. Install it so that the pa int mark
faces the front.
C. Align the clip with the paint mark on the fuel
tank drain hose and install it. Make sure not
to install the hose clip on the raised portion of
the hose fitting.
D. Insert the fuel tank breather hose up to the
section where the fuel tank pipe increases in
diameter. Install it so that the pa int mark
faces the front.
E. Face the tip of the clip forward from the cen-
tral axis of the fuel tank breather hose.
F. Face the tip of the clip forward from the cen-
tral axis of the fuel tank drain hose.
G. Install the fuel tank drain hose on the projec-
tion side of the fuel tank.

2-56
 CABLE ROUTING

Canister (for MT09MC/MT09SPMC)

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2-57
 CABLE ROUTING

1. Frame
2. Fuel tank breather hose (fuel tank to canister)
3. Canister
4. Canister breather hose
5. Fuel tank drain hose
6. Canister purge hose (purge cut valve sole-
noid to canister)

A. Front side of the vehicle

B. Right side of the vehicle
C. Face the yellow paint mark on the canister
purge hose (purge cut valve solenoid to can-
ister) upward.
D. Install the clip with its end facing the down.
E. Insert each hose until it stops each part.
F. Install the clip with its end facing the rear.
G. Fit the fuel tank drain hose into the canister
holder as shown in the illustration.
H. Face the blue paint mark on the canister
purge hose (purge cut valve solenoid to can-
ister) upward.
I. Install the clip with its end facing the top.
J. Face the white paint mark on the fuel tank
breather hose (fuel tank to canister) upward.

2-58
 CABLE ROUTING

Starter motor (top view) (tor MT09M/MT09SPM)

2-59
 CABLE ROUTING

1. Fuel tank drain hose

2. Fuel tank breather hose

2-60
 CABLE ROUTING

Air filter case and throttle bodies (left side view)

2-61
 CABLE ROUTING

1. Throttle body
2. Yellow paint mark
3. White paint mark
4. Cylinder head breather hose
5. Canister purge hose (purge cut valve sole-
noid to hose joint) (for MT09MC/MT09SPMC)
6. Hose clamp
A. Face the bolt head to the position as shown
in the figure.
B. 123°
C. 105°
D. 10°
E. Hose until it butts against the purge cut valve
solenoid. (for MT09MC/MT09SPMC)
F. The end of the clip should face the upward.
(for MT09MC/MT09SPMC)
G. Hose until it butts against the throttle body
joint. (for MT09MC/MT09SPMC)
H. The end of the clip should face the forward.
(for MT09MC/MT09SPMC)
I. The end of the clip should face the left. (for
MT09MC/MT09S PMC)
J. The end of the clip should face the right. (for
MT09MC/MT09S PMC)
K. Hose until it butts against the throttle body.
(for MT09MC/MT09SPMC)
L. 5-7 mm (0.20--0.28 in) (3 places) (for
MT09MC/MT09S PMC)
M. Insert the cylinder head breather hose until it
reaches the rounded end of the p ipe. Install
the cylinder head breather hose with the yel-
low paint mark facing the left. Install the clip
with its end facing the left.
N. Insert the cylinder head breather hose until it
reaches the rounded end of the p ipe. Install
the cylinder head breather hose with the
white paint mark facing the right. Install the
clip with its end facing the right.
0. 1-3 mm (0.04--0.12 in)

2-62
 CABLE ROUTING

Radiator (front side view)

2-63
 CABLE ROUTING

1. Front tum signal/position light lead (left)

2. Radiator
3. Radiator outlet hose
4. Thermostat assembly
5. Front tum signal/position light lead (right)
6. Radiator cap
7. Coolant reservoir hose
8. Water jacket joint
9. Radiator inlet hose
A. Face the tip of the clip toward the yellow paint
mark on the radiator outlet hose.
B. Align the yellow paint mark on the radiator
outlet hose with the rib on the th,ermostat
assembly.
C. Insert the radiator outlet hose urntil it touches
the rib of the thermostat assembly.
D. Install the radiator hose (cylinder head to
radiator) with its white paint mark facing for-
ward.
E. Install the radiator hose (cylinder head to
radiator) up to the base of the bend in the
radiator pipe.
F. Install the clip with its end facing the down.
G. Insert the coolant reservoir hose up to the
section where the radiator pipe increases in
diameter.
H. Fit the clip with its end facing inward. Fit the
clip in the center between the spools, never
ride on the spool.
I. Insert the radiator inlet hose unti l it touches
the rib of the water jacket joint.
J. Align the yellow paint mark on the radiator
inlet hose with the rib on the water jacket
joint.
K. Install the hose clamp screw to face it top
side.
L. Install the hose clamp with the screw head
facing the inward.
M. Install the radiator inlet hose with its white
paint mark facing outward.
N. Insert the radiator inlet hose up to the section
where the fuel tank pipe increases in diame-
ter.
0. Insert the radiator outlet hose up to the sec-
tion where the fuel tank pipe increases in
diameter.
P. Install the radiator outlet hose with its white
paint mark facing outward.
Q. Hose clamp fixed position details.
R. 3 mm (0.12 in) or more
S. 0-1 mm (0-0.04 in)
T. Hose plug-in section
U. Make sure not to install the hose clamp on
the raised portion of the hose fitting.
V. Hose clip fixed position details.
W. Make sure not to install the hose clip on the
raised portion of the hose fitting.

2-64
 CABLE ROUTING

Radiator (right side view)

.,.,1

_,,, ·.:/ft-._
- -· '. '.

,.A, \,:::~. .
I
.-.}~~,~-f,
-'\_:. ·. :·.- -
(
I~
··>_? .. --.
~. ✓\t?---···

[ru
l. ,,
;'\ : . ,
I
, ,
.,:,
..•'

',, ••
=
= .//
--

, '.•. - '.
•"'

·,

:-~~
...~...
-~t - ·?:

/)
l'..r
___
--~
,•
.

~-; · ~ i)
. L-:.
A

2-65
 CABLE ROUTING

1. Radiator
2. Radiator hose (cylinder head to radiator)
3. Radiator fan motor lead
4. Radiator fan cover
A. Direction of the hose tip does not matter.
B. Pass the coolant reservoir hose through the
front side panel (right) guide.
C. Pass the radiator hose (cylinder head to radi-
ator) through the notch of the radiator fan
cover.
D. Pass the radiator fan motor lead through the
notch of the radiator fan cover.

2-66
 CABLE ROUTING

. ht 8 ·,de view)
Radiator (ng

[j] ~
~
IE]

2-67
 CABLE ROUTING

1. Radiator hose (cylinder head to radiator)

A . Insert the radiator hose (cylinder head to

radiator) to the root of the radiator property.
B. 0-2 mm (Cl---0.08 in)
C. Front side of the vehicle
D. Right side of the vehicle
E. Install the clip with its end facing the rear.
F. 3 mm (0.12 in) or more
G . Make sure not to install the hose clip on the
raised portion of the hose fitting.
H. Hose plug-in section
I. Hose clip fixed position details.

2-68
 CABLE ROUTING

Oil cooler and thermostat (front side view)

Q] [Q]

2-69
 CABLE ROUTING

1. Water jacket joint

2. Water pump inlet hose
3. Thermostat assembly
4. Oil cooler
5. Oil cooler outlet hose
6. Oil cooler inlet hose
7. Radiator inlet hose

A. Install the clip with its end facing the front.

B. Face the white paint mark on the oil cooler
outlet hose forward and insert until the hose
stops.
C. Align the yellow paint mark on the water
pump inlet hose with the rib on the thermo-
stat assembly, and insert until the hose stops.
D. Install the clip with its end facing the rear.
E. Install the hose clamp with its end the screw
head facing the down.
F. Fit the clip at a position more than 1 mm
(0.04 in) from the end of the hose, and do not
ride on the spool.
G. Face the yellow paint mark on the hoses for-
ward, insert them up to the step where the
thick part of pipe.
H. Install the clip with its end facing the right.
I. Align the white paint mark on the oil cooler
inlet hose with the rib on the water jacket
joint, and insert until the hose stops.
J. Hose clamp fixed position details.
K. 3 mm (0.12 in) or more
L. 0-1 mm (0-0.04 in)
M. Hose plug-in section
N. Make sure not to install the hose clamp on
the raised portion of the hose fitting.
0. Hose clip fixed position details.
P. Make sure not to install the hose clip on the
raised portion of the hose fitting.

2-70
 CABLE ROUTING

Water pump (left side view)

'
', ) ,._,, ,, \

\~
~\ \v-"-j~ V

v/ .
-

)/7,ff~·.
~ ":~ ,A(1~ (1~
@-

\~ ,I
\

i'
,F r~

- --.
N'o1'JJi)..:~" j \\
1 --?c\.Jll~JD ', ~--
' ,_ __//
''----. _ _

\1 - - ~=~

[BJ

2-71
 CABLE ROUTING

1. Water pump inlet hose

2. Water pump assembly
3. Radiator outlet hose
4. Radiator
A. Align the white paint mark on Iha water pump
inlet hose with the rib on the water pump and
insert until the hose stops.
B. Hose clamp fixed position details.
C. 3 mm (0.12 in) or more
D. 0- 1 mm (0-0.04 in)
E. Hose plug-in section
F. Make sure not to install the hose clamp on
the raised portion of the hose fitting.

2-72
 CABLE ROUTING

2-73
 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 .............................................. 3-8
SYNCHRONIZING THE THROTTLE BODIES......... ................................. 3-8

El
CHECKING THE THROTTLE BODY JOINTS ........................................ 3-10
CHECKING THE CYLINDER HEAD BREATHER HOSE ....................... 3-10
CHECKING THE EXHAUST SYSTEM ..................... ............................... 3-10
CHECKING THE CANISTER (for MT09MC/MT09SPMC) ...................... 3-11
CHECKING THE PURGE CUT VALVE SOLENOID
(for MT09MC/MT09SPMC) ................................................... .................. 3-11
REPLACING THE AIR FILTER ELEMENT ............................................. 3-11
ADJUSTING THE CLUTCH LEVER FREE PLAY ................................... 3-12
CHECKING THE BRAKE OPERATION .................................................. 3-12
CHECKING THE BRAKE FLUID LEVEL. ................................................ 3-13
ADJUSTING THE FRONT DISC BRAKE ... .............. ............................... 3-13
CHECKING THE FRONT BRAKE PADS ................................................ 3-13
ADJUSTING THE REAR DISC BRAKE ................... ............................... 3-14
CHECKING THE REAR BRAKE PADS .................................................. 3-14
CHECKING THE FRONT BRAKE HOSES ............................................. 3-14
CHECKING THE REAR BRAKE HOSE .................................................. 3-15
BLEEDING THE HYIDRAULIC BRAKE SYSTEM (ABS) ......................... 3-15
CHECKING THE WHEELS ..................................................................... 3-16
CHECKING THE T IRES .......................................................................... 3-16
CHECKING THE WHEEL BEARINGS .................................................... 3-17
CHECKING THE SWINGARM OPERATION .......................................... 3-17
LUBRICATING THE SWINGARM PIVOT ............................................... 3-17
DRIVE CHAIN SLACK. ......................... ..................... .............................. 3-17
LUBRICATING THE DRIVE CHAIN ......................... ............................... 3-19
CHECKING AND ADJUSTING THE STEERING HEAD ......................... 3-19
LUBRICATING THE STEERING HEAD ................... ............................... 3-20
CHECKING THE CHASSIS FASTENERS .............................................. 3-20
LUBRICATING THE BRAKE LEVER ...................................................... 3-20
LUBRICATING THE CLUTCH LEVER .................................................... 3-20
LUBRICATING THE PEDAL ... .................................. .............................. 3-20
ADJUSTING THE SHIFT PEDAL. ............................ ............................... 3-20
CHECKING THE SIDESTAND .............................................. .................. 3-20
LUBRICATING THE SIDESTAND........................................................... 3-20
CHECKING THE SIDESTAND SWITCH ............ ...... .......................... ..... 3-20
CHECKING THE FRONT FORK ............................................................. 3-20
ADJUSTING THE FRONT FORK LEGS (for MT09M/MT09MC) ............ 3-21
ADJUSTING THE FRONT FORK LEGS (for MT09SPM/MT09SPMC) ... 3-22
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 3-24
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
(for MT09M/MT09M C) ............................................. ..... .......................... 3-25
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
(for MT09SPM/MT09SPMC) ..................... ............................................. 3-26
CHECKING THE CONNECTING ARM AND RELAY ARM ..................... 3-27
CHECKING THE EN GINE OIL LEVEL. .............. ..................................... 3-27
CHANGING THE ENGINE OIL ............................................................... 3-28
MEASURING THE ENGINE OIL PRESSURE ......... ............................... 3-29
CHECKING THE COOLANT LEVEL. ...................................................... 3-30
CHECKING THE COOLING SYSTEM .................... ................................ 3-31
CHANGING THE COOLANT ................ ..................... .............................. 3-31
CHECKING THE FRONT BRAKE LIGHT SWITCH . ............................... 3-33
ADJUSTING THE REAR BRAKE LIGHT SWITCH .. ............................... 3-33
CHECKING AND LUBRICATING THE CABLES .................................... 3-33
CHECKING THE THROTTLE GRIP .......................... .............................. 3-33
CHECKING AND CHARGING THE BATTERY ........ ............................... 3-34
CHECKING THE FUSES ........................... ............................................. 3-34
ADJUSTING THE HEADLIGHT BEAM ................................................... 3-34
 PERIODIC MAINTENANCE

EA""""2

PERIODIC MAINTENANCE
"""""""
INT RODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
foll'.o wed, 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.

""""""'
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi
(13000 km) or 12 months.
• Items marked with an asterisk require special tools, data and technical skills, have a Yamaha dealer
perform the service.

INITIAL ODOMETER READINGS

600ml 4000ml 8000ml 12000 m l 16000ml 20000 m l

No. rrEM ROUTINE
(1000 km) (7000 km) (13000 (19000 (25000 (31000
or or km)or km)or km)or km)or
1 month 6 months 12 months 18 mon1hs 24months 30 months

1 . Fuelllne
• Check fuel hoses for cracks or
damage.
• Replace H necessary.
✓ ✓ ✓ ✓ ✓

2 . Spar1<plugs
• Check condition.
• Adjust gap and clean .
• Replace.
✓ ✓ ✓ ✓

Every 12000 mi (19000 km) or 18 mon1hs

✓

3 . Valve clearance
• C heck and adju'91 valve clear-
ance when engi ne Is cold.
Every 26600 mi (42000 km)

4 . Crankcase breath- • Check breather hose for

cracks or damage . ✓ ✓ ✓ -./ ✓

.
er system
• Replace H necessary.
5 Fuel lnjecdon • Adjust synchronizat ion . ✓ ✓ ✓ ✓ -./ ✓

6 . Exhaust system
• C heck for leakage.
• Tighten H neces sary.
• Replace gasket(s) ,f neces- ✓ ✓ ✓ ✓ -./ ✓
sary.

7 . Evaporadve emls-
slon control sys-
tern \lor California
• Check control system for
damage .
• Replace H necessary.
✓ ✓
only

EA"""'15
GENERAL MAINTENANCE AND LUBRICATION CHART
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi
(13000 km) or 12 months.
• Items marked with an asterisk require special tools, data and technical skills, have a Yamaha dealer
perform the service.

3-1
 PERIODIC MAINTENANCE

INITIAL ODOMETER READINGS

No. 600ml 4000ml 8000ml 12000 ml 16000ml 20000 m l

rrEM ROUTINE
(1000 km) (7000 Ion) (13000 (19000 (25000 (31000
or or km)or Ion) or km)or km)or
1 month 6 months 12 months 18 mon1hs 24months 30 mon1hs

1 . Dlagnosllc sys- • Perfonn dynami c Inspection

using Yamaha d iagnostic tool. ✓ ✓ ✓ ✓ ✓ ✓

.
temcheck
• Check the error codes.
2 Air filter elernen1 • Replace . Every 24000 mi (37000 km)

3 • Clutch
• Check operat ion.
• Adjust o r replaoe cable.
✓ -J ✓ ✓ ✓ ✓

4 . Front brake
• Check or.;irat ion, fluid level,
and for f uid leal<a~e.
• Replace brake pa s if neces- ✓ ✓ ✓ ✓ ✓ ✓
sary.

5 . Rear brake
• Check or.;irat ion, fluid level,
and for f uid leal<a~e.
• Replace brake pa s if neces- ✓ ✓ ✓ ✓ ✓ ✓
sary.

6 . Brake hoses
• C heck for cracks or damage.
• C heck for correct routing and
clamping.
✓ ✓ ✓ ✓ ✓

7 . Brake fluid
• Replace.
• Change.
Every 4 years
Every 2 years

8 . Wheels
• Check runoul and for damage.
• Replace tt necessary.
✓ ✓ ✓ ✓ ✓

9 . Tires
• Check tread depth and for
damage.
• Replace tt necessary.
• Check air pressure .
✓ ✓ ✓ ✓ ✓

• Correct if necessary.
• C heck bearings for smooth
10 ' Wheel bearings operation. ✓ ✓ ✓ ✓ ✓
• Replace tt necessary.

11 . Swlngarm pivot
bearings
• C heck operation and for ex-
cesslve play.
• Moderately repack with ltthi-
✓ ✓ ✓

Every 32000 mi (50000 km)

✓ ✓

um-soap-based grease.
• C heck chain sla ck, allgnmen1
and condition.
12 Every 600 mi (1000 km) and after washing the motorcycle, riding in the
Drive chain • Adjust and lubricate chain wtth rain or riding In wet areas
a special O-ring chain lub ri-
can1 thoroughly.
• Check bearing assemblies for ✓
✓ ✓ ✓ ✓ ✓
looseness.
13 ' Steering bearings
• Moderately repack wtth lithi-
Every 12000 mi (19000 km)
um-soap-based grease.
• Check all chassis fitting and
14 ' Chassis fasteners fasteners. ✓ ✓ ✓ ✓ ✓
• Correct if necessary.
Brake lever pivot
15 • Apply silicone g rease lightly. ✓ ✓ ✓ ✓ ✓
shaft
Brake pedal pivot • Apply lithium-soap-based
16 ✓ ✓ ✓ ✓ ✓
shaft grease lightly.
Clutch lever pivot • Apply lithium-soap-based
17 ✓ ✓ ✓ ✓ ✓
shaft grease lightly.
Shift pedal pivot • Apply lithium-soap-based
u shaft grease lightly.
✓ ✓ ✓ ✓ ✓

• Check operation.
u Sldestand pivot • Apply lithium-soap-based ✓ ✓ ✓ ✓ ✓
grease lightly.
• Check operation and replace
20 ' Sldestand switch ✓ -./ ✓ -./ ✓ ✓
tt necessary.
• Check operation and for oil
21 ' From fork
. leakage.
Replace tt necessary.
✓ ✓ ✓ ✓ ✓

3-2
 PERIODIC MAINTENANCE

INITIAL ODOMETER READINGS

600ml 4000ml 8000ml 12000 ml 16000 ml 20000ml

No. FTEM ROUTINE
(1000km) (7000 km) (13000 (19000 (25000 (31000
or or km) or km)or km) or km)or
1 month 6 months 12 months 18months 24 months 30mon1hs

12: . Shock absorber

assembly
• Check operation and for oil
leakage.
• Replace tt necessary.
..J ✓ ..J ✓ ..J

Rear suspension • Check ogeration.

2:1 • ✓ ✓
link pivots • Correct necessary.
• Change (warm engine before ✓
2, Engine oil ..J ✓ ..J ✓ ..J
draining).
Engine oil filter ✓
2! • Replace. ✓ ✓
cartridge

21 . Cooling system
• Check coolant level and vehi-
cle for coolant leakage.
..J ✓ ..J ✓ ..J

.
• Change coolant. Every 3 yea rs
Front and rear
2, • Check operation . ✓ ..J ✓ ..J ✓ ..J
brake switches

2l . Control cables
• Ap~ Yamaha cable lubricant
or er suitable cable lubri-
cant thoroughly.
✓ ..J ✓ ..J ✓ ..J

• Check operation.
29 • Throttle grip • Lubricate throttle glip housing ..J ✓ ..J ✓ ..J
tubeguidM.
31 . Lights, slinals
and swttc es
• Check operation.
• Adjust headligh1 beam.
✓ ..J ✓ ..J ✓ ..J

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Air filter
• This model uses a disposable oil-coated paper element. This element cannot be cleaned with com-
pressed ai r, 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 as necessary.
• Every two years replace the internal component s of the brake master cylinders and calipers, and
change the brake fluid.
• Replace the brake hoses every four years or sooner if cracked o r damaged.

3-3
 PERIODIC MAINTENANCE

EAS32""' EAS30<19
CHECKING THE VEHICLE USING THE CHECKING THE FUEL LINE
YAMAHA DIAGNOSTIC TOOL The following procedure applies to all of the fuel,
Use the VDT 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. • Fuel tank center cover
2. Remove the protective cap, and then connect Refer to "GENERAL CHASSIS (1)" on
the VDT to the coupler. page 4-1.
Refer to ''YDT' on page 9-3. • Fuel tank
Refer to "FUEL TANK" on page 7-1 .
Yamaha diagnostic tool use 2. Check:
(US) • Fuel hose "1"
90890-03269 • Fuel tank breather hose "2"
Yamaha diagnostic tool (A/1) • Fuel tank drain hose "3"
90890-03264 Cracks/damage ➔ Replace.
Loose connection ➔ Connect property.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ ECA14940

• Yamaha diagnostic tool (All) (90890-03264) in- NOTICE

cl udes VDT sub harness (6P) (90890-03266). ------------
Make sure the fuel tank breather hose is rout-
• If you already have Yamaha diagnostic tool (A/ ed correctly.
I) (90890-03262), VDT sub harness (6P)
(90890-03266) is separately required. TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Before removing the fuel hoses, place a few
3. Check:
rags in the area under where it will be removed.
• OTC
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Use the "Diagnosis of malfunction" function of
the VDT to check the OTC. For information
about using the VDT, refer to the operation man-
ual that is included with the tool.
OTC No. is displayed ➔ Check and repair the
probable cause of the malfunction.
Refer to "SELF-DIAGNOSTIC FUNCTION
AND DIAGNOSTIC CODE TABLE" on
page 9-39. 3. Install:
4. Perform: • Fuel tank
• Dynamic inspection Refer to "FUEL TANK" on page 7-1.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ • Fuel tank center cover
Use the "Dynamic inspection" function of the Refer to "GENERAL CHASSIS (1 )" on
VDT version 3.0 and after to perform the dynam- page 4-1.
ic inspection. For information about using the • Rider seat
VDT, refer to the operation manual that is includ- Refer to "GENERAL CHASSIS (1 )" on
ed with the tool. page 4-1.

5. Install:
• Rider seat
Refer to "GENERAL CHASSIS (1 )" on
page 4-1.

3-4
 PERIODIC MAINTENANCE

...,.,.,.
CHECKING THE SPARK PLUGS
The following procedure applies to all of the
spark plugs.
1. Remove:
• Rider seat
Refer to "GENERAL CHASSIS (1 )" on
page 4-1. 1
• Fuel tank center cover
Refer to "GENERAL CHASSIS (1 )" on G088879
page 4-1. 7. Install:
• Fuel tank • Spark plug
Refer to "FUEL TANK" on page 7-1. • Ignition coil
• Air filter case
Refer to "GENERAL CHASSIS (2)" on Spark plug
page 4-10. 13 N-m (1.3 kgf•m, 9.6 lb•ft)
2. Remove:
• Ignition coil TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Spark plug Before installing the spark plug, clean the spark
ECA13320
plug and gas.ket surface.
NOTICE
------------
Before removing the spark plugs, blow away 8. Install:
any dirt accumulated in the spark plug wells • Air filter case
with compressed air to prevent it from falling Refer to "GENERAL CHASSIS (2)" on
into the cylinders. page 4-10.
• Fuel tank
3. Check: Refer to "FUEL TANK" on page 7-1.
• Spark plug type • Fuel tank center cover
Incorrect ➔ Change. Refer to "GENERAL CHASSIS (1)" on
page 4-1.
Manufacturer/model • Rider seat
NGK/LMAR9A-9
Refer to "GENERAL CHASSIS (1 )" on
4. Check: page 4-1.
• Electrode "1" EAS,0.,0

Damage/wear ➔ Replace the spark plug. ADJUSTING THE VALVE CLEARANCE

• Insulator "2" The following procedure applies to all of the
Abnormal color ➔ Replace the spark plug. valves.
Normal color is medium-to-light tan. TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
5. Clean: Valve clearance adjustment should be made on
• Spark plug a cold engine, at room temperature.
(with a spark plug cleaner or wire brush)
6. Measure: 1. Remove:
• Spark plug gap "a" • Rider seat
(with a wire thickness gauge) Refer to "GENERAL CHASSIS (1 )" on
Out of specification ➔ Regap. page 4-1.
• Fuel tank center cover
Spark plug gap Refer to "GENERAL CHASSIS (1)" on
0.8-0.9 mm (0.031-0.035 in) page 4-1.
• Fuel tank
Refer to "FUEL TANK" on page 7-1.
• Air filter case
Refer to "GENERAL CHASSIS (2)" on
page 4-10.

3-5
 PERIODIC MAINTENANCE

• Front side panel TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __

Refer to "GENERAL CHASSIS (1 )" on TDC on the compression stroke can be found
page 4-1 . when the camshaft lobes are turned away from
• Radiator each other.
Refer to "RADIATOR" on page 6-3.
2. Remove: c. Measure the valve clearance with a thick-
• Ignition coil ness gauge.
• Spark plug
• Cylinder head cover Thickness gauge
• Cylinder head cover gasket 90890-03268
Refer to "CAMSHAFTS" on page 5-16. Feeler gauge set
3. Remove: VU-26900-9
• Timing mark accessing bolt "1"
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Crankshaft end cover "2"
• If the valve clearance is incorrect, record the
measured reading.
• Measure the valve clearance in the following
sequence.

Valve clearance measuring sequence

Cylinder #1 ➔ #2 ➔ #3

4. Measure:
• Valve clearance
Out of specification ➔ Adjust.

Valve clearance (cold)

Intake
0.11--0.20 mm (0.0043--0.0079
00
in) G088882 #1 #2 #3
Exhaust A. Front
0.28--0.32 mm (0.0110-0.0126
in) d. To measure the valve clearances of the
other cylinders, starting with cylinder #1 at
a. Tum the crankshaft counterclockwise. TDC, tum the crankshaft counterclockwise
b. When piston #1 is at TDC on the compres- as specified in the following table.
sion stroke, align the TDC mar k "a" on the
B o· 240• 490• 120·
generator rotor with the generator rotor cov-
er mark"b". ::::::::===> I....__....._
I ____._I_____.I
#1 D
C #2 D
#3 D

B. Degrees that the crankshaft is turned coun-

terclockwise
C. Cylinder
D. Combustion cycle

3-6
 PERIODIC MAINTENANCE

Cylinder#2 240° Example:

If the valve pad is marked "158", the pad
Cylinder#3 480° thickness is 1.58 mm (0.062 in).

5. Remove:
• Camshaft a
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Refer to "CAMSHAFTS" on page 5-16.
c5 -;)_:j
;....
• When removing the timing chain and cam-
shafts, fasten the timing chain with a wire to re-
trieve it if it falls into the crankcase.

6. Adjust:
• Valve clearance
G088885
) -~ ···
'-.i..

, ,
.. ~)
-~

:""-' ;

d. Calculate the sum of the values obtained in

-~

steps (b) and (c) to determine the required

a . Remove the valve lifter and the valve pad
valve pad thickness and the valve pad num-
with a valve lapper.
ber.
Example:
Valve lapper (B14)
90890-04101 1.58 mm (0.062 in) + 0.05 mm (0.002 in) =
Valve lapper (ta14) 1.63 mm (0.064 in)
VM-A8998 The valve pad number is 163.
e. Round off the valve pad number according
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ to the following table, and then select the
• Cover the timing chain opening with a rag to suitable valve pad.
prevent the valve pad from falling into the Last digit Rounded value
cr ankcase.
0, 1, 2 0
• Make a note of the position of each valve lifter
and valve pad so that they can be installed in 3, 4, 5,6 5
the correct place. 7, 8, 9 10
b. Calculate the difference between the spec-
ified valve clearance and the measured
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
valve clearance. Refer to the following table for the available
Example: valve pads.
Specified valve clearance= 0.11-0.20 mm
(0.004-0.008 in) Valve pad range Nos. 150- 240
Measured valve clearance = 0.25 mm Valve pad thickness 1.50-2.40 mm
(0.010 in) (0.0590-0.0944 in)
0.25 mm (0.010 in) - 0.20 mm (0.008 in) = Available valve pads 25 thicknesses in
0.05 mm (0.002 in) 0.05 mm (0.002 in) in-
c. Check the thickness of the current valve crements
pad.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ Example:
The thickness "a" of each valve pad is marked in Valve pad number= 163
hundredths of millimeters on the side that touch- Rounded value = 165
es the valve lifter. New valve pad number = 165
f. Install the new valve pad and the valve lift-
er.

3-7
 PERIODIC MAINTENANCE

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Lubricate the valve pad with molybdenum di- Engine idling speed
sulfide oil. 1200-1400 r/min
• Lubricate the valve lifter (Top side) with molyb- 3. Check:
denum disulfide oil.
• ISC (idle speed control) learning value
• Lu bricate the valve lifter (Outer side) with en- "00" or "0 1" ➔ Check the intake system.
gine oil. "02" ➔ Clean the throttle bodies.
• Install the valve lifter and the valve pad in the Refer to "CHECKING AND CLEANING THE
correct place. THROTTLE BODIES" on page 7-7.
• The valve lifter must turn smoothty when rotat-
ed by hand. a. Connect the YDT.
Use the diagnostic code number "67''.
g. Install the exhaust and intake camshafts, Refer to "DIAGNOSTIC CODE: SENSOR
timing chain and camshaft caps. OPERATION TABLE" on page 9-62.
b. Check the ISC (idle speed control) leaning
Camshaft cap bolt value.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
EAS30"'7

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ SYNCHRONIZING THE THROTTLE BODIES

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Refer to "CAMSHAFTS" on page 5-16.
• Lubricate the camshaft lobes andl camshaft Before synchronizing the throttle bodies, check
journals. the following items:
• First, install the exhaust camshaft. • Valve clearance
• Align the camshafts marks with the camshaft • Spark plug
cap marks. • Air filter element
• Turn the crankshaft counterclockwise several • Throttle body joint
full turns to seat the parts. • Fuel hose
• Exhaust system
h. Measure the valve clearance again. • Breather hose
i. If the valve clearance is still out of specifica-
tion, repeat all of the valve clearance ad-
Checking the throttle body synchronization
justment steps until the specified clearance
1. Stand the vehicle on a level surface.
is obtained.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
7. Install: Place the vehicle on a maintenance stand.
• All removed parts
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ 2 . Remove:
For installation, reverse the removal procedure. • Rider seat
Refer to "GENERAL CHASSIS (1)" on
EAS31017
page 4-1.
CHECKING THE ENGINE IDLING SPEED • Fuel tank center cover
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ Refer to "GENERAL CHASSIS (1)" on
page 4-1.
Prior to checking the engine idling speed, the
throttle body synchronization should be adjusted • Fuel tank
properly, the air filter element should be clean,
Refer to "FUEL TANK" on page 7-1.
• Air filter case
and the engine should have adequate compres-
Refer to "GENERAL CHASSIS (2)" on
sion.
page 4-10.
1. Start the engine and let it warm up for several
minutes.
2. Check:
• Engine idling speed
Out of specification ➔ Go to next step.

3-8
 PERIODIC MAINTENANCE

3. Remove: Adjusting the throttle body synchronization

• Service hose cap "1" 1. Adjust:
• Throttle body synchronization
a. Start the engine, warm it up for several min-
utes, and then let it run at the specified en-
gine idling speed.

Engine idling speed

1200--1400 r/min

b. Using the throttle body that has the bypass

air screw "1" with a white paint mark as the
4. Install: standard, adjust the other throttle bodies by
• Vacuum gauge "1" turning its bypass air screw in or out.
ECA21300

)fb Vacuum gauge

90890-03094
NOTICE
-------------
Do not tum the bypass air screw (white pai'nt
mark) of the throttle body that is the stan-
Vacuummate
YU-44456 dard. Otherwise, the engine may run roughly
at idle and the throttle bodies may not oper-
ate properly.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Turn the bypass air screw using the carburetor
angle driver.
• After each step, rev the engine two or three
times, each time for less than a second, and
check the synchronization again.
• If a bypass air screw was removed, turn the
screw in fully and be sure to synchronize the
5. Install:
throttle bodies.
• Air filter case
• If the throttle body synchronization can not be
Refer to "GENERAL CHASSIS (2)" on
adjusted using the bypass air screw, clean or
page 4-10.
replace the throttle bodies.
• Fuel tank
• The difference in vacuum pressure between
Refer to "FUEL TANK" on page 7-1. the throttle bodies should not exceed 1.3 kPa
6. Check:
(10 mmHg).
• Throttle body synchronization
a . Start the engine, warm it up for several min-
utes, and then let it run at the specified en-
gine idling speed.
)fb Carburetor angle driver 2
90890-03173

Engine idling speed

1200-1400 r/min

b. Check the vacuum pressure.

Difference in vacuum pressure

between the cylinders
0-1 .3 kPa (10 mmHg, 0.4 inHg)

If out of specification ➔ Adjust the throttle

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

3-9
 PERIODIC MAINTENANCE

3. Install: 2. Check:
• Service hose cap • Cylinder head breather hose "1"
4. Install: Cracks/damage ➔ Replace.
• Air filter case Loose connection ➔ Connect properly.
ECA14920
Refer to "GENERAL CHASSIS (2)" on
page 4-10. NOTICE _ _ _ _ _ _ _ _ _ _ __
• Fuel tank Make sure the cylinder head breather hose is
Refer to "FUEL TANK" on page 7-1 . routed correctly.
• Fuel tank center cover
Refer to "GENERAL CHASSIS (1 )" on
page 4-1.
• Rider seat
Refer to "GENERAL CHASSIS (1 )" on
page 4-1.
...,.,,.
CHECKING THE THROTTLE BODY JOINTS
1. Remove:
• Throttle body
Refer to ''THROTTLE BODIES" on page 7-5. 3. Install:
2. Check: • Air filter case
• Throttle body joint Refer to "GENERAL CHASSIS (2)" on
Cracks/damage ➔ Replace. page 4-10.
3. Install: • Fuel tank
• Throttle body Refer to "FUEL TANK" on page 7-1 .
Refer to ''THROTTLE BODIES" on page 7-5. • Fuel tank center cover
...,...,
CHECKING THE CYLINDER HEAD
Refer to "GENERAL CHASSIS (1 )" on
page 4-1.
• Rider seat
BREATHER HOSE
1. Remove: Refer to "GENERAL CHASSIS (1)" on
page 4-1.
• Rider seat
Refer to "GENERAL CHASSIS (1 )" on EAS30«1!5

page 4-1. CHECKING THE EXHAUST SYSTEM

• Fuel tank center cover 1. Check:
Refer to "GENERAL CHASSIS (1 )" on • Muffler assembly "1"
page 4-1. Cracks/damage ➔ Replace.
• Fuel tank • Gasket "2"
Refer to "FUEL TANK" on page 7-1 . Exhaust gas leaks ➔ Replace.
• Air filter case 2. Check:
Refer to "GENERAL CHASSIS (2)" on Tightening torque
page 4-10. • Exhaust p ipe nut "3"
• Muffler bolt "4"

Ex haust pipe nut

20 N,m (2.0 kgf,m, 15 lb,ft)
Muffler bolt
2 0 N,m (2.0 kgf,m, 15 lb,ft)

3-10
 PERIODIC MAINTENANCE

...,,...
CHECKING THE PURGE CUT VALVE
SOLENOID (for MT09MC/MT09SPMC)
Refer to "CHECKING THE PURGE CUT VALVE
SOLENOID (for MT09MC/MT09SPMC)" on
page 7-4.

REPLACING THE AIR FILTER ELEMENT

1. Remove:
• Rider seat
Refer to "GENERAL CHASSIS (1)" on
page 4-1.
• Fuel tank center cover
Refer to "GENERAL CHASSIS (1)" on
page 4-1.
• Fuel tank
Refer to "FUEL TANK" on page 7-1 .
2. Remove:
• ECU (Engine Control Unit) "1"
• Air filter case cover "2"
Refer to "GENERAL CHASSIS (2)" on
EAS319122 page 4-10.
CHECKING THE CANISTER (for MT09MC/
MT 09SPMC) 1
1. Remove:
• Rider seat
2
Refer to "GENERAL CHASSIS (1 )" on
page 4-1.
• Fuel tank center cover
Refer to "GENERAL CHASSIS (1 )" on
page 4-1.
• Fuel tank
Refer to "FUEL TANK" on page 7-1 . 3. Check:
2. Check: • Air filter element "1"
• Canister • Air filter seal
• Canister purge hose Damage ➔ Replace.
• Fuel tank breather hose TIP_ _ _ _ _ _ _ _ _ _ _ _ __
• Canister breather hose • Replace the air filter element every 40000 km
Cracks/damage ➔ Replace. (24000 mi) of operation.
Loose connection ➔ Connect properly. • The air filter needs more frequent service if you
Refer to "FUEL TANK" on page 7-1. are riding in unusually wet or dusty areas.
3. Install:
• Fuel tank
Refer to "FUEL TANK" on page 7-1.
• Fuel tank center cover
Refer to "GENERAL CHASSIS (1 )" on
page 4-1.
• Rider seat
Refer to "GENERAL CHASSIS (1 )" on
page 4-1.

3-11
 PERIODIC MAINTENANCE

4. Install: Handlebar side

• Air filter element a. Turn the adjusting bolt "1" until the specified
• Air filter case cover clutch lever tree play is obtained.
• ECU (Engine Control Unit)
Refer to "REPLACING THE ECU (Engine
Control Unit)" on page 8-55.
E ~IO

NOTICE
------------
Never operate the engine without the air filter
element installed. Unfiltered air will cause
rapid wear of engine parts and may damage
the engine. Operating the engine without the
air filter element will also affect throttle body G088888
synchronization, leading to poor engine per- TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
formance and possible overheating.
If the specified cl utch lever free play cannot be
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ obtained on the handlebar side of the cable, use
the adjusting nut on the engine side.
When installing the air filter element into the air
filter case cover, make sure that the sealing sur-
faces are aligned to prevent any air leaks. Engine side
a. Loosen the locknut "1".
5. Install: b. Turn the adjusting nut "2" until the specified
• Fuel tank clutch lever tree play is obtained.
Refer to "FUEL TANK" on page 7-1 . c. Tighten t he locknut "1".
• Fuel tank center cover
Refer to "GENERAL CHASSIS (1 )" on Clutch cable locknut
page 4-1. 7 N,m (0.7 kgf,m, 5.2 lb,ft)
• Rider seat
Refer to "GENERAL CHASSIS ( 1)" on
page 4-1.
EA""""9

ADJUSTING THE CLUTCH LEVER FREE

PLAY
1. Check:
• Clutch lever free play "a"
Out of specification ➔ Adjust.

Clutch lever free play

10.0-15.0 mm (0.39-0.59 in) EAS30e01

CHECKING THE BRAKE OPERATION

1 . Check:
• Brake operation
Brake not working properly ➔ Check the
brake system.
Refer to "FRONT BRAKE" on page 4-25 and
"REAR BRAK E" on page 4-37.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Drive on the dry road, operate the front and rear
G088887 brakes separately and check to see if the brakes
are operating properly.
2. Adjust:
• Clutch lever free play

3-12
 PERIODIC MAINTENANCE

EA"""32
CHECKING THE BRAKE FLUID LEVEL
1. Stand the vehicle on a level surface.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Place the vehicle on a maintenance stand.
• Make sure the vehicle is upright.
2. Check:
• Brake fluid level
Below the minimum level mark ➔ Add the G088889
specified brake fluid to the proper level.
a. Push the brake lever forward.
b. Tum the adjusting dial "1" until the brake le-
Front brake
ver is in the desired position.
Specified brake fluid
DOT4 c. Align the appropriate setting on the adjust-
Rear brake ing dial with the mark "a" on the brake lever.
Specified brake fluid
DOT4
EWA t!3000

A WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubb er seals to
d eteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brak e fluid that
is already in the system. Mixing brake fluids E\YA17'll50

may result in a harmful chemical reaction, ~ WARNING

leading to poor brake perfonnance. • After adjusting the brake lever position,
• When refilling, be careful that water does make sure the pin on the brake lever hold er
not enter the brake fluid reserv,o ir. Water is firmly inserted in the hole in the adjustin g
will significantly lower the boiling point of dial.
the brake fluid and could cause vapor lock. • A soft or spongy feeling in the brake lever
ECA135,CO
can indicat e the presence of air in the brake
system. Before the vehicle is operated, th e
NOTICE
-------------
Brake fluid may damage painted surfaces
air must be removed by bleeding the brake
system. Air in the brake system will consid-
and plastic parts. Therefore, always clean up
erably reduce brake performance resulting
any spilt brake fluid immediately.
in loss of control and possibly cause an ac-
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ cident. Therefore, check and if necessary,
In order to ensure a correct reading of the brake bleed the brake system.
fluid level, make sure the top of the brake fluid ECA13490

reservoir is horizontal. NOTICE

-------------
After adjusting the brake lever position,
O!ro!OO make sure there is no brake drag.
ADJUSTING THE FRONT DISC BRAKE
1. Adjust: EAS30<33
• Front brake lever position CHECKING THE FRONT BRAKE PADS
(distance "a" from the throttle grip to the brake The following procedure applies to all of the
lever) brake pads.
1. Operate the brake.

3-13
 PERIODIC MAINTENANCE

2. Check:
• Front brake pad
Wear indicators "1" almost touch the brake
disc ➔ Replace the brake pads as a set.
Refer to "FRONT BRAKE" on page 4-25.

1
2. Adjust:
• Rear brake light switch
Refer to "ADJUSTING THE REAR BRAKE
LIGHT SWITCH" on page 3-33.
EA"'°""
EA"""31
CHECKING THE REAR BRAKE PADS
ADJUSTING THE REAR DISC BRAKE
1. Adjust: The following procedure applies to all of the
• Brake pedal position brake pads.
1. Operate the brake.
a . Loosen the locknut "1".
2. Check:
b. Tum the adjusting bolt "2" until the specified • Rear brake pad
brake pedal position is obtained. Wear indicator grooves "1" almost disap-
EWA1:883'l

A WARNING peared ➔ Replace the brake pads as a set.

Refer to "REAR BRAKE" on page 4-37.
After adjusting the brake pedal position,
check that the end of the adjusting bolt "a" is
visible through the hole "b".
c. Tighten the locknut "1" to specification.

Rear brake master cyllinder lock-

nut
18 N•m (1.8 kgf•m, 13 lb,ft)
EWA t17'1XJO

A WARNING
EAS30G315
A soft or spongy feeling in the brake pedal
CHECKING THE FRONT BRAKE HOSES
can indicate the presence of air in the brake
The following procedure applies to all of the
system. Before the vehicle is operated, the
brake hoses and brake hose holders.
air must be removed by bleeding the brake
1. Check:
system. Air in the brake system will consid-
• Brake hose
erably reduce braking perfonnance.
Cracks/damage/wear ➔ Replace.
ECA13510
2. Check:
NOTICE • Brake hose holder
After adju-s-.ti=-
n-g-.th=-e----=-
b-ra-=-k-e-ped
---;-
al; -pos
---::it;;-io:-:n:-,- Loose ➔ Tighten the holder bolt.
make sure there is no brake drag. 3. Hold the vehicle upright and apply the brake
several times.
4. Check:
• Brake hose
Brake fluid leakage ➔ Replace the damaged
hose.
Refer to "FRONT BRAKE" on page 4-25.

3-14
 PERIODIC MAINTENANCE

EAS3CJE36
1. Bleed:
CHECKING THE REAR BRAKE HOSE
•ABS
1. Check:
• Brake hose a. Fill the brake fluid reservoir to the proper
Cracks/damage/wear ➔ Replace.
level with the specified brake fluid.
2. Check: b. Install the brake fluid reservoir diaphragm.
• Brake hose holder c. Connect a clear plastic hose "1" tightly to
Loose Connection ➔ Tighten the holder bolt. the bleed screw "2".
3. Hold the vehicle upright and apply the rear
brake several times.
4. Check:
• Brake hose
Brake fluid leakage ➔ Replace the damaged
hose.
Refer to "REAR BRAKE" on page 4-37.
EAS3Cle00
BLEEDING THE HYDRAULIC BRAKE
SYSTEM (ABS)
EWAt!40CIO

A WARNING
Always bleed the brake system when the
brake related parts are removed_

NOTICE
-------------
• Bleed the brake system in the following or-
der.
• 1st step: Front brake master cylinder
• 2nd step: Front brake calipers
• 3rd step: Rear brake caliper
E\VA U&30

A WARNING
Bleed the ABS whenever:
• the system is disassembled.
• a brake hose is loosened, disconnected or
replaced.
• the brake fluid level is very low.
• brake operation is faulty. A. Front brake master cylinder
B. Front brake caliper (left/right)
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ C. Rear brake caliper
• Be careful not to spill any brake fluid or allow d. Place the other end of the hose into a con-
the brake fluid reservoir to overflow.
tainer.
• When bleeding the ABS, make sure that there e. Slowly apply the brake several times.
is always enough brake fluid before applying f. Fully squeeze the brake lever or fully de-
the brake. Ignoring this precaution could allow press the brake pedal and hold it in position.
air to enter the ABS, considerably lengthening g. Loosen ·the bleed screw.
the bleeding procedure.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours. Loosening the bleed screw will release the pres-
• Repeat the bleeding procedure when the tiny sure and cause the brake lever to contact the
b ubbles in the hose have disappeared. throttle grip or the brake pedal to fully extend.
h. Tighten the bleed screw and then release
the brake lever or brake pedal.

3-15
 PERIODIC MAINTENANCE

i. Repeat steps (e) to (h) until all of the air

CHECKING THE TIRES
bubbles have disappeared from the brake
fluid in the plastic hose. The following procedure applies to both of the
tires.
j. Check the operation of the hyd raulic unit.
1. Check:
Refer to "HYDRAULIC UNIT O PERATION
TESTS" on page 4-53. • Tire air pressure
ECA17061 Out of specification ➔ Regulate.
E\VAt3181
NOTICE
-------------
Make sure that the main switch is turned to
A WARNING
• The tire pressure should only be checked
"OFF" before checking the operation of the
and regulated when the tire temperature
hydraulic unit.
equals the ambient air temperature.
k. After operating the ABS, repeat steps (e) to • The tire pressure and the suspension must
(i), and then fill the brake fluid reservoir to be adjusted according to the total weight
the proper level with the specified brake flu- (including cargo, rider, passenger and ac-
id. cessories) and the anticipated riding
I. Tighten the bleed screw to specification. speed.
• Operation o f an overloaded vehicle could
Front brake master cylinder cause tire damage, an accident or an injury.
bleed screw NEVER OVERLOAD THE VEHICLE.
5 N•m (0.5 kgf•m, 3.7 lb-ft)
Brake caliper bleed screw
5 N•m (0.5 kgf•m, 3.7 lb-ft) Tire air pressure (measured on
cold tires)
nn. Fill the brake fluid reservoir to the proper Up to 90 kg (198 lb) load
level with the specified brake fl uid. Front
Refer to "CHECKIN G THE BRAKE FLUID 250 kPa (2.50 kgf/cm2, 36 psi)
LEVEL" on page 3-13. Rear
E\VA1!3110 290 kPa (2.90 kgf/cm2, 42 psi)
A WARNING 90 k g (198 lb) load- maximum load
After bleeding the hydraulic brake system, Front
check the brake operation. 250 kPa (2.50 kgf/cm2, 36 psi)
Rear
290 kPa (2.90 kgt/cm2, 42 psi)
CHECKING THE WHEELS Maximum load
The following procedure applies to both of the 166 kg (366 lb)
wh eels. • Maximum load: Total weight of rider, pas-
1. Check: senger, cargo and accessories
• Wheel
2. Check:
Damage/out-of-round ➔ Replace.
EWA t!30!iO • Tire surfaces
A WARNING Damage/wear ➔ Replace the tire.
E\VAt3180
Never attempt to make any repairs to the
wheel.
A WARNING
It is dangerous to ride with a worn-out tire.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ When the tire tread reaches the wear limit, re•
After a tire or wheel has been changed or re- place the tire immediately.
placed, always balance the wheel.
Wear limit (front)
1.0 mm (0.04 in)
Wear limit (rear)
1.0 mm (0.04 in)

3-16
 PERIODIC MAINTENANCE

EWA1!4000 EAS30&11

A WARNING CHECKING THE WHEEL BEARINGS

After extensive tests, the tires listed below The following procedure applies to all of the
have been approved by Yamaha Motor Co., wheel bearing.
Ltd. for this model. The front and rear tires 1. Check:
should always be by the same manufacturer • Wheel bearing
and of the same design. No guarantee con- Refer to "CHECKING THE FRONT WHEEL"
cerning handling c haracteristics can be giv- on page 4 -13 and "CHECKING THE REAR
en if a tire combination other than one WHEEL" on page 4-2 1.
ap;proved by Yamaha is used on this vehicle. EAS30ell0

CHECKING THE SWINGARM OPERATION

1. Check:
Front tire
• Swingarm operation
Size
Swingarm not working properly ➔ Check the
12on0ZR17M/C (58W)
swingarm.
Manufacturer/model
Refer to "SW INGARM" on page 4-83.
BRIDGESTONE/BATTLAX HY·
PERSPORT S22F 2. Check:
• Swingarm excessive play
Refer to "SW INGARM" on page 4-83.
Rear tire
EAS30G43
Size
LUBRICATING THE SWINGARM PIVOT
180/55ZR17M/C (73W)
1. Lubricate:
Manufacturer/model
•Dustcover
BRIDGESTONE/BATTLAX HY·
PERSPORT S22R • Pivot shaft
• Bearing
EWA1!3210
• Oil seal
A WARNING • Collar
New tires have a relatively low grip on the
road surface until they have bee:n slightly Recommended lubricant
worn. Therefore, approximately 100 km Lithium-soap-based grease
should be traveled at normal speed before
any high-speed riding is done. Refer to "IN STALLING THE SWINGARM" on
page 4-84 .
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
EAS31923
For tires with a direction of rotation mark "1 ": DRIVE CHAIN SLACK
• Install the tire with the mark pointing in the di-
rection of wheel rotation. Checking the drive chain slack
• Align the mark "2" with the valve installation EWA13120

point. A WARNING
Securely support the vehicle so that there is
no danger of it falling over.
ECA13550

NOTICE
.- - : - , - - - - - - - - - - -
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.

3-17
 PERIODIC MAINTENANCE

2. Check: Adjusting the drive chain slack

EWA t3120
• Drive chain slack
Out of specification ➔ Adjust. ~ WARNING
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ Securely support the vehicle so that there is
no danger of it falling over.
• Measure the distance "a" between the rib end
on the drive chain guide "1" and the center 1. Loosen:
point of the drive chain "2". • Wheel axle nut
• The center point "b" of the drive chain is ap- Refer to "REAR WHEEL" on page 4-18.
prox. 32 mm (1 .26 in) "d' forward from the edge 2. Adjust:
"d" of the drive chain guide. • Drive chain slack
a. Loosen both locknuts "1".
Drive chain slack (Sidestand) b. Tum both adjusting bolts "2" until the spec-
36.0-41.0 mm (1.42-1.61 in) ified drive chain slack is obtained.
Drive chain slack (Maintenance
stand) '
36.0-41.0 mm (1.42-1.61 in)
' '
•'
Drive chain slack limit (Side- ' <' .,__---,;:::-
stand) ' '<
46.0 mm (1.81 in) <
< "
• < (
< ---r--
l~ : l l le 4 / ;

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• To maintain the proper wheel alignment, adjust
both sides evenly.
• There should be no clearance between the ad-
justing block and adjusting bolt.
c. Tighten the wheel axle nut to specification.

Rear wheel axle nut

105 N,m (10.5 kgf,m, n lb,ft)

d. Tighten the locknuts to specification.

Chain puller adjusting bolt lock-

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

NOTICE
-------------
1m:proper drive chain slack will overload the
engine as well as other vital parts of the mo-
torcycle and can lead to chain sl:ippage or
breakage. If the drive chain slacl< is more
than the specified limit, the chain can dam-
age the frame, swingarm, and other parts. To
prevent this from occurring, keep the drive
chain slack within the specified limits.

3-18
 PERIODIC MAINTENANCE

EAS3Cle00
LUBRICATING THE DRIVE CHAIIN
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
chain should be serviced, especially when the
velhicle is used in dusty areas.
This vehicle has a drive chain with small rubber
O-rings between each side plate. Steam clean-
ing, high-pressure washing, certain solvents, G088892
and the use of a coarse brush can damage b. Loosen the lower ring nut "4" and then tight-
these O-rings. Therefore, use only kerosene to en it to specification with a steering nut
clean the drive chain. Wipe the drive chain dry wrench "5".
and thoroughly lubricate it with engine oil or TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
chain lubricant that is suitable for O- ring chains.
• Set the torque wrench at a right angle to the
Do not use any other lubricants on the drive
steering nut wrench.
chain since they may contain solvents that could
• Move the steering to the left and right a couple
damage the O-rings.
of times to check that it moves smoothly.
Recommended lubricant
Chain lubricant suitable for O·
ring chains

EAS3CJGooo
CHECKING AND ADJUSTING THE
STEERING HEAD
1. Stand the vehicle on a level surface.
E\VA tl3120

A WARNING
Securely support the vehicle so that there is
no danger of it falling over.
Steering nut wrench
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ 90890-01403
Place the vehicle on a maintenance stand so Exhaust flange nut wrench
VU-A9472
that the front wheel is elevated.
2. Check:
Lower ring nut (initial tightening
• Steering head
torque)
Grasp the bottom of the front fork legs and 52 N,m (5.2 kgf,m, 38 lb,ft)
gently rock the front fork.
Blinding/looseness ➔ Adjust the steering c. Loosen the lower ring nut completely, then
head. tighten it to specification.
3. Remove: EWA1 3140

• Upper bracket A WARNING

4. Adjust: Do not overt.ighten the lower ring nut.
• Steering head
a. Remove the lock washer "1 ", tine upper ring Lower ring nut (final tightening
nut "2", and the rubber washer "3". torque)
14 N,m (1.4 kgf,m, 10 lb,ft)

3-19
 PERIODIC MAINTENANCE

d . Check the steering head for looseness or EA"'°""

LUBRICATING THE CLUTCH LEVER
binding by turning the front fork all the way
Lubricate the pivoting point and metal-to-metal
in both directions. If any binding is felt, re-
moving parts of the lever.
move the lower bracket and check the up-
per and lower bearings.
Recommended lubricant
Refer to "STEERING HEAD" on page 4-74.
Lithium-soap-based grease
e . Install the rubber washer "3".
f. Install the upper ring nut "2". EAS30640
g . Finger tighten the upper ring nut, then align LUBRICATING THE PEDAL
the slots of both ring nuts. If necessary, hold Lubricate the pivoting point and metal-to-metal
the lower ring nut and tighten the upper ring moving parts of the pedal.
nut until their slots are aligned.
h. Install the lock washer "1". Recommended lubricant
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ Lithium-soap-based grease
Make sure the lock washer tabs "a" sit correctly
in the ring nut slots "b". ADJUSTING THE SHIFT PEDAL
Refer to "ADJUSTING THE SHIFT PEDAL" on
page 4-91.

CHECKING THE SIDESTAND

1. Check:
• Sidestand operation
Check that the sidestand moves smoothly.
Rough movement ➔ Repair or replace.

LUBRICATING THE SIDESTAND

5. Install: Lubricate the pivoting point, metal-to-metal mov-
• Upper bracket ing parts and spring contact point of the side-
Refer to "HANDLEBAR" on page 4-57. stand.
EA.,....

LUBRICATING THE STEERING HEAD Recommended lubricant

1. Lubricate: Molybdenum disulfide grease
• Upper bearing
EAS30Gl!O
• Lower bearing CHECKING THE SIDESTAND SWITCH
• Bearing race Refer to "ELECTRICAL COMPONENTS" on
page 8-51.
Recommended lubricant
Lithium-soap-based grease EA""""3
CHECKING THE FRONT FORK
EAS31186 1. Stand the vehicle on a level surface.
E\VAt3120
CHECKING THE CHASSIS FASTENERS
Make sure that all nuts, bolts, and screws are A WARNING
properly lightened. Securely support the vehicle so that there is
Refer to "CHASSIS TIGHTENING TORQUES" no danger of it falling over.
on page 2-12. 2. Check:
EA"""°' • Inner tube
LUBRICATING THE BRAKE LEVER Damage/scratches ➔ Replace.
Lubricate the pivoting point and metal-to-metal • Front fork leg
moving parts of the lever. Oil leaks between inner tube and outer tube
➔ Replace the oil seal.
Recommended lubricant 3. Hold the vehicle upright and apply the front
Silicone grease brake.

3-20
 PERIODIC MAINTENANCE

4. Check: TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Front fork operation The spring preload setting is determined by
Push down hard on the handlebar several measuring the distance "c" shown in the illustra-
times and check if the front fork rebounds tion. The shorter distance "cf' is, the higher the
smoothly. spring preload; the longer distance "cf' is, the
Rough movement ➔ Repair. lower the spring preload.
Refer to "FRONT FORK" on page 4-63.
...,...,.
ADJUSTING THE FRONT FORK LEGS (for
MT 09M/MT09MC)
The following procedure applies to both of the
front fork legs. C
E\VA T!3"120

A WARNING
Securely support the vehicle so that there is
no danger of it falling over.

Spring preload
EWA t17'040 Spring preload
A WARNING Adjustment value (Soft)
19.0 mm (0.75 in)
Always adjust both front fork legs evenly.
Uneven adjustment can result in poor han- Adjustment value (STD)
15.0 mm (0.59 in)
dling and loss of stability.
Adjustment value (Hard)
ECA13S90 4.0 mm (0.16 in)
NOTICE
-------------
Never go beyond the maximum or minimum
adjustment positions. Rebound damping (right side only)
ECA13590

1. Adjust:
• Spring preload
NOTICE
-------------
Never go beyond the maximum or minimu m
a. Tum the adjusting bolt "1" in direction "a" or adjustment positions.
"b". 1. Adjust:
• Rebound damping
Direction "a"
a. Tum the adjusting screw "1" in direction "a"
Spring preload is increased (suspen-
sion is harder). or "b".
Direction "b"
Spring preload is decreased (suspen- Direction "a"
sion is softer). Rebound damping is increased (sus-
pension is harder).
Direction "b"
Rebound damping is decreased (sus-
pension is softer).

3-21
 PERIODIC MAINTENANCE

Rebound damping Compression damping

Adjustment value from the start Adjustment value from the start
position (Soft) position (Soft)
11 (MT09M,MT09MC) 11 (MT09M, MT09MC)
Adjustment value from the start Adjustment value from the start
position (STD) position (STD)
6 (MT09M,MT09MC) 6 (MT09M, MT09MC)
Adjustment value from the start Adjustment value from the start
position (Hard) position (Hard)
1 1 (MT09M, MT09MC)
• Start position: With the adjusting screw • Start position: With the adjusting screw
fully turned in direction "a" fully turned in direction "a"

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Although the total number of clicks of a damping Although the total number of clicks of a damping
force adjusting mechanism may not exactly force adjusting mechanism may not exactly
match the above specifications due to small dif- match the above specifications due to small dif-
ferences in production, the actual number of ferences in production, the actual number of
clicks always represents the entire adjusting clicks always represents the entire adjusting
range. To obtain a precise adjustment, it would range. To obtain a precise adjustment, it would
be advisable to check the number of clicks of be advisable to check the number of clicks of'
each damping force adjusting mechanism and each damping force adjusting mechanism and
to modify the specifications as necessary. to modify the specifications as necessary.

EAS32000
Compression damping (left side only) ADJUSTING THE FRONT FORK LEGS (for
ECA13'90

NOTICE MT09SPM/MT09SPMC)
-------------
Never go beyond the maximum or minimum
The following procedure applies to both of the
front fork legs.
adjustment positions. EWA13120

1. Adjust: A WARNING
• Compression damping Securely support the vehicle so that there is
a. Tum the adjusting screw "1" in direction "a" no danger of it falling over.
or"b".
Spring preload
EWA17040
Direction "a"
Compression damping is increased A WARNING
(suspension is harder). Always adjust both front fork legs evenly.
Direction "b" Uneven adjustment can result in poor han-
Compression damping is decreased dling and loss of stability.
(suspension is softer).

3-22
 PERIODIC MAINTENANCE

ECA13S90
Rebound damping
NOTICE
-------------
Never go beyond the maximum or minimum
ECA13590

NOTICE
adjustment positions.
-------------
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
• Spring preload 1. Adjust:
a. Tum the adjusting bolt "1" in direction "a" or • Rebound damping
"b". a. Tum the adjusting screw "1" in direction "a"
or "b".
Direction "a"
Spring preload is increased (suspen- Direction "a"
sion is harder). Reboun.d damping is increased (sus-
Direction "b" pension is harder).
Spring preload is decreased (suspen- Direction "b"
sion is softer). Reboun.d damping is decreased (sus-
pension is softer).

Rebound damping
Adjustment value from the start
position (Soft)
26 (MT09SPM, MT09SPMC)
Adjustment value from the start
position (STD)
15 (MT09SPM, MT09SPMC)
Adjustment value from the start
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ position (Hard)
1
The spring preload setting is determined by
• Start position: With the adjusting screw
measuring the distance "c" shown in the illustra-
fully turned in direction "a"
tion. The shorter distance "cf' is, the higher the
spring preload; the longer distance "cf' is, the TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
lower the spring preload. Although the total number of clicks of a damping
force adjusting mechanism may not exactly
match the above specifications due to small dif-
ferences in production, the actual number of
clicks always represents the entire adjusting
range. To obtain a precise adjustment, it would
C be advisable to check the number of clicks of
each damping force adjusting mechanism and
to modify the specifications as necessary.

Spring preload
Adjustment value (Soft)
19.0 mm (0.75 in)
Adjustment value (STD)
15.0 mm (0.59 in)
Adjustment value (Hard)
4.0 mm (0.16 in)

3-23
 PERIODIC MAINTENANCE

Compression damping 2. Adjust:

ECA13'90
• Compression damping (slow compression
NOTICE damping)
:-------:----:----------
Never go beyond the maximum or minimum
a. Tum the adjusting bolt "1" in direction "a" or
adjustment positions.
"b".
1. Adjust:
• Compression damping Direction "a"
Compression damping is increased
a. Tum the adjusting screw "1" in direction "a"
(suspension is harder).
or "b".
Direction "b"
Compression damping is decreased
Direction "a" (suspension is softer).
Compression damping is increased
(suspension is harder).
Direction "b" Slow compression damping
Compression damping is decreased Adjustment value from the start
(suspension is softer). position (Soft)
18 (MT09SPM, MT09SPMC)
Adjustment value from the start
Fast compression damping
position (STD)
Adjustment value from the start 12 (MT09SPM, MT09SPMC)
position (Soft) Adjustment value from the start
51/2 (MT09SPM, MT09SPMC) position (Hard)
Adjustment value from the start 1 (MT09SPM, MT09SPMC)
position (STD)
• Start position: With the adjusting bolt ful-
31/4 (MT09SPM, MT09SPMC)
ly turned in direction "a"
Adjustment value from the start
position (Hard) TIP_ _ _ _ _ _ _ _ _ _ _ _ __
0 (MT09SPM, MT09SPMC)
• Start position: With the adjusting screw Although the total number of clicks of a damping
fully turned in direction "a" force adjusting mechanism may not exactly
match the above specifications due to small dif-
TIP_ _ _ _ _ _ _ _ _ _ _ _ __ ferences in production, the actual number of
Although the total number of clicks of a damping clicks always represents the entire adjusting
force adjusting mechanism may not exactly range. To obtain a precise adjustment, it would
match the above specifications due to small dif- be advisable to check the number of clicks of
each damping force adjusting mechanism and

,.
ferences in production, the actual number of
clicks always represents the entire adjusting to modify the specifications as necessary.
range. To obtain a precise adjustment, it would
be advisable to check the number of clicks of
each damping force adjusting mechanism and
to modify the specifications as necessary. '
'
''. ' (
.
'

''
''
EAS30808
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY
Refer to "CHECKING THE REAR SHOCK AB-
SORBER ASSEMBLY" on page 4-80.

3-24
 PERIODIC MAINTENANCE

...,.,...
ADJUSTING THE REAR SHOCK ABSORBER
Rebound damping
ECA13590
ASSEMBLY (for MT09M/MT09MC) NOTICE
E\VA1!3120 -------------
Never go beyond the maximum or minimum
A WARNING adjustment positions.
Securely support the vehicle so that there is
no danger of it falling over. 1. Adjust:
• Rebound damping
Spring preload a. Tum the adjusting screw "1 " in direction "a"
ECA13'90 or "b".
NOTICE
-------------
Never go beyond the maximum or minimum Direction "a"
adjustment positions. Reboun.d damping is increased (sus-
pension is harder).
1. Adjust: Direction "b"
• Spring preload Reboun.d damping is decreased (sus-
a. Adjust the spring preload with the special pension is softer).
wrench "1" and extension bar "2" included
in the owner's tool kit.
Rebound damping
b. Tum the adjusting ring "3" in di:rection "a" or Adjustment value from the start
"b". position (Soft)
c. Align the desired position on the adjusting 2 1/2 (MT09M,MT09MC)
ring with the stopper "4". Adjustment value from the start
position (STD)
Direction "a" 1 (MT09M,MT09MC)
Spring preload is increased (suspen- Adjustment value from the start
sion is harder). position (Hard)
Direction "b" 0
Spring preload is decreased (suspen- • Start position: With the adjusting screw
sion is softer). fully turned in direction "a"
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Spring preload Although the total number of turns of a damping
Adjustment value (Soft) force adjusting mechanism may not exactly
1 (MT09M, MT09MC) match the above specifications due to small dif-
Adjustment value (STD) ferences in production, the actual number of
4 (MT09M, MT09MC)
turns always represents the entire adjusting
Adjustment value (Hard)
range. To obtain a precise adjustment, it would
7 (MT09M, MT09MC)
be advisable to check the number of turns of
each damping force adjusting mechanism and
to modify the specifications as necessary.

3-25
 PERIODIC MAINTENANCE

EA~,soo
ADJUSTING THE REAR SHOCK ABSORBER
Spring preload
ASSEMBLV (for MT09SPM/MT09SPMC)
E\VA1!3120 Adjustment value (Soft)
A WARNING 154.0 mm (6.06 in) (MT09SPM,
MT09SPMC)
Securely support the vehicle so that there is
Adjustment value (STD)
no danger of it falling over.
154.0 mm (6.06 in) (MT09SPM,
MT09SPMC)
Spring preload Adjustment value (Hard)
ECA13'90 146.0 mm (5.75 in) (MT09SPM,
NOTICE MT09SPMC)
------------
Never go beyond the maximum or minimum
adjustment positions. Rebound damping
ECA13590
1. Adjust: NOTICE
• Spring preload ------------
Never go beyond the maximum or minimum
a . Tum the adjusting knob "1" in direction "a" adjustment positions.
or "b".
1. Adjust:
• Rebound damping
Direction "a" a. Tum the adjusting knob "1 " in direction "a"
Spring preload is increased (suspen-
or "b".
sion is harder).
Direction "b"
Spring preload is decreased (suspen- Direction "a"
sion is softer). Rebound damping is increased (sus-
pension is harder).
Direction "b"
Rebound damping is decreased (sus-
pension is softer).

Rebound damping
Adjustment value from the start
position (Soft)
30 (MT09SPM, MT09SPMC)
Adjustment value from the start
position (STD)
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ 18 (MT09SPM, MT09SPMC)
The spring preload setting is determined by Adjustment value from the start
measuring the distance "c" shown i n the illustra- position (Hard)
tion. The shorter distance "cf' is, the higher the 0
spring preload; the longer distance "c" is, the • Start position: With the adjusting screw
lower the spring preload. fully turned in direction "a"

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Although the total number of clicks of a damping
force adjusting mechanism may not exactly
match the above specifications due to small dif-
ferences in production, the actual number of
cl icks always represents the entire adjusting
range. To obtain a precise adjustment, it would
be advisable to check the number of cl icks of
each damping force adjusting mechanism and
to modify the specifications as necessary.

3-26
 PERIODIC MAINTENANCE

EAS30800
Compression damping CHECKING THE CONNECTING ARM AND
ECA13'90

NOTICE RELAY ARM

------------
Never go beyond the maximum or minimum
Refer to "CHECKING THE CONNECTING ARM
AND RELAY ARM" on page 4-81.
adjustment positions.
EAS30G!O
1. Adjust: CHECKING THE ENGINE OIL LEVEL
• Compression damping 1 . Stand the vehicle on a level surface.
a. Tum the adjusting knob "1" in direction "a" TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
or "b".
• Place the vehicle on a maintenance stand.
• Make sure the vehicle is upright.
Direction "a"
Compression damping is increased 2. Start the engine, warm it up for several min-
(suspension is harder). utes, and then tum it off.
Direction "b" 3. Check:
Compression damping is decreased • Engine oil level
(suspension is softer). The engine oil level should be between the
minimum level mark "a" and maximum level
Compression damping mark"b".
Adjustment value from the start Below the minimum level mark ➔ Add the
position (Soft) recommended engine oil to the proper level.
20 (MT09SPM, MT09SPMC)
Adjustment value from the start
position (STD)
10 (MT09SPM, MT09SPMC)
Adjustment value from the start
position (Hard)
0 (MT09SPM, MT09SPMC)
• Start position: With the adjusting knob
fully turned in direction "a"

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Although the total number of clicks of a damping Recommended brand
force adjusting mechanism may not exactly YAMALUBE
match the above specifications due to small dif- SAE viscosity grades
ferences in production, the actual number of 10W-40, 10W-50, 15W-40, 20W•
40 or20W-50
clicks always represents the entire adjusting
Recommended engine oil grade
range. To obtain a precise adjustment, it would
API service SG type or higher,
be advisable to check the number of clicks of
.!IASO standard MA
each damping force adjusting mechanism and
to modify the specifications as necessary.

3-27
 PERIODIC MAINTENANCE

0 10 30 50 70 90 110 130 . F
I I I I I I 1 I

(SAE; 10W-40!

i SAE 10.W·S~

SAE 15W•fl0
C$AE 20W-40(

!: SAE
:
20W-50
: :
j I I I I I I I
-20 - 10 O 10 20 30 40 50 ' C
ECA13361
4. Drain:
NOTICE ---,....,.---:---~-:--:-----:-:'.:-- • Engine oil
• Engine oil also lubricates the clutch and the (completely from the crankcase)
wrong oil types or additives could cause 5. If the oil filter cartridge is also to be replaced,
clutch slippage. Therefore, do not add any perform the following procedure.
chemical additives or use engine oils with a
a. Remove the oil filter cartridge "1" with an oil
grade of "CD" or higher and do not use oils
filter wrench "2".
labeled "ENERGY CONSERVING 11".
• Do not allow foreign materials to enter the Oil filter wrench
crankcase. 90890-01426
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ Oil filter wrench
YU-38411
Before checking the engine oil level, wait a few
minutes until the oil has settled.

4. Start the engine, warm it up for several min-

utes, and then tum it off.
5. Check the engine oil level again.
TIP_ _ _ _ _ _ _ _ _ _ _ _ __
Before checking the engine oil level, wait a few
minutes until the oil has settled.
2 1
llAS"""7
CHANGING THE ENGINE OIL b. Lubricate the O-ring of the new oil filter car-
1. Start the engine, warm it up for several min- tridge with a thin coat of engine oil.
utes, and then tum it off. Ec.<2!090

2. Place a container under the engine oil drain NOTICE -----:-----:-:---:----:::--

bolt. Make sure tine O-ring is positioned correctly
3. Remove: in the groove of the oil filter cartridge.
• Engine oil filler cap "1"
c. Tighten the new oil filter cartridge to specifi-
• Engine oil drain bolt "2"
cation with an oil filter wrench.
• Gasket "3"
Oil filter cartridge
17 N•m (1.7 kgf•m, 13 lb-ft)

6. Install:
• Engine oil drain bolt
(along with the gasket ml'))

Engine oil drain bolt

43 N•m (4.3 kgf•m, 32 lb-ft)

3-28
 PERIODIC MAINTENANCE

7. Fill: 3. Remove:
• Crankcase • Oil pressu re switch joint boll "1"
(with the specified amount of the recom- • Oil pressUJre switch joint (with the oil pressure
mended engine oil) switch) "2"
EWAt2980

Engine oil quantity ... WARNING

Quantity (disassembled) The engine, muffler and engine oil are ex-
3.50 L (3.70 US qt, 3.08 Imp.qt) tremely hot.
Oil change .....
2.80 L (2.96 US qt, 2.46 Imp.qt)
With oil filter removal
3.20 L (3.38 US qt, 2.82 Imp.qt)

8. Install:
• Engine oil filler cap
(along with the O-ring ml'J)
9. Start the engine, warm ii up for several min-
utes, and then tum ii off.
10.Check:
• Engine
(for engine oil leaks)
11 .Check:
--
4 . Install:
• Oil pressu re gauge joint 18 mm "1"
• Oil pressu re switch joint boll "2"
• Engine oil level
Oil pressure gauge joint 18 mm
Refer to "CHECKING THE ENGINE OIL
90890-04176
LEVEL" on page 3·27. YU-04176
EAS3Cl010
MEASURING THE ENGINE OIL PRESSURE
Oil pressure switch joint bolt
1. Check:
10 N•m (1.0 kgf•m, 7.4 lb•ft)
• Engine oil level
Below the minimum level mark "a" ➔ Add the
recommended engine oil to the proper level.

r= ~ 0-a 5. Install:
• Oil pressure gauge "1"
2. Start the engine, warm ii up for several min- • Adapter C "2"
utes, and then tum it off.
ECA13'10
Oil pressure gauge set
NOTICE
------------
When the engine is cold, the engine oil will
90890-03120

have a higher viscosity, causing the engine

oil pressure to increase. Therefore, be sure
to measure the engine oil pressure after
warming up the engine.

3-29
 PERIODIC MAINTENANCE

6. Start the engine, warm it up for several min- EAS30811

utes. CHECKING THE COOLANT LEVEL
ECA13'10
1. Stand the vehicle on a level surface.
NOTICE - - - , - - - - - - - - - - - TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
When the engine is cold, the engine oil will
have a higher viscosity, causing the engine • Place the vehicle on a maintenance stand.
oil pressure to inc-rease. Therefore, be sure • Make sure the vehicle is upright.
to measure the engine oil pressure after 2. Check:
warming up the engine. • Coolant level
The coolant level should be between the
7. Measure:
maximum level mark "a" and minimum level
• Engine oil pressure
(at the following conditions) mark "b".
Below the minimum level mark ➔ Add the
recommended coolant to the proper level.
Oil pressure
300.0 kPa/5000 r/min at 100 °C
(3.00 kgf/cnl2/5000 r/min at 100
°C, 43.5 psi/5000 r/min at 212 °F)

Out of specification ➔ Check.

Engine oil pressure Possible causes
Below specification • Faulty oil pump
• Clogged oil filter
• Leaking oil passage
• Broken or damaged ECA21281

oil seal NOTICE _ _ _ _ _ _ _ _ _ _ __

Above specification • Faulty oil filter • Adding water instead of coolant dilutes the
• Oil visco sity too high antifreeze concentration of the coolant. tf
water is used instead of coolant; check,
8. Remove: and if necessary, correct the antifreeze
• Oil pressure gauge concentration of the coolant.
• Adapter C • Use only distilled water. However, if dis-
• Oil pressure switch joint bolt tilled water is not available, soft water may
• Oil pressure switch joint (with the O- ring) be used.
9. Install:
3. Start the engine, warm it up for several min-
• O-ring "1" Gm utes, and then tum it off.
• Oil pressure switch joint (with the oil pressure 4. Check:
switch) "2" • Coolant level
• Oil pressure switch joint bolt "3" TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Before checking the coolant level, wait a few
Oil pressure switch joint bolt
minutes until it settles.
10 N•m (1.0 kgf•m, 7.4 lb•ft)

3-30
 PERIODIC MAINTENANCE

EAS30612 EWA13000

CH ECKING THE COOLING SYSTEM A WARNING

1. Check: A hot radiator is under pressure. Therefore,
• Radiator "1" do not remove the radiator cap when the en-
• Water pump inlet hose "2" gine is hot. Scalding hot fluid and steam may
• Thermostat housing "3" be blown out, which could cause serious in-
• Thermostat "4" jury. When the engine has cooled, open the
• Thermostat cover "5" radiator cap as follows:
• Radiator outlet hose "6" Place a thick rag or a towel over the radiator
• Water pump "7" cap and slowly tum the radiator cap counter-
• Radiator inlet hose "8" clockwise toward the detent to allow any re-
• Oil cooler outlet hose "9" sidual pressure to escape. When the hissing
• Water jacket joint "10" sound has stopped, press down on the radi-
• Oil cooler inlet hose "11" ator cap and turn it counterclockwise to re-
• Oil cooler "12" move.
Cracks/damage ➔ Replace.
Refer to "RADIATOR" on page 6-3, "O IL
COOLER" on page 6-7, "THERMOSTAT' on
page 6-9, and "WATER PUMP" on page 6-
11 .

2. Remove:
• Coolant reservoir bolt
• Coolant reservoir cover "1"

,r10 •
•
Coolant reservoir "2"
Collar

- Refer to "RADIATOR" on page 6-3.

'I

2 1
........
CHANGING THE COOLANT
3. Remove:
• Coolant reservoir cap "1"
1. Remove:
~
• Front side panel (right side)
Refer to "GENERAL CHASSIS (1 )" on (
page 4-1 .
• Radiator cap "1"

3-31
 PERIODIC MAINTENANCE

4. Drain:
• Coolant Recommended antifreeze
(from the coolant reservoir) High-quality ethylene glycol anti-
5. Remove: freeze containing corrosion
• Water pump drain bolt "1" inhibitors for aluminum engines
• Copper washer "2" Mixing ratio
1 :1 (antifreeze:water)
Radiator (including all routes)
1.72 L (1.82 US qt, 1.51 Imp.qt)
Coolant reservoir (up to the max-
imum level mark)
0.28 L (0.30 US qt, 0.25 Imp.qt)

Handling notes for coolant

Coolant is potentially harmful and should be
handled with special care.
E\VA t3040

6. Drain: A WARNING
• Coolant • If coolant splashes in your eyes, thorough-
(from the engine and radiator) ly wash them with water and consult a doc-
7. Install: tor.
• Water pump drain bolt • If coolant splashes on your clothes, quickly
• Copper washer Im wash it away with water and then with soap
and water.
Water pump drain bolt • If coolant is swallowed, induce vomiting
10 N•m (1.0 kgf•m, 7.4 lb•ft) and get immediate medical attention.
E~ l291
8. Install:
NOTICE
• Collar -------------
• Adding water instead of coolant dilutes the
• Coolant reservoir
• Coolant reservoir cover antifreeze concentration of the coolant. tf
• Coolant reservoir bolt water is used instead of coolant; c heck,
Refer to "RADIATOR" on page 6-3. and if necessary, correct the antifreeze
concentration of the coolant.
Coolant reservoir bolt (MS) • Use only distilled water. However, if dis-
0.5 N•m (0.05 kgf•m, 0.37 lb•ft) tilled water is not available, soft water may
Coolant reservoir bolt (M6) be used.
9 N•m (0.9 kgf•m, 6.6 lb•ft) • If coolant comes into contact with painted
LOCTITE® surfaces, immediately wash them with wa-
ter.
9. Fill: • Do not mix different types of antifreeze.
• Cooling system
(with the specified amount of the recom- 10.lnstall:
mended coolant) • Radiator cap
11 .Fill:
• Coolant reservoir
(with the recommended coolant to the maxi-
mum level mark "a")

3-32
 PERIODIC MAINTENANCE

12. lnstall:
EAS30G!O
• Coolant reservoir cap CHECKING AND LUBRICATING THE
13.Start the engine, warn, it up for several min-
CABLES
utes, and then tum it off. The following procedure applies to all of the in-
14.Check: ner and outer cables.
• Coolant level
Refer to "CHECKING THE COO LANT LEV- A WARNING
EL" on page 3-30. Damaged outer cable may cause the cable to
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ corrode and interfere with its movement. Re-
Before checking the coolant level, wait a few place damaged outer cable and inner cables
minutes until the coolant has settled. as soon as possible.

...,..,,
CHECKING THE FRONT BRAKE LIGHT
1. Check:
• Outer cable
Damage ➔ Replace.
SWITCH
2. Check:
Refer to "ELECTRICAL COMPONENTS" on
• Cable operation
page 8-51.
...,....
ADJUSTING THE REAR BRAKE LIGHT
Rough movement ➔ Lubricate.

Recommended lubricant
SWITCH Engine oil or a suitable cable lu-
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ bricant
The rear brake light switch is operated by move-
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
ment of the brake pedal. The rear brake light
switch is properly adjusted when the brake light Hold the cable end upright and pour a few drops
cormes on just before the braking effect starts. of lubricant into the cable sheath or use a suit -
able lubricating device.
1. Check:
• Rear brake light operation timing EAS30815
Incorrect ➔ Adjust. CHECKING THE THROTTLE GRIP
2. Adjust: 1. Check:
• Rear brake light operation timing • Throttle grip movement
a . Hold the main body "1" of the rear brake Rough movement ➔ Lubricate or replace the
light switch so that it does not rotate and defective part(s).
turn the adjusting nut "2" until the rear brake
light comes on at the proper time. Recommended lubricant
Suitable cable lubricant

3-33
 PERIODIC MAINTENANCE

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
With the engine stopped, turn the th rottle grip
slowly and release it. Make sure that the throttle
grip turns smoothly and returns property when
released.
Repeat this check with the handlebar turned all
the way to the left and right.

EAS3001S
CHECKING AND CHARGING THE BATTERY
Refer to "CHECKING AND CHARGING THE
BATTERY'' on page 8-56.

CHECKING THE FUSES

Refer to "CHECKING THE FUSES~ on page 8-
55.

ADJUSTING THE HEADLIGHT BEAM

1. Adjust:
• Headlight beam (vertically)
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
To adjust the headlight beam (vertically), insert a
phillips screwdriver into the either holes "a" on
the headlight front cover and turn the adjusting
screw.

a . Tum the adjusting screw "1".

3-34
 CHASSIS

GENERAL CHASSIS (1) ................................................................................. 4-1

REMOVING THE SEAT ............................................................................ 4-7
REMOVING THE HEADLIGHT FRONT COVER ..................................... .4-7
REMOVING THE FUEL TANK SIDE COVER .......................................... .4-7
INSTALLING THE FILJEL TANK SIDE COVER ........................................ .4-7
INSTALLING THE HEADLIGHT FRONT COVER ..................................... 4-8
INSTALLING THE IMU .............................................................................. 4-8
INSTALLING THE S EAT ........................................................................... 4-9

GENERAL CHASSIS (2) ............................................................................... 4-10

FRONT WHEEL ..............................................................•.............................. 4-11

REMOVING THE FRONT WHEEL. ............ ..... ........................... .............4-13
DISASSEMBLING THE FRONT WHEEL. .............................................. .4-1 3
CHECKING THE FRONT WHEEL ......................................................... .4- 13
ASSEMBLING THE FRONT WHEEL. ... .................................................. 4-14

II
MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR
ROTOR ........ ........................................................................................... 4- 15
ADJUSTING THE FRONT WHEEL STATIC BALANCE .........................4-15
INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS) .............. .4-1 6

REAR WHEEL ............................................................................................... 4-18

REMOVING THE REAR WHEEL ........................................................... .4-21
DISASSEMBLING THE REAR WHEEL .................. ............................... .4-21
CHECKING THE REAR WHEEL.. ........................................................... 4-21
CHECKING THE REAR WHEEL DRIVE HUB ....................................... .4-21
CHECKING AND REPLACING THE REAR WHEEL SPROCKET ........ .4-22
ASSEMBLING THE REAR WHEEL ........................................................4-22
MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR
ROTOR ................................................................................................... 4-22
ADJUSTING THE REAR WHEEL STATIC BALANCE ............................4-22
INSTALLING THE REAR WHEEL (REAR BRAKE DISC) ......................4-23

FRONT BRAKE .............................................................................................4-25

INTRODUCTION .............................................................................. ....... 4-31
CHECKING THE FRONT BRAKE DISCS ....................................... ........ 4-31
REPLACING THE FRONT BRAKE PADS .............................................. 4-31
REMOVING THE FRONT BRAKE CALIPERS ....................................... 4-33
DISASSEMBLING THE FRONT BRAKE CALIPERS ......................... .....4-33
CHECKING THE FRONT BRAKE CALIPERS ........................................ 4-33
ASSEMBLING THE FRONT BRAKE CALIPERS ................................... .4-33
INSTALLING THE FRONT BRAKE CALIPERS ..................................... .4-34
REMOVING THE FRONT BRAKE MASTER CYLINDER .......................4-35
CHECKING THE FRONT BRAKE MASTER CYLINDER ................... ..... 4-35
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ................... 4-35
INSTALLING THE FRONT BRAKE MASTER CYLINDER ...................... 4-35
REAR BRAKE ................................................................•.............................. 4-37
ADJUSTING THE FOOTREST POSITION ............................................ .4-43
INTRODUCTION ..................................................................................... 4-43
CHECKING THE REAR BRAKE DISC ....................................................4-43
REPLACING THE REAR BRAKE PADS .................................................4-44
REMOVING THE REAR BRAKE CALIPER ............................................ 4-45
DISASSEMBLING THE REAR BRAKE CALIPER .................................. 4-45
CHECKING THE REAR BRAKE CALIPER ............................................. 4-45
ASSEMBLING THE REAR BRAKE CALIPER ........................................ 4-46
INSTALLING THE REAR BRAKE CALIPER ...........................................4-46
REMOVING THE REAR BRAKE MASTER CYLINDER ......................... 4-47
CHECKING THE REAR BRAKE MASTER CYLINDER .......................... 4-47
ASSEMBLING THE REAR BRAKE MASTER CYLINDER ...................... 4-47
INSTALLING THE REAR BRAKE MASTER CYLINDER ........................ 4-47

ABS (ANTI-LOCK BRAKE SYSTEM) ........................................................... 4-49

REMOVING THE HYDRAULIC UNIT ASSEMBLY ................................. 4-51
CHECKING T HE HYDRAULIC UNIT ASSEMBLY .................................. 4-51
CHECKING THE BRAKE PIPES............................................................. 4-52
INSTALLING THE HYDRAULIC UNIT ASSEMBLY ................................ 4-52
HYDRAULIC UNIT OPERATION TESTS................................................ .4-53
CHECKING T HE ABS WARNING LIGHT ............................................... 4-56

HANDLEBAR .................................................................•.............................. 4-57

ADJUSTING THE HANDLEBAR POSITION ........................................... 4-59
REMOVING THE HANDLEBAR .............................................................. 4-59
CHECKING THE HANDLEBAR ..............................................................4-60
INSTALLING THE HANDLEBAR ............................................................4-60

FRONT FORK. ..............•.................................................•..............................4-63

REMOVING THE FRONT FORK LEGS .................................................. 4-66
DISASSEMBLING THE FRONT FORK LEGS ....................................... .4-66
CHECKING THE FRONT FORK LEGS .................................................. 4-67
ASSEMBLING THE FRONT FORK LEGS .............................................. 4-68
INSTALLING THE FRONT FORK LEGS ................................................ 4-72

STEERING HEAD.......................................................................................... 4-74

REMOVING THE LOWER BRACKET..................................................... 4-76
CHECKING THE STEERING HEAD .......................................................4-76
INSTALLING THE STEERING HEAD ..................................................... 4-77
REAR SHOCK ABSORBER ASSEMBLY .....................•.............................. 4-78
HANDLING THE REAR SHOCK ABSORBER ........................................ 4-80
DISPOSING OF A REAR SHOCK ABSORBER
(for MT09M/MT09M C) ............................................. ............................... 4-80
DISPOSING OF A REAR SHOCK ABSORBER
(for MT09SPM/MT09SPMC) .................................... .............................. 4-80
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY ................... 4-80
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 4-80
CHECKING THE CONNECTING ARM AND RELAY ARM ..................... 4-81
INSTALLING THE RELAY ARM .............................................................. 4-81
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ................. 4-81

SWINGARM ................................................................................................... 4-83

REMOVING THE SWINGARM ................................................................ 4-84
CHECKING THE SWINGARM ................................................................ 4-84
INSTALLING THE SWINGARM .............................................................. 4-84

CHAIN DRIVE ................................................................................................ 4-86

REMOVING THE DRIVE CHAIN .............................. ............................... 4-87
CHECKING THE DRIVE CHAIN ............................................................. 4-87
CHECKING THE DRIVE SPROCKET..................................................... 4-88
CHECKING THE REAR WHEEL SPROCKET .......... .............................. 4-88
CHECKING THE REAR WHEEL DRIVE HUB .......... ............................. .4-88
INSTALLING THE DRIVE CHAIN ........................................................... 4-89
ADJUSTING THE SHIFT PEDAL .............................. .............................. 4-91
 GENERAL CHASSIS (1)

...,.,.,,.
GENERAL CHASSIS (1)
Removing the seat and battery

· 7 N-m (0. 7 kgf•m, 5.2 lb-It)

Order Job/Parts to remove Q'ty Remarks

Rider seat
2 Battery holding bracket
3 Negative battery lead Disconnect.
4 Positive battery lead Disconnect.
5 Battery

4-1
 GENERAL CHASSIS (1)

Removing the rear cover

' ·~ 7 N-m (0. 7 kgf-m, 5.2 lb-It) 7 N-m (0.7 kgf-m, 5.2 lb-It)

13
Ill

9
•

• ' • 8~
·- '.
• 1 ./ &

I \\
. \}.\ 11 ,
' 2]i>~ (4) ' "

' ~ (4) '•

, ~ # (0.40 kgf-m, 3.0 lb-It)

,,,

'
•J,

r
(4) . ,
s (4) . \- 10
Order Job/Parts to remove Q'ty Remarks
Refer to "GENERAL CHASSIS (1)" on
Rider seat page 4-1.
Refer to "GENERAL CHASSIS (1)" on
Battery
page 4-1.
Seat bracket
2 Rear side cover (left)
3 Rear side cover (right)
4 Rear turn signal light coupler 2 Disconnect.
5 License plate light coupler Disconnect.
6 Mudguard assembly
7 Lower fender cover
8 Tail/brake light coupler Disconnect.
9 Tail/brake light
10 Cover
11 IMU (Inertial Measurement Unit)
12 IMU coupler Disconnect.
13 Rectifier/regulator cover
14 Rectif ier/regulator coupler Disconnect.
15 Rectif ier/regulator

4-2
 GENERAL CHASSIS (1)

Removing the headlight assembly, auxiliary light and meter assembly

,--,----------,
,·, 4.3 N-m (0.43 kgf-m, 3.2 lb-ft) ____ ____ '~ 7 N-m (0. 7 kgl-m, 5.2 lb~)

' .

**
11

• For MT09M/MT09MC
.. For MT09SPM/MT09SPMC
Order Job/Parts to, remove Q'ty Remarks
1 Auxiliary light coupler Disconnect.
2 Headlight front cover
3 Headlight side cover (left)
4 Headlight side cover (right)
5 Auxiliary light
6 Meter assembly coupler Disconnect.
7 Meter assembly
8 Headlight control untt cover
9 Headlight assembly
Headlight control untt coupler (headlight assem-
10 Disconnect.
bly side)
Headlight control untt coupler (wire harness
11 Disconnect.
side)
12 Headlight control untt 1
13 Horn lead connector 2 Disconnect.

4-3
 GENERAL CHASSIS (1)

Removing the headlight assembly, auxiliary light and meter assembly

,.,...-,----------,
,·, 4.3 N-m (0.43 kgf-m, 3.2 lb-ft) ____ ____ ' ~ 7 N-m (0. 7 kgl-m, 5.2 lb~)
0

/ -,, 1.5 N-m (0.1°5 kgf-m, 1.1 -I~

I
I

.,

..=~ - - - - ---~--~ -
1.5 N-m (0.15 kgf-m, 1.1 lb-ft) I
~
,. l
__.1//
N-m (0.07 kgf-m, 0.52 lb-ft) -><_
1.8 N-m (0.18 kgf-m, 1.3 lb•lt)
,,
**

17

16

• For MT09M/MT09MC
.. For MT09SPM/MT09SPMC
Order Job/Parts to• remove Q'ty Remarks
14 Handlebar switch coupler 2 (right) Disconnect.
15 Front brake light switch coupler Disconnect.
16 Handlebar switch coupler 1 (right) Disconnect.
17 Accelerator position sensor coupler Disconnect.
18 Clutch swttch coupler Disconnect. (for MT09SPM/MT09SPMC)
19 Harness clamp/Coupler clamp Disconnect.
20 Meter assembly bracket

4-4
 GENERAL CHASSIS (1)

Removing the front side panel

,,, 1.5 N-m (0.15 kgf-m, 1.1 lb-ft)

L .>
x, 7 N•m (0.7 kgf-m, 5.2 lb-It)

Order Job/Parts to remove Q'ty Remarks

Radiator cover (left)
2 Radiator cover (right)
3 Front tum signaVposition light coupler (left) Disconnect.
4 Front side panel (left)
5 Front tum signaVposit ion light coupler (right) Disconnect.
6 Front side panel (right)

4-5
 GENERAL CHASSIS (1)

Removing the air scoop and fuel tank center cover

,:. 1.0 N-m (0.10 kgfrn, 0.73 lb-ft)

" • 1.0 N-m (0.10 kgf-m, 0.73 lb-ft)

Order Job/Parts to remove Q'ty Remarks

1 Fuel tank side cover (left)
2 Fuel tank side cover (right)
3 Fuel tank center cover
4 Air scoop (left)
5 Air scoop (right)

4-6
 GENERAL CHASSIS (1)

EAS3:1229
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".

EAS32778
INSTALLING THE FUEL TANK SIDE COVER
The following procedure applies to both of the
fuel tank side cover.
1. Install:
• Fuel tank side cover (left) "1"
b. While holding the key in that position, slide
the seat backward and then lilt the rear of a. Insert the projection "a" on the fuel tank side
the seat up, and then pull the seat off. cover into the grommets "b" and insert the
...,_.
REMOVING THE HEADLIGHT FRONT
projection "c" on the fuel tank side cover
into the hole.
b. Install the fuel tank side cover bolt "2" and
COVER
quick fastener "3", and then tighten the
1. Remove:
bolts to specification.
• Headlight front cover "1"
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Fuel tank side cover bolt
Remove the projection "a" on the headlight front 1.0 N-m (0.10 kgf-m, 0.73 lb•ft)
cover from grommet "b".

EAS3"'77
REMOVING THE FUEL TANK SIDE COVER
The following procedure applies to both of the
fuel tank side cover.
1. Remove:
• Fuel tank side cover (left) "1"
a. Remove the fuel tank side cover bolt (left)
"2" and quick fastener "3".
b. Remove the fuel tank side cover (left).
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Remove projections "a" on the fuel tank side
cover from grommets "b".
• Remove projections "c" on the fuel tank side
cover from hole.

4-7
 GENERAL CHASSIS (1)

EAS3:lG415
1. Install:
INSTALLING THE HEADLIGHT FRONT
• IMU (Inertial Measurement Unit) "1 "
COVER
1. Install: a. Connect the IMU coupler "2" to the IMU.
• Headlight front cover "1" b. Install the grommets, collars, IMU "1 ",
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ washers, IMU nuts and IMU bolts, and the n
tighten ~he bolts to specification.
Insert the projection "a" on the headlight front TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
cover into the grommet "b".
Apply a thin coat of silicone grease onto the col-
lars and washers where contacting the grom-
mets.

Recommended lubricant
Silicone grease

IMU bolt
2.0 N,m (0.20 kgf,m, 1.5 lb,ft)

EA~1S3S
INSTALLING THE IMU
ECA2:21511

NOTICE
------------
• Do not per1orm 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 on'.l y 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 open ing and do
not blow it with compressed air.
• When replacing the collar or grommet, re-
place all tour collars and grommets.

4-8
 GENERAL CHASSIS (1)

...,.,,.
INSTALLING THE SEAT
1. Install:
• Seat
a. Insert the projections "1" into the seat hold-
ers "2" as shown.

b. Push the rear of the seat down to lock it in

place.
TIP_ _ _ _ _ _ _ _ _ _ _ _ __
Make sure that the seat is property secured be-
fore riding.

4-9
 GENERAL CHASSIS (2)

...,.,,.
GENERAL CHASSIS (2)
Re moving the air tilter case
.--, 7 N•m (0. 7 kgl-m, 5.2 lb-It)

Order Job/Parts to remove Q'ty Remarks

Refe r to "GENERAL CHASSIS (1)" on
Rider seat page 4-1.
Refer to "GENERAL CHASSIS (2)" on
Air scoop
page 4-10.
Fuel tank Refer to "FUEL TANK" on page 7-1.
1 ECU coupler 3 Disconnect.
2 ECU (Engine Control Unit )
3 Intake air temperature sensor Disconnect.
4 Air filt er case cover
5 Air filter element 1
6 Air filter case joint clamp screw 3 Loosen.
7 Cylinder head breather hose Disconnect.
8 Air filt er case

4-10
 FRONT WHEEL

..FRONT
.,.,.,,.
WHEEL
Re mo ving the front wheel and bra ke discs

-~-
~ -
i
7
-~ - -'-...._/·
, ,.
.

~ -

... 35 N·m (3.5 kgf·m, 26 lb•ft)

>t 18 N·m (1.8 kgf·m, 13 lb·ft)

8

Order Job/Parts to remove Q'ty Remarks

1 Front brake caliper 2
2 Reflector bracket 2
3 Front wheel sensor
4 Wheel axle pinch bolt Loosen.
5 Wheel axle
6 Front wheel
7 Collar 2
8 Front brake disc 2

4-11
 FRONT WHEEL

Disassembling the front wheel

Order Job/Pa rts to remove Q'ty Remarks

1 Front wheel sensor rotor 1
2 Oil seal 2
3 Whee l bearing 2
4 Spacer

4-12
 FRONT WHEEL

EA~1t48
1. Remove:
REMOVING THE FRONT WHEEL
Ec.<20981 • Oil seal
• Wheel bearing
NOTICE
-------------
• Keep any type of magnets (incl uding mag- a. Clean the suriace of the front wheel hub .
netic pick-up tools, magnetic screwdrivers, b. Remove the oil seals "1" with a flat-heacl
e1c.) 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
subject it to shocks.
• If any solvent gets on the front wheel sen-
sor rotor, wipe it off immediately.
1. Stand the vehicle on a level surface.
E\VA T!3"120

A WARNING
Securely support the vehicle so that there is
no danger of it falling over. G0888✓
c. Remove the wheel bearings with a general
2. Remove:
bearing puller.
• Brake caliper (left)
• Brake caliper (right) EAS30147

• Front wheel sensor CHECKING THE FRONT WHEEL

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 E\VAt3460

to any metal part when removing the front A 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 T IRES" on
4. Loosen: page 3-16 and "CHECKING THE WHEELS"
• Wheel axle pinch bolt on page 3 -1 6.
5. Remove: 3. Measure:
• Wheel axle • Radial wheel runout "1"
• Front wheel • Lateral wheel runout "2"
Over the specified limits ➔ Replace.
eA~1t-0
DISASSEMBLING THE FRONT WHEEL
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.

4-13
 FRONT WHEEL

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Place a suitable washer "1" between the socket
"2" and the bearing so that both the inner race
"3" and outer race "4" are pressed at the same
time, and then press the bearing until the inner
race makes contact with the spacer "5".

G088897 +
4. Check:
• Wheel bearing
Front wheel turns roughly or is loose ➔ Re-
place the wheel bearings.
• Oil seal
Damage/wear ➔ Replace.
G088899
EAS311!50
d. Install the new oil seals.
ASSEMBLING THE FRONT WHEEL
ECA213'0
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)
tor, wipe it off immediately. LOCTITE®
1. Install: ECA17200

• Wheel bearing Imm NOTICE

-------------
• Oil seal Imm Rep Iace the wheel sensor rotor bolts with
new ones.
a. Install the new wheel bearing (left side).
ECA1e 110
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
NOTICE
-------------
Do not contact the wheel bearing inner race
Install the wheel sensor rotor with the stamped
mark "1" facing outward.
"1" or balls "2". Contact should be made
only with the outer race "3".
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Use a socket "4" that matches the diameter of
the wheel bearing outer race.

+
4
3. Measure:
• Wheel sensor rotor runout
Out of specification ➔ Correct the wheel sen-
1 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 (right side).
on page 4-15.

4-14
 FRONT WHEEL

Wheel sensor rotor runout limit Wheel sensor rotor runout limit
0.25 mm (0.01 in) 0.25 mm (0.01 in)

EAS311151
a. Hold the dial gauge at a right angle against
MAINTENANCE OF THE FRONT WHEEL
the wheel sensor rotor surface .
SENSOR AND SENSOR ROTOR b. Measure the wheel sensor rotor runout.
ECA2'10'70

NOTICE - - - - - - - - - - , - - : : - : - - -
• Handle the ABS components with care
since they have been accuratelly adjusted.
Keep them away from dirt and do not sub-
ject them to shocks.
• The front wheel sensor cannot be disas-
sembled. Do not attempt to disassemble it.
If faulty, replace with a new one.
• Keep any type of magnets (incl uding mag- G088902
netic pick-up tools, magnetic screwdrivers, c. If the runout is above specification, remove
e1c.) away from the front wheel sensor or the sensor rotor from the wheel, rotate it by
front wheel sensor rotor. two or three bolt holes, and then install it.
• Do not drop or shock the wheel sensor or
the wheel sensor rotor. Wheel sensor rotor bolt
1. Check: 8 N-m (0.8 kgf-m, 5.9 lb•ft)
LOCTITE®
• Front wheel sensor "1"
Cracks/bends/distortion ➔ Replace. ECA17200

Iron powder/dust ➔ Clean.

NOTICE------------::------:"..,.......-
Replace the wheel sensor rotor bolts with
new ones.
d. If the runout is still above specification, re-
place the wheel sensor rotor.
EAS.1011'.52
ADJUSTING THE FRONT WHEEL STATIC
BALANCE
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• After replac ing the tire, wheel or both, the front
2. Check:
wheel static balance should be adjusted.
• Front wheel sensor rotor
• Adjust the tront wheel static balance with the
Cracks/damage/scratches ➔ Replace the
brake disc installed.
front wheel sensor rotor.
• Refer to "ADJUSTING THE WHELL STATIC
Iron powder/dusVsolvent ➔ Clean.
BALANCE" in "BASIC INFORMATION" (sepa-
TIP_ _ _ _ _ _ _ _ _ _ _ _ __
rate volume).
• The wheel sensor rotor is installed on the inner
si de of the wheel hub. 1. Remove:
• W hen cleaning the wheel sensor rotor, be • Balancing weight(s)
careful not to damage the surface of the sensor 2. Find:
rotor. • Front whe el's heavy spot
3. Adjust:
3. Measure: • Front whe el static balance
• Wheel sensor rotor runout 4. Check:
Out of specification ➔ Clean the installation • Front whe el static balance
surface of the wheel sensor rotor and correct
the w heel sensor rotor runout, or replace the
wheel sensor rotor.

4-15
 FRONT WHEEL

EA~13Z7

INSTALLING THE FRONT WHEEL (FRONT

BRAKE DISCS)
1. Install:
• Front brake disc

Front brake disc bolt

18 N•m (1.8 kgf•m, 13 lb,ft)
LOCTITE®
ECA119150

NOTICE 6. Install:
-------------
Rep Iace the brake disc bolts with new ones. • Front wheel sensor

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ Front wheel sensor bolt

Tighten the brake disc bolts in stages and in a 7 N•m (0.7 kgf•m, 5.2 lb,ft)
crisscross pattern. ECA21020

2. Check: NOTICE _ _ _ _ _ _ _ _ _ _ __
• Front brake disc Make sure there are no foreign materials in
Refer to "CHECKING THE FRONT BRAKE the front wheel sensor rotor and front wheel
DISCS" on page 4·31. sensor. Foreign materials cause damage to
3. Lubricate: the front wheel sensor rotor and front wheel
• Oil seal lip sensor.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Recommended lubricant
Lithium-soap-based grease When installing the front wheel sensor, check
the wheel sen sor lead for twists.
4. Install:
7. Measure:
• Collar
• Front wheel • Distance "a"
• Wheel axle (between the wheel sensor rotor "1" and
5. Tighten: wheel sensor "2")
Out of specification ➔ Check the wheel bear-
• Wheel axle
• Wheel axle pinch bolt ing for looseness, and the front wheel sensor
and sensor rotor installation conditions
Front wheel axle (warpage caused by overtorque, wrong in-
72 N•m (7.2 kgf•m, 53 lb,ft) stallation d irection, rotor decentering, LOC-
Front wheel axle pinch bolt TITE® on the mounting surface of the roto r,
23 N•m (2.3 kgf•m, 17 lb,ft) deformation caused by an impact during ser-
vice and caught foreign materials). If there is
ECA19700
any defective part, repair or replace the de-
NOTICE fective part.
Before tightening the wheel axle, push down
ha:rd on the handlebars several times and Distance "a" (between the wheel
check if the front fork rebounds smoothly. sensor rotor and front wheel sen-
sor)
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ 0.&-1 .8 mm (0.02--0.07 in)
Check that wheel axle end "a" is flush with front
fork surface "b" and then tighten the wheel axle
pinch bolt. If wheel axle end "a" is not flush with
surface "b", align the ends manually or with a
plastic hammer.

4-16
 FRONT WHEEL

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Measure the distance between the front wheel
sensor rotor and front wheel sensor in several
places in one rotation of the front wheel. Do not
tum the front wheel while the thickness gauge is
ins1alled. This may damage the front wheel sen-
sor rotor and the front wheel sensor.

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

8. Install:
• Front brake caliper

Front brake caliper bolt

35 N•m (3.5 kgf•m, 26 lb•ft)
EWA1!3!SCIO

A WARNING
Make sure the brake hose is routed properly.

4-17
 REAR WHEEL

..REAR
.,.,.,..
WHEEL
Removing the rear wheel

...
bi- I 105N·m(10.5kgf·m,nlb·fl)!y - ~ s S r. 7 N·m (0.7 kgl·m, 5.2 lb·ft)

-~
- · . · ~.

, . /·
. /
~-'------/
,,:7 6

\\
1
0' 1

. "'·~ ....,..
;/
!,·J 16 N·m (1.6 kgf·m, 12 lb·fl)I [.~ I16 N·m (1.6 kgHn, 12 lb·lt)!
Order Job/Parts to remove Q'ty Remarks
Rear brake caliper Refe r to "REAR BRAKE" on page 4-37.
1 Rear wheel sensor
2 Locknut 2 Loosen.
3 Adjusting bolt 2 Loosen.
4 Wheel axle nut
5 Washer
6 Wheel axle
7 Adjusting block (left)
8 Adjusting block (right)
9 Rear wheel
10 Brake caliper bracket assembly

4-18
 REAR WHEEL

Removing the brake disc and rear wheel sprocket

30 N·m (3.0 kgf·m, 22 lb·ft) 4 8 N·m (0.8 kgl·m, 5.9 lb·ft)

1Q
(5) ~

,. 80 N·m (8.0 kgl·m, 59 lb·ft)

mm
5

Order Job/Parts to remove Q'ty Remarks

1 Rear wheel sensor rotor
2 Rear brake disc
3 Bracket
4 Rear wheel sprocket
5 Collar
6 Collar
7 Oil seal
8 Bearing
9 Rear wheel drive hub
10 Collar
11 Oil seal
12 Rear wheel drive hub damper 5
13 Rear wheel

4-19
 REAR WHEEL

Disassembling the rear wheel

Order Job/Parts to remove Q'ty Remarks

Oil seal
2 Wheel bearing
3 Spacer
4 Wheel bearing

4-20
 REAR WHEEL

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
REMOVING THE REAR WHEEL
E~ 1030 Push the rear wheel forward and remove the
drive chain from the rear wheel sprocket.
NOTICE
-------------
• Keep any type of magnets (incl uding mag-
netic pick-up tools, magnetic screwdrivers, EAS31 1154

e1c.) away from the rear wheel sensor or DISASSEMBLING THE REAR WHEEL
E~ 1300
rear wheel sensor rotor; otherwise, the sen-
sor or rotor may be damaged, resulting in
improper performance of the A.BS system.
NOTICE
-------------
• Do not drop the wheel sensor rotor or sub•
• Do not drop the rear wheel sensor rotor or ject it to shocks.
• If any solvent gets on the wheel sensor ro-
subject it to shocks.
tor, wipe it off immediately.
• If any solvent gets on the rear wheel sensor
rotor, wipe it off immediately. 1. Remove:
1. Stand the vehicle on a level surface. • Oil seal
EWAt!)l20 • Wheel bearing
A WARNING Refer to "DISASSEMBLING THE FRONT
Securely support the vehicle so that there is WHEEL" on page 4-13.
no danger of it falling over. EAS3011!9

TIP_ _ _ _ _ _ _ _ _ _ _ _ __ CHECKING THE REAR WHEEL

1. Check:
Place the vehicle on a maintenance stand so • Wheel axle
that the rear wheel is elevated. • Wheel bearing
2. Remove: • Oil seal
Refer to "CHECKING THE FRONT WHEEL"
• Rear brake caliper
• Rear wheel sensor on page 4 -13.
2. Check:
NOTICE _ _ _ _ _ _ _ _ _ _ __ • Tire
• Do not depress the brake peda'I when re- • Rear wheel
moving the brake caliper. Damage/wear ➔ Replace.
• Be sure not to contact the sensor electrode Refer to "CHECKING THE TIRES" on
to any metal part when removing the rear page 3-16 and "CHECKING THE WHEELS"
wheel sensor from the rear bralke caliper on page 3-16.
bracket assembly. 3. Measure:
• Radial wheel runout
3. Loosen: • Lateral wheel runout
• Locknut Refer to "CHECKING THE FRONT WHEEL"
• Adjusting bolt on page 4 -13.
4. Remove:
• Wheel axle nut EAS30100

• Washer CHECKING THE REAR WHEEL DRIVE HUB

• Wheel axle
1. Check:
• Rear wheel drive hub
• Rear wheel
Cracks/da mage ➔ Replace.
• Brake caliper bracket assembly
• Rear wheel drive hub damper
NOTICE Damage/wear ➔ Replace.
-------------
Be sure to remove the rear wheel sensor be-
fore removing the brake caliper bracket as-
sembly, otherwise the sensor could be
damaged.

4-21
 REAR WHEEL

EAS301"1
1. Install:
CHECKING AND REPLACING THE REAR
WHEEL SPROCKET
• Wheel bearing (right side) em
1. Check: • Wheel bearing (left side) em
• Rear wheel sprocket •Oilsea1em
More than 1/4 tooth "a" wear ➔ Replace the Refer to "ASSEMBLING THE FRONT
drive sprocket, the rear wheel sprocket and WHEEL" on page 4-14.
the drive chain as a set.
EAS311158
Bent teeth ➔ Replace the drive sprocket, the
MAINTENANCE OF THE REAR WHEEL
rear wheel sprocket and the drive chain as a
SENSOR AND SENSOR ROTOR
set. ECA21060

NOTICE
-------------
• Handle the ABS components with care
since they have been accurately adjusted.
Keep them away from dirt and do not sub-
ject them to shocks.
• The rear wheel sensor cannot be disassem-
bled. Do not attempt to disassemble it. If
faulty, replace with a new one.
G088904
• Keep any type of magnets (including mag-
netic pick-up tools, magnetic screwdrivers,
b. Correct etc.) away ·f rom the rear wheel sensor or
1. Drive chain roller rear wheel sensor rotor.
2. Rear wheel sprocket • Do not drop or shock the wheel sensor or
the wheel sensor rotor.
2. Replace:
• Rear wheel sprocket 1. Check:
a. Remove the rear wheel sprocket nuts and • Rear wheel sensor
the rear wheel sprocket. Refer to "MAINTENANCE OF THE FRONT
b. Clean the rear wheel drive hub with a clean WHEEL SENSOR AND SENSOR ROTOR"
cloth, especially the surfaces that contact on page 4-15.
the sprocket. 2 . Check:
c. Install the new rear wheel sprocket. • Rear wheel sensor rotor
Refer to "MAINTENANCE OF THE FRONT
Rear wheel sprocket nut WHEEL SENSOR AND SENSOR ROTOR"
80 N•m (8.0 kgf•m, 59 lb•ft) on page 4 -15.
3. Measure:
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ • Wheel sensor rotor runout
Tighten the rear wheel sprocket nuts in stages Refer to "MAINTENANCE OF THE FRONT
and in a crisscross pattern. WHEEL SENSOR AND SENSOR ROTOR"
on page 4-15.
EAS30103 EAS301..
ASSEMBLING THE REAR WHEEL ADJUSTING THE REAR WHEEL STATIC
ECA213CO
BALANCE
NOTICE
-------------
• Do not drop the wheel sensor rotor or sub-
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __

ject it to shocks. • After replacing the tire, wheel or both, the rear
• If any solvent gets on the wheel sensor ro- wheel static balance should be adjusted.
tor, wipe it off immediately. • Adjust the rear wheel static balance with the
brake disc and rear wheel drive hub installoo.

1. Adjust:
• Rear wheel static balance
Refer to "ADJUSTING THE FRONT WHEEL
STATIC BALANCE" on page 4-15.

4-22
 REAR WHEEL

EA~11157

INSTALLING THE REAR WHEEL (REAR

BRAKE DISC)
1. Install:
• Rear brake disc

Rear brake disc bolt

30 N•m (3.0 kgf•m, 22 lb•ft)
LOCTITE®
ECA119150

NOTICE
------------
Re pIace the brake disc bolts with new ones.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Tighten the brake disc bolts in stages and in a
crisscross pattern.
2. Check:
• Rear brake disc
Refer to "CHECKING THE REAR BRAKE
DISC" on page 4-43. A. Left side
3. Lubricate: B. Right side
• Oil seal lip
5. Install:
Recommended lubricant • Rear brake caliper
Lithium-soap-based grease • Rear brake caliper bolt
6. Adjust:
4. Install: • Drive chain slack
• Brake caliper bracket assembly Refer to "DRIVE CHAIN SLACK" on page 3-
• Rearwheel 17.
• Adjusting block
• Wheel axle Drive chain slack (Maintenance
• Washer stand)
• Wheel axle nut 36.0-41.0 mm (1.42- 1.61 in)
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ Drive chain slack (Sidestand)
36.0-41.0 mm (1.42- 1.61 in)
• Do not install the brake caliper.
Drive chain slack limit (Side-
• Align the projection "a" in the swingarm with the
stand)
sl ot "b" of the brake caliper bracket assembly .
46.0 mm (1.81 in)
• Install the adjusting block (left) so that projec-
tion "c" faces to the front of the vehicle. 7. Tighten:
• Install the adjusting block (right) with the cham- • Wheel axle nut
fered "d" facing the inside. • Rear brake caliper bolt

Rear wheel axle nut

105 N-m (10.5 kgf-m, 77 lb-ft)
Rear brake caliper bolt (front)
27 N•m (2.7 kgf•m, 20 lb•ft)
Rear brake caliper bolt (rear)
22 N•m (2.2 kgf•m, 16 lb•ft)
LOCTITE®
E\VA13l!OO

A WARNING
Make sure the brake hose is routed properly.

4-23
 REAR WHEEL

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ 9. Measure:
When tightening the wheel axle nut, there • Distance "a"
should be no clearance "a" between the adjust- (between the wheel sensor rotor "1" and rear
ing block "1" and adjusting bolt "2". 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·
.o .:1 'I TITE® on the mounting surface of the roto r,
= c,f. ✓
'/ .;,1\
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.

Im . ~ Distance "a" (between the wheel

sensor rotor and rear wheel sen-
sor)
0.6-1.7 mm (0.02--0.07 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
tum the rear wheel while the thickness gauge is
A. Left side installed. This may damage the rear wheel sen-
B. Right side sor rotor and the rear wheel sensor.
8. Install:
• Rear wheel sensor
Thickness gauge
90890-03268
Rear wheel sensor bolt Feeler gauge set
7 N•m (0.7 kgf•m, 5.2 lb•ft) YU-26900·9
ECA2·1090

NOTICE
-------------
Make sure there are no foreign materials in
the rear wheel sensor rotor and rear wheel
sensor. Foreign materials cause damage to
the rear wheel sensor rotor and rear wheel
sensor.
a
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
When installing the rear wheel sensor, check the G088906
rear wheel sensor lead for twists.

4-24
 FRONT BRAKE

EA"""'°
FRONT BRAKE
Removing the front brake pads

5 N·m (0.5 kgl·m, 3.7 lb·ft)

6
;··.l
l~ : -

4 3

2 1 ~

Order Job/Parts to remove Q'ty Remarks

The following procedure applies to both of
the front brake calipers.
Brake pad c lip 2
2 Brake pad pin
3 Brake pad spring
4 Brake pad 2
5 Front brake caliper
6 Bleed screw

4-25
 FRONT BRAKE

Removing the front brake master cylinder

2
** .............. ,'!! •••• :,,, 7 N-m (0. 7 kgf-m, 5.2 lb-ft)

!..a~ .............. •. a-O '................... 5

**
:··················-·· * 4-------- ------ --,
···1···: '----- \
'
: '
s I : 6 ··1 ~ -
··········· ' ·~
========= /t ' ·\------ '
. . - - , - - - - - - - - - - - , '~
1 ,,j 1.2 N-m (0.12 kgfm, 0.88 lb-ft) !
.,'
.__j

. i/
..- -·: j .
~. 6 N-m (0.6 kgf-m, 4. . r::.~ !/:)m
·\ir~... •·t··· ** . .
.-I ,"~"",)'""1-.2- N_-m
_ (0- .-12_k_gf
_m_,0-.88
- 1-b •-ft...,.-
)I

'/, 30 N-m (3.0 kgf-m, 22 lb-ft)

• For MT09M/MT09MC
.. For MT09SPM/MT09SPMC
Order Job/Parts to• remove Q'ty Remarks
Rearview mirror (right) Refer to "HANDLEBAR'' on page 4•57.
Drain.
Brake fluid Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)" on page 3· 15.
Brake fluid reservoir cap stopper
2 Brake fluid reservoir cap
3 Brake fluid reservoir diaphragm holder
4 Brake fluid reservoir diaphragm
5 Brake fluid reservoir bracket
6 Brake fluid reservoir
7 Brake fluid reservoir hose
8 Brake lever
9 Front brake light switch connector 2 Disconnect. (for MT09M/MT09MC)

4-26
 FRONT BRAKE

Removing the front brake master cylinder

**
.. . ·····~
' ··.············:
,'!! ••••••• ••. ;,,, 7 N-m (0, 7 kgf-m, 5.2 lb-ft)

** ------------ ---- ---,

·---------
'
' ''
*
~ :
,..........---___,,
···..... .. .· ~
._, / ~ / / \-------- .
.......,..---------.-~ ·--
1,,) 1,2 N-m (0.12 kgfm, 0,88 lb-It) ! .__j
14

·----1
"• 6 N-m (0.6 kgf-m, 4. r.ij
-.----~~·~i~
\ ~15~
1, .. --· '>- ---~
/~
11

:*~ --- ** I ' 11 · -

I s,j1.2 N-m (0.12 kgfm, 0.88 lb-It) I ~
'r, 30 N-m (3.0 kgf-m, 22 lb-ft) 10
• For MT09M/MT09MC
.. For MT09SPM/MT09SPMC

Order Job/Parts to• remove Q'ty Remarks

10 Brake hose union bolt
11 Brake hose gasket 2
12 Brake hose
13 Front brake master cylinder holder
14 Front brake master cylinder
15 Front brake light switch

4-27
 FRONT BRAKE

Disassembling the front brake ma.ster cylinder

1,, J s N·m (0.5 kgl·m, 3.7 lb·lt)I s

---- ~ 2

~ - 3

Order Job/Parts to remove Q'ty Remarks

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

4-28
 FRONT BRAKE

Removing the front brake calipers

,t 35 N-m (3.5 kgf-m, 26 I

I •.I3.8 N-m (0.38 kgf-m, 2.8 lb-ft)

/'
/-......__ ' 6

---
,.._____
-= . . _ . . _
z

5
=-
-~

✓., 30 ~m (3.0 kgf,m, 22 lb-It)

Order Job/Parts to remove Q'ty Remarks

The following procedure applies to both of
the front brake calipers.
Drain.
Brake fluid Refer to"BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)" on page 3-15.
Brake hose union bolt
2 Brake hose gasket 3
3 Brake hose 2
4 Reflector bracket
5 Reflector
6 Front brake caliper

4-29
 FRONT BRAKE

Disassembling the front brake calipers

~ ~.-, _S
_ N_· m
- (0-.-
5 -kg
- l-·m
- , 3- .7
-S-l b-·lt
~)

/'•, \
,,.;,· ·- ·-....
,/ \;;fjl

•.' . ·- ,,?
'•··-;x:,··-.
......,:

2
r<::; 1 mm
6
5
1mm
~
(m 7 0
D 0 6 Im
7

5 mm
6GI'/!!I
1mm
Order Job/Parts to remove Q'ty Remarks
The following procedure applies to both of
the front brake calipers.
1 Brake pad c lip 2
2 Brake pad pin
3 Brake pad spring
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

4-30
 FRONT BRAKE

EAS30108
INT RODUCTION
E\VA1!410 1

A 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 G088908
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 th e 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 4.0 mm (0.16 in)
and plastic parts. Therefore, always clean
4. Replace:
up any spilt brake fluid immed~ately.
• Brake disc
• Avoid brake fluid coming into contact with
Refer to "FRONT WHEEL" on page 4-11 .
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING
Front brake disc bolt
THE EYES:
18 N,m (1.8 kgf,m, 13 lb,ft)
• Flush with water for 15 minutes and get im- LOCTITE®
mediate medical attention.
ECA19 160

EAS301'9
CHECKING THE FRONT BRAKE DISCS
NOTICE
-------------
RepIace the brake disc bolts with new ones.
The following procedure applies to both brake
discs. TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
1. Check: Tighten the b rake disc bolts in stages and in a
• Front brake disc crisscross pattern.
Damage/galling ➔ Replace.
2. Measure: EAS301>0

• Brake disc runout REPLACING THE FRONT BRAKE PADS

Out of specification ➔ Replace. The following procedure applies to both brake
calipers.
Brake disc runout limit (as mea- TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
sured on wheel) When replacing the brake pads, it is not neces-
0.10 mm (0.0039 in) sary to disconnect the brake hose or disassem-
ble the brake caliper.
a. Place the vehicle on a maintenance stand
so that the front wheel is elevated. 1. Remove:
b. Remove the brake caliper. • Brake pad clip "1"
c. Hold the dial gauge at a right angle against • Brake pad pin "2"
the brake disc surface. • Brake pad spring "3"
d . Measure the runout 1.5 mm (0.06 in) below
the edge of the brake disc.

4-31
 FRONT BRAKE

b. Loosen the bleed screw and push the brake

caliper pistons into the brake caliper with
your finger.

~ ,,
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)

d. Install the brake pads and brake pad spring.

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
The arrow mark "a" on the brake pad spring
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)

a 6. Install:

al 11
Iol •
•
•
Brake pad pin
Brake pad clip
Front brake caliper

Front brake ca liper bolt

4. Remove: 3 5 N•m (3.5 kgf•m, 26 lb•ft)
• Brake caliper bolt
5. Install: 7. Check:
• Brake pad • Brake fluid level
• Brake pad spring Below the minimum level mark ➔ Add the
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ specified brake fluid to the proper level.
Refer to "CHECKING THE BRAKE FLUID
Always install new brake pads and new brake LEVEL" on page 3-13.
pad spring as a set. 8. Check:
• Brake lever operation
a. Connect a clear plastic hose "1 " tightly to
Soft or spongy feeling ➔ Bleed the brake sys-
the bleed screw "2". Put the other end of the
tem.
hose into an open container.
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)" on page 3-15.

4-32
 FRONT BRAKE

EAS30n< EAS301'3

REMOVING THE FRONT BRAKE CALIPERS CHECKING THE FRONT BRAKE CALIPERS
The following procedure applies to both of the The following procedure applies to both of the
brake calipers. brake calipers.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Recommended brake component
Before removing the brake caliper, drain the replacement schedule
brake fluid from the entire brake system.
Brake pads If necessary
1. Remove: Piston seals Every two years
• Brake hose union bolt
Piston dust seals Every two years
• Brake hose gasket
• Brake hose Brake hoses Every four years
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ Brake fluid Every two years and
Put the end of the brake hose into a container whenever the brake is
and pump out the brake fluid carefully . disassembled

EAS30172
1. Check:
DISASSEMBLING THE FRONT BRAKE • Brake caliper piston
CALIPERS RusVscratches/wear ➔ Replace the brake
The following procedure applies to both of the caliper pistons.
brake calipers. • Brake caliper cylinder
1. Remove: Scratches/wear ➔ Replace the brake caliper
• Brake caliper piston assembly.
• Brake caliper piston dust seal • Brake caliper body
• Brake caliper piston seal Cracks/da mage ➔ Replace the brake caliper
a. Secure the right side brake caliper pistons assembly.
with a piece of wood "a". • Brake fluid delivery passages
b. Blow compressed air into the b rake hose (brake caliper body)
joint opening "b" to force out the left side Obstruction ➔ Blow out with compressed air.
E\VA13S'l 1
pistons from the brake caliper.
E\VA tl10e0
A WARNING
A WARNING Whenever a brake caliper is disassembled,
• Never try to pry out the brake caliper pis- replace the brake caliper piston dust seals
tons. and brake caliper piston seals.
• Do not loosen the bolts "4".
EAS.10174
ASSEMBLING THE FRONT BRAKE
CALIPERS

A WARNING
• Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.
a b • Never use solvents on internal brake com-
ponents as they will cause the brake caliper
piston dust seals and brake caliper piston
c. Remove the brake caliper piston dust seals seals to swell and distort.
and brake caliper piston seals . • Whenever a brake caliper is disassembled,
d . Repeat the previous steps to force out the replace the brake caliper piston dust seals
right side pistons from the brake caliper. and brake caliper piston seals.

Specified brake fluid

DOT4

4-33
 FRONT BRAKE

EAS301715
3. Install:
INSTALLING THE FRONT BRAKE CALIPERS
• Brake pad
The following procedure applies to both of the
• Brake pad spring
brake calipers.
• Brake pad pin
1. Install:
• Brake pad clip
• Front brake caliper "1"
• Front brake caliper
(temporarily)
• Brake hose gasket Gm Front brake caliper bolt
• Brake hose "2" 3 5 N,m (3.5 kgf,m, 26 lb,ft)
• Brake hose union bolt "3"
Refer to "REPLACING THE FRONT BRAKE
Front brake caliper bolt PADS" on page 4-31 .
35 N•m (3.5 kgf•m , 26 lb•ft) 4 . Fill:
• Brake master cylinder reservoir
EWA t!3G31
(with the specified amount of the specified
A WARNING
brake fluid)
Proper brake hose routing is essential to in-
sure safe vehicle operation.
Specified brake fluid
ECA2 1410 DOT4
NOTICE - - - - - , - - - , - - , - - -:--:-=--- EWAt3000
• When installing the brake hose onto the
brake caliper "1 ", make sure the brake pipe
A WARNING
• Use only the designated brake fluid. Other
"a" touches the projection "b" on the brake
brake fluids may cause the rubber seals 10
caliper.
deteriorate, causing leakage and poor
• Install the brake pipe " c" so that it is
brake performance.
aligned with the brake pipe " a" .
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to ipoor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
3 the brake fluid and could cause vapor lock.
ECA13500

NOTICE -----,-----:--:--.--:;:-:::-:-::--
Brake fluid may damage painted surfaces
ffil and plastic parts. Therefore, always clean 1.1p
any spilt brake fluid immediately.
2 5. Bleed:
a • Brake system
Refer to "BLEEDING THE HYDRAULIC
b BRAKE SYSTEM (ABS)" on page 3-15.
6. Check:
1 • Brake fluid level
Below the minimum level mark ➔ Add the
A. Right side specified brake fluid to the proper level.
B. Left side Refer to "CHECKING THE BRAKE FLU ID
2. Remove: LEVEL" on page 3-13.
• Front brake caliper

4-34
 FRONT BRAKE

7. Check: EAS30181
ASSEMBLINIG THE FRONT BRAKE MASTER
• Brake lever operation
CYLINDER
Soft or spongy feeling ➔ Bleed the brake sys- EWAt3!5:20
tem. A WARNING
Refer to "BLEEDING THE HYDRAULIC • Before installation, all internal brake com-
BRAKE SYSTEM (ABS)" on page 3-15.
ponents should be cleaned and lubricated
EAS30179 with clean or new brake fluid.
REMOVING THE FRONT BRAKE MASTER • Never use solvents on internal brake com-
CYLINDER ponents.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Before removing the front brake master cylinder,
Specified brake fluid
drain the brake fluid from the entire brake sys- DOT4
tem.
e,s,o,o,
1. Disconnect: INSTALLING THE FRONT BRAKE MASTER
• Brake light switch connector (for MT09SPM/ CYLINDER
MT09SPMC) 1. Install:
(from the front brake light switch) • Front brake master cylinder
2. Remove: • Front brake master cylinder holder
• Brake hose union bolt
• Brake hose gasket Front brake master cylinder hold·
• Brake hose er bolt
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ 16 N,m (1.6 kgf,m, 12 lb,ft)
To collect any remaining brake fluid, place a
container under the master cylinder and the end
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
of the brake hose. • Install the front brake master cylinder holder

...,.,,.
CHECKING THE FRONT BRAKE MASTER
with the "UP" mark "a" facing up.
• Align the end of the front brake master cylinder
holder with the punch mark "b" on the handl:e-
CYLINDER bar.
1. Check: • First, tighten the upper bolt, then the lower bolt.
• Brake master cylinder
Damage/scratches/wear ➔ Replace.
• Brake fluid delivery passages
(brake master cylinder body)
Obstruction ➔ Blow out with compressed air.
2. Check:
• Brake master cylinder kit
Damage/scratches/wear ➔ Replace.
3. Check:
• Brake master cylinder reservoir b a
• Brake master cylinder reservoir diaphragm 2. Install:
holder
Cracks/damage ➔ Replace.
• Brake hose gasket Im
• Brake hose
• Brake master cylinder reservoir diaphragm
• Brake hose union bolt
Damage/wear ➔ Replace.
4. Check:
Front brake hose union bolt
• Brake hose
30 N,m (3.0 kgf,m, 22 lb,ft)
Cracks/damage/wear ➔ Replace.

4-35
 FRONT BRAKE

EWA1!3G31
4. Bleed:
A WARNING • Brake system
Proper brake hose routing is essential to in- Refer to "BLEEDING THE HYDRAULIC
sure safe vehicle operation. BRAKE SYSTEM (ABS)" on page 3-15.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
5. Check:
• Brake fluid level
• When installing the brake hose onto the master Below the minimum level mark ➔ Add the
cylinder, make sure the projection "a" on the specified brake fluid to the proper level.
brake hose touches the projection "b" on the Refer to "CHECKING THE BRAKE FLUID
master cylinder. LEVEL" on page 3-1 3.
• Turn the handlebar to the left and right to make 6. Check:
sure the brake hose does not touch other parts • Brake lever operation
(e.g., wire harness, cables, leads). Correct if Soft or spongy feeling ➔ Bleed the brake sys-
necessary. tem.
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)" on page 3-15.

3. Fill:
• Brake master cylinder reservoir
(with the specified amount of the specified
brake fluid)

Specified brake fluid

DOT4
£\VAt!:moio

A 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
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake perfonnance.
• When refilling, be careful that water does
not enter the brake master cylinder reser-
voir. Water will significantly lower the boil-
ing point of the brake fluid and could cause
vapor lock.
ECA1~

NOTICE
-:-----,-:------:--:--:--::----
8 rake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.

4-36
 REAR BRAKE

EA""""'1

REAR BRAKE

" • 17 N-m (1.7 kgf-m, 13 lb-ft)

• Three Bond No. 1521 .

Order Job/Parts to• remove Q'ty Remarks
1 Screw plug
2 Brake pad retaining bolt
3 Rear brake caliper
4 Brake pad 2
5 Brake pad shim 2
6 Brake pad insulator 2
7 Brake pad spring
8 Bleed screw
9 Brake caliper bracket assembly

4-37
 REAR BRAKE

Removing the rear brake master cylinder

30 N·m (3.0 kgf·m, 22 lb·ft)

~-
, ~

LS

1 ~
36 r 9
e-4
2

7
N·m (2.3 kgf·m, 17 lb·ft)

- :.-----------
m (0.15 kgf·m, 1.1 lb·ft) _ \ '\

, 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) ~ ~ -0

Order Job/Parts to remove Q'ty Remarks
Refer to "GENERAL CHASSIS (1)" on
Rider seat page 4-1.
Refer to "GENERAL CHASSIS (1)" on
Fuel tank center cover
page 4-1.
Fuel tank Refer to "FUEL TANK" on page 7-1.
Drain.
Brake fluid Refer to"BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)" on page 3-15.
Brake fluid reservoir bracket
2 Brake fluid reservoir cap
3 Brake fluid reservoir diaphragm holder
4 Brake fluid reservoir diaphragm
5 Brake fluid reservoir
6 Brake fluid reservoir hose
7 Brake hose union bolt
8 Brake hose gasket 2
9 Brake hose

4-38
 REAR BRAKE

Removing the rear brake master cylinder

30 N·m (3.0 kgf·m, 22 lb·ft)

~-
, ~

LS

-
• -~ mm~V
_t}✓- ' I'>' !
V\
N·m (2.3 kgf·m, 17 lb·ft)

30 N·m (3.0 kgf·m, 22 lb·ft) I

m(0.15kgf·m,1.11b·ft) _ \
11 '\

, 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) ~ ~ -0

Order Job/Parts to remove Q'ty Remarks
10 Footrest assembly (right)
11 Rear brake master cylinder assembly
12 Rear brake light switch bracket
13 Rear brake light switch coupler Disconnect.
14 Rear brake light switch

4-39
 REAR BRAKE

Disassembling the rear brake master cylinder

4
3 mm
x 18 N·m (1.8 kgf·m, 13 lb·ft)

Order Job/Parts to remove Q'ty Remarks

Brake master cylinder yoke
2 Brake master cylinder kit
3 Hose joint
4 Bushing
5 Brake master cylinder body

4-40
 REAR BRAKE

Removing the rear brake caliper

' 30 N·m (3.0 kgf·m, 22 lb·ft)

' Gm,1 2

'>, 22 N-m (2.2 kgl-m, 16 lb•ft)

Order Job/Parts to remove Q'ty Remarks

Drain.
Brake fluid Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)" on page 3-15.
Brake hose union bolt
2 Brake hose gasket 2
3 Brake hose
4 Rear brake caliper

4-41
 REAR BRAKE

Disassembling the rear brake caliper

9
mm

,; 17 N·m (1 .7 kgf·m, 13 lb·ft)

4 2.5 N·m (0.25 kgl· m, 1.8 lb· ft)

Order Job/Parts to remove Q'ty Remarks

1 Screw plug
2 Brake pad retaining bolt 1
3 Brake pad 2
4 Brake pad shim 2
5 Brake pad insulator 2
6 Brake pad spring
7 Brake caliper piston
8 Brake caliper piston dust s eal
9 Brake caliper piston seal
10 Bleed screw

4-42
 REAR BRAKE

EA"""'21 EAS30183
ADJUSTING THE FOOTREST POSITION INTRODUCT ION
EWA1 4 10 1
1. Check:
• Footrest position ~ WARNING
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ Disc brake components rarely require disas-
sembly. Therefore, always follow these pre-
The rider footrests can be adjusted to one of two
ventive measures:
positions. From the factory, the footrests are in
the low position.
• Never disassemble brake components un-
less absolutely necessary.
2. Adjust: • If any connection on the hydraulic brake
a. Remove the footrest assembly (left and system is disconnected, the entire brake
right) "1". system must be disassembled, drained,
b. Adjust the footrest position (low or high po- cleaned, properly filled, and bled after reas-
sition). sembly.
c. Install the footrest assembly (left and right). • Never use solvents on internal brake com-
ponents.
Footrest assembly bolt • Use only clean or new brake fluid for clean-
28 N•m (2.8 kgf•m, 21 lb-ft) ing brake components.
• Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
• Avoid brake fluid coming into contact wit h
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get im-
mediate medical attention.

EAS3018'
CHECKING THE REAR BRAKE DISC
1. Check:
• Rear brake disc
Damage/galling ➔ Replace.
2. Measure:
• Brake disc runout
Out of specification ➔ Replace.
Refer to "CHECKING THE FRONT BRAK E
DISCS" on page 4·31.
A. Left side
B. Right side Brake disc runout limit (as mea-
sured on wheel)
0.15 mm (0.0059 in)

3. Measure:
• Brake disc thickness
Measure th e brake disc thickness at a few dif-
ferent locations.
Out of specification ➔ Replace.
Refer to "CHECKING THE FRONT BRAK E
DISCS" on page 4-31.

Brake disc thickness limit

4.5 mm (0.18 in)

4-43
 REAR BRAKE

4. Replace:
• Brake disc
Refer to "REAR WHEEL" on page 4-18.

Rear brake disc bolt

30 N-m (3.0 kgt-m, 22 lb•ft)
LOCTITE®

REPLACING THE REAR BRAKE PADS

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ c. Tighten the bleed screw.
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose o r disassem- Brake caliper bleed screw
ble the brake caliper. 5 N-m (0.5 kgt-m, 3.7 lb•ft)
1. Measure: d. Install the brake pad insulators and brake
• Brake pad wear limit "a" pad shims onto each brake pads.
Out of specification ➔ Replace the brake TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
pads as a set.
Apply silicone grease between the brake pad in-
sulator and brake pad shim.
Brake pad lining thickness limit
1.0 mm (0.04 in) ECA14Ui0

NOTICE
-------------
• Do not allow grease to contact the brake,
pads.
• Remove any excess grease.
a e. Install the brake pads and brake pad spring.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
l:I
I IT 1
._I-'--'-----'------'----'-------'---' The longer tangs "a" of the brake pad spring
must point in the direction of the brake caliper
piston.

2. Install:
• Brake pad insulator
• Brake pad shim
(onto the brake pad)
• Brake pad spring
(into the rear brake caliper)
• Brake pad
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Always install new brake pads, brake pad insu-
lators, brake pad shims, and brake pad spring as
a set. 3. Lubricate:
• Rear brake caliper bolt
a. Connect a clear plastic hose "1 " tightly to
the bleed screw "2". Put the other end of the Recommended lubricant
hose into an open container. Silicone grease
b. Loosen the bleed screw and push the brake ECAt, 160
caliper piston into the brake caliper with NOTICE
your finger. -------------
• Do not allow grease to contact the brake,
pads.
• Remove any excess grease.

4-44
 REAR BRAKE

EWA t3l!l50
4. Install:
• Rear brake caliper A WARNING
• Brake pad retaining bolt • Cover the brake caliper piston with a rag.
• Screw plug Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
Rear brake caliper bolt (front) • Never try to pry out the brake caliper pis-
27 N•m (2.7 kgf•m, 20 lb•ft) ton.
Rear brake caliper bolt (rear)
22 N•m (2.2 kgf•m, 16 lb·ft)
LOCTITE®
Rear brake pad retaining bolt
17 N•m (1.7 kgf•m, 13 lb•ft)
Rear brake caliper screw plug
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)

5. Check:
• Brake fluid level
Below the minimum level mark ➔ Add the
specified brake fluid to the proper level. b. Remove the brake caliper piston dust seal
Refer to "CHECKI NG THE BRAKE FLUID and brake caliper piston seal.
LEVEL" on page 3-13. EASOOUI!
6. Check: CHECKING THE REAR BRAKE CALIPER
• Brake pedal operation
Soft or spongy feeling ➔ Bleed the brake sys- Recommended brake component
replacement schedule
tem .
Refer to "BLEEDING THE HYDRAULIC Brake pads If necessary
BRAKE SYSTEM (ABS)" on page 3-15. Piston seal Every two years
EAS30186 Piston dust seal Every two years
REMOVING THE REAR BRAKE CALIPER
Brake hoses Every four years
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Brake fluid Every two years and
Before disassembling the brake caliper, drain
whenever the brake is
the brake fluid from the entire brake system. disassembled
1. Remove:
• Brake hose union bolt 1. Check:
• Brake hose gasket • Brake caliper piston
• Brake hose RusVscratches/wear ➔ Replace the brake
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ caliper piston.
• Brake caliper cylinder
Put the end of the brake hose into a container
Scratches/wear ➔ Replace the brake caliper
and pump out the brake fluid carefully.
assembly.
• Brake caliper body
EAS301"7
DISASSEMBLING THE REAR BRAKE Cracks/damage ➔ Replace the brake caliper
CALIPER assembly.
1. Remove: • Brake fluid delivery passages
• Brake caliper piston (brake caliper body)
• Brake caliper piston dust seal Obstruction ➔ Blow out with compressed air.
EWA13G01
• Brake caliper piston seal
A WARNING
a. Blow compressed air into the b rake hose Whenever a brake caliper is disassembled,
joint opening "a" to force out the piston from replace the brake caliper piston dust seal
the brake caliper. and brake caliper piston seal.

4-45
 REAR BRAKE

2. Check:
• Rear brake caliper bracket a
• Rear brake caliper bracket retainer
Cracks/damage ➔ Replace the rear brake
caliper bracket assembly.
Refer to "REAR WHEEL" on page 4-18.
...,.,.. \
ASSEMBLING THE REAR BRAKE CALIPER
£\VAtlfte!I
\,
1\ ~
-
A WARNING
• Before installation, all internal brake com- 2. Remove:
ponents should be cleaned and lubricated • Rear brake caliper
with clean or new brake fluid. 3. Install:
• Never use solvents on internal brake com- • Brake pad insulator
ponents as they will cause the brake caliper • Brake pad shim
piston dust seal and brake caliper piston (onto the brake pad)
seal to swell and distort. • Brake pad spring
• Whenever a brake caliper is disassembled, (into the rear brake caliper)
replace the brake caliper piston dust seal • Brake pad
and brake caliper piston seal. • Rear brake caliper
Refer to "REPLACING THE REAR BRAKE
PADS" on page 4-44.
Specified brake fluid
DOT4 Rear brake caliper bolt (front)
27 N,m (2.7 kgf,m, 20 lb,ft)
EAS30190
Rear brake caliper bolt (rear)
INSTALLING THE REAR BRAKE CALIPER 22 N,m (2.2 kgf,m, 16 lb,ft)
1. Install: LOCTITE®
• Brake caliper bracket retainer Rear brake pad retaining bolt
• Rear brake caliper 17 N,m (1.7 kgf,m, 13 lb,ft)
(temporarily) Rear brake caliper screw plug
• Brake hose gasket Gm 2.5 N,m (0.25 kgf,m, 1.8 lb,ft)
• Brake hose
• Brake hose union bolt 4. Fill:
• Brake fluid reservoir
Rear brake hose union bolt (with the specified amount of the specified
30 N-m (3.0 kgf-m, 22 lb,ft) brake fluid)

E\VA Tl3G31
Specified brake fluid
A WARNING DOT4
Proper brake hose routing is essential to in-
sure safe vehicle operation.
ECA19:)8(1

NOTICE
-------------
When installing the brake hose onto the
brake caliper "1 " , make sure the brake pipe
"a" passes between the projections "b" on
the brake caliper.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Apply Three Bond No. 1521 onto the mating sur-
faces of the brake caliper bracket and brake cal-
iper bracket retainer.

4-46
 REAR BRAKE

EWA1!3000 EAS3019'

A WARNING CHECKING THE REAR BRAKE MASTER

• Use only the designated brake fluid. Other CYLINDER
brake fluids may cause the rubb er seals to 1. Check:
d eteriorate, causing leakage and poor • Brake master cylinder
brake performance. Damage/scratches/wear ➔ Replace.
• Refill with the same type of brak e fluid that • Brake fluid delivery passages
is already in the system. Mixing brake fluids (brake master cylinder body)
may result in a harmful chemical reaction, Obstruction ➔ Blow out with compressed air.
leading to poor brake perfonnance. 2. Check:
• When refilling, be careful that water does • Brake master cylinder kit
not enter the brake fluid reserv,o ir. Water Damage/scratches/wear ➔ Replace.
will significantly lower the boiling point of 3. Check:
the brake fluid and could cause vapor lock. • Brake fluid reservoir
• Brake fluid reservoir diaphragm holder
ECA135,Ci0
Cracks/da mage ➔ Replace.
NOTICE
-------------
Brake fluid may damage painted surfaces
• Brake fluid reservoir diaphragm
Damage/wear ➔ Replace.
and plastic parts. Therefore, always clean up 4. Check:
any spilt brake fluid immediately.
• Brake hose
5. Bleed: • Brake fluid reservoir hose
• Brake system Cracks/damage/wear ➔ Replace.
Refer to "BLEEDING THE HYDRAULIC ....,.,,.
BRAKE SYSTEM (ABS)" on page 3-15. ASSEMBLINIG THE REAR BRAKE MASTER
6. Check: CYLINDER
E\VAt3520
• Brake fluid level
Below the minimum level mark ➔ Add the A WARNING
specified brake fluid to the proper level. • Before installation, all internal brake com-
Refer to "CHECKING THE BRAKE FLUID ponents should be cleaned and lubricated
LEVEL" on page 3-13. with clean or new brake fluid.
7. Check: • Never use solvents on internal brake com-
• Brake pedal operation ponents.
Solt or spongy feeling ➔ Bleed the brake sys-
tem.
Specified brake fluid
Refer to "BLEEDING THE HYDRAULIC
DOT4
BRAKE SYSTEM (ABS)" on page 3-15.
EAS30193
1. Install:
REMOVING THE REAR BRAKE MASTER • Brake master cylinder kit Glm
CYLINDER
EAS301,.
1. Remove: INSTALLING THE REAR BRAKE MASTER
• Brake hose union bolt CYLINDER
• Brake hose gasket 1. Install:
• Brake hose
• Brake hose gasket Gm
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Brake hose
To collect any remaining brake fluid, place a • Brake fluid reservoir hose
corntainer under the master cylinder and the end • Brake hose union bolt
of the brake hose.
Rear brake hose union bolt
30 N,m (3.0 kgf,m, 22 lb,ft)

4-47
 REAR BRAKE

EWA1!3G31
4. Check:
A WARNING • Brake fluid level
Proper brake hose routing is essential to in- Below the minimum level mark ➔ Add the
sure safe vehicle operation. specified brake fluid to the proper level.
ECA14100 Refer to "CHECKING THE BRAKE FLUID
NOTICE LEVEL" on page 3-1 3.
------------
When installing the brake hose onto the 5. Adjust:
brake master cylinder, make sure the brake • Brake pedal position
pipe touches the projection " a" as shown. Refer to "ADJUSTING THE REAR DISC
BRAKE" on page 3-14.
6. Adjust:
• Rear brake light operation timing
Refer to "ADJUSTING THE REAR BRAKE
LIGHT SWITCH" on page 3-33.

2. Fill:
• Brake fluid reservoir
(with the specified amount of the specified
brake fluid)

Specified brake fluid

DOT4
E\VA tl3000

A WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
d eteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brak e fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake perfonnance.
• When refilling, be careful that water does
not enter the brake fluid reserv,o ir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
ECA135,CO

NOTICE
------------
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
3. Bleed:
• Brake system
Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)" on page 3-15.

4-48
 ABS (ANTI-LOCK BRAKE SYSTEM)

"""""""'
ABS (ANTI-LOCK BRAKE SYSTEM)

"·· 7 N·m (0.7 kgf·m, 5.2 lb·ft)

7 N·m (0.7 kgf·m, 5.2 lb·ft)

i

Order Job/Parts to remove Q'ty Remarks

Refer to "GENERAL CHASSIS (1)" on
Rider seat/Battery page 4-1.
Refer to "GENERAL CHASSIS (1)" on
Fuel tank center cover
page 4-1.
Fuel tank Refer to "FUEL TANK" on page 7-1.
Refer to "GENERAL CHASSIS (2)" on
Air filt er case
page 4-10.
Throttle bodies Refer to "THROTTLE BODIES" on page 7-5.
Drain.
Brake fluid Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)" on page 3-15.
1 Brake hose union bolt 2
2 Gasket 4

4-49
 ABS (ANTI-LOCK BRAKE SYSTEM)

Removing the hydraulic unit assembly

I ,,I 30 N·m (3.0 kgf·m, 22 lb•fl)l 1.J. I < I7 N·m (0.7 kgl·m, 5.2 lb·ft) I
mmd
3~~ " 16 N ·m (1.6 kgf·m, 12 lb·ft)
-"' 16 N·m (1.6 kgl· ; _ , i ~
1
8 - :12 -

I 1·:fr \
v !
• •c=::7-,~
I -1
'7 ' '

- -:--:.:::. ·
,

Order Job/Parts to remove Q'ty Remarks

Brake hose (hydraulic unit: to front brake cali-
3 Disconnect.
pers)
Brake hose (front brake master cylinder to
4 Disconnect.
hydraulic unit)
5 Bracket
6 Hydraulic unit bracket
7 ABS ECU coupler Disconnect.

8 Hydraulic unit brake pipe ( rear brake master cyl- Disconnect.

inder to hydraulic unit)
Hydraulic unit brake pipe (hydraulic unit to rear Disconnect.
9
brake caliper)
Hydraulic unit brake pipe (hydraulic unit to front
10 brake calipers)
Hydraulic unit brake pipe (front brake master
11 cylinder to hydraulic unit)
12 Hydraulic unit assembly

4-50
 ABS (ANTI-LOCK BRAKE SYSTEM)

EAS301"7
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
REMOVING THE HYDRAULIC UNIT
ASSEMBLY • Do not operate the brake lever and brake pedal
while removing the brake hoses.
NOTICE • Do not bend the brake pipe when loosening the
-------------
UnIess necessary, avoid removing and in- brake pipe flare nuts.
stalling the brake hoses of the hydraulic unit ECA19900
assembly. NOTICE _ _ _ _ _ _ _ _ _ _ __
EWA1l3!m • When removing the brake hoses and brake
A WARNING pipes, cover the area around the hydraulic
Refill with the same type of brake fluid that is unit assembly to catch any spilt brake fluid.
aIr,eady in the system. Mixing fl u ids may re- Do not allow the brake fluid to contact other
su'lt in a harmful chemical reaction, leading parts.
to poor braking per1ormance. • Before disconnecting the brake pipes from
ECA118241
the hydraulic unit assembly, do not lift up
NOTICE or move the brake pipes.
-------------
• Handle the ABS components with care 3. Remove:
since they have been accurateEy adjusted. • Hyd raulic unit assembly "1"
Keep them away from dirt and do not sub- TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
ject them to shocks.
To avoid brake fluid leakage and to prevent for-
• Do not turn the main switch to "ON" when eign materials from entering the hydraulic unit
removing the hydraulic unit assembly. assembly, insert a rubber plug "a" or a bolt (M10
• Do not clean with compressed air. x 1.0) into each brake hose union bolt hole.
• Do not reuse the brake fluid.
ECA19810
• Brake fluid may damage painted sur1aces
NOTICE
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
-------------
When using a bolt, do not tighten the bolt un-
• Do not allow any brake fluid to contact the til the bolt head touches the hydraulic unit.
couplers. Brake fluid may damage the cou- Otherwise, the brake pipe seating sur1ace
plers and cause bad contacts. could be deformed.
• If the union bolts for the hydraulic unit as-
sembly have been removed, be sure to
tighten them to the specified torque and
bleed the brake system. A
Ua
1. Disconnect:
• ABS ECU coupler "1"
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ 1
While pushing the portion "a" of the ABS ECU
coupler, pull the lock lever "2" up to release the
lock.
EAS301'8

CHECKING THE HYDRAULIC UNIT

ASSEMBLY
1. Check:
• Hyd raulic unit assembly
Cracks/da mage ➔ Replace the hydraulic unit
assembly and the brake pipes that are con-
nected to the assembly as a set.

• Brake hose

4-51
 ABS (ANTI-LOCK BRAKE SYSTEM)

EAS3CJOOl5
CH ECKING THE BRAKE PIPES
Hydraulic unit brake pipe flare
The following procedure applies to all of the nut
brake pipes. 16 N-m (1.6 kgf-m, 12 lb•ft)
1. Check:
ECA19820
• Brake pipe end (flare nut)
NOTICE
Damage ➔ Replace the hydraulic unit as-
sembly, brake pipes, and related parts as a
------------
1f the brake pipe flare nut does not turn easi-
set. ly, replace th e hydraulic unit assembly,
...,.,,,.
INSTALLING THE HYDRAULIC UNIT
brake pipes, and related parts as a set.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
ASSEMBLY
Do not bend the brake pipe when tightening tlhe
1. Install:
brake pipe flare nuts.
• Hyd raulic unit assembly
5. Install:
NOTICE
------------
Do not remove the rubber plugs or bolts
• Gasket ml')
• Brake hose union bolt "1"
(M10 x 1.0) installed in the brake hose union • Brake hose
bolt holes before installing the hydraulic unit Refer to "CABLE ROUTING" on page 2-15 .
assembly.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ After holding the protrusion "a" (17 mm (0.67 in))
Do not allow any foreign materials t o enter the on the brake hose joint w ith an appropriate tool,
hydraulic unit assembly, brake hoses or brake tighten the brake hose union bolts to the speci-
pipes when installing the hydraulic uni1 assem- fied torque.
bly .

a. Install the hydraulic unit assembly "1" on Front brake hose union bolt
30 N-m (3.0 kgf-m, 22 lb•ft)
the hydraulic uni1 bracket "2".
b. Tighten the hydraulic unit assembly bolt "3",
and bolt "4" to the specified torque in this or-
der.

Hydraulic unit assembly bolt

7 N•m (0.7 kgf-m, 5.2 lb•ft)

6. Connect:
• ABS ECU coupler "1"
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Connect the ABS ECU coupler, and then push
the lock lever "a" of the coupler in the direction of
the arrow shown.

2. Remove:
• Rubber plugs or bolt (M10 x 1.0)
3. Install:
• Hyd raulic unit brake pipe
4. Tighten:
• Hyd raulic unit brake pipe flare nut

4-52
 ABS (ANTI-LOCK BRAKE SYSTEM)

10.Delete the DTC. (Refer to "SELF-DIAGNOS-

TIC FUNCTION AND DIAGNOSTIC CODE
TABLE" on page 9·39.)
11 .Pertorm a trial run. (Refer to "CHECKING
THE ABS WARNING LIGHT" on page 4-56.)
EAS30000
HYDRAULIC UNIT OPERATION TESTS
The reaction-force pulsating action generated in
the brake lever and brake pedal when the ABS is
activated can be tested when the vehicle is
7. Fill:
stopped.
• Brake fluid reservoir
The hydraulic unit operation can be tested using
(with the specified amount of the specified
the following two methods.
brake fluid)
• Brake line routing confirmation: this test
checks the ·function of the ABS after the sys-
Specified brake fluid
tem was disassembled, adjusted, or serviced.
DOT4
• ABS reaction-force confirmation: this test gen-
EWAl17'29'l erates the same reaction-force pulsating action
A WARNING that is generated in the brake lever and brake
• Use only the designated brake fluid. Other pedal when the ABS is activated.
brake fluids may cause the rubber seals to
d eteriorate, causing leakage and poor Brake line routing confirmation
E\VA t3120
brake performance.
• Refill with the same type of brake fluid that A WARNING
is already in the system. Mixing brake fluids Securely support the vehicle so that there is
may result in a harmful chemical reaction, no danger of it falling over.
leading to poor brake perfonnance. TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• When refilling, be careful that water does
not enter the brake master cylinder reser- • For the brake line routing confirmation, use the
voir or brake fluid reservoir. Water will sig- diagnosis of function of the VDT.
• Before pertorming the brake line routing confir-
nificantly lower the boiling point of the
mation, make sure that no malfunctions have
brake fluid and could cause vapor lock.
been detected in the ABS ECU and that the
ECA1~
wheels are not rotating.
NOTICE
-------------
Brake fluid may damage painted surfaces 1. Place the vehicle on a maintenance stand.
and plastic parts. Therefore, always clean up 2. Tum the main switch to "OFP'.
any spilt brake fluid immediately. 3. Remove:
• Rider seat
8. Bleed: Refer to "GENERAL CHASSIS (1 )" on
• Brake system page 4-1.
Refer to "BLEEDING THE HYDRAULIC 4. Check:
BRAKE SYSTEM (ABS)" on page 3-15. • Battery vo ltage
9. Check the operation of the hydraulic unit ac- Lower than 12.8 V ➔ Charge or replace the
cording to the brake lever and the brake ped- battery.
al response. (Refer to "HYDRAULIC UNIT
OPERATION T ESTS" on page 4-53.) Battery voltage
ECA14770
Higher than 12.8 V
NOTICE
-------------
A Iways check the operation of the hydraulic TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
unit according to the brake lever and the
If the battery voltage is lower than 12.8 V, charge
brake pedal response.
the battery, and then pertorm brake line routing
confirmation.

4-53
 ABS (ANTI-LOCK BRAKE SYSTEM)

5. Removing the protective cap, and then con-

nect the VDT to the VDT coupler (6P).

Yamaha diagnostic tool USB

(US)
90890-03269
Yamaha diagnostic tool (A/1)
90890-03264

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ G088911

• Yamaha diagnostic tool (A/I) (90890-03264) in- TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __

cludes VDT sub harness (6P) (90890-03266). "ON" and "OIFF" on the tool screen indicate
• If you already have Yamaha diagnostic tool (A/ when the brakes are being applied and released
I) (90890-03262), VDT sub harness (6P) respectively.
(90890-03266) is separately required .
ECA173'71

Refer to "VDT' on page 9-3. NOTICE

6. Start the VDT and display the diagnosis of
-------------
• Check that the pulse is felt in the brake le-
function screen. ver, brake pedal, and again in the brake l'.e -
7. Select code No. 2, "Brake line routing confir- ver, in this order.
mation". • If the pulse is felt in the brake pedal before
8. Click "Actuator Check", and then operate the it is felt in the brake lever, check that the
brake lever "1" and brake pedal "2" simulta- brake hoses and brake pipes are connected
neously. correct.ly to the hydraulic unit assembly.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ • If the pulse is hardly felt in either the brake
• The hydraulic unit operates 1 second after the lever or brake pedal, check that the brake
brake lever and brake pedal are operated si- hoses and brake pipes are connected cor-
multaneously and continues for approximately rectly to the hydraulic unit assembly.
5 seconds. 10.lf the operation of the hydraulic unit is normal,
• The operation of the hydraulic unit can be con- delete all of the OTC.
firmed using the indicator.
On: The hydraulic unit is operating. ABS react.ion-force confirmation
Flashing: The conditions for operating the hy- E\VAt3120

draulic unit have not been met. ~ WARNING

Off: The brake lever and brake pedal are not Securely support the vehicle so that there is
being operated. no danger of it falling over.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• For the ABS reaction-force confirmation, use
the diagnosis of function of the VDT. For more
information, refer to the operation manual of
the VDT.
• Before performing the ABS reaction-force con-
firmation, make sure that no malfunctions have
been detected in the ABS ECU and that the
G088909
wheels are not rotating.
9. Check: 1. Place the vehicle on a maintenance stand.
• Hydraulic unit operation 2. Tum the main switch to "OFP'.
Click "Actuator Check", a single pulse will be 3. Remove:
generated in the brake lever "1", brake pedal • Rider seat
"2", and again in the brake lever "1 ", in this or- Refer to "GENERAL CHASSIS (1 )" on
der. page 4-1.

4-54
 ABS (ANTI-LOCK BRAKE SYSTEM)

4. Check:
• Battery voltage
Lower than 12.8 V ➔ Charge or replace the
battery.

Battery voltage
Higher than 12.8 V

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
If the battery voltage is lower than 12.8 V, charge G088909

the battery, and then periorm ABS reaction- 9. A reaction -force pulsating action is generated
force confirmation. in the brake lever "1" and continues for a few
seconds.
5. Removing the protective cap, and then con- TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
nect the VDT to the VDT coupler (6P).
• The reaction-force pulsating action consists of
quick pulses.
Yamaha diagnostic tool USB
(US) • Be sure to continue operating the brake lever
90890-03269 and brake pedal even after the pulsating action
Yamaha diagnostic tool (A/1) has stopped.
90890-03264 • "ON" and "OFP' on the tool screen indicate
when the brakes are being applied and re-
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ leased respectively.
• Yamaha diagnostic tool (A/1) (90890-03264) in-
cludes VDT sub harness (6P) (90890-03266).
• If you already have Yamaha diagnostic tool (A/
I) (90890-03262), VDT sub harness (6P)
(90890-03266) is separately required.
Refer to "VDT' on page 9-3.
6. Start the VDT and display the diagnosis of
function screen.
7. Select code No. 1, "ABS reaction-force con-
G088913
firmation".
10.Afler the pulsating action has stopped in tlhe
8. Click "Actuator Check", and then operate the
brake lever, it is generated in the brake pedal
brake lever "1" and brake pedal "2" simulta-
"1" and continues for a few seconds.
neously.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• The reaction-force pulsating action consists of
• The hydraulic unit operates 1 second after the
quick pulses.
brake lever and brake pedal are o perated si-
• Be sure to continue operating the brake lever
multaneously and continues for approximately
and brake pedal even after the pulsating action
5 seconds.
has stopped.
• The operation of the hydraulic unit can be con-
• "ON" and "OFP' on the tool screen indicate
firmed using the indicator.
when the brakes are being applied and re-
On: The hydraulic unit is operating.
leased respectively.
Flashing: The conditions for operating the hy-
draulic unit have not been met.
Off: The brake lever and brake pedal are not
being operated.

4-55
 ABS (ANTI-LOCK BRAKE SYSTEM)

G088914

11.After the pulsating action has stopped in the

brake pedal, it is generated in the brake lever
and continues for a few seconds.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• The reaction-force pulsating action consists of
quick pulses.
• "ON" and "OFP' on the tool screen indicate
when the brakes are being applied and re-
leased respectively.
ECA17371

NOTICE
-------------
• Check that the pulse is felt in the brake le-
v,er, brake pedal, and again in the brake le-
v,er, in this order.
• 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
correct.ly to the hydraulic unit assembly.
• If the pulse is hardly felt in either the brake
lever or brake pedal, check that the brake
hoses and brake pipes are connected cor-
rectly to the hydraulic unit assembly.
12.Turn the main switch to "OFF".
13.Remove the VDT from the VDT coupler, and
then install the protective cap.
14.Turn the main switch to "ON".
15.Set the stop/run/start switch to"n ".
16.Check for brake fluid leakage around the hy-
draulic unit.
Brake fluid leakage ➔ Replace the hydraulic
unit, brake pipes, and related parts as a set.
17.lf the operation of the hydraulic unit is normal,
delete all of the DTC.

""""""'
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 mi/h) or performing a trial run.

4-56
 HANDLEBAR
EA""""'3

HANDLEBAR
Removing the handlebar
" 17 N·m (1.7 kgf·m, 13 lb·ft)

~ 1.8 N·
"'· 1.8 N·m (0.18 kgl·m, 1.3 lb•ft

-~

• For MT09M/MT09MC
.. For MT09SPM/MT09SPMC
Order Job/Parts to• remove Q'ty Remarks
Refer to "GENERAL CHASSIS (1)" on
Meter assembly bracket
page 4-1.
1 Rearview mirror (right)
2 Front brake light switch connector 2 Disconnect. (for MT09M/MT09MC)
3 Front brake master cylinder holder
4 Front brake master cylinder assembly
5 Grip end (right)
6 Throttle grip
7 Handlebar switch (right)
8 Rearview mirror (left)
9 Grip end (left)
10 Clutch switch connector 2 Disconnect. (for MT09M/MT09MC)
11 Handlebar switch (left)
12 Handlebar switch holder 2 For MT09SPM/MT09SPMC.
13 Handlebar grip

4-57
 HANDLEBAR

Removing the handlebar

;, (0.18 kgf·m, 1.3 lb·ft)

,f 3.5 N·m (0.35 kgl·m, 2.6 lb·ft)
, I 17 N·m (1.7 kgf·m, 13 lb·ft)!
18
~
:.· ;_ : ····· .. ;~· 11 N·m (1.1 kgf·m, 8.1 lb·ft)

£ ---,, 1 ,, 1.i/*
I ;fl, ' . ,
' 16 I
/ • ;~ ~~ ~ ~ ~~~--m-,~2.~B~lb~·ft=)

- ----- ---------- - ---

1.8 N·m (0.18 kgf
x 1.8 N·m (0.18 kgl·m, 1.3 lb·ft)

/ ~ J,
~---
1:; I 40 N·m (4.0 kgf·m, 30 lb·ft)I
• For MT09M/MT09MC
.. For MT09SPM/MT09SPMC
Order Job/Parts to• remove Q'ty Remarks
14 Clutch cable Disconnect.
15 Clutch lever holder
16 Clutch switch 1
17 Upper handlebar holder 2
18 Handlebar 1
19 Lower handlebar holder 2

4-58
 HANDLEBAR
EA~1386
ADJUSTING THE HANDLEBAR POSITION
Upper handlebar holder bolt
1. Check:
22 N-m (2.2 kgf•m, 16 lb-ft)
• Handlebar position
TIP_ _ _ _ _ _ _ _ _ _ _ _ __ ECA18300

The handlebar position can be adjusted in two NOTICE-----,-----,---.-.:---:--:--:----;:::--

positions to suit the rider's preferelilce. First, tighten the bolts on the front side of the
handlebar h,older, and then on the rear side.

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Align the punch mark "a" on the handlebar W:ith
the left side•upper suriace of the lower handle-
bar holder (left) "3".
• The upper handlebar holders should be in-
stalled with the punch marks "b" facing for-
ward.

2. Remove:
• Air scoop (left and right)
Refer to "GENERAL CHASSIS (1 )" on
page 4-1.
3. Adjust:
• Handlebar position
a. Remove the upper handlebar holders "1"
and handlebar "2". 3
e. Tighten the lower handlebar holder nuts.

Lower handlebar holder nut

40 N•m (4.0 kgf-m, 30 lb-ft)

2
EAS30000

REMOVING THE HANDLEBAR

1. Stand the vehicle on a level surface.
E\VA t3120

" r; A WARNING
b. Loosen the lower handlebar holder nuts. Securely support the vehicle so that there is
c. Adjust the handlebar position by rotating no danger of it falling over.
both of the lower handlebar holders "1" in
180°. 2. Remove:
• Handlebar grip "1"
1 1 TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Blow compressed air between the handlebar
(left) and the handlebar grip, and gradually push
the grip off the handlebar.

d. Install the handlebar "1" and upper han e-

bar holders "2".

4-59
 HANDLEBAR

3 a 2
...,.,,,.
G088918
3. Tighten:
CHECKING THE HANDLEBAR • Lower handlebar holder nut
1. Check:
• Handlebar Lower handlebar holder nut
Bends/cracks/damage ➔ Replace. 40 N-m (4.0 kgf-m, 30 lb-ft)
EWAt!31580

A WARNING 4. Install:
Do not attempt to straighten a bent handle• • Handlebar switch (right)
ba:r as this may dangerously weaken it. • Throttle grip
• Grip end (right)

""""""'
INSTALLING THE HANDLEBAR Handlebar switch screw
1. Stand the vehicle on a level surface. 1.8 N-m (0.18 kgf-m, 1.3 lb•ft)
EWAt!:H20 Grip end bolt
A WARNING 3.8 N-m (0.38 kgf-m, 2.8 lb-ft)
Securely support the vehicle so that there is
no danger of it falling over. a. Fit the slot "a" in the throttle grip "1" into the
projection "b" in the handlebar switch (righ t,
2. Install: front side) "2" and the throttle grip onto th e
• Lower handlebar holder handlebar "3".
(temporarily)
• Handlebar "1" b a 1

~~, ~ ~
• Upper handlebar holder "2"

Upper handlebar holder bolt

22 N-m (2.2 kgf-m, 16 lb-ft)
ECA18300

NOTICE
- - -:\-;.
.: i~i.!:-. a
------------
First, tighten the bolts on the front side of the b
3
handlebar holder, and then on the rear side.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ b. Make sure that the throttle grip "1" turns
• Align the punch mark "a" on the handlebar w ith smoothly .
the left side upper surface of the lower handle-
b ar holder (left) "3".
• The upper handlebar holders should be in-
stalled with the punch marks "b" facing for-
ward.

4-60
 HANDLEBAR

c. Install the handlebar switch (right, rear side)

"4".
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Align the projection "c" on the handlebar switch
(right, rear side) with the hole "d" in the handle-
bar "3".

7. Install:
• Handlebar grip
• Grip end (left) "1"

Grip end bolt

3.8 N•m (0.38 kgf•m, 2.8 lb•ft)

d. Install the grip end (right) "5". a. Apply a thin coat of rubber adhesive onto
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ the end of the handlebar (left).
There should be 1-3 mm (0.04--0.12 in) of clear- b. Side the handlebar grip over the end of the
ance "e" between the throttle grip and the grip handlebar (left).
end. c. Wipe off any excess rubber adhesive with a
clean rag.
EWA13700

A WARNING
Do not touch the handlebar grip until the rub-
ber adhesive has fully dried.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
There should be 1-3 mm (0.04--0.12 in) of clear-
e 5 ance "a" between the handlebar grip and the grip
end.

5. Install:
• Front brake master cylinder assembly
Refer to "INSTALLING THE FRONT BRAKE a
MASTER CYLINDER" on page 4-35.
6. Install:
• Clutch lever holder "1"
• Clutch cable

Clutch lever holder pinch bolt G088918

\1
11 N•m (1.1 kgf•m, 8.1 lb-ft)
8. Install:
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ • Handlebar switch holder (for MT09SPM/
MT09SPMC)
Align the center of slit on the clutch lever holder
• Handlebar switch screw (left)
with the punch mark "a" on the handlebar.
Handlebar switch holder screw
(for MT09SPM/MT09SPMC)
3.5 N•m (0.35 kgf-m, 2.6 lb•ft)
Handlebar switch screw
1.8 N•m (0.18 kgf-m, 1.3 lb•ft)

4-61
 HANDLEBAR

TIP_ _ _ _ _ _ _ _ _ _ _ _ __
Align the projection "a" on the handlebar switch
(left) with the hole "b" in the handlebar.

IA] b

A. For MT09M/MT09MC
B. For MT09SPM/MT09SPMC
9. Adjust:
• Clutch lever free play
Refer to "ADJUSTING THE CLUTCH LEVER
FREE PLAY" on page 3-12.

Clutch lever free play

10.0-15.0 mm (0.39-0.59 in)

4-62
 FRONT FORK

..FRONT
.,.,.,..
FORK
Removing the front fork legs

r--,
'

23 N·m (2.3 kgf·m, 17 lb·f1)

f- 5
'

..
'
,'
. /

..
'
'
. .
' . .
''

"~ ............ ,/
.,
Order Job/Parts to remove Q'ty Remarks
The following procedure applies to both of
the front fork legs.
Front wheel Refer to "FRONT WHEEL" on page 4-11.
1 Front fender
2 Upper bracket pinch bolt Loosen.
3 Cap bolt 1 Loosen.
4 Lower bracket pinch bolt 2 Loosen.
5 Front fork leg

4-63
 FRONT FORK

Disassembling the front fork leg

llll!ll :~
6 -
<I"
'.~,I 23 N-m (2.3 kgl-m, 17 lb-ft) I

N-m (<.S kg,m, H ISft)I

~
.
EY13mm
-
3---© .

·-0 el1
/ 9
'
s-
! '

1~,~
.

g:;" u '·-~
12 mm ' ~

L D 10mm
r-

. '~!
~ ·; ) ~ ?Jm
~ ~ 1mm

Order
o/
Job/Parts to remove
,/

Q'ty
/
, /
/ :'--
t>
I ;.;. 23 N-m (2.3 kgf,m, 17 lb-ft) I

Remarks
The following procedure applies to both of
the front fork legs.
1 Cap bolt 1
2 O-ring 1
3 Washer 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

4-64
 FRONT FORK

Disassembrmg the front fork leg

18

15 pinch bolt Q'ty · gf-m, 17 lb-It)

-ffl•
~=====--===t=~][=-~~~~~~~~~~~~~~~~~~~~~~~
rn C
Damper rod =•mbOy ""' '
17 opper washer 1
Damper
_ _ _ _.L'..'.ln:n~e~r rod
t~u~be as;sse~m~b~IY
: ___ 1
18 Right side only.

4-65
 FRONT FORK

EAS30000 EAS300m
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.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ 1. Remove:
For MT09M/MT09MC: • Cap bolt "1"
Each front fork leg is equipped with a spring pre- (from the damper rod assembly)
load adjusting bolt, the fork leg (right) is • Washer"2"
equipped with a rebound damping force adjust- • Spacer "3"
ing screw, the fork leg (left) is equipped with a • Locknut "4"
compression damping force adjusting screw. a. Press down on the spacer with the fork
Pay attention not to mistake the right and left. spring compressor "5".
b. Install the rod holder "6" between the lock-
1. Stand the vehicle on a level surface.
EWA t!)'l20
nut "4" and the washer "2".
A WARNING
Fork spring compressor
Securely support the vehicle so that there is
90890-01441
no danger of it falling over.
Fork spring compressor
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ VM-01441
Place the vehicle on a maintenance stand so Rod holder
90890-01434
that the front wheel is elevated.
Damper rod holder double ended
2. Remove: VM-01434
• Front brake caliper
Refer to "FRONT BRAKE" on page 4-25.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Front wheel Use the side of the rod holder that is marked "B".
Refer to "FRONT WHEEL" on page 4-11.
3. Loosen:
• Upper bracket pinch bolt "1"
• Cap bolt "2"
• Lower bracket pinch bolt "3"
E\VAtl3640

A WARNING
Before loosening the upper and lower brack-
et pinch bolts, support the front fork leg.

c. Hold the cap bolt and loosen the locknut.

d. Remove the cap bolt.
e. Remove the rod holder and fork spring
compressor.
y 3 f. Remove the washer, spacer and locknut.
2. Drain:

4. Remove:
. fl \\ • Fork oil
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Stroke the damper rod assembly "1" several
• Front fork leg times while draining the fork oil.

4-66
 FRONT FORK

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
While holding the damper rod with the damper
rod holder "1", loosen the damper rod assembly
bolt.

Damper rod holder (027)

90890-01582
Damper rod holder
G088919 VM-01582
3. Remove:
• Dust seal "1"
• Oil seal cl ip "2"
(with a flat-head screwdriver)
ECA119100

NOTICE
--,--,-----,-------
Do not scratch the outer tube.

EAS30<1ll8
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Check:
G088920 • Inner tube
4. Remove: • Outer tube
• Outer tube Bends/damage/scratches ➔ Replace.
EWA138l50
a. Hold the front fork leg horizontally. ~WARNING
b. Securely clamp the brake caliper bracket in
Do not attempt to straighten a bent inner
a vise with soft jaws.
tube as this may dangerously weaken it.
c. Separate the outer tube from the inner tube
by pulling the outer tube forcefully but care- 2. Measure:
fully. • Fork spring free length "a"
ECA119890
Out of specification ➔ Replace.
NOTICE - - - - - - - - , - - : - - - : - - : - - -
Excessive force will damage the bushings. Fork spring free length limit
Damaged bushings must be replaced. 268.9 mm (10.59 in)

!/.....____________
! ....... a
i ·-----------..__ _
'

G088921

5. Remove:
• Damper rod assembly bolt
• Damper rod assembly

4-67
 FRONT FORK

3. Check: TIP·_ _ _ _ _ _ _ _ _ _ _ _ __
• Damper rod • When assem bling the front fork leg, be sure to
Damage/wear ➔ Replace. replace the following parts:
Obstruction ➔ Blow out all of the oil passag- - Inner tube bushing
es with compressed air. - Outer tube bushing
ECA19 110
- Oil seal
NOTICE ----,------:-:-:-:----:--. - Oil seal cl ip
• The front fork leg has a very sophisticated - Dust seal
internal construction, which are particular- - Copper washer
ly sensitive to foreign material.
- 0-ring
• When disassembling and assembling the
• Before assembling the front fork leg, make
front fork leg, do not allow any foreign ma-
sure all of the components are clean.
terial to enter the front fork.
1. Install:
4. Check:
• Damper rod assembly
• Cap bolt "1"
Cracks/damage ➔ Replace.
NOTICE - - - - - - - - - . . . . , . , - , - -
Allow the damper rod assembly to slide
slowly down the inner tube. Be careful not to
damage the inner tube.

2. Tighten:
• Damper rod assembly bolt
(along with the copper washer Imm)

Front fork damper rod assembly

bolt
23 N-m (2.3 kgf•m, 17 lb•ft)
EAS3ClQOO
LOCTITE®
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the TIP_ _ _ _ _ _ _ _ _ _ _ _ __
front fork legs.
While holding the damper rod assembly with the
For MT09M/MT09MC:
EWA117000 damper rod holder "1", tighten the damper rod
A WARNING assembly bolt.
• Note that the amount of the fork oil is differ-
ent in the left and right front fork legs. Make Damper rod holder (027)
sure to fill each of the left and right front 90890-01582
fork legs with the specified amount of the Damper rod holder
fork oil. VM-01582
• 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.
For MT09SPM/MT09SPMC:
EWAJ:83GO

A 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:
• Inner tube's outer surface

4-68
 FRONT FORK

Recommended oil Fork seal driver

Yamaha Suspension Oil 01 90890-01442
Adjustable fork seal driver (36-
4. Install: 46 mm)
• Dust seal "1" Gm VM-01442
Gm
• Oil seal clip "2"
• Oil seal "3" mD
• Washer"4"
• Outer tube bushing "5" Gllmi
• Inner tube bushing "6" Gm
ECA119170

NOTICE
------------
Make sure the numbered side of the oil seal
faces bottom side.
G088923
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ 7. Install:
• Before installing the oil seal, lubricate its lips • Oil seal "1"
with lithium-soap-based grease. (with the fork seal driver "2")
• Lubricate the outer surface of the inner tube
with fork oil. Fork seal driver
• Before installing the oil seal, cover the top of 90890-01442
the front fork leg with a plastic bag to protect Adjustable fork seal driver (36-
the oil seal during installation. 46 mm)
VM-01442

G088924

8. Install:
• Oil seal clip "1"
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Adjust the oil seal clip so that it fits into the outer
tube's groove.

G088922

5. Install:
• Outer tube
(to the inner tube)
6. Install:
• Outer tube bushing "1"
• Washer"2"
G088925
(with the fork seal driver "3")

4-69
 FRONT FORK

9. Install:
• Dust seal "1" Recommended oil
(with the fork seal driver "2") Yamaha Suspension Oil 01
Quantity (left)
Fork seal driver 468.0 cm3 (1 5.82 US oz, 16.51
90890-01442 Imp.oz) (MT09M, MT09MC)
Adjustable fork seal d river (36- 473.0 cm3 (1 5.99 US oz, 16.68
46 mm) Imp.oz) (MT09SPM, MT09SP·
YM-01442 MC)
Quantity (right)
472.0 cm3 (15.96 US oz, 16.65
Imp.oz) (MT09M, MT09MC)
473.0 cm3 (1 5.99 US oz, 16.68
Imp.oz) (MT09SPM, MT09SP·
2 MC)
ECA1'230

NOTICE
------------
• Be sure to use the recommended fork oil.
Other oils may have an adverse effect on
G088928
front fork performance.
10. lnstall:
• When disassembling and assembling the
• Rod puller "1"
front fork leg, do not allow any foreign ma-
• Rod puller attachment (M1 0) "2"
terial to errter the front fork.
(onto the damper rod "3")
12.After filling the front fork leg, slowly stroke the
Rod puller damper rod "1" up and down (at least ten
90890-01437 times) to distribute the fork oil.
Universal damping rod bleeding TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
tool set
Be sure to stroke the damper rod slowly be-
YM-A8703
cause the fork oil may spurt out.
Rod puller attachment (M10 long)
90890-01578
Universal damping rod bleeding
tool set
YM-A8703

1
1

2
G088929

13.Before measuring the fork oil level, wait ten

3 minutes until the oil has settled and the air
bubbles have dispersed.
G088927
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
11 . Fill: Be sure to bleed the front fork leg of any residual
• Front fork leg air.
(with the specified amount of the recom-
14.Measure:
mended fork oil)
• 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.

4-70
 FRONT FORK

g. Press down on the spacer with the fork

Level (left) spring compressor "1".
107 mm (4.2 in) (MT09M, h. Pull up t he rod puller and install the rod
MT09MC) holder "2" between the locknut "3" and the
110 mm (4.3 in) (MT09SPM, washer "4".
MT09SPMC)
Level (right) Rod puller
107 mm (4.2 in) (MT09M, 90890-01437
MT09MC)
Universal damping rod bleeding
110 mm (4.3 in) (MT09SPM, tool set
MT09SPMC) VM-A8703
Rod puller attachment (M10 long)
90890-01578
Universal damping rod bleeding
a tool set
VM-A8703
Fork spring compressor
90890-01441
Fork spring compressor
VM-01441
G0889:l0
Rod holder
90890-01434
15. lnstall:
Damper rod holder double ended
• Fork spring VM-01434
• Spacer
• Locknut TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Damper adjusting rod (damper md assem- Use the side of the rod holder that is marked "B".
bly)
• Washer
• Cap bolt
(along with the O-ring Gm)
a. Remove the rod puller and rod puller at-
tachment.
b. Install the fork spring.
TIP_ _ _ _ _ _ _ _ _ _ _ _ __
Install the fork spring with the smaller diameter
"a" facing up "A".
i. Remove the rod puller and rod puller at-
tachment.
- - - A j. Position the locknut "3" as distance "b".

Di stance "b"
12 mm (0.47 in)

G088931

c. Install the locknut all the way onto the

damper rod assembly.
d. Install the rod puller and rod puller attach-
ment.
e . Install the spacer and washer.
f. Install the fork spring compressor.

4-71
 FRONT FORK

k . Set the cap bolt distance "d' to specifica- ...,.,.,.

INSTALLING THE FRONT FORK LEGS
tion.
The following procedure applies to both of the
front fork legs.
Distance "c"
1. Install:
13 mm (0.51 in)
• Front fork leg
Temporarily tighten the upper and lower
bracket pinch bolts.

Installed length (from the top of

th,e outer tube) "a"
211.5 mm (8.33 in)

C A WARNING
Make sure the brake hoses are routed prop-
erly.
I. Install the damper adjusting rod and cap
bolt, and then finger tighten the cap bolt.
E\VA tl3G70 TIP·- - - - - - - - - - - - - - : - -
A WARNING When installing the front fork, set the outer tube
with the specified length "a" from the top of the
Always use a new cap bolt O-ring.
outer tube to the top of the lower bracket.
nn. Hold the cap bolt "5" and tighten the locknut
"3" to specification.

Front fork cap bolt locknut

15 N•m (1.5 kgf,m, 11 lb•ft)

,_____ 5

2. Tighten:
• Lower bracket pinch bolt "1"

Lower bracket pinch bolt

23 N,m (2.3 kgf,m, 17 lb,ft)
n. Remove the rod holder and fork spring
• Cap bolt "2"
compressor.
16.lnstall: Front fork cap bolt
• Cap bolt 23 N,m (2.3 kgf,m, 17 lb,ft)
(to the outer tube)
TIP_ _ _ _ _ _ _ _ _ _ _ __ • Upper bracket pinch bolt "3"
• Temporarily tighten the cap bolt. Upper bracket pinch bolt
• When to tighten the cap bolt to the specified 26 N,m (2.6 kgf,m, 19 lb,ft)
torque is after installing the front fork leg to the
vehicle and tightening the lower bracket pinch
bolts.

4-72
 FRONT FORK

r..-t.i
~-
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
For MT09SPM/MT09SPMC:
When installing the front fork legs, make sure
that the letters on the cap bolts are positioned
within the angle range shown in the illustration.

3. Check:
• Cable routing
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Make sure the brake hoses, clutch cable, and
handlebar switch leads are routed property. Re-
fer to "CABLE ROUTING" on page 2-15.

4. Adjust:
• Spring preload
• Rebound damping
• Compression damping
Refer to "ADJUSTING THE FRONT FORK
LEGS (for MT09M/MT09MC)" on page 3-21
and "ADJUSTING THE FRONT FORK LEGS
(for MT09SPM/MT09SPMC)" on page 3-22.

4-73
 STEERING HEAD

EA""""'
STEERING HEAD
Removing the lower bracket

!.,,I110 N-m (11 kgf.m, 81 ll>ft)i

• Loosen the lower ring nut completely, and then tighten it to specification.
Order Job/Parts to• remove Q'ty Remarks
Refer to "GENERAL CHASSIS (1)" on
Meter assembly bracket
page 4-1.
Handlebar Refer to "HANDLEBAR" on page 4-57.
Front fork legs Refer to "FRONT FORK" on page 4-63.
Front brake hose bracket
2 Headlight bracket
3 Horn bracket
4 Lower bracket cap
5 Steering stem nu1
6 Upper bracket
7 Lock washer
8 Upper ring nut
9 Rubber washer
10 Lower ring nut

4-74
 STEERING HEAD

Removing the lower bracket

,,, 110 N-m (11 kgf•m, 81 ll>ft)

1st 52 N·m
'2nd 14 N·m

., 7 N-m (0. 7 kgf-m, 5.2 ll>ft)

• Loosen the lower ring nut completely, and then tighten it to specification.
Order Job/Parts to• remove Q'ty Remarks
11 Lower bracket
12 Bearing cover
13 Lower bearing dust seal
14 Upper bearing
15 Lower bearing

4-75
 STEERING HEAD

EAS3Cm3
2. Check:
REMOVING THE LOWER BRACKET
• Bearing
1. Stand the vehicle on a level surface.
E\VA1!3120
• Bearing race
A WARNING Damage/pitting ➔ Replace the bearings and
Securely support the vehicle so that there is bearing races as a set.
3. Replace:
no danger of it falling over.
• 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
E\VA1!3730
bracket with a floor chisel "4" and hammer.
A WARNING 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. ECA1'2?0

NOTICE
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ -------------
1f the bearing race is not installed properly,
• Hold the lower ring nut with ring nut wrench "3",
the steering head pipe could be damaged.
and then remove the upper ring nut with the
steering nut wrench "4". TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Remove the lower ring nut with the steering nut • Always replace the bearings and bearing races
wrench.
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 1

G088933

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.

4-76
 STEERING HEAD

INSTALLING THE STEERING HEAD

1. Lubricate:
• Upper bearing
• Lower bearing

Recommended lubricant
Lithium-soap-based grease

2. Install:
• Lower ring nut "1"
• Rubber washer "2"
• Upper ring nut "3"
• Lock washer "4"
Refer to "CHECKING AND ADJ USTING
THE STEERING HEAD" on page 3-19.

3. Install:
• Upper bracket
• Steering stem nut
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Temporarily tighten the steering stem nut.
4. Install:
• Front fork legs
Refer to "FRONT FORK" on page 4-63.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Temporarily tighten the upper and lower bracket
pinch bolts.
5. Tighten:
• Steering stem nut

Steering stem nut

110 N-m (11 kgf•m, 81 lb•ft)

6. Tighten:
• Lower bracket pinch bolt

Lower bracket pinch bolt

23 N•m (2.3 kgf•m, 17 lb•ft)

• Upper bracket pinch bolt

Upper bracket pinch bolt

26 N-m (2.6 kgf•m, 19 lb•ft)

4-n
 REAR SHOCK ABSORBER ASSEMBL V

EA""""'6

REAR SHOCK ABSORBER ASSEMBLY

Removing the rear shock absorber assembly (for MT09M/MT09MC)

I -",I44 N-m (4.4 kgl-m, 3211>lt) II

Order Job/Parts to remove Q'ty Remarks

Rear shock absorber assembly lower nut/Bolt 1/1
Rear shock absorber assembly upper nut/
2 Washer/Bolt 1/1/1

3 Rear shock absorber asse mbly

4 Relay arm nut/Bolt 1/1
5 Connecting arm upper nutiBolt 1/1
6 Relay arm 2
7 Connecting arm lower nut/Bolt 1/1
8 Connecting arm 1
9 Collar/Oil seal/Bearing 1/2/1
10 Collar/Oil seal/Bearing 1/2/1
11 Collar/Oil seal/Bearing 1/2/1
12 Collar/Oil seal/Bearing 1/2/1
13 Collar

4-78
 REAR SHOCK ABSORBER ASSEMBL V

Removing the rear shock absorber assembly (for MT09SPM/MT09SPMC)

9
Order Job/Parts to remove Q'ty Remarks
Rear shock absorber assembly lower nut/Bott 1/1
Rear shock absorber assembly upper nut/
2 Washer/Bolt 1/1/1

3 Bracket
4 Gas cylinder bracket
5 Rear shock absorber assembly
6 Relay arm nut/Bott 1/1
7 Connecting arm upper nut/Bolt 1/1
8 Relay arm 2
9 Connecting arm lower nut/Bolt 1/1
10 Connecting arm 1
11 Collar/Oil seaVBearing 1/2/1
12 Collar/Oil seaVBearing 1/2/1
13 Collar/Oil seaVBearing 1/2/1
14 Collar/Oil seaVBearing 1/2/1
15 Collar 1

4-79
 REAR SHOCK ABSORBER ASSEMBL V

EAS30835 EWA13760
HANDLING THE REAR SHOCK ABSORBER
E\VA1!3'740
A WARNING
Wear eye protection to prevent eye damage
A WARNING from released gas or metal chips.
Th is 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.
• 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 EAS30019

heat. High heat can cause an explosion due REMOVING THE REAR SHOCK ABSORBER
to excessive gas pressure. ASSEMBLY
• Do not deform or damage the rear shock 1. Stand the vehicle on a level surface.
E\VAt3120
absorber in any way. Rear shock absorber
damage will result in poor damping perfor- A WARNING
mance. Securely support the vehicle so that there is
no danger of it falling over.
EAS310G4
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
DISPOSING OF A REAR SHOCK ABSORBER
(for MT09M/MT09MC) • Place the vehicle on a maintenance stand so
1. Gas pressure must be released before dis- that the rea.r wheel is elevated.
posing of a rear shock absorber. To release • When removing the bolt, hold the swingarm so
the gas pressure, drill a 2-3 mm (0.08--0.12 that it does not drop down.
in) hole through the rear shock absorber at a
point 20-25 mm (0.7~.98 in) from its end EAS30<120

as shown. CHECKING THE REAR SHOCK ABSORBER

E\VA tl3790 ASSEMBLY
A WARNING 1. Check:
Wear eye protection to prevent eye damage • Rear shock absorber rod
from released gas or metal chips. Bends/damage ➔ Replace the rear shock
absorber assembly.
20-25 mm • Rear shock absorber assembly
Gas leaks/oil leaks ➔ Replace the rear shock
(0.79-0.98 in)
absorber assembly.
• Spring
• Bushing
Damage/wear ➔ Replace the rear shock ab-
sorber assembly.
• Hose (for MT09SPM/MT09SPMC)
Cracks/damage/wear ➔ Replace the rear
shock absorber assembly.
EAS30r.!9 • Bolt
DISPOSING OF A REAR SHOCK ABSORBER Bends/damage/wear ➔ Replace.
(for MT09SPM/MT09SPMC)
1. Gas pressure must be released before dis-
posing of a rear shock absorber. To release
the gas pressure, drill a 2-3 mm (0.08--0.12
in) hole through the flat portion of the gas cyl-
inder as shown.

4-80
 REAR SHOCK ABSORBER ASSEMBL V

EAS""21

c:
CHECKING THE CONNECTING ARM AND
3
RELAY ARM
1. Check:
• Connecting arm 1
• Relay arm
Damage/wear ➔ Replace. mm 2 2 mm
2. Check:
a a
• Bearing
Damage/pitting ➔ Replace. 5
3. Check:
• Collar mm mm
Damage/scratches ➔ Replace. ~ rn:J
a a

INSTALLING THE RELAY ARM 4

1. Lubricate:
• Collar a a
• Oil seal ml')
Recommended lubricant
Lithium-soap-based grease
mm 2 mm
3. Relay arm
2. Install: 4. Connecting arm
• Bearing "1" 5. Swingarm
(to the connecting arm and swingarm)
A. Left side
• Oil seal "2" m.l'J B. Right side
(connecting arm and swingarm)
3. Tighten:
Installed depth "a" • Connecting arm upper nut
0-1.0 mm (0-0.04 in} • Relay arm nut

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ Connecting arm upper nut

• When installing the oil seals "2" to the relay 44 N,m (4.4 kgf,m, 32 lb,ft)
arm, face the character stamp of 1he oil seals Relay arm nut
outside. 44 N,m (4.4 kgf,m, 32 lb,ft)
• Install the connecting arm upper bolt and relay
EAS300:1!!
arm bolt from the left. INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLY
1. Install:
• Gas cylinder bracket bolt (for MT09SPM/
MT09SPMC)
• Rear shock absorber assembly
• Bracket bolt (for MT09SPM/MT09SPMC)
• Rear shock absorber assembly upper bolt
• Rear shock absorber assembly upper nut
• Rear shock absorber assembly lower bolt
• Rear shock absorber assembly lower nut

4-81
 REAR SHOCK ABSORBER ASSEMBL V

TIP_ _ _ _ _ _ _ _ _ _ _ _ __
• Install the rear shock absorber assembly upper
bolt and rear shock absorber assembly lower
bolt from the left.
• When installing the rear shock absorber as-
sembly, lift up the swingarm.
2. Tighten:
• Gas cylinder bracket bolt (for MT09SPM/
MT09SPMC)
• Bracket bolt (for MT09SPM/MT09SPMC)
• Rear shock absorber assembly upper nut
• Rear shock absorber assembly lower nut

Gas cylinder bracket bolt (for

MT09SPM/MT09SPMC)
7 N•m (0.7 kgf•m, 5.2 lb•ft)
LOCTITE®
Bracket bolt (for MT09SPM/
MT09SPMC)
7 N•m (0.7 kgf•m, 5.2 lb·ft)
Rear shock absorber assembly
upper nut
44 N•m (4.4 kgf•m, 32 lb•ft)
Rear shock absorber assembly
lower nut
44 N•m (4.4 kgf•m, 32 lb•ft)

4-82
 SWINGARM

EA""""'7

SWINGARM
Removing the swingarm

..-, 7 N-m (0. 7 kgf-m, 5.2 lb-It)

,: 7 N-m (0. 7 kgl-m, 5.2 11>11)

Order Job/Parts to remove Q'ty Remarks

Rear brake caliper Refer to "REAR BRAKE" on page 4-37.
Rear wheel Refer to "REAR WHEEL" on page 4-18.
Refer to "REAR SHOCK ABSORBER
Relay ann nut/Bolt ASSEMBLy• on page 4 -78.
Pivot shaft nut
2 Washer
3 Pivot shaft
4 Swingarm
5 Rear fender
6 Drive chain guide
7 Bracket
8 Dustcover 2
9 Collar
10 Bearing 2

4-83
 SWINGARM

...,.,,.
REMOVING THE SWINGARM
EWA13'770

A WARNING
1. Stand the vehicle on a level surface. Do not attempt to straighten a bent pivot
E\VA1!3120

A WARNING shaft.
Securely support the vehicle so that there is 3. Wash:
no danger of it falling over. • Pivot shaft
•Dustcover
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Collar
Place the vehicle on a maintenance stand so
that the rear wheel is elevated. Recommended cleaning solvent
Kerosene
2. Measure:
• Swingarm side play 4. Check:
• Swingarm vertical movement • Dust cover "1"
a. Measure the tightening torque of the pivot • Oil seal "2"
shaft nut. Damage/wear ➔ Replace.
• Collar "3"
Pivot shaft nut Damage/scratches ➔ Replace.
105 N-m (10.5 kgf•m, n lb-ft) • Bearing "4"
Damage/pitting ➔ Replace.
b. Check the swingarm side play "A" by mov-
• Collar "5"
ing the swingarrn from side to side. Damage/scratches ➔ Replace.
If the swingarrn has side-to-side play, check
the collars, bearings, and dust covers. 4
c. Check the swingarm vertical movement "B"
::::::.-1-- 1
4
by moving the swingarm up and down. \-✓• ____ - 2
If the swingarm vertical movement is not
smooth or if there is binding, check the pivot
shaft, collar, bearings, and dust covers.
2
Ji4 3
"'- 1

INSTALLING THE SWINGARM

1. Lubricate:
•Dustcover
• Pivot shaft
G088936
• Bearing
•Oilsealel'l!I
3. Remove: • Collar
• Swingarm
EAS""27 Recommended lubricant
CHECKING THE SWINGARM Lithium-soap-based grease
1. Check:
• Swingarm 2. Install:
Bends/cracks/damage ➔ Replace. • Bearing "1"
2. Check: (to the swingarm)
• Pivot shaft • Oil seal "2" Gl!'J
Roll the pivot shaft on a flat surface. (to the swingarm)
Bends ➔ Replace.
Installed depth "a"
0-1.0 mm (0-0.04 in)

4-84
 SWINGARM

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
When installing the oil seals to the swingarm,
face the character stamp of the oil seals outside.

A. Left side
B. Right side
3. Install:
• Swingarm
• Pivot shaft

Relay arm nut

44 N•m (4.4 kgf•m, 32 lb•ft)
Pivot shaft nut
105 N•m (10.5 kgf•m, n
lb•ft)

4. Install:
• Rear w heel
Refer to "REAR WHEEL" on page 4-18.
5. Adjust:
• Drive chain slack
Refer to "DRIVE CHAIN SLACK" on page 3-
17.

Drive chain slack (Sidestand)

36.0-41.0 mm (1.42- 1 .61 in)
Drive chain slack (Maintenance
stand)
36.0-41.0 mm (1.42- 1.61 in)
Drive chain slack limit (Side-
stand)
46.0 mm (1.81 in)

4-85
 CHAIN DRIVE

EA""""'8

CHAIN DRIVE

10

,<;. 7 N-m (0. 7 kgf-m, 5.2 lb-It)

Order Job/Parts to remove Q'ty Remarks

Fuel tank Refer to "FUEL TANK" on page 7-1.
Shift sensor coupler Disconnect
2 Locknut 3
3 Shift sensor
4 Shift rod
5 Shift arm
6 Shift rod joint 2
7 Shift pedal
8 Drive sprocket cover
9 Drive chain guide
10 Drive chain
11 Drive sprocket nut
12 Washer
13 Drive sprocket

4-86
 CHAIN DRIVE

EAS30029
a. Measure the length "b" between the inner
REMOVING THE DRIVE CHAIN
sides of the pins and the length "c" between
1. Stand the vehicle on a level surface.
E\VA1!3120
the outer sides of the pins on a 15-link sec-
A WARNING tion of the drive chain as shown in the illl!Js-
Securely support the vehicle so that there is tration.
b. Calculate the 15-link section length "a" of
no danger of it falling over.
the 15-link section of the drive chain using
2. Straighten the drive sprocket nut ribs "a". the following formula.
Drive chain 15-link section length "a" "'
(length "b" between pin inner sides + length
"c" between pin outer sides)/2
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
a • When measuring a 15-link section of the drive
chain, make sure that the drive chain is taut.
• Perform this procedure 2-3 times, at a different
location each time.

3. Loosen:
• Drive sprocket nut
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Loosen the drive sprocket nut while pressing the
brake pedal.
4. Remove:
• Drive chain
ECA17410
G088937
NOTICE
-------------
Be sure to put on safety goggles when work-
ing.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Cut the drive chain with the drive chain cut & riv-
et tool.

C
Drive chain cut & rivet tool
G088938
90890-01550
Drive chain cut & rivet tool 2. Check:
YM-01550 • Drive chain
Stiffness ➔ Clean and lubricate or replace.
CHECKING THE DRIVE CHAIN
1. Measure:
• 15-link section length "a" of the drive chain
Out of specification ➔ Replace the drive
chain.

15-link length limit

239.3 mm (9.42 in)
G088939

4-87
 CHAIN DRIVE

3. Clean:
• Drive chain 3
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 1
and completely dry it.
ECA18')9(1

NOTICE
-------------
• This vehicle has a drive chain with small G088943

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-
EAS30031
rate the O- rings. A coarse brush can also CHECKING THE DRIVE SPROCKET
damage the O-rings. Therefore, use only 1. Check:
kierosene to clean the drive chain. • Drive sprocket
• Do not soak the drive chain in kerosene for More than 1/4 tooth "a" wear ➔ Replace th e
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
EAS30Q32
CHECKING THE REAR WHEEL SPROCKET
G088941 Refer to "CHECKING AND REPLACING THE
REAR WHEEL SPROCKET' on page 4-22.
4. Check:
• 0 -ring "1" EAS30033

Damage ➔ Replace the drive chain. CHECKING THE REAR WHEEL DRIVE HUB
• Drive chain roller "2" Refer to "CHECKING THE REAR W HEEL
DRIVE HUB" on page 4-21 .
Damage/wear ➔ Replace the d rive chain.
• Drive chain side plate "3"
Damage/wear/cracks ➔ Replace the drive
chain.

4-88
 CHAIN DRIVE

EA"'°""
INSTALLING THE DRIVE CHAIN
1. Install:
• Drive chain
ECA17 410

NOTICE
-------------
8 e sure to put on safety goggles when work-
ing.

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Install the drive chain joint with the drive chain
cut & rivet tool.
2. Lubricate:
• Drive chai n
Drive chain cut & rivet tool
90890-01 550 Recommended lubricant
Drive chain cut & rivet tool Chain lubricant suitable for C-
YM-01550 ring chains

a. When press fitting the connecting plate "1", 3. Install:

make sure the space "a" between the end • Drive sprocket
of the connecting pin "2" and th e connecting • Washer "1"
plate is 1.2- 1.4 mm (0.0~.06 in). • Drive sprocket nut "2" Gm
Dr ive sprocket nut
160 N-m (16 kgf•m, 118 lb•ft)
LOCTITE®
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Thoroughly clean all the drive sprocket nut
seat and threads of drive axle.
• While applying the rear brake, tighten the drive
sprocket nut.
• Install wash er "1" with the "OUT' mark "a" fac-
b. After riveting, make sure the diameter be-
ing out.
tween the edges "b" of the connecting pin
• Stake the drive sprocket nut "2" at cutouts "b" in
"2" is 5.7- 6.0 mm (0.22-0.24 i n).
the drive axle securely.

~~ 2
~
J

b
-
c. After riveting, make sure the space "c", ,..._ v-- , ~
Ou~

which is inside of the connecting link "3" and

inside of the connecting plate "1", is 14.35-
14.55 mm (0.56~.573 in).

4-89
 CHAIN DRIVE

1.
4. Install: a. 24 mm' (0.94 in)
• Shift arm "1" b. 24.4 mm (0.96 in)
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
6. Adjust:
Before installing, make sure to align the mark "a" • Installed shift rod length
of the shift shaft with the punch mark "b" of the Refer to "ADJUSTING THE S HIFT PEDAL"
shift arm. on page 4 -91.
7. Adjust:
Shift arm bolt • Drive chain slack
14 N•m (1.4 kgf•m, 10 lb•ft) Refer to "DRIVE CHAIN SLACK" on page 3-
17.

Drive chain slack (Sidestand)

36.0-41.0 mm (1.42- 1.61 in)
Drive chain slack (Maintenance
stand)
36.0-41.0 mm (1.42- 1.61 in)
Drive chain slack limit (Side-
stand)
46.0 mm (1.81 in)
ECA13550
5. Install: NOTICE
• Shift rod joint "1" --,---,--,---.-:----:-:-:----:---:--
A drive chain that is too tight will overload
• Shift sensor "2"
the engine a.nd other vital parts, and one that
• Shift rod "3"
is too loose can skip and damage the swing-
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
arm or cause an accident. Therefore, keep
• In stall the shift rod joint and shift sensor in the the drive chain slack within the specified lim-
direction shown in the illustration. its.
• The allowable twist of the shift rod joint and
shift sensor is ±5°.
• In stall the shift rod so that the side "c" faces up-
ward as shown in the illustration.

Shift rod joint bolt

10 N•m (1.0 kgf•m, 7.4 lb•ft)
LOCTITE®
Shift sensor locknut
7 N•m (0.7 kgf•m, 5.2 lb•ft)

4-90
 CHAIN DRIVE

EA~1129

ADJUSTING THE SHIFT PEDAL

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
The shift pedal position is detemiined by the in-
stalled shift rod length.
1. Measure:
• Installed shift rod length "a"
Incorrect ➔ Adjust.

Installed shift rod length

236.4-238.4 mm (9.31- 9.39 in)

2. Adjust:
• Installed shift rod length
a . Loosen both locknuts "1".
b. Tum the shift rod "2" until the specified in-
stalled shift rod length is obtained.

·r ', ~ •
~ .
,l\' l--~
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)

d . Make sure the installed shift rod length is

within specification.

4-91
 ENGINE

LUBRICATION SYSTEM CHART AND DIAGRAMS...................................... 5-1

ENGINE OIL LUBRICATION CHART ....................................................... 5·1
LUBRICATION DIAGRAMS ...................................................................... 5-2

ENGINE INSPECTION .................................................................................... 5-7

MEASURE THE COMPRESSION PRESSURE ........................................ 5-7

ENGINE REMOVAL ........................................................................................ 5-9

REMOVING THE ENGINE ...................................................................... 5-14
INSTALLING THE ENGINE..................................................................... 5-14

CAMSHAFTS................................................................................................. 5-16
REMOVING THE CAMSHAFTS ....................................................... ....... 5-1 9
CHECKING THE CAMSHAFTS ......... ................... ... ............................... 5-20
CHECKING THE T IMING CHAIN AND CAMSHAFT SPROCKET ......... 5-21
CHECKING THE T IMING CHAIN GUIDES ............................................. 5-21
CHECKING THE T IMING CHAIN TENSIONER ...................................... 5-21
INSTALLING THE CAMSHAFTS ............................................................ 5-22

CYLINDER HEAD...........................................................•.............................. 5-26

I
REMOVING THE CYLINDER HEAD ....................................................... 5-27
CHECKING THE T IMING CHAIN GUIDE (EXHAUST SIDE) ................. 5-27
CHECKING THE CYLINDER HEAD ....................................................... 5-27
INSTALLING THE CYLINDER HEAD ..................................................... 5-28

VALVES AND VALVE SPRINGS ...................................•.............................. 5-29

REMOVING THE VALVES ...................................................................... 5-31
CHECKING T HE VALVES AND VALVE GUIDES .................................. 5-31
CHECKING THE VALVE SEATS ............................................................ 5-33
CHECKING THE VALVE SPRINGS ........................................................ 5-34
CHECKING THE VALVE LIFTERS ......................................................... 5-34
INSTALLING THE VALVES .................................................................... 5-34

GENERATOR AND STARTER CLUTCH.......................•.............................. 5-36

REMOVING THE GENERATOR ............................................................. 5-38
REMOVING THE STARTER CLUTCH .................................................... 5-38
CHECKING T HE STARTER CLUTCH .................................................... 5-38
INSTALLING THE STARTER CLUTCH .................................................. 5-39
INSTALLING THE G ENERATOR ............................................................ 5-39

ELECTRIC STARTER ....................................................•.............................. 5-41

CHECKING T HE STARTER MOTOR ..................................................... 5-43
ASSEMBLING THE STARTER MOTOR ................................................. 5-43
INSTALLING THE STARTER MOTOR ................................................... 5-44
CLUTCH ........................................................................................................ 5.45
REMOVING THE CLUTCH ..................................................................... 5-49
CHECKING THE FRICTION PLATES..................................................... 5-50
CHECKING THE CLUTCH PLATES ....................................................... 5-50
CHECKING THE CLUTCH SPRINGS ..................................................... 5-51
CHECKING THE CLUTCH HOUSING .................................................... 5-51
CHECKING THE CLUTCH BOSS ........................................................... 5-52
CHECKING THE PRESSURE PLATE .................................................... 5-52
CHECKING THE PRIMARY DRIVE GEAR ............................................. 5-52
CHECKING THE PRIMARY DRIVEN GEAR .......................................... 5-52
CHECKING THE PULL LEVER SHAFT AND PULL ROD ...................... 5-52
INSTALLING THE CLUTCH ..................................................................... 5-52

SHIFT SHAFT................................................................................................ 5-55

CHECKING THE SHIFT SHAFT ............................................................. 5-56
CHECKING THE STOPPER LEVER ...................................................... 5-56
INSTALLING THE SHIFT SHAFT ........................................................... 5-56

OIL PUMP ...................................................................................................... 5·57

CHECKING THE SPROCKET AND CHAIN ............................................ 5-59
CHECKING THE OIL PUMP ................................................................... 5-59
CHECKING THE RELIEF VALVE ........................................................... 5-59
ASSEMBLING THE OIL PUMP ............................................................... 5-59
INSTALLING THE O IL PUMP ................................................................. 5-60

OIL PAN ........................................................................................................ 5-61

REMOVING THE OIL PAN ...................................................................... 5-62
CHECKING THE OIL STRAINER ........................................................... 5-62
INSTALLING THE O IL PAN .................................................................... 5-62

CRANKCASE ................................................................................................ 5-63

DISASSEMBLING THE CRANKCASE .................................................... 5-65
CHECKING THE CRANKCASE .............................................................. 5-65
ASSEMBLING THE CRANKCASE .......................................................... 5-65
INSTALLING THE O IL PRESSURE SWITCH ......................................... 5-67
INSTALLING THE GEAR POSITION SENSOR ...................................... 5-68

CONNECTING RODS AND PISTONS .......................................................... 5-69

REMOVING THE CONNECTING RODS AND PISTONS ....................... 5-70
CHECKING THE CYLINDER AND PISTON ........................................... 5-70
CHECKING THE PISTON RINGS........................................................... 5-71
CHECKING THE PISTON PIN ................................................................ 5-72
CHECKING THE CONNECTING RODS ................................................. 5-72
INSTALLING THE CONNECTING ROD AND PISTON ..................... ..... 5-75
CRANKSHAFT AND BALANCER SHAFT ................................................... 5-80
REMOVING THE CRANKSHAFT AND BALANCER SHAFT. ................. 5-81
CHECKING THE OIL NOZZLES ............................................................. 5-81
CHECKING THE CRANKSHAFT ............................................................ 5-81
CHECKING THE BALANCER SHAFT .................................................... 5-83
INSTALLING THE CRANKSHAFT .......................................................... 5-85
INSTALLING THE BALANCER ASSEMBLY ........................................... 5-85

TRANSMISSION............................................................................................ 5-86
REMOVING THE TRANSMISSION ........................................................ 5-91
CHECKING THE SHIFT FORKS ............................................................. 5-91
CHECKING THE SHIFT DRUM ASSEMBLY .......................................... 5-92
CHECKING THE TRANSMISSION ......................................................... 5-92
ASSEMBLING THE MAIN AXLE AND DRIVE AXLE .............................. 5-93
INSTALLING THE TRANSMISSION ....................................................... 5-93
 LUBRICATION SYSTEM CHART AND DIAGRAMS

........
LUBRICATION SYSTEM CHART AND DIAGRAMS
...,,,..
ENGINE OIL LUBRICATION CHART

10

1. Oil strainer 15. Intake camshaft

2. Oil pump 16. Exhaust camshaft
3. Relief valve
4. Oil cooler
5. Oil filter cartridge
6. Main gallery
7. Oil pressure switch
8. Mission shower
9. Main axle
10. Drive axle
11. Crankshaft
12. Oil nozzle
13. Balancer shaft
14. Timing chain tensioner

5-1
 LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS3"'63
LUBRICATION DIAGRAMS

1. Oil filter cartridge union bolt

2. Oil filter cartridge
3. Oil delivery pipe
4. Drive axle
5. Main axle

5-2
 LUBRICATION SYSTEM CHART AND DIAGRAMS

10

r~7 9

1. Timing chain tensioner

2. Intake camshaft
3. Exhaust camshaft
4. Balancer shaft
5. Crankshaft
6. Oil cooler
7. Oil strainer
8. Oil drain bolt
9. Oil pump driven sprocket
10. Oil delivery pipe

5-3
 LUBRICATION SYSTEM CHART AND DIAGRAMS

1. Oil cooler
2. Oil filter cartridge
3. Oil pressure switch
4. Oil strainer
5. Oil pump

5-4
 LUBRICATION SYSTEM CHART AND DIAGRAMS

1. Balancer shaft
2. Crankshaft
3. Oil delivery pipe
4. Main axle
5. Drive axle
6. Oil gallery bolt

5-5
 LUBRICATION SYSTEM CHART AND DIAGRAMS

3
4 5

~blg;~~s~o~;=::~§=~=rFO~§~~r~ 6

1. Cylinder head
2. Intake camshaft
3. Exhaust camshaft
4. Oil passage to the cylinder head
5. Oil passage to the clutch chamber
6. Oil return passage from the cylinder head
7. Crankshaft
8. Main gallery

5-6
 ENGINE INSPECTION

EA"""'41

ENGINE INSPECTION
........
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 tum it off. 1365-1758 kPa/600 r/min (13.7-
3. Remove: 17.6 kgf/cnl2/600 r/min, 194.3-
250.1 psi/600 r/min)
• Rider seat
Refer to "GENERAL CHASSIS (1 )" on
a. Set the main switch to "ON".
page 4-1.
b. With the throttle wide open, crank the en-
• Fuel tank center cover
gine until the reading on the compression
Refer to "GENERAL CHASSIS (1 )" on
gauge stabilizes.
page 4-1. EWA1 7100

• Fuel tank A WARNING

Refer to "FUEL TANK" on page 7-1 . To prevent sparking the plug, remove all ig-
• Air filter case nition coil couplers and fuel injector cou-
Refer to "GENERAL CHASSIS (2)" on plers before cranking the engine.
page 4-10.
• Ignition coil TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Spark plug The difference in compression pressure be-
Refer to "CAMSHAFTS" on page 5-16. tween cylinders should not exceed 100 kPa (1
ECA13:M(I
kg/cm2 , 15 psi).
NOTICE
-------------
8 efore removing the spark plugs, use com- c. If the compression pressure is above the
pressed air to blow away any dirt accumulat- maximum specification, check the cylinder
ed in the spark plug wells to prevent it from head, valve surfaces and piston crown for
falling into the cylinders. carbon deposits.
Carbon deposits ➔ Eliminate.
4. Install: d. If the compression pressure is below the
• Compression gauge "1" minimum specification, pour a teaspoonful
• Extension "2" of engine oil into the spark plug bore and
measure again.
Compression gauge Refer to the following table.
90890-03081
Engine compression tester
YU-33223
Compression gauge extension
122mm
90890-04136
Compression gauge extension
122mm
YM-04136

5-7
 ENGINE INSPECTION

Compression pressure (with oil applied into

the cylinder)
Reading Diagnosis
Higher than without Piston ring(s) wear or
oill 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)

7. Install:
• Ignition coil
Refer to "CAMSHAFTS" on page 5-16.
• Air filler case
Refer to "GENERAL CHASSIS (2)" on
page 4-10.
• Fuel tank
Refer to "FUEL TANK" on page 7-1 .
• Fuel tank center cover
Refer to "GENERAL CHASSIS (1 )" on
page 4-1.
• Rider seat
Refer to "GENERAL CHASSIS (1 )" on
page 4-1 .

5-8
 ENGINE REMOVAL

EA"""'42

ENGINE REMOVAL
Removing the muffler and exhaust pipe

C",...

~
~ {
~;
~

I. & 20 N-m (2.0 kgf.m, 15 lb-ft)

~ -

Ii

(6)/ 2

, · . 20 N-m (2.0 kgf-m, 15 lb-ft)

• YAMAHA GREASE "G"

Order Job/Parts to• remove Q'ty Remarks
Radiator bracket Refer to "RADIATOR" on page 6-3.
0 2 sensor coupler Disconnect.
2 Muffler assembly
3 Exhaust gasket 3

4 Remove the 0, sensor only when neces-

0 2 sensor
sary.

5-9
 ENGINE REMOVAL

Disconnecting the leads and hoses

Order Job/Parts to remove Q'ty Remarks

Refer to "GENERAL CHASSIS (1)" on
Rider seat page 4-1.
Refer to "GENERAL CHASSIS (1)" on
Fuel tank center cover
page 4-1.
Fuel tank Refer to "FUEL TANK" on page 7-1.

Air filter case Refer to "GENERAL CHASSIS (2)" on

page 4-10.

Canister Refer to "FUEL TANK" on page 7-1.

For MT09MC/MT09SPMC
Throttle bodies Refer to "THROTTLE BODIES" on page 7-5.
Refer to "GENERAL CHASSIS (1)" on
Front side panel
page 4-1.
Radiator Refer to "RADIATOR" on page 6-3.

5-10
 ENGINE REMOVAL

Disconnecting the leads and hoses

Order Job/Parts to remove Q'ty Remarks

Footrest assembly (right) Refer to "REAR BRAKE" on page 4-37.
Shift rod/Drive sprocket Refer to "CHAIN DRIVE" on page 4-86.
1 Clutch cable Disconnect.
2 Starter motor lead Disconnect.
Disconnect.
3 Purge cut valve solenoid coupler
For MT09MC/MT09SPMC
4 Ignition coil coupler 3 Disconnect.
5 Coolant temperature sensor coupler Disconnect.
6 Neutral switch coupler Disconnect.
7 Gear position sensor coupler Disconnect.
8 Crankshaft position sensor coupler Disconnect.
9 Stator coil coupler Disconnect.
10 Oil pressure switch connector Disconnect.

5-11
 ENGINE REMOVAL

Re moving the engine

,, 7 N·m (0.7 kgf·m, 5.2 lb·ft)

;; 55 N,m (5.5 kgf,m, 41 lb.ft)

Order Job/Parts to remove Q'ty Remarks

Engine mounting bolt (right front upper side)/
Engine mounting bolt (left front upper side) 1/1
Engine bracket bolt (right)/Engine bracket bolt
2 (left)
2/2

3 Engine bracket (right)

4 Engine bracket (left)
5 Engine mounting bolt (right front lower side)
6 Collar
7 Collar
8 Engine mounting bolt (left front lower side)
9 Engine mounting nut (lower)
10 Muffler bracket bolt
11 Muffler bracket
12 Sidestand switch coupler Disconnect.
13 Muffler bracket bolt
14 Muffler bracket
15 Pivot shaft nut Loosen.

5-12
 ENGINE REMOVAL

Re moving the engine

20

;,, 7 N•m (0.7 kgf•m, 5.2 lb•ft)

;; 55 N,m (5.5 kgf,m, 41 lb.ft)

Order Job/Parts to remove Q'ty Remarks

16 Engine mounting nut (upper)
17 Engine mounting bolt (rear lower side)
18 Engine mounting bolt (rear upper side)
19 Engine
20 Engine mounting adjust bo lt 2

5-13
 ENGINE REMOVAL

...,.,,.,
REMOVING THE ENGINE
5. Install:
• Engine mounting bolt (left front lower side) '7''
1. Loosen:
(temporarily tighten)
• Engine mounting adjust bolt (rear)
6. Install:
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Collar"8"
Loo sen the engine mounting adjust bolts with • Collar"9"
the pivot shaft wrench "1" and pivot shaft wrench • Engine mounting bolt (right front lower side)
adapter "2". "10"
(temporarily tighten)
7. Tighten:
Pivot shaft wrench
90890-01 518 • Engine mounting adjust bolt (lower) "1"
Frame spanner socket TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
YM-01518 • Tighten the engine mounting adjust bolt to
Pivot shaft wrench adapter specification with the pivot shaft wrench and
90890-01476 pivot shaft wrench adapter.
• Make sure that the flange on the engine
mounting adjust bolt contacts the engine.

Engine mounting adjust bolt

(lower)
7 N•m (0.7 kgf-m, 5.2 lb-ft)

Pivot shaft wrench

90890-01518
Frame spanner socket
VM-01518
Pivot shaft wrench adapter
90890-01476

8. Install:
• Muffler bracket "11"
• Muffler bracket bolt "12"
(temporariily tighten)
9. Tighten:
• Engine mounting nut (lower) "13"
• Muffler bracket bolt "4", "12"
"'""""'
INSTALLING THE ENGINE
1. Install: Engine mounting nut (lower)
• Engine mounting adjust bolt (lower) "1" 5 5 N-m (5.5 kgf•m, 41 lb-ft)
(temporarily tighten) Muffler bracket bolt
• Engine mounting adjust bolt (upper) "2" 5 5 N-m (5.5 kgf•m, 41 lb-ft)
(temporarily tighten) LOCTITE®
2. Install:
• Muffler bracket "3"
• Muffler bracket bolt "4"
(temporarily tighten)
3. Install:
• Engine
4. Install:
• Engine mounting bolt (rear lower side) "5"
• Engine mounting bolt (rear upper side) "6"

5-14
 ENGINE REMOVAL

10. Tighten: 15.lnstall:

• Engine mounting bolt (left front lower side) "7" • Engine bracket (right) "19"
• Engine mounting bolt (right front lower side) • Engine bracket bolt (right) "20"
"10" (temporariily tighten)
• Engine mounting bolt (right front upper side)
Engine mounting bolt (left front "21"
lower side) (temporariily tighten)
60 N•m (6.0 kgf•m, 44 lb,ft) 16. Tighten:
Engine mounting bolt (right front • Engine bracket bolt (left) "17'
lower side) • Engine mounting bolt (left front upper side)
60 N•m (6.0 kgf•m, 44 lb,ft) "18"
• Engine bracket bolt (right) "20"
11 . Tighten:
• Engine mounting bolt (right front upper side)
• Pivot shaft nut "14"
"21"
Pivot shaft nut
105 N,m (10.5 kgf,m, n lb,ft) Engine bracket bolt (left)
25 N,m (2.5 kgf,m, 18 lb,ft)
12. Tighten: Engine mounting bolt (left front
• Engine mounting adjust bolt (upper) "2" upper side)
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ 45 N,m (4.5 kgf,m, 33 lb,ft)
Engine bracket bolt (right)
• Tighten the engine mounting adjust bolt to 25 N,m (2.5 kgf,m, 18 lb,ft)
specification with the pivot shaft wrench and
Engine mounting bolt (right front
pivot shaft wrench adapter. upper side)
• Make sure that the flange on the engine 45 N,m (4.5 kgf,m, 33 lb,ft)
mounting adjust bolt contacts the engine.

Engine mounting adjust bolt (up-

per)
7 N•m (0.7 kgf,m, 5.2 lb,ft)

Pivot shaft wrench

90890-01518
Frame spanner socket
YM-01518
Pivot shaft wrench adapter
90890-01476

13. Tighten:
• Engine mounting nut (upper) "15"

Engine mounting nut (upper)

45 N,m (4.5 kgf,m, 33 lb,ft)

14.lnstall:
• Engine bracket (left) "16"
• Engine bracket bolt (left) "17'
(temporarily tighten)
• Engine mounting bolt (left front upper side)
"18"
(temporarily tighten)

5-15
 CAMSHAFTS

EAS20043

CAMSHAFTS
Removing the cylinder head cover

1 ~ 10 N-m (1.0 kgf-m, 7.4 lb-11)

.,,__ 10 N-m (1.0 kgf-m, 7.4 lb-11
,,,-------......_
- --------/:;:;;•, ~
. . .;:;1/,f f ·-
______,

, mm
------------------~ * - I ,;J 13 N-m (1.3 kgf-m, 9.6 lb-11
-----------J
• Three Bond No. 1541C®
Order Job/Parts to• remove Q'ty Remarks
Refer to "GENERAL CHASSIS (1)" on
Rider seat
page 4-1.
Refer to "GENERAL CHASSIS (1)" on
Fuel tank center cover page 4-1.
Fuel tank Refer to "FUEL TANK" on page 7-1.
Refer to "GENERAL CHASSIS (2)" on
Air filter case
page 4-10.
Refer to "GENERAL CHASSIS (1)" on
Front side panel page 4-1.
Radiator Refer to "RADIATOR'' on page 6-3.
Ignition coil coupler 3 Disconnect.
2 Ignition coil 3
3 Spark plug 3
4 Cylinder head cover
5 Cylinder head cover gasket
6 Timing chain guide (top side)

5-16
 CAMSHAFTS

Removing the camshafts

~ "'- 10 N-m (1.0 kgf-m, 7.4 11>lt)

( "',I 10 N-m (1.0 kgl•m, 7.411>lt) !

.;, 10 N-m (1.0 kgl-m, 7.4 lb•lt)

, , )
5 -
'
7
~

~/
' ~~ 9

_I,
2

L________J
.,, 12 N-m (1.2 kgf-m, 8.9 lb~)

Order Job/Parts to remove Q'ty Remarks

Crankshaft end covermming mark accessing Refer to "GENERATOR AND STARTER
bolt CLUTCH" on page 5-36.
1 Holder 2
2 Timing chain cover
3 Timing chain cover gasket
4 Timing chain tensioner
5 Timing chain tensioner gasket
6 Intake camshaft cap
7 Exhaust camshaft cap
8 Camshaft cap 1
9 Dowel pin 6
10 Intake camshaft
11 Exhaust camshaft

5-17
 CAMSHAFTS

Removing the camshafts

~ "'- 10 N-m (1.0 kgf-m, 7.4 11>11)

( ,.,,,I 10 N-m (1.0 kgl•m, 7.411>11) !

.;, 10 N-m (1.0 kgl-m, 7.4 lb•lt)

-
~

~/

14

I
L__ __ _ __ _ __ _ _

.,, 12 N-m (1.2 kgf-m, 8.9 lb~)

15 16 17

Order Job/Parts to remove Q'ty Remarks

12 Intake camshaft sprocket
13 Exhaust camshaft sprocket
14 Timing chain bolt
15 Dowel pin
16 Timing chain guide (intake side)
17 Timing chain

5-18
 CAMSHAFTS

...,.,,.
REMOVING THE CAMSHAFTS
4. Remove:
• Camshaft cap
1. Remove:
• Intake camshaft cap
• Timing mark accessing bolt "1"
• Exhaust camshaft cap
• Crankshaft end cover "2" ECA13'7'20

NOTICE
-------------
To prevent damage to the cylinder head,
camshafts or camshaft caps, loosen the
camshaft cap bolts in stages and in a criss-
cross pattern, working from the outside in.
5. Remove:
• Intake camshaft "1"
• Exhaust camshaft "2"
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
2. Align : To prevent the timing chain from falling into the
• Mark "a" on the generator rotor crankcase, fasten it with a wire "3".
(with the generator rotor cover mark "b")
a. Tum the crankshaft counterclockwise. 2 i-
b. When piston #1 is at BTDC125° on the
compression stroke, align the BTDC125°
mark "a" on the generator rotor with the
generator rotor cover mark "b" .
=·=t:;:=@~t
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
BTDC125° on the compression stroke can be
found when the camshaft lobes are turned away
from each other.
~ -;-~@ . \ 4'

I
6. Remove:
3. Remove: • Camshaft sprocket "1"
• Timing chain tensioner "1" TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Timing chain tensioner gasket
Use the camshaft wrench "2" and loosen the
r camshaft sprocket bolt.

Camshaft wrench
90890-04162
Camshaft wrench
VM-04162

5-19
 CAMSHAFTS

lfQ 4. Measure:
• Camshaft-journal-to-camshaft-cap clearance
Out of specification ➔ Measure the camshaft
1 journal diameter.
2
Camshaft-journal-to-camshaft-
~'==~~a cap clea rance limit
0.080 mm (0.0032 in)

a. Install the camshaft into the cylinder head

(without the camshaft caps).
b. Position strip of Plastigauge® "1" onto the
CHECKING THE CAMSHAFTS
camshaft journal as shown.
1. Check:
• Camshaft lobes
Blue discoloration/pitting/scratches ➔ Re-
place the camshaft.
2. Measure:
• Camshaft lobe dimensions "a"
Out of specification ➔ Replace the camshaft.

Camshaft lobe dimensions 0

Lobe height limit (Inta ke) G088947
35.590 mm (1.401 2 in) c. Install the dowel pins and camshaft caps.
Lobe height limit (Exhaust) Refer to "INSTALLING THE CAMSHAFTS"
35.620 mm (1.4024 in)
on page 5-22.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
a Do not turn the camshaft when measuring the
camshaft journal-to-camshaft cap clearance
with the Plastigauge®.

d. Remove the camshaft caps, and then mea-

sure the width of the Plastigauge® "1".

G088948

3. Measure:
• Camshaft runout
Out of specification ➔ Replace.

Camshaft runout limit

0.030 mm (0.0012 in}

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.

Camshaft journal diameter

24.459-24.472 mm (0.9630-
0.9635 in)

5-20
 CAMSHAFTS

CHECKING THE TIMING CHAIN TENSIONER

1. Check:
• Timing chain tensioner
Cracks/damage/rough movement ➔ Re-
place.
a. Using the valve spring compressor "1",
push and insert timing chain tensioner rod
"2" into the liming chain tensioner housing.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
........
CHECKING THE TIMING CHAIN AND
Push the timing chain tensioner rod in direction
"a", and tum tthe timing chain tensioner body "3"
CAMSHAFT SPROCKET in direction "b" until the circlip fits into the groove.
1. Check:
• Timing chain
Damage/stiffness ➔ Replace the timing 1
chain and camshaft and camshaft sprocket
as a set.
2. Check:
• Camshaft sprocket
More than 1/4 tooth wear "a" ➔ Replace the
camshaft sprockets and the timing chain as a
set.

G088950

a. 1/4 tooth
b. Correct b. Lock the timing chain tensioner rod by set-
ting the circlip "4" to groove "5" while push-
1. Timing chain ing the timing chain tensioner rod.
2. Camshaft sprocket

""""""'
CHECKING THE TIMING CHAIN GUIDES
1. Check:
• Timing chain guide (intake side)
• Timing chain guide (top side)
Damage/wear ➔ Replace the defective
part(s).

c. Push the timing chain tensioner rod "cf'.

d. If the circlip does not unlock even though
you press the timing chain tensioner rod in
the "cf' direction, rotate the timing chain ten-
sioner rod clockwise.

5-21
 CAMSHAFTS

e. Make sure that the timing chain tensioner TIP_ _ _ _ _ _ _ _ _ _ _ _ __

rod comes out "d" of the timing chain ten- • Install the camshaft projection "a" at the posi-
sioner housing smoothly. If there is rough tion shown in the illustration.
movement, replace the timing chain ten- • Tighten the camshaft sprocket bolt with the
sioner. camshaft wrench "3".

Camshaft wrench
90890-04162
Camshaft wrench
VM-04162

1
a

...,.,..
INSTALLING THE CAMSHAFTS
1. Remove:
• Timing mark accessing bolt "1"
• Crankshaft end cover "2"

2. Align :
• Mark "a" on the generator rotor
4. Install:
(with the generator rotor cover mark "b")
• Exhaust camshaft "1"
a. Tum the crankshaft counterclockwise. • Intake camshaft "2"
b. When piston #1 is at BTDC125°, align the TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
mark "a" on the generator rotor with the
generator rotor cover mark "b"'. Make sure the punch mark "a" on each camshaft
faces up.

:@ \Y, u~

3. Install:
• Intake camshaft sprocket "1" 5. Install:
• Exhaust camshaft sprocket "2" • Camshaft cap
• Intake camshaft cap
Camshaft sprocket bolt • Exhaust camshaft cap
24 N•m (2.4 kgf•m, 18 lb•ft)

5-22
 CAMSHAFTS

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Make sure each camshaft cap is installed in its Tighten the camshaft cap bolts in stage and in a
original place. Refer to the identification marks crisscross pattern, working from the inner caps
as follows: out.
"IL": Intake left side camshaft cap mark ECA17430
"EL": Exhaust left side camshaft cap mark NOTICE
• Make sure the arrow mark "a" on each cam- -------------
• Lubricate the camshaft cap bolts with the
shaft points toward the right side of the engine.
engine oil.
• The camshaft cap bolts must be tightened
evenly or damage to the cylinder head,
camshaft caps, and camshafts will result.
• Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.

6. Tighten:
• Camshaft cap bolt "1"

Camshaft cap bolt

10 N•m (1.0 kgf•m, 7.4 lb•ft)

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
8. Check:
Tighten the camshaft cap bolts in the tightening
• Camshaft punch mark "a"
sequence as shown.
Make sure the camshaft punch mark "a" on
ECA17430 the camshaft is aligned with the camshaft cap
NOTICE
-------------
• Lubricate the camshaft cap bolit s with the
alignment mark "b".

engine oil.
• The camshaft cap bolts must be tightened
evenly or damage to the cylinder head,
camshaft caps, and camshafts will result.
• Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.

9. Install:
• Timing chain tensioner gasket Gm
• Timing chain tensioner
a. Using the valve spring compressor "1",
push and insert liming chain tensioner rod
"2" into the timing chain tensioner housing.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Push the timing chain tensioner rod in direction
7. Tighten:
"a", and tum tthe timing chain tensioner body "3"
• Camshaft cap bolt "1"
in direction "b" until the circl ip fits into the groove.
Camshaft cap bolt
10 N•m (1.0 kgf•m, 7.4 lb•ft)

5-23
 CAMSHAFTS

12.Check:
• Mark "a"
Make sure the mark "a" on the generator rotor
is aligned with the generator rotor cover mark
"b".
• Camshaft punch mark "c"
Make sure the camshaft punch mark "c" on
the camshaft is aligned with the camshaft cap
alignment mark "d".
Out of alignment ➔ Adjust.
Refer to the installation steps above.
"\Jr. C U I( '

b. Lock the timing chain tensioner rod by set-

ting the circlip "4" into groove "5" while
pushing the timing chain tensioner rod.

13.Measure:
• Valve clearance
c. Install the timing chain tensioner to the cyl- Out of specification ➔ Adjust.
inder block. Refer to "ADJUSTING THE VALVE CLEAR-
TIP_ _ _ _ _ _ _ _ _ _ _ _ __ ANCE" on page 3-5.
Always use a new gasket. 14.lnstall:
• Timing mark accessing bolt "1"

Timing chain tensione r bolt Timing mark accessing bolt

10 N-m (1.0 kgf-m, 7.4 lb•ft) 15 N-m (1.5 kgf-m, 11 lb•ft)
d . Tum the crankshaft clockwise several times • Crankshaft end cover "2"
to release the timing chain tensioner rod.
10.Turn: Crankshaft end cover
• Crankshaft 10 N-m (1.0 kgf-m, 7.4 lb•ft)
(several turns counterclockwise)
11 .Confirm the timing chain tension property.

5-24
 CAMSHAFTS

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Install the ignition coils "1" in the direction shown
in the illustration.

15.lnstall:
• Timing chain guide (top side)
• Cylinder head cover gasket "1" ell'J
• Cylinder head cover

Cylinder head cover bolt

10 N-m (1.0 kgf-m, 7.4 lb-ft)

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Apply Three Bond No. 1541 C® onto the mat-
ing surfaces of the cylinder head cover and cyl-
inder head cover gasket.
• After installing the cylinder head cover gasket
"1" to the cylinder head cover, cut off the "a"
section.

16. lnstall:
• Spark plug
• Ignition coil "1"

Spark plug
13 N-m (1.3 kgf-m, 9.6 lb-ft)

5-25
 CYLINDER HEAD

..CYLINDER
.,..,..
HEAD
Removing the cylinder head
1st 20 N·m
~ f-2_n_
d+-
30_ N_
·m_,_
(3_.0~ kg"-f_·m
_,c..2_2_Ib
_ ·_fl.l.y
10 N·m (1 .0 kgf·m, 7.4 lb·ft) • rd 15 N·m (1 .5 kgf·m, 11 lb· ft)
3
Specified angle 120°

I :,, I 10 N·m (1 .0 kgf·m, 7.4 lb·fl)I

1

• Following the tightening order, loosen the bolt one by one, and then reti ghten it to the specific torque and the
specified angle.
Order Job/Parts to• remove Q'ty Remarks
Engine Refe r to "ENGINE REMOVAL" on page 5··9.
Intake camshaft Refer to "CAMSHAFTS" on page 5-1 6.
Exhaust camshaft Refer to "CAMSHAFTS" on page 5· 16.
Timing chain Refer to "CAMSHAFTS" on page 5-16.
Coolant temperature sensor
2 Cylinder head
3 Cylinder head gasket
4 Dowel pin 2
5 Timing chain guide (exhaust side)

5-26
 CYLINDER HEAD

...,..,.
REMOVING THE CYLINDER HEAD
W.arpage limit
1. Remove:
0.10 mm (0.0039 in)
• Intake camshaft
• Exhaust camshaft
Refer to "REMOVING THE CAMSHAFTS"
on page 5-19.
2. Remove:
• Cylinder head bolt (M6) (x4)
• Cylinder head bolt (M9) (x8)
TIP_ _ _ _ _ _ _ _ _ _ _ _ __
• Loosen the bolts in the proper sequence as
shown.
G088955
• Loosen each bolt 1/2 of a tum at a time. After
all of the bolts are fully loosened, remove them. a. Place a straightedge "1" and a thickness
gauge "2" across the cylinder head.
--,
Thickness gauge
90890-03268
1.
•
'
Feeler gauge set
YU-26900· 9

~- ·1~~1
I ~

........
CHECKING THE TIMING CHAIN GUIDE
{EXHAUST SIDE)
1. Check:
• Timing chain guide (exhaust side)
G088957
Damage/wear ➔ Replace.
...,..,,
CHECKING THE CYLINDER HEAD
b. Measure the warpage.
c. If the limit is exceeded, resurface the cyl'in-
der head as follows.
1. Eliminate:
d. Place a 400-600 grit wet sandpaper on the
• Combustion chamber carbon deposits surface [Plate and resurface the cylinder
(with a rounded scraper)
head using a figure-eight sanding pattern.
TIP·_ _ _ _ _ _ _ _ _ _ _ _ __
TIP·_ _ _ _ _ _ _ _ _ _ _ _ __
Do not use a sharp instrument to avoid damag-
To ensure an even surface, rotate the cylinder
ing or scratching:
head several times.
• Spark plug bore threads
• Valve seats
2. Check:
• Cylinder head
Damage/scratches ➔ Replace.
• Cylinder head water jacket
Mineral deposits/rust ➔ Eliminate.
3. Measure:
• Cylinder head warpage
Out of specification ➔ Resurface the cylinder
head.

5-27
 CYLINDER HEAD

EA""""'
INSTALLING THE CYLINDER HEAD
1. Install:
• Timing chain guide (exhaust side) "1"
• Cylinder head gasket "2" ml')
• Dowel pin "3"

4. Install:
• Exhaust camshaft
• Intake camshaft
Refer to "INSTALLING THE CAMSHAFTS"
on page 5 -22.

2. Install:
• Cylinder head
• Cylinder head bolt (M6) (x4)
• Cylinder head bolt (M9) (x8) mm!)
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Pass the timing chain through the timing chain
cavity.
• Lubricate the cylinder head boll (M9) thread
and mating surface with engine oil.
3. Tighten:
• Cylinder head bolt "1 "-"8"
• Cylinder head bolt "9"-"12"

Cylinder head bolt " 1"-"8"

1st: 20 N•m (2.0 kgf•m, 15 lb•ft)
2nd: 30 N-m (3.0 kgf.m, 22 lb-ft)
*3rd: 15 N•m (1.5 kgf-m, 11 lb•ft)
Specified angle 120°
Cylinder head bolt "9"-"12"
10 N-m (1.0 kgf•m, 7.4 lb•ft)

• Following the tightening order, loosen the

bolt one by one and then retighten it to the
specified torque and the specified angle.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Tighten the cylinder head bolts "1"- "8" in the
tightening sequence as shown and torque them
in 3 stages.

5-28
 VALVES AND VALVE SPRINGS

EA"""'415

VALVES AND VALVE SPRINGS

Removing the valves and valve springs

Order Job/Parts to remove Q'ty Remarks

Cylinder head Refer to "CYLINDER HEAD" on page 5-26.
1 Intake valve lifter 6
2 Intake valve pad 6
3 Intake valve cotter 12
4 Intake valve spring retainer 6
5 Intake valve spring 6
6 Intake valve 6
7 Intake valve stem seal 6
8 Intake valve spring seat 6
9 Intake valve guide 6
10 Exhaust valve lifter 6
11 Exhaust valve pad 6
12 Exhaust valve cotter 12
13 Exhaust valve spring retainer 6
14 Exhaust valve spring 6

5-29
 VALVES AND VALVE SPRINGS

Removing the valves and valve springs

~ 10 0
.i~ 1
0 0 1

1illf'i:i'I
m!J 16 ~
17- - - 0 0 1
~ _ • .,,

0
-1

·~~~~:::::~~::-·~~~ .

,__18
15

Order
a Job/Parts to remove Q'ty Remarks
15 Exhaust valve 6
16 Exhaust valve stem seal 6
17 Exhaust valve spring seat 6
18 Exhaust valve guide 6

5-30
 VALVES AND VALVE SPRINGS

EAS3CJOS3
REMOVING THE VALVES
Valve spring compressor
The following procedure applies to all of the 90890-04200
valives and related components.
Valve spring compressor
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ VM-04019
Before removing the internal parts of the cylinder Valve spring compressor attach-
head (e.g., valves, valve springs, valve seats), ment (e23)
make sure the valves properly seal. 90890-04179
Valve spring compressor adapter
1. Remove: (e.2 3)
• Valve lifter VM-04179
• Valve pad
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Make a note of the position of each valve lifter
and 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.
G088959
Refer to "CHECKING THE VALVE SEATS"
on page 5-33. 4. Remove:
• Valve spring retainer
a. Pour a clean solvent "a" into the intake and
• Valve spring
exhaust ports.
• Valve
b. Check that the valves properly seal.
• Valve stem seal
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Valve spring seat
There should be no leakage at the valve seat "1 ". TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Identify the position of each part very carefully so
that it can be reinstalled in its original place.

...,,,,..
CHECKING THE VALVES AND VALVE
GUIDES
The following procedure applies to all of the
valves and valve guides.
1. Measure:
G088958 • Valve-stem-to-valve-guide clearance
3. Remove: Out of specification ➔ Replace the valve
guide.
• Valve cotter
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ • Valve-stem-to-valve-guide clearance =
Remove the valve cotters by compressing the Valve guide inside diameter "a" -
Valve stem diameter "b"
valive spring with the valve spring compressor
"1" and the valve spring compresso-r attachment
"2".
Valve-stem-to-valve-guide clear-
amce limit (intake)
0 .080 mm (0.0032 in)
Valve-stem-to-valve-guide clear-
amce limit (exhaust)
0 .100 mm (0.0039 in)

5-31
 VALVES AND VALVE SPRINGS

G088960 G088963 C
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.

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 ("4.5)
90890-04116
Valve guide remover (4.5 mm)
VM-04116
Valve guide installer ("4.5)
90890-04117
Valve guide installer (4.5 mm)
VM-04117
G088962
Valve guide reamer ("4.5)
b. Install the new valve guide with the valve 90890-04118
guide installer "2" and valve guide remover Valve guide reamer (4.5 mm)
"1". VM-04118

Valve guide position 3. Eliminate:

13.3-13.7 mm (0.52-0.54 in) • 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.

5-32
 VALVES AND VALVE SPRINGS

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.
/ /

....,.,.. 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 a. Apply a coarse lapping compound "a" to the
Pitting/wear ➔ Replace the cylinder head. valve face.
3. Measure: ECA13'790

NOTICE
• Valve seat contact width "a"
Out of specification ➔ Replace the cylinder
-------------
Do not let the lapping compound enter the
head. gap between the valve stem and the valve
guide.
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)

G088968

b. Apply molybdenum disulfide oil onto the

valve stem.
c. Install the valve into the cylinder head.

i
G088966

5-33
 VALVES AND VALVE SPRINGS

d. Tum the valve until the valve face and valve EAS300ll6
CHECKING THE VALVE SPRINGS
seat are evenly polished, then clean off all
The following procedure applies to all of the
of the lapping compound.
valve springs.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
1. Measure:
For the best lapping results, lightly tap the valve • Valve spring tree length "a"
seat while rotating the valve back and forth be- Out of specification ➔ Replace the valve
tween your hands. spring.

J~,~
Free length limit (intake)
37.34 mm (1.47 in)
Free length limit (exhaust)
35.89 mm (1.41 in)

,_ ~~t
e. Apply a fine lapping compound to the valve
face and repeat the above steps.
I. After every lapping procedure, be sure to
clean off all of the lapping compound from
the valve face and valve seat. G088971
g. Apply blue layout fluid "b" onto the valve
EAS300l!7
face.
CHECKING THE VALVE LIFTERS
The following procedure applies to all of the
valve litters.
1. Check:
• Valve litter
Damage/scratches ➔ Replace the valve lrft-
ers and cylinder head.

INSTALLING THE VALVES

G088967 The following procedure applies to all of the
h. Install the valve into the cylinder head. valves and related components.
i. Press the valve through the valve guide and 1. Deburr:
onto the valve seat to make a clear impres- • Valve stem end
sion. (with an oil stone)
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.

G088972
2. Lubricate:

I
G088970
• Valve stem
• Valve stem seal
(with the recommended lubricant)

5-34
 VALVES AND VALVE SPRINGS

Recommended lubricant
Molybdenum disulfide oil

3. Install:
• Valve spring seat "1"
• Valve stem seal "2" Gm
• Valve "3"
• Valve spring "4"
• Valve spring retainer "5" G088959

(into the cylinder head) 5. To secure the valve cotters onto the valve
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ stem, lightly tap the valve tip with a soft-face
hammer.
• Make sure each valve is installed in its original ECA13900
place.
• Install the valve springs with the larger pitch "a"
facing up.
NOTICE
-------------
Hitting the valve tip with excessive force
could damage the valve.

G088973
G088975
b. Smaller pitch 6. Lubricate:
4. Install: • Valve pad
• Valve cotter (with the recommended lubricant)
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Recommended lubricant
Install the valve cotters by compressing the
Molybdenum disulfide oil
valive spring with the valve spring compressor
"1" and the valve spring compressor attachment • Valve lifter
"2". (with the recommended lubricant)

Valve spring compressor Recommended lubricant

90890-04200 Engine oil
Valve spring compressor 7. Install:
YM-04019
• Valve pad
Valve spring compressor attach-
• Valve lifter
ment (023)
90890-04179 TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Valve spring compressor adapter • The valve lifter must move smoothly when ro-
(023) tated with a finger.
YM-04179 • Each valve lifter and valve pad must be rein-
stalled in its original position.

5-35
 GENERATOR AND STARTER CLUTCH

EAS20t40

GENERATOR AND STARTER CLUTCH

Removing the stator coil, genera1or rotor and starter clu1ch

~
. /·
/ /4
/ ' "'--~ .

~ .
I~ . /- n4
s • ~ ------~
./ · ,·, 10 N-m (1.0

10 N·m (1 .0 kgl·m, 7.4 lb•ft)

• YAMAHA bond No. 1215 (Three bond No. 1215®)

Order Job/Parts to- remove Q'ty Remarks

Refer to "GENERAL CHASSIS (1)" on
Rider seat
page 4-1.
Refer to "GENERAL CHASSIS (1)" on
Fuel tank center cover page 4-1.
Fuel tank Refer to "FUEL TANK" on page 7-1.
Water pump Refer to "WATER PUMP" on page 6-11.
Drain.
Engine oil Refer to "CHANGING THE ENGINE Oil" on
page 3-28.
Stator coil coupler Disconnect.
2 Crankshaft position sensor coupler Disconnect.
3 Holder (fuel tank overflow hose) 3
4 Bracket
5 Generator cover
6 Generator cover gasket

5-36
 GENERATOR AND STARTER CLUTCH

Removing the stator coil, generator rotor and starter clutch

✓, 12 N·m (1.2 kgl·m, 8.9 lb·lt)

• YAMAHA bond No. 1215 (Three bond No. 1215®)

Order Job/Parts to•remove Q'ty Remarks
7 Dowel pin 2
8 Stator coil lead holder
Stator coil assembly (stator coil/crankshaft posi•
9
lion sensor)
10 Generator rotor
11 Starter clutch
12 Starter clutch gear
13 Woodruff key
14 Starter clutch idle gear shaft
15 Starter clutch idle gear
16 Crankshaft end cover
17 Timing mark accessing bolt
18 Water pump outlet pipe

5-37
 GENERATOR AND STARTER CLUTCH

...,...,
REMOVING THE GENERATOR
1. Remove:
• Generator rotor bolt "1"
• Washer
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
While holding the generator rotor "2" with the
sheave holder "3", loosen the generator rotor
bolt.

EAS30808
Sheave holder
REMOVING THE STARTER CLUTCH
90890-01903
Primary clutch holder
1. Remove:
YS-01880-A • Starter clutch bolt
• Starter clutch
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
While holding the generator rotor "1" with the
sheave holder "2", loosen the starter clutch
bolts.

Sheave holder
90890-01903
I 2 Primary clutch holder
1 YS-01880-A
2. Remove:
• Generator rotor "1"
(with the flywheel puller "2")
• Woodruff key
ECA13890

NOTICE
------------
To protect the end of the crankshaft, place an
ap;propriate sized socket between the fly-
wheel puller set center bolt and the crank•
shaft.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ EAS30809

• Install the flywheel puller bolts to the threaded CHECKING THE STARTER CLUTCH
holes of the starter clutch. 1. Check:
• Make sure the flywheel puller is centered over • Starter clutch roller
the generator rotor. Damage/wear ➔ Replace.
2. Check:
• Starter clutch idle gear
Flywheel puller • Starter clutch gear
90890-01362 Burrs/chips/roughness/wear ➔ Replace the
Heavy duty puller
defective part(s).
YU-33270-8
3. Check:
• Starter clutch gear contact surfaces
Damage/pitting/wear ➔ Replace the starter
clutch gear.

5-38
 GENERATOR AND STARTER CLUTCH

4. Check:
• Starter clutch operation
a . Install the starter clutch gear " 1" onto the
generator rotor "2" and hold the generator
rotor.
b. When turning the starter clutch gear clock-
wise "A", the starter clutch and the starter
clutch gear should engage, oth erwise the
starter clutch is faulty and must be re-
placed.
c . When turning the starter clutch gear coun-
terclockwise "B", it should turn freely, other-
wise the starter cl utch is faulty and must be
replaced.

EA""""2
INSTALLING THE GENERATOR
1. Install:
• Woodruff Ikey
• Generator rotor
EAS300TI
• Washer Gm
INSTALLING THE STARTER CLUTCH
1. Install: • Generator rotor bolt
• Starter clutch "1" TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Clean the tapered portion of the crankshaft and
Starter clutch bolt the generator rotor hub.
32 N-m (3.2 kgf-m, 24 lb•ft) • When installing the generator rotor, make sure
LOCTITE® the woodruff key is properly seated in the key-
way of the crankshaft.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ • Lubricate the washer with engine oil.
• Install the starter cl utch so that the side of the • Lubricate the generator rotor bolt threads and
starter clutch roller assembly with the arrow washer mating surfaces with engine oil.
mark "a" is toward the generator rotor "2".
2. Tighten:
• While holding the generator rotor with the
• Generator rotor bolt "1"
sh eave holder "3", tighten the starter clutch
bolts.
Generator rotor bolt
7 5 N-m (7.5 kgf•m, 55 lb•ft)
Sheave holder
90890-01903 TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Primary clutch holder While holding the generator rotor "2" with the
YS-01880-A sheave holder "3", tighten the generator rotor
bolt.

~
Sheave holder
90890-01903
Primary clutch holder
VS-01880-A

5-39
 GENERATOR AND STARTER CLUTCH

5. Connect:
• Stator coill coupler
• Crankshaft position sensor coupler
TIP_ _ _ _ _ _ _ _ _ _ _ _ __
To route the s tator coil lead, refer to "CABLE
ROUTING" on page 2-15.

1
3. Apply:
• Sealant
(onto the stator coil assembly lead grommet)

~
Yamaha bond No. 1215
90890-85505
Three bond No. 121 5®

G088980
4. Install:
• Generator cover gasket m?l!I
• Generator cover

Generator c-0ver bolt .. 1,,

12 N-m (1.2 kgf-m, 8.9 lb•ft)
LOCTITE®
Generator cover bolt ..2,,
12 N-m (1.2 kgf-m, 8.9 lb•ft)

TIP_ _ _ _ _ _ _ _ _ _ _ _ __
Tighten the generator cover bolts in stages and
in a crisscross pattern.

5-40
 ELECTRIC STARTER

EA""'°"'
ELECTRIC STARTER
Removing the starter motor

12 ~m (1.2 kgf-m, 8.9 lb-It)

,,,,---·
/'

1
f~ ~ 1 ,

'tllr,.,_.I"'
/ / ,

et 7 N-m (0. 7 kgl-m, 5.2 lb.ft)

• For MT09M/MT09SPM
- For MT09MCIMT09SPMC
Order Job/Parts to• remove Q'ty Remarks
Purge cut valve solenoid Refer to "FUEL TANK" on page 7-1.
Throttle bodies Refer to "THROTTLE BODIES" on page 7-5.
Starter motor lead Disconnect.
2 Starter motor
3 Canister holder For MT09MCIMT09SPMC.
4 Holder For MT09M/MT09SPM.

5-41
 ELECTRIC STARTER

-4 5 N-m (0.5 kgf-m, 3.7 lb-ft)

Order Job/Parts to remove Q'ty Remarks

0 -ring
2 Starter motor front cover
3 Starter motor yoke
4 Armature assembly
5 Gasket 2
6 Brush holder set
7 Starter motor rear cover

5-42
 ELECTRIC STARTER

...,_
CHECKING THE STARTER MOTOR
4. Measure:
• Brush length "a"
1. Check:
Out of specification ➔ Replace the brush
• Commutator
holder set.
Di rt ➔ Clean with 600 grit sandpaper.
2. Measure:
Brush overall length limit
• Mica undercut "a" 6.5 mm (0.26 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)

0.70 mm (0.03 in)

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
The mica of the commutator must be undercut to
ensure proper operation of the commutator.
G088989 a
5. Check:
I ■ ■ ■ ■ • Gear teeth
Damage/ wear ➔ Replace the starter motor
assembly.
6. Check:
• Bearing
• Oil seal
Damage/wear ➔ Replace the starter motor
G088986 assembly.
3. Check: EA"'°""'
• Armature assembly ASSEMBLINIG THE STARTER MOTOR
a. Connect the digital circuit tester and check 1. Install:
the continuity. • Brush holder set
• Insulator "1"
Digital circuit tester (CD732) TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
90890-03243 Install the insulator as shown in the illustration.
Model 88 Multimeter with ta-
chometer
YU-A1927

b. If there is no continuity, replace the starter

motor.

2. Install:
• Starter motor rear cover "1"
• Starter motor yoke "2"
• Starter motor front cover "3"
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Align the match marks "a" on the starter motor
yoke with the match marks "b" on the front and
rear cover.

5-43
 ELECTRIC STARTER

EA""""7
INSTALLING THE STARTER MOTOR
1. Install:
• Canister holder (for MT09MC/MIT09SPMC)
• Holder (for MT09M/MT09SPM)
• Starter motor
• Starter motor bolt
TIP_ _ _ _ _ _ _ _ _ _ _ _ __
Tighten the starter motor bolts in the tightening
sequence as shown.

Starter motor bolt

12 N,m (1.2 kgf,m, 8.9 lb,ft)

• Starter motor lead

Starter motor lead nut

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

5-44
 CLUTCH

..CLUTCH
.,.,.,,.

Removing the clutch cover

~ I ...)7 N-m (0.7 kgf•m, 5.2 lb-It) ! 1~

~ /'

12 N,m (1.2 kgf,m, 8.9 lb•ft)

" • 1.5 N-m (0.15 kgf-m, 1.1 lb-It)

/'

. .

6 4 mffl
/ 3

Order Job/Parts to remove Q'ty Remarks

Drain.
Engine oil Refer to "CHANGING THE ENGINE OIL" on
page 3-28.
Clutch cable Disconnect.
2 Cover
3 Clutch cover
4 Clutch cover gasket
5 Dowel pin 2
6 Oil filler cap

5-45
 CLUTCH

Removing th e pull lever shaft

_,,..,,~-----

mas 7 8

\~\
~
~P' I/ [ ,0~ / / -""
v/ rmm \
1 2

- Order
1 1 --+-;:;--,---
Circlip Job/Parts
O
remove
Remarks

Pull lever Q'ty

32 p 1
1
ult lever sp.nng

-6
4
Circlip --=======----===t~=t=-
65 --+;;;Pu~ll~le~v~er~sh.haiiitt- 1
Oil seal
7 Bearing
8 Bearing

5-46
 CLUTCH

<· 125 N-m (12.5 kg f,m ' 92 lb-ft)

Order Job/Parts to rem

ove Refer to
Oil pump driven sprocket
1 Pressure plate 1
Clutch spring 3
- -22- II tP..;r,~e'.'.:'..
ssure plate 2
3
4 Pull rod
5 Bearing 1
6 Friction plate 2 3 . 126 mm (4.96 in)
Inside diameter. mm (4.57 in)
7 Clutch plate 1 d . meter. 116
Inside ia · (4 13 in)
8 Clutch plate 2 7 . ter. 105 mm .
Inside d1ame : 119 mm (4.69 in)
9 Friction plate 1 6 Inside diameter.

- -110) I ,C_,,l utch damper spring

· seat
1 Clutch damper spring
11 I
12 Clutch boss nu
13 . washer
Conical spring
14 Washer
:=r=-----
5-47
 CLUTCH

" 125 N-m (12.5 kg f,m ' 92 lb-ft)

Order Job/Parts to remove

15 Clutch boss
16 Thrust plate 1
17 Clutch housing . 1
18 Oilpump dnv
· echam
19 Bearing
20 Spacer 1
21 Thrust plate 1
22 Thrust plate

5-48
 CLUTCH

4. Remove:
REMOVING THE CLUTCH
• Friction plate 2 "1"
1. Remove:
• Cover "1"
• Clutch cover "2"
• Gasket
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Loosen each bolt 1/4 of a tum at a time, in stag-
es and in a crisscross pattern.
After all of the bolts are fully loose111ed, remove
them.

5. Remove:
• Clutch plate 1 "1"
• Clutch plate 2
• Friction plate 1
• Clutch damper spring
• Clutch damper spring seat

2. Remove:
• Oil pump driven sprocket "1"
Refer to "OIL PUMP" on page 5 -57.

~-
6. Straighten the clutch boss nut rib "a".

3. Remove:
• Clutch spring bolt "1"
• Pressure plate 1 "2"
• Clutch spring G088992
• Pressure plate 2 "3" 7. Loosen:
• Pull rod "4"
• Clutch boss nut "1"
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
While holding the clutch boss "2" with the univer-
sal clutch holder "3", loosen the clutch boss nut.

Clutch holder
90890-04199
Universal clutch holder
VM-91042

5-49
 CLUTCH

IKI [ID
1

8. Remove:
A. Friction p late 1
• Clutch boss nut
B. Friction plate 2
• Conical spring washer
• Washer EAS30040

• Clutch boss CHECKING THE CLUTCH PLATES

• Thrust plate The following procedure applies to all of the
• Clutch housing clutch plates.
• Oil pump drive chain 1. Check:
• Clutch plate 1, 2
EAS30048
Damage ➔ Replace the clutch plates as a
CHECKING THE FRICTION PLATES
set.
The following procedure applies to all of the fric-
2 . Measure:
tion plates.
• Clutch plate 1, 2 thickness
1. Check:
(with a surface plate and thickness gauge)
• Friction plate 1, 2
Out of specification ➔ Replace the clutch
Damage/wear ➔ Replace the friction plates
plates as a set.
as a set.
2. Measure:
Thickness gauge
• Friction plate 1, 2 thickness
90890-03268
Out of specification ➔ Replace the friction
Feeler gauge set
plates as a set. VU-2690().9
TIP_ _ _ _ _ _ _ _ _ _ _ _ __
Measure the friction plate at four places.
Clutch plate 1 thickness
2.18-2.42 mm (0.086-0.095 in)
Friction plate 1 thickness Warpage limit
2.92-3.08 mm (0.115-0.121 in) 0.10 mm (0.004 in)
Wear limit Clutch plate 2 thickness
2.82 mm (0.111 in) 1.90-2.10 mm (0.075-0.083 in)
Friction plate 2 thickness Warpage limit
2.92-3.08 mm (0.115-0.121 in) 0.10 mm (0.004 in)
Wear limit
2.82 mm (0.111 in) 3. Measure:
• Assembly width "a" of the friction plates and
clutch plates
Out of specification ➔ Adjust.

Assembly width
42.7-43.5 mm (1.68-1.71 in)

5-50
 CLUTCH

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Perfom, the thickness measurement without
applying the oil.
• This step should be perfomied only if the fric-
tion plates and clutch plates were replaced.
• To measure the total width of the f riction plates
and clutch plates, combine 9 friction plates and
8 clutch plates as shown.

EAS30051
CHECKING THE CLUTCH SPRINGS
The following procedure applies to all of the
clutch springs.
1. Check:
• Clutch spring
Damage ➔ Replace the clutch springs as a
set.
a. Assembly width adjusted by c'.lutch plate 2 2. Measure:
"1" and "2". • Clutch spring free length
b. Select the clutch plate 2 from the following Out of specification ➔ Replace the clutch
table. springs as a set.

Clutch plate 2 "1" Clutch spring free length limit

B R9-16324-00 1.6 mm (0.063 in) 42.53 mm (1.67 in)
SVY-16325-00 2.0 mm (0.079 in) STD EAS30<!!!0

4B1-16325-00 2.3 mm (0.091 in) CHECKING THE CLUTCH HOUSING

1. Check:
• Clutch housing dogs
Clutch plate 2 "2" Damage/pitting/wear ➔ Deburr the clutch
BR9-16324-00 1.6 mm (0.063 in) housing dogs or replace the clutch housing.
SVY-16325-00 2.0 mm (0.079 in) STD TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
4B1 -16325-00 2.3 mm (0.091 in) Pitting on the clutch housing dogs will cause er-
ratic clutch operation.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
When adjusting the clutch assembly width [by
replacing the clutch plate(s)J, be sure to replace
the clutch plate 2 "1" first.
After replacing the clutch plate 2 "1 ", it specifica-
tions cannot be met, replace the clutch plate 2
lf
"2".

G088994

2. Check:
• Oil pump drive sprocket "1"
Cracks/damage/wear ➔ Replace the oil
pump drive chain and clutch housing as a set.

5-51
 CLUTCH

EAS300l57
CHECKING THE PRIMARY DRIVEN GEAR
1
1. Check:
• Primary driven gear
Damage/wear ➔ Replace the clutch housing
and crankshaft as a set.
Excessive noise during operation ➔ Replace
the clutch housing and crankshaft as a set.
,..,_
CHECKING THE PULL LEVER SHAFT AND
3. Check: PULL ROD
1. Check:
• Bearing
Damage/wear ➔ Replace the bearing and • Pull lever shaft pinion gear teeth
clutch housing. • Pull rod teeth
Damage/wear ➔ Replace the pull rod and
EAS3Cl<ll!3 pull lever shaft as a set.
CHECKING THE CLUTCH BOSS 2. Check:
1. Check: • Pull rod bearing
• Clutch boss splines Damage/wear ➔ Replace.
Damage/pitting/wear ➔ Replace the clutch
boss. EAS30003

TIP_ _ _ _ _ _ _ _ _ _ _ _ __ INSTALLING THE CLUTCH

1. Install:
Pitting on the clutch boss splines will cause er- • Oil pump drive chain "1 •
rati c clutch operation.
• Clutch housing "2"
TIP_ _ _ _ _ _ _ _ _ _ _ _ __

lf Install the oil pump drive chain onto the oil pump
drive sprocket "a".

'QJV
·cf✓
,,•
G088995

EA""""
CHECKING THE PRESSURE PLATE
1. Check:
..-T..~-:i\._ •
,,Q/
• Pressure plate 1
2. Install:
• Pressure plate 2
• Thrust plate
Cracks/damage ➔ Replace.
• Clutch boss "1"
• Bearing
• Washer
Damage/wear ➔ Replace.
• Conical spring washer "2"
EAS3Cl<ll!O
CHECKING THE PRIMARY DRIVE GEAR
• Clutch boss nut "3" Im
1. Check:
Clutch boss nut
• Primary drive gear 125 N,m (12.5 kgf-m, 92 lb,ft)
Damage/wear ➔ Replace the crankshaft and
clutch housing as a set.
Excessive noise during operation ➔ Replace
the crankshaft and clutch housing as a set.

5-52
 CLUTCH

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Install the conical spring washer on the main
axle with the "OUT' mark "a" facing away from
the vehicle.
• While holding the clutch boss "1" with the uni-
versal clutch holder "4", tighten the clutch boss
nut.
• Stake the clutch boss nut at cutouts "b" in the
main axle.
4. Install:
Clutch holder • Pull rod
90890-04199 • Pressure plate 2
Universal clutch holder • Clutch spring
YM-91042 • Pressure plate 1
• Clutch spring bolt "1"

Clutch spring bolt

10 N•m (1.0 kgf•m, 7.4 lb•ft)

• Oil pump driven sprocket "2"

Oil pump driven sprocket bolt

15 N•m (1.5 kgf•m, 11 lb•ft)
LOCTITE®

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Tighten the clutch spring bolts in stages and in
a crisscross pattern.
• Apply lithium-soap-based grease onto the pull
rod.
• Position the pull rod so that the teeth "a" face
towards the hole "b". Then, install the clutch
cover.

3. Install:
• Clutch damper spring seat
• Clutch damper spring
• Friction plate 2
• Clutch plate 2
• Friction plate 1
• Clutch plate 1
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• First, install a friction plate and then alternate
between a clutch plate and a friction plate.
• Install the last friction plate "1" offset from the
other friction plates "2", making sure to align a
projection on the friction plate witln the punch
mark "a" on the clutch housing.

5-53
 CLUTCH

5. Install: 7. Connect:
• Dowel pin • Clutch cable "1"
• Clutch cover gasket Gm TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Clutch cover • For the clutch cable "1", turn the nut "2" in fully
• Cover and then adjust the length "a" by using the nut
"3" so that the cable length is 47.1-54.8 mm
Clutch cover bolt (1 .85-2.16 in).
12 N•m (1.2 kgf•m, 8.9 lb•ft) • Measure the length while keeping the measur-
ing surface "b" parallel.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• After installing the clutch cable, bend the pro-
• Apply engine oil onto the bearing. jection "c" on the pull lever.
• Tighten the clutch cover bolts in stages and in
a crisscross pattern.
6. Install:
• Pull lever
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Install the pull lever with the "O" mark facing to-
ward lower side.
• When installing the pull lever, push the pull le•
ver and check that the punch mark "a" on the
pull lever aligns with the mark "b" on the clutch
cover. Make sure that the pull rod teeth and 8. Adjust:
pull lever shaft pinion gear are engaged. • Clutch lever free play
Refer to "ADJUSTING THE CLUTCH LEVER
FREE PLAY'' on page 3· 12.

Clutch lever free play

10.0-15.0 mm (0.39-0.59 in)

5-54
 SHIFT SHAFT

EA""""7

SHIFT SHAFT
Removing the shift shaft and stopper lever

~
I~
I' 13 ~
mm

z
1mm

Order Job/Parts to remove Q'ty Remarks

Clutch assembly Refer to "CLUTCH' on page 5-45.
Shift arm Refer to "CHAIN DRIVE' on page 4-86.
Circlip
2 Washer
3 Shift shaft
4 Washer
5 Circlip
6 Washer
7 Stopper lever
8 Stopper lever spring
9 Collar
10 Shift shaft spring
11 Shift shaft spring stopper
12 Oil seal
13 Bearing

5-55
 SHIFT SHAFT

EAS30077
2. Install:
CHECKING THE SHIFT SHAFT
• Bearing
1. Check:
• Shift shaft •Oilsealml!I
Bends/damage/wear ➔ Replace. • Washer "1"
• Shift shaft spring • Circlip "2" m1!J
• Collar TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Damage/wear ➔ Replace. Lubricate the oil seal lips with lithium-soap-
...,_
CHECKING THE STOPPER LEVER
based grease.

1. Check:
• Stopper lever
Bends/damage ➔ Replace.
Roller turns roughly ➔ Replace the stopper
lever.
EA"""81
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)
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.

5-56
 OIL PUMP

..OIL
.,..,..
PUMP
Removing the oil pump

~
, ......_ ,
C
>

4, 10 N-m (1.0 kgf•m, 7.4 lb-11)

Order Job/Parts to remove Q'ty Remarks

Clutch cover Refer to "CLUTCH' on page 5-45.
Oil pump driven sprocket
2 Oil pump assembly

5-57
 OIL PUMP

Disassembling the oil pump

I✓.,j 3.8 N-m (0.38 kgf-m, 2.8 lb-ft) !

1

Order Job/Parts to remove Q'ty Remarks

1 Oil pump cover
2 Oil pump shaft
3 Pin
4 Oil pump inner rotor
5 Oil pump outer rotor
6 Washer
7 Spring
8 Relief valve
9 Dowel pin 2

5-58
 OIL PUMP

EAS3Cl006
CHECKING THE SPROCKET AND CHAIN
1. Check:
• Oil pump drive sprocket
Refer to "CHECKING THE CLUTCH HOUS-
ING" on page 5-51.
2. Check:
• Oil pump drive chain
Damage/stiffness ➔ Replace the oil pump
drive chain and oil pump drive sprocket
(clutch housing) as a set.
EA""""7 ASSEMBLINIG THE OIL PUMP
CHECKING THE OIL PUMP 1. Lubricate:
1. Check: • Inner rotor
• Oil pump driven sprocket • Outer rotor
Cracks/damage/wear ➔ Replace the oil • Oil pump shaft
pump drive chain and oil pump driven sprock-
et as a set. Recommended lubricant
• Oil pump housing Engine oil
• Oil pump cover
• Oil pump shaft 2. Install:
• Oil pump inner rotor • Outer rotor "1"
• Oil pump outer rotor • Inner rotor "2"
Cracks/damage/wear ➔ Replace the oil • Pin "3"
pump assembly. • Oil pump cover "4"
2. Check: • Oil pump cover screw
• Oil pump operation
Rough movement ➔ Replace the oil pump Oil pump cover screw
assembly. 3.8 N-m (0.38 kgf-m, 2.8 lb-ft)

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Align the pin "3" in the oil pump shaft with the
groove in the inner rotor "2''.

G088997

CHECKING THE RELIEF VALVE

1. Check:
• Relief valve "1"
• Spring "2" 3. Check:
Damage/wear ➔ Replace the oil pump as- • Oil pump operation
sembly. Refer to "CHECKING THE OIL PUMP" on
page 5-59.

5-59
 OIL PUMP

EAS30043
INSTALLING THE OIL PUMP
1. Install:
• Oil pump "1"
• Oil pump bolt "2"

Oil pump bolt

10 N•m (1.0 kgf•m, 7.4 lb•ft)

• Oil pump driven sprocket "3"

Oil pump driven sprocket bolt

15 N•m (1.5 kgf•m, 11 lb•ft)
LOCTITE®

NOTICE
------------
After installing the oil pump drive chain and
driiven sprocket, make sure the oil pump
turns smoothly.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• 1 RC mark of the oil pump driven sprocket is in-
stalled at oil pump side.
• Install the oil pump drive chain onto the oil
pump driven sprocket.

j . o~.,. ~

>0
- . 2
./ , .

5-60
 OIL PAN

EAS,0,77

OIL PAN
Removing the oil pan

I.
• I
ec:y--
mm
•

',, 13 ~m (1.3 kglm, 9.6 lb-It) /, 10 N-m (1.0 kgl-m, 7.4 lb-It) --',. 10 ~ (1.0 kgl-m, 7.4 lb-It)

Order Job/Parts to remove Q'ty Remarks

Muffler assembly Refer to "ENGINE REMOVAL" on page 5-:9.
Drain.
Engine oil Refer to "CHANGING THE ENGINE OIL" on
page 3-28.
Oil pan
2 Oil pan gasket
3 Oil strainer

5-61
 OIL PAN

EAS310G8

REMOVING THE OIL PAN

1. Remove:
• Oil pan
• Oil pan gasket
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Loosen each bolt 1/4 of a tum at a time, in stag-
es and in a crisscross pattern. After all of the
bolts are fully loosened, remove them.

EAS310G9

CHECKING THE OIL STRAINER

1. Check:
• Oil strainer
Damage ➔ Replace.
Contaminants ➔ Clean with solvent.
EAS31070

INSTALLING THE OIL PAN

1. Install:
• Oil pan gasket bi¥1
• Oil pan

Oil pan bolt

13 N-m (1.3 kgf•m, 9.6 lb-ft)
LOCTITE®

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Tighten the oil pan bolts in stages and in a criss-
cross pattern.
2. Install:
• Gasket Gm
• Engine oil drain bolt

Engine oil drain bolt

43 N-m (4.3 kgf•m, 32 lb-ft)

5-62
 CRANKCASE
..CRANKCASE
.,.,.,,.

Separating the crankcase

1st 25 N-m (2.5 kgf-m, 18 lb-It)
", , 20 N-m (2.0 kgf,m, 15 lb-It)
1st 25 N-m (2.5 kgf-m, 18 lb-It) 20
ed angle so•
,,,._ , d 16 N,m (1.6 kgf,m, 12 lb-It)
2 (2.2 kgf-m, 16 lb-It)
n Specified angle so•
.8 N-m (0.18 kgf-m, 1.3 lb~)

13 N-m (1.3 kgl-m, 9.6 lb-It)

·\ 10 N-m (1.0 kgf-m, 7.4 lb-It)

.·, 70 N-m (7.0 kgf-m, 52 lb•ft)

"• 17 N-m (1.7 kgf-m, 13 lb•ft)

• Following the tightening order, loosen the bolt one by one, and then reti ghten it to the specific torque and the
~ecified angle.
YAMAHA Bond No. 1215B®
Order Job/Parts to• remove Q'ty Remarks
Engine Refer to "ENGINE REMOVAL" on page 5-·9.
Cylinder head Refer to "CYLINDER HEAD" on page 5-26.
Water pump Refer to "WATER PUMP" on page 6-1 1.
Oil cooler Refer to "OIL COOLER'' on page 6-7.
Water jacket joint Refer to "OIL COOLER'' on page 6-7.
Thermostat assembly Refer to "THERMOSTAT" on page 6-9.
Refer to "GENERATOR ANO STARTER
Starter clutch
CLUTCH" on page 5-36.

Starter motor Refer to "ELECTRIC STARTER" on page 5-

41.
Clutch housing Refer to "CLUTCH" on page 5-45.
Oil strainer Refer to "OIL PAN" on page 5-61.

5-63
 CRANKCASE

Se parating the crankcase

~ 10 N,m (1.0 kgf,m, 7.4 lb-It) 1st 25 N,m (2.5 kgf,m, 18 lb-It)
.t, • 20 N,m (2.0 kgf,m, 15 lb-It)
1st 25 N,m (2.5 kgf,m, 18 lb-It) 2
n Specified angle so•
':<_ , d 16 N,m (1.6 kgf,m, 12 lb-It)
2
n Specified angle so• ! (2.2 kgf,m, 16 lb-It) !
,; 10 ~m (1.0 kgf,m, 7.4 lb-It) I~ 8 N,m (0.18 kgf-m, 1.3 lb
. .
✓~ 24 ~m (2.4 kgf-m, 18 lb-It)
4
0 1
3N,m 1.3
\ ' - - " - - - - . . _ ~ . _ _ - ' - - - ~'-'

1**

8 (1.0 kgf,m, 7.4 lb-It)

.<, 12 N,m (1.2 kgf-m, 8.9 lb•lt)

~. 4.0 N,m (0.40 kgf-m, 3.0 lb•ft "• 17 N,m (1.7 kgf,m, 13 lb•ft)

• Followi ng the tightening order, loosen the bolt one by one, and then retighten it to the specific torque and th e
~ecified angle.
YAMAHA Bond No. 12158®
Order Job/Parts to• remove Q'ty Remarks
1 Oil filter cartridge
2 Oil filter cartridge union bolt
3 Oil pressure switch
4 Oil pressure switch joint
5 Gear posttion sensor
6 Neutral switch
7 Clutch cable holder
8 Lower crankcase
9 Dowel pin 3

5-64
 CRANKCASE
EAS3Cl<l89 EAS30000
DIS ASSEMBLING THE CRANKCASE CHECKING THE CRANKCASE
1. Place the engine upside down. 1. Thoroughly wash the crankcase halves in a
2. Remove: mild solvent.
• Crankcase bolt (x31) 2. Thoroughly clean all the gasket surfaces and
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ crankcase mating surfaces.
• Loosen each bolt 1/4 of a turn at a time, in stag- 3. Check:
es and in a crisscross pattern. After all of the • Crankcase
b olts are fully loosened, remove them. Cracks/da mage ➔ Replace.
• Loosen the bolts in the proper sequence as • Oil delivery passages
shown. Obstruction ➔ Blow out with compressed a ir.
• The numbers embossed on the crankcase in- EAS30007
dicate the crankcase tightening sequence . ASSEMBLIIIIG THE CRANKCASE
1. Lubricate:
• Crankshaft journal bearing inner surface
(with the recommended lubricant)

Recommended lubricant
Engine oil

2. Apply;
• Sealant
(onto the crankcase mating surfaces)

Yamaha bond No. 1215

90890-85505
Three bond No. 121 5®

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Do not allow any sealant to come into contact
with the oil gallery or crankshaft journal bear-
ings, or balancer shaft journal bearings.
[i;J • Make sure that the sealant does not get into
the groove "a" in the crankcase.
3. Remove:
• Lower crankcase
ECA13900

NOTICE
-------------
Ta;p on one side of the crankcase with a soft-
face hammer. Tap only on reinforced por-
tions of the crankcase, not on the crankcase
mating surfaces. Work slowly and carefully
and make sure the crankcase halves sepa-
rate evenly.
4. Remove:
• Dowel pin
5. Remove:
• Crankshaft journal lower bearing
• Balancer shaft journal bearing
(from the lower crankcase)
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Identify the position of each part very carefully so
that it can b e reinstalled in its original place.

5-65
 CRANKCASE

3. Install:
• Dowel pin
4. Set the shift drum assembly and transmission
gears in the neutral position. 19 20 21 25
24
5. Install: 15 ~ 22~ 23-
• Lower crankcase "1" - =9 1 12
...
(onto the upper crankcase "2") 11
ECA13980
5
NOTICE
------------
Before tightening the crankcase bolts, make p
sure the transmission gears shift correctly
when the shift drum assembly is turned by
6
hand.

7. Tighten:
• Crankcase bolt "1 "- "8"

Crankcase bolts "1 "-"6"

6. Install: 1st: 25 N,m (2.5 kgf,m, 18 lb,ft)
• Crankcase bolt (x31) "'2nd: 16 N,m (1.6 kgf,m, 12 lb,ft)
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ Specified angle 60°
• Lubricate the bolts "1 "- "8" thread, mating sur- Crankcase bolts "7"-"8"
faces and washers with engine oil. 1st: 25 N,m (2.5 kgf,m, 18 lb,ft)
• Lubricate the bolts "9"- "12" thread, mating sur- "'2nd: 20 N,m (2.0 kgf,m, 15 lb,ft)
faces and O-rings with engine oiL Specified angle 60°
• Lubricate the bolts "13"- "31" thread and mat- • Following the tightening order, loosen the
ing surfaces with engine oil. bolt one by one and then retighten it to the
• M9 x 100 mm (3.94 in) bolt with washer: "7', specified t orque and the specified angle.
E\VA1156"10
"B" mm!I ~ WARNING
• M9 x 85 mm (3.35 in) bolt with w asher: "1"-
If the bolt is tightened more than the speci -
"6" mm!I fied angle, do not loosen the bolt and then re-
• MB x 78 mm (3.07 in) bolt with new O- ring: tighten it. Instead, replace the bolt with a new
"9"- "12" one and perform the procedure again.
• MB x 60 mm (2.36 in) bolt: "13", "14"
• MG x 85 mm (3.35 in) bolt: "18"
NOTICE
•
•
MG x 65 mm (2.56 in)
MG x 65 mm (2.56 in)
bolt:
bolt:
"15", "16"
"26"
------------
Do not use a torque wrench to tighten the
• MG x 50 mm (1.97 in) bolt: "17', "19"- ''21", bolt to the specified angle.
"23"-"25", "27"- "31" TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• MG x 40 mm (1.57 in) bolt: "22"
Tighten the bolts in the tightening sequence cast
on the crankcase.

5-66
 CRANKCASE
EAS310T1

INSTALLING THE OIL PRESSURE SWITCH

1. Install:
• Oil pressure switch "1"

~~~
• Oil pressure switch lead "2"

Oil pressure switch

13 N-m (1.3 kgf-m, 9.6 lb•ft)
Oil pressure switch lead bolt
~ 1.8 N-m (0.18 kgf-m, 1.3 lb•ft)
.. TIP_ _ _ _ _ _ _ _ _ _ _ _ __

1- ?~ ---t'~~ ~ ...-:=f • Apply Three Bond No. 1215B® to the threads

"a" of the oil pressure switch. However, do not
apply Three Bond No. 1215B® to the portion
"b" of the oil pressure switch.
• Install the oil pressure switch lead so that it is
routed within the range shown in the illustra-
tion.

8. Tighten:
• Crankcase bolt "9"- "31"

Crankcase bolts "9"-"12"

22 N-m (2.2 kgf-m, 16 lb•ft)
Crankcase bolts "13"-"14"
24 N-m (2.4 kgf-m, 18 lb•ft)
Crankcase bolts "15"-"31 "
10 N-m (1.0 kgf-m, 7.4 lb•ft)
TIP_ _ _ _ _ _ _ _ _ _ _ _ __
Tighten the bolts in the tightening sequence cast
on the crankcase.

5-67
 CRANKCASE

INSTALLING THE GEAR POSITION SENSOR

NOTICE
------------
To prevent damage to the gear position sen-
so:r, keep magnets (including any pickup tool
with a magnet, magnetized screwdrivers,
etc.) away from the gear position sensor.
1. Install:
• 0 -ring effl'J
• Gear position sensor "1"

Gear position sensor !bolt

4.0 N•m (0.40 kgf,m, 3.0 lb,ft)
LOCTITE®

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Lubricate the 0 -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".

5-68
 CONNECTING RODS AND PISTONS

..CONNECTING
.,.,.,
RODS AND PISTONS
Removing the connecting rods and pistons
,. 1st 20 ~m (2.0 kgf-m, 15 lb-ft)
· 2nd Specified angle 1so·

, / 7

mm
m 3

01 .,
4
mm a
9
8

Order Job/Parts to remove Q'ty Remarks

Lower crankcase Refer to "CRANKCASE" on page 5-63.
1 Connecting rod cap 3
2 Big end lower bearing 3
3 Piston pin clip 6
4 Piston pin 3
5 Piston 3
6 Connecting rod 3
7 Big end upper bearing 3
8 Top ring 3
9 2nd ring 3
10 Oil ring 3

5-69
 CONNECTING RODS AND PISTONS

EAS,0,40
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
REMOVING THE CONNECTING RODS AND
PISTONS When removing a piston ring, open the end gap
The following procedure applies to all of the con- with your fingers and lift the other side of the ring
necting rods and pistons. over the piston crown.
1. Remove:
• Connecting rod cap
• Connecting rod
• Big end bearing
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Identify the position of each big end bearing so
that it can be reinstalled in its original place.
• After removing the connecting rods and con-
necting rod caps, care should be taken not to
G088999
damage the mating surfaces of the connecting
rods and connecting rod caps. EAS.10747

CHECKING THE CYLINDER AND PISTON

2. Remove:
1. Check:
• Piston pin clip • Piston walll
• Piston pin "1"
• Cylinder wall
• Piston "2"
ECA13810
Vertical scratches ➔ Replace the cylinder,
NOTICE and replace the piston and piston rings as a
-------------
Do not use a hammer to drive the piston pin
set.
2. Measure:
out.
• Piston-to-cylinder clearance
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ a. Measure cylinder bore "C" with the cylinder
• For reference during installation, put identifica- bore gauge.
tion marks on the piston crown. TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Before removing the piston pin, deburr the pis- Measure cylinder bore "C" by taking side-to-side
ton pin clip groove and the piston pin bore ar- and front-to-back measurements of the cylinder.
ea. If both areas are deburred and the piston
pin is still difficult to remove, remove it with the
piston pin puller set "3". Bore
78.000-78.010 mm (3.0709-
3.0713 in)
Piston pin puller set Wear limit
90890-01304 78.060 mm (3.0732 in)
Piston pin puller
YU-01304

G088998
G089000
3. Remove:
b. If out of specification, replace the cylinder,
• Top ring
and replace the piston and piston rings as a
• 2nd ring
set.
• Oil ring

5-70
 CONNECTING RODS AND PISTONS

c. Measure piston skirt diameter "b" with the

micrometer.

Piston
Diameter
77.975-77.990 mm (3.0699--
3.0705 in)

G089002

2. Install:
a • Piston ring
(into the cylinder)
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Use the piston crown to level the piston ring near
bottom of cylinder, where cylinder wear is low-
G089001 est.
a. 9.0 mm (0.35 in) from the bottom edge of the 3. Measure:
piston
• Piston ring end gap
d. If out of specification, replace the piston and Out of specification ➔ Replace the piston
piston rings as a set. ring.
e. Calculate the piston-to-cylinder clearance TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
with the following formula. The oil ring expander spacer's end gap cannot
Piston-to-cylinder clearance = Cylinder bore be measured. If the oil ring rail's gap is exces-
"C" - Piston skirt diameter "b" sive, replace all three piston rings.

Top ring
Piston-to-cylinder clearance
End gap limit
0.010-0.035 mm (0.0004-0.0014 0.50 mm (0.0197 in)
in) 2nd ring
I. If out of specification, replace the cylinder, End gap limit
and replace the piston and piston rings as a 1.15 mm (0.0453 in)
set.
EAS,0,48

CHECKING THE PISTON RINGS

1. Measure:
• Piston ring side clearance
Out of specification ➔ Replace the piston
and piston rings as a set.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Before measuring the piston ring side clearance,
G089003
eliminate any carbon deposits from the piston
ring grooves and piston rings. a. Bottom of cylinder
b. Upper of cylinder

Top ring
Side clearance limit
0.115 mm (0.0045 in)
2nd ring
Side clearance limit
0.115 mm (0.0045 in)

5-71
 CONNECTING RODS AND PISTONS

EAS307l!O
CHECKING THE PISTON PIN CHECKING THE CONNECTING RODS
The following procedure applies to all of the pis- 1. Measure:
ton pins. • Crankshaft-pin-to-big-end-bearing cl ea ran ce
1. Check: Out of specification ➔ Replace the big end
• Piston pin bearings.
Blue discoloration/grooves ➔ Replace the
piston pin and then check the lubrication sys- Oil clearance
tem. 0.027-0.051 mm (0.0011-0.002.0
2. Measure: in)
• Piston pin outside diameter "a"
Out of specification ➔ Replace the piston pin. The following procedure applies to all of the con-
necting rods.
ECA13930
Piston pin outside dia meter limit
16.970 mm (0.6681 in)
NOTICE
-------------
Do not interchange the big end bearings and
connecting rods. To obtain the correct
crankshaft-pin-to-big-end-bearing clear-
ance and prevent engine damage, the big
end bearing.s must be installed in their origi-
nal positions.

a. Clean the big end bearings, crankshaft

pins, and the inside of the connecting rods
halves.
G089004 b. Install the big end upper bearing into the
3. Measure: connecting rod and the big end lower bear-
• Piston pin bore inside diameter "b" ing into the connecting rod cap with the
Out of specification ➔ Replace the piston. connecting rod big end metal installer "1 ".
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Piston pin bore inside diameter • From the 3 types, choose the connecting rod
limit big end metal installer "1" that fits exactly, and
17.043 mm (0.6710 in) install it to the connecting rod and connecting
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.

Connecting rod big end bearing

installer
90890-04193
Connecting rod big end bearing
installer
YM-04193

5-72
 CONNECTING RODS AND PISTONS

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• 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.

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Install by carrying out the following procedures in
order to assemble in the most suitable condition.
e. Tighten the connecting rod bolt while
1 checking that the sections shown "a" and
"b" are flush with each other by touching the
2 surface.

c. Put a piece of Plastigauge® "1" on the Connecting rod bolt

crankshaft pin. 30 N-m (3.0 kgf-m, 22 lb•ft)

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
To install the big end bearing, care should be
taken not to install it at an angle and the position
should not be out of alignment.

G089008

d. Assemble the connecting rod halves. b

ECA18390

NOTICE
-------------
Tighten the connecting rod bolts using the
plastic-region tightening angle m ethod. Al·
ways install new bolts.
a. Side machined face
b. Thrusting faces

5-73
 CONNECTING RODS AND PISTONS

f. Loosen the connecting rod bolt, remove the

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- E\VAU!&"IO

necting rod cap faces the same direction as the _..WARNING

"Y" mark "b" on the connecting rod . If the bolt is tightened more than the speci -
• Make sure the "Y" marks "b" on the connecting fied angle, do not loosen the bolt and then re-
rods face towards the left side of the crank- tighten it. Instead, replace the bolt with a new
shaft. one and perform the procedure again.

NOTTCE - - - - - - - - - - : - - - - : - -
Do not use a torque wrench to tighten the
bolt to the specified angle.
j. After the installation, check that the section
shown "a" is flush with each other by touch-
ing the surface.
a

g. Tighten the connecting rod bolts with a

torque wrench.

Connecting rod bolt (1st)

20 N-m (2.0 kgf-m, 15 lb•ft)

h. Put a mark "1" on the corner of the connect-

ing rod bolt "2" and the connecting rod cap ,,...._
"3". k. Remove the connecting rod and big end
bearings.
I. Measure the compressed Plastigauge®
width "e" on the crankshaft pin. If the crank-
shaft-pin-to-big-end-bearing clearance is
out of specification, select replacement big
end bearings.
/

i. Tighten the connecting rod bolts further to

reach the specified angle 180° .

Connecting rod bolt (final)

Specified angle 180°
G089010

5-74
 CONNECTING RODS AND PISTONS

2. Select:
• Big end bearing (P1-P3)
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.
• "P i"- "P3" refer to the bearings shown in the
crankshaft illustration.
For example, if the connecting rod "Pi" and EAS30m

the crankshaft web "Pi" numbers are 5 and 2 INSTALLING THE CONNECTING ROD AND
respectively, then the bearing size for "Pi" is: PISTON
The following procedure applies to all of the con-
"P1" (connecting rod) - "Pi" (crankshaft)= 5 - 2 necting rods and pistons.
= 3 (brown) 1. Install:
• Big end bearing
• Connecting rod cap
Bearing color code (onto the connecting rod)
Code1 TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Blue
Code 2 • Be sure to reinstall each big end bearing in its
Black original place.
Code 3 • From the 3 types, choose the connecting rod
Brown big end metal installer "1" that fits exactly, and
Code4 install it to the connecting rod and connecting
Green rod cap as shown in the illustration.
• Align the projections "a" on the big end bear-
ings with the notches "b" in the connecting rods
and connecting rod caps.
• Push the big end bearing "2" down and install it
to the connecting rod and connecting rod cap.
• Make sure that the projection "d' on the con-
necting rod cap faces the same direction as the
''Y" mark "d" on the connecting rod.

Connecting rod big end bearing

installer
9 0890-04193
Connecting rod big end bearing
installer
V M-04193

5-75
 CONNECTING RODS AND PISTONS

"b" are flush with each other by touching th e

surface.

Connecting rod bolt

30 N•m (3.0 kgf •m, 22 lb•ft)

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
To install the big end bearing, care should be
taken not to install it at an angle and the position
should not be out of alignment.

1 b

a. Side machined face

b. Thrusting faces
e. Loosen the connecting rod bolt, remove the
connecting rod and connecting rod cap and
install these parts to the crankshaft with the
big end bearing kept in the current condi -
C tion.
3. Install:
2. Tighten: • Oil ring expander "1"
• Connecting rod bolt e?ffl • Lower oil ring rail "2"
ECA18'90 • Upper oil ring rail "3"
NOTICE
-------------
Tighten the connecting rod bolts using the
• 2nd ring "4"
• Top ring "5"
plast.io-region tightening angle m ethod. Al· (into the piston)
ways install new bolts. TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ Be sure to install the piston rings so that the
manufacturer's marks or numbers "a" face up.
Install by carrying out the following procedures in
order to assemble in the most suitable condition.

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-
denum disulfide oil.
c . After installing the big end bearing, assem-
ble the connecting rod and con necting rod
cap without installing them ont o the crank-
shaft.
d . Tighten the connecting rod bolt while
checking that the sections shown "a" and

5-76
 CONNECTING RODS AND PISTONS

4. Install: 6. Offset:
• Piston "1" • Piston ring end gap
(onto the respective connecting rod "2")
~
• Piston pin "3" go•
• Piston pin clip "4" ml!I
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Apply engine oil onto the piston pin.
• Make sure that the "Y" mark "a" on the connect- go•
ing rod faces left when the punch mark ''b" on
the piston is pointing up as shown.
• Make sure that the clip ends "c" are positioned
away from the cutout "d" in the piston as shown
a. Top ring
in the illustration.
b. 2nd ring
• Reinstall each piston into its original cylinder.
C. Upper oil ring rail
d. Oil ring expander
e. Lower oil ring rail

2 A. Exhaust side
1
7. Lubricate:
• Crankshaft pin
• Connecting rod big end bearing inner surface
(with the recommended lubricant)
mffl40
G08901 3 Recommended lubricant
Engine oil

8. Install:
• Piston assembly "1"
(into the cylinder "2" and onto the crankshaft
pin)

Piston installing tool

90890-04161
Piston installing tool
5. Lubricate: VM-04161
• Piston ECA21490
• Piston ring NOTICE
• Cylinder -------------
1f the projection "a" of the piston installing
(with the recommended lubricant) tool damages, you cannot use it. Please han-
dle with care.
Recommended lubricant
Engine oil TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Fit the projection "a" of the piston installing tool
"3" and blunt-edged part "b" of the cylinder, fix
the position of the piston installing tool, and then
push the piston up to the cylinder.

s-n
 CONNECTING RODS AND PISTONS

9. Install:
c. Tighten the connecting rod bolts further to
• Connecting rod cap
reach the specified angle 180°.
• Connecting rod bolt
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Connecting rod bolt (final)
• Make sure the "Y" marks "a" on the connecting Specified angle 180°
rods face towards the left side of the crank-
shaft.
• Make sure that the projection "b" on the con-
necting rod cap faces the same direction as the
"Y" mark "a" on the connecting rod .
• Apply Molybdenum disulfide oil to the bolt
threads and seats.

EWA11!&10

.4.WARNING
If the bolt is tightened more than the speci -
fied angle, do not loosen the bolt and then re-
b tighten it. Instead, replace the bolt with a new
one and perform the procedure again.

10. Tighten:
• Connecting rod bolt
NOTICE
-------------
Do not use a torque wrench to tighten the
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ bolt to the specified angle.
Tighten the connecting rod bolts using the fol-
d. After the installation, check that the section
lowing procedure.
shown "a" is flush with each other by touch-
a. Tighten the connecting rod bolts with a ing the surface.
E\VA17120
torque wrench.
.4.WARNING
Connecting rod bolt (ilst) If the connecting rod and cap are not flush
20 N-m (2.0 kgf-m, 15 lb-ft) with each other, remove the connecting rod
bolts and big end bearing and restart from
b. Put a mark "1" on the corner of the connect- step (1 ). In this case, make sure to replace
ing rod bolt "2" and the connecting rod cap the connecting rod bolts.
"3".

5-78
CONNECTING RODS AND PISTONS

5-79
 CRANKSHAFT AND BALANCER SHAFT

...,.,,.
CRANKSHAFT AND BALANCER SHAFT
Removing the crankshaft and balancer shaft

Order Job/Parts to remove Q'ty Remarks

Lower crankcase Refer to "CRANKCASE" on page 5-63.
Refer to "REMOVING THE CONNECTING
Connecting rod
RODS AND PISTONS" on page 5-70.
Balancer shaft
2 Balancer shaft journal lowe r bearing 2
3 Balancer shaft journal upper bearing 2
4 Crankshaft
5 Crankshaft journal lower bearing 4
6 Crankshaft journal upper bearing 4
7 Oil nozzle 3

5-80
 CRANKSHAFT AND BALANCER SHAFT

EAS31171
2. Check:
REMOVING THE CRANKSHAFT AND
• Crankshaft journal surfaces
BALANCER SHAFT
• Crankshaft pin surfaces
1. Remove:
• Bearing surfaces
• Balancer shaft "1"
Scratches/wear ➔ Replace the crankshaft.
• Balancer shaft journal bearing
3. Measure:
• Crankshaft assembly "2"
• Crankshaft-journal-to-crankshaft-joumal-
• Crankshaft journal bearing
bearing clearance
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Out of specification ➔ Replace the crank•
Identify the position of each balancer shaft jour- shaft journal bearings.
nal bearings and crankshaft journal bearings so
that it can be reinstalled in its original place. Journal oil clearance
0.013-0.037 mm (0.0005-0.0015
in)
ECA13920

NOTICE
-------------
Do not interchange the crankshaft journal
bearings. To obtain the correct crankshaft•
journal-to-crankshaft-journal-bearing clear-
ance and prevent engine damage, the crank•
shaft journa.l bearings must be installed in
their original positions.
EAS3U 74

CHECKING THE OIL NOZZLES a. Clean the crankshaft journal bearings,

The following procedure applies to all of the oil crankshaft journals, and bearing portions of
nozzles. the crankcase.
1. Check: b. Place the upper crankcase upside down on
• Oil nozzle a bench.
Damage/wear ➔ Replace the oil nozzle. c. Install the crankshaft journal upper bear-
• Oil passage ings "1" and the crankshaft into the upper
Obstruction ➔ Blow out with compressed air. crankcase.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
EAS31075

CHECKING THE CRANKSHAFT Align the projections "a" on the crankshaft jour-
1. Measure: nal upper bearings with the notches "b" in the up-
• Crankshaft runout per crankcase.
Out of specification ➔ Replace the crank-
shaft.

Runout limit
0.030 mm (0.0012 in)

G089019

d. Put a piece of Plastigauge® "1" on each

crankshaft journal.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Do not put the Plastigauge® over the oil hole in
G089017 the crankshaft journal.

5-81
 CRANKSHAFT AND BALANCER SHAFT

4. Select:
• Crankshaft journal bearing (J 1--J4 )
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• The numbers "A" stamped into the crankshaft
web and the numbers "B" stamped into the
lower crankcase are used to detem,ine the re-
placement crankshaft journal bearing sizes.
• "Ji"- "J/ refer to the bearings shown in the
crankshaft and lower crankcase illustration.
e. Install the crankshaft journal lower bearings For example, if the crankcase "Ji" and crank-
"1" into the lower crankcase and assemble shaft web "Ji" numbers are 7 and 2 respec-
the crankcase halves.
tively, then the bearing size for "Ji" is:
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Align the projections "a" of the crankshaft jour- "Ji" (crankcase) - "Ji" (crankshaft web) -1 = 7
- 2 - 1 = 4 (green)
nal lower bearings with the notches "b" in the
lower crankcase.
• Do not move the crankshaft until the clearance
measurement has been completed. Bearing color code
CodeO
White
Code 1
Blue
Code2
Black
Code3
Brown
Code4
Green

I. Tighten the bolts to specification in the tight-

ening sequence cast on the crankcase.
Refer to "CRANKCASE" on page 5·63.
g. Remove the lower crankcase and the
crankshaft journal lower bearings.
h. Measure the compressed Plastigauge®
width "a" on each crankshaft journal.
If the crankshaft-journal-to-crankshaft-jour-
nal-bearing clearance is out of specifica-
tion, select replacement crankshaft journal
bearings.

5-82
 CRANKSHAFT AND BALANCER SHAFT

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.
c. Install the balancer shaft journal upper
bearings "1" and the balancer shaft into the
upper crankcase.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Align the projections "a" on the balancer shalt
EAS31078

CHECKING THE BALANCER SHAFT journal upper bearings with the notches "b" in the
1. Measure: upper crankcase.
• Balancer shaft runout
Out of specification ➔ Replace the balancer
shaft.
1
Balancer shaft runout limit a
0.030 mm (0.001 2 in)
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
the balancer shaft journal.

2. Check:
• Balancer shaft journal surfaces
• Bearing surfaces
Scratches/wear ➔ Replace the balancer
shaft.
3. Measure:
• Balancer shaft journal-to-balancer shaft bear-
ing clearance
Out of specification ➔ Replace the balancer
shaft journal bearings.
~
e. Install the balancer shaft journal lower bear-
ings "1" into the lower crankcase and as-
Balancer shaft journal to balanc- semble the crankcase halves.
er shaft bearing clearance TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
0.023-0.047 mm (0.0009-0.0019
• Align the projections "a" of the balancer shaft
in)
journal lower bearings with the notches "b" in
ECA1&s00 the crankcase.
NOTICE
-------------
Do not interchange the balancer shaft jour-
• Do not move the balancer shaft until the clear-
ance measu rement has been completed.
na'I 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.

5-83
 CRANKSHAFT AND BALANCER SHAFT

Bearing color code

1 Code 1
Blue
a
Code2
b Black
Code3
Brown
Code4
G08901 9 Green
f. Tighten the bolts to specification in the tight- Codes
ening sequence cast on the crankcase. Re- Yellow
fer to "CRANKCASE" on page 5-63.
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
shaft journal bearings.

~~
a~

4. Select:
• Balancer shaft journal bearing (Jc--12)
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.
• "Ji"- "J2" refer to the bearings shown in the bal-
ancer shaft and lower crankcase illustration.
For example, if the crankcase "Ji" and bal-
ancer shaft web "Ji" numbers are 5 and 2 re•
spectively, then the bearing size for "Ji" is:
"J 1" (crankcase) - "J 1" (balancer shaft web) =
5 - 2 = 3 (brown)

5-84
 CRANKSHAFT AND BALANCER SHAFT

EA~1077
2. Install:
INSTALLING THE CRANKSHAFT
• Balancer shaft
1. Install:
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Crankshaft journal upper bearing
(into the upper crankcase) Install by aligning the crankshaft match mark "a"
• Crankshaft journal lower bearing and the balancer shaft match mark "b".
(into the lower crankcase)
• Crankshaft
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Align the projections "a" on the crankshaft jour-
nal bearings "1" with the notches "b" in the
cr ankcase.
• Be sure to install each crankshaft journal bear-
ings in its original place.

EA~1172
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
cr ankcases.
• Be sure to install each balancer shaft journal
bearing in its original place.

a
b

G089019

5-85
 TRANSMISSION

""""""'
TRANSMISSION

4~-
Removing the transmission, shift drum assembly, and shift forks
.< 12 N-m (1.2 kgf-m, 8.9 lb-

Order Job/Parts to remove Q'ty Remarks

Lower crankcase Refer to "CRANKCASE" on page 5-63.
Shift shaft Refer to "SHIFT SHAFT" on page 5-55.
Drive axle assembly
2 Oil seal
3 Bearing
4 Circlip
5 Washer
6 Shift drum retainer 2
7 Shift fork guide bar 2
8 Spring 4
9 Shift fork-L
10 Shift fork-A
11 Shift fork guide bar 1
12 Shift drum assembly
13 Shift fork-C

5-86
 TRANSMISSION

Removing the transmission, shift drum assembly, and shift forks

x 12 N-m (1.2 kgf-m, 8.91

~
- -. / " ' 16

.---')5
.5 N,m (0.05 kgf-m, 0.37

[\)~
- ~ \/
,,
',

a~ 1"' 110 N,m (1.0 kgf,m, 7.4 lb-11) 1

Order Job/Parts to remove Q'ty Remarks
14 Main axle assembly
15 Oil delivery pipe
16 O-ring
17 Oil nozzle
18 Bearing cover plate
19 Bearing

5-87
 TRANSMISSION

Disassembling the main axle assembly

5
6
. 7 \

\C)' .
•~ ~~ M

Order Job/Parts to remove Q'ty Remarks

1 2nd pinion gear
2 Toothed lock washer
3 Toothed lock washer retainer
4 6th pinion gear
5 Collar
6 Washer
7 Circlip
8 3rd pinion gear
9 Circlip
10 Washer
11 5th pinion gear
12 Collar
13 Bearing housing
14 Bearing
15 Main axle

5-88
 TRANSMISSION

Disassembling the drive axle assembly

Order Job/Parts to remove Q'ty Remarks

1 1st wheel gear
2 Collar
3 5th wheel gear
4 Circlip
5 Washer
6 3rd wheel gear
7 Collar
8 Toothed lock washer
9 Toothed lock washer retainer
10 4th wheel gear
11 Collar
12 Washer
13 Circlip
14 6th wheel gear
15 Circlip

5-89
 TRANSMISSION

Disassembling the drive axle assembly

Order Job/Parts to remove Q'ty Remarks

16 Washer
17 2nd wheel gear
18 Collar
19 Collar
20 Bearing
21 Circlip
22 Drive axle

5-90
 TRANSMISSION

EAS30430
REMOVING THE TRANSMISSION 2 4
1. Remove:
• Drive axle assembly "1"
3
• Shift drum retainer "2"
• Shift fork guide bar 2
• Spring
• Shift fork-L
• Shift fork-A
• Shift fork guide bar 1
• Spring
EAS30431
• Shift drum assembly
CHECKING THE SHIFT FORKS
• Shift fork-C
The following procedure applies to all of the shift
forks.
1. Check:
• Shift fork cam follower "1"
• Shift fork pawl "2"
Bends/damage/scoring/wear ➔ Replace the
shift fork.

2. Remove:
• Bearing housing "1"
• Main axle assembly "2" 2
a . Insert two bolts "3" of the proper size, as
shown in the illustration, into the main axle
assembly bearing housing.
2. Check:
• Shift fork guide bar 1
• Shift fork guide bar 2
2
Roll the shift fork guide bar on a flat surface.
Bends ➔ Replace.
EWAt2840

A WARNING
Do not attempt to straighten a bent shift fork
guide bar.
3
b. Tighten the bolts until they contact the 3. Check:
crankcase surface. • Shift fork movement
c . Continue tightening the bolts until the main (along the shift fork guide bar)
axle assembly comes free from the upper Rough movement ➔ Replace the shift forks
crankcase. and shift fork guide bar as a set.

3. Remove:
• Oil delivery pipe "1"
• Oil nozzle "2"
• Bearing cover plate "3"
• Bearing "4"

G089023

5-91
 TRANSMISSION

EAS30432
CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:
• 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- 3. Check:
sembly. • Transmission gear
Blue discoloration/pitting/wear ➔ Replace
the defective gear(s).
• Transmission gear dogs
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 (each pinion gear to its respective wheel
0.08 mm (0.0032 in) gear)
Incorrect ➔ Reassemble the transmission
axle assemblies.
5. Check:
• Transmission gear movement
Rough movement ➔ Replace the defective
part(s).
6. Check:
• Circlip
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)

5-92
 TRANSMISSION

EAS304a5
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
ASSEMBLING THE MAIN AXLE AND DRIVE
AXLE • With the toothed lock washer retainer in the
1. Install: groove "a" in the axle, align the projection on
• Toothed washer "1" the retainer with an axle spline, and then inst.all
the toothed lock washer.
• Circlip ''2" W3 • Be sure to align the projection on the toothed
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ lock washer that is between the alignment
• Be sure the circlip sharp-edged comer "a" is marks "b" with the alignment mark "cf' on the re-
positioned opposite side to the toothed washer tainer.
and gear.
• Align the opening between the ends "b" of the
circlip with a groove "cf' in the axle.
• Install the circlip so that a spline "d" is in the
center of the gap between the circlip ends "e"
as shown.

2 1

)&
a

A. Main axle
B. Drive axle
EAS30438
INSTALLING THE TRANSMISSION
1. Install:
• Bearing "1"
[ID
• Bearing cover plate "2"
• Oil nozzle "3"
• Oil delivery pipe "4"
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Face the seal side of bearing to the outside.
• Install beari:ng cover plate "2" with the "OUT'
mark "a" facing out.

A. Main axle Bearing cover plate screw

B. Drive axle 12 N-m (1.2 kgf-m, 8.9 lb•ft)
LOCTITE®
2. Install: Oil nozzle
• Toothed lock washer retainer "1" 0.5 N-m (0.05 kgf-m, 0.37 lb•ft)
• Toothed lock washer "2"

5-93
 TRANSMISSION

4. Install:
• Shift fork-A "1"
• Shift fork-L "2"
• Spring
• Shift fork guide bar 2
• Shift drum retainer "3"
• Bearing "4"
• Circlip "5" ml!!I
• Oil seal m!!I
• Drive axle assembly "6"
2. Install:
• Main axle assembly "1"
Shift drum retainer bolt
• Bearing housing "2" 10 N•m (1.0 kgf•m, 7.4 lb•ft)
LOCTITE®
Main axle bearing housing bolt
14 N•m (1.4 kgf•m, 10 lb•ft) TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
LOCTITE®
• Install shift fork-A into the groove "a" in the 5th
wheel gear and shift fork-L into the groove "b"
in the 6th wheel gear on the drive axle.
• Face the seal side of bearing "4" to the outside.
• Install the shift drum retainer with its "OUT"
mark "c" facing outward.
• Make sure that the projection "d" on the drive
axle assembly is inserted into the slot in the
crankcase.
• Make sure that the drive axle bearing circlips
"5" is inserted into the grooves "e" in the upper
3. Install: crankcase.
• Shift fork-C "1"
• Shift drum assembly "2"
• Spring
• Shift fork guide bar 1 "3"
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• The embossed marks on the shift forks should
face towards the right side of the engine and be
in the following sequence: "R", "C", "L".
• Carefully position the shift forks so that they
are installed correctly into the transmission
gears.
• Install shift fork-C into the groove "a" in the 3rd
pinion gear on the main axle.

5-94
 TRANSMISSION

5. Check:
• Transmission
Rough movement ➔ Repair.
TIP_ _ _ _ _ _ _ _ _ _ _ _ __
Oil each gear, shaft, and bearing thoroughly.

5-95
 COOLING SYSTEM

COOLING SYSTEM DIAGRAMS .................................................................... 6-1

RADIATOR ...................................................................................................... 6-3

CHECKING THE RADIATOR .................................................................... 6-5
INSTALLING THE RADIATOR .................................................................. 6-5

OIL COOLER ................................................................................................... 6•7

CHECKING THE OIL COOLER ................................................................ 6-8
INSTALLING THE O IL COOLER .............................................................. 6-8

THERMOSTAT ................................................................................................. 6-9

CHECKING THE THERMOSTAT............................................................ 6-10
INSTALLING THE TiHERMOSTAT ASSEMBLY ..................................... 6-10

WATER PUMP............................................................................................... 6-11

DISASSEMBLING THE WATER PUMP .................................................. 6-13
CHECKING THE WATER PUMP ............................................................ 6-13
ASSEMBLING THE WATER PUMP........................................................ 6-13

I
 COOLING SYSTEM DIAGRAMS

........
COOLING SYSTEM DIAGRAMS

1. Water pump
2. Thermostat
3. Radiator

6-1
 COOLING SYSTEM DIAGRAMS

1 2 3

4
1. Water jacket
2. Thermostat
3. Water pump
4. Oil cooler
5. Coolant reservoir

6-2
 RADIATOR

EA""""3

RADIATOR
Removing the radiator
,; 7 N·m (0.7 kgf·m, 5.2 lb·ft)

- •, 7
t\ ·,""~~
8 '

~ '
-~- '

-~
- -
·,, p,
,,~-~
'
-~-

1~,f f.---~, .
1~ )
3

11~
fur ~·lf) 6

. - J
' '
0.5 N·m (0.05 kgf·m, 0.37 lb•ft)

,., 9 N·m (0.9 kgf·m, 6.6 lb·ft)

Order Job/Parts to remove Q'ty Remarks

Refer to "GENERAL CHASSIS (2)" on
Air filter case
page 4-10.
Refer to "GENERAL CHASSIS (1)" on
Front side panel
page 4-1.
Drain.
Coolant Refer to "CHANGING THE COOLANT" on
page 3-31.
Coolant reservoir hose Disconnect.
2 Coolant reservoir cover
3 Coolant reservoir
4 Coolant reservoir cap
5 Coolant reservoir breather hose
6 Radiator cap
7 Radiator fan motor couple, Disconnect.
8 Radiator hose (cylinder he ad to radiator) Disconnect.
9 Radiator inlet hose Disconnect.
10 Radiator outlet hose Disconnect.

6-3
 RADIATOR

Removing the radiator

-
., ~~,- , d
1
~
- -~-
8 N·m (0.8 kgf·m, 5.9

~· -~- , ' - '

~ -~ -~
1Q ~X, I_ --~ -

. ; e f ~)}PJ ,~ )
.- . 1Yv" t-- :i:
-1/ )J'!J:) • -
,J~'I
(· ·(r 0,
·,lV ' '
, -
,, 0.5 N·m (0.05 kgf·m, 0.37 lb·ft)

>> 9 N·m (0.9 kgf·m, 6.6 lb·ft)

·-·----
Order Job/Parts to remove Q'ty Remarks
11 Radiator
12 Radiator fan cover
13 Radiator fan
14 Radiator bracket

6-4
 RADIATOR

CHECKING THE RADIATOR

1. Check:
• Radiator fin
Obstruction ➔ Clean.
Apply compressed air to the rear of the radia-
tor.
Damage ➔ Repair or replace.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Straighten any flattened fins with a thin, flat-head G089029

screwdriver. b. Apply specified pressure to the radiator cap

and then, make sure to check the specified
pressure for at least 10 seconds. If it is not
keep the pressure, replace it.
4. Check:
• Radiator fan
Damage ➔ Replace.
Malfunction ➔ Check and repair.
Refer to "COOLING SYSTEM" on page 8-39.
£ASM4,jb
G089028
INSTALLING THE RADIATOR
2. Check: 1. Install:
• Radiator hose • All removed parts
Cracks/damage ➔ Replace. 2. Fill:
3. Measure: • Cooling system
• Radiator cap valve opening pressure (with the specified amount of the recom-
Below the specified pressure ➔ Replace the mended coolant)
radiator cap. Refer to "CHANGING THE COOLANT' on
page 3-31.
Radiator cap valve opening pres- 3. Check:
sure
• Cooling system
107.9-137.3 kPa (1.08-1.37 kgf/
Leaks ➔ Repair or replace any faulty part.
cm 2, 15.6-19.9 psi)
a. Attach the radiator cap tester "1" and radia-
a. Install the radiator cap tester "1" and radia- tor cap tester adapter "2" to the radiator.
tor cap tester adapter "2" to the radiator cap
"3". Radiator cap tester
90890-01325

~
Radiator cap tester Mityvac cooling system tester kit
90890-01325 YU-24460-A
Mityvac cooling system tester kit Radiator cap tester adapter
YU-24460-A 90890-01352
Radiator cap tester adapter Pressure tester adapter
90890-01352 YU-33984
Pressure tester adapter
YU-33984

6-5
 RADIATOR

G089031

b. Apply the specified pressure.

Cooling system leak test pres-

sure
137.3 kPa (1.37 kgf/cm 2, 19.9
psi)

NOTICE
-------------
• Do not apply such a high pressure as ex-
c,eeds the test pressure.
• Make sure that a checkup after the cylinder
h:ead gasket is replaced is made after 3 min-
uites of warm-up.
• Make sure that coolant is filled up to the up-
per level beforehand.

4. Check:
• Pressure value
No stay for 5 to 10 seconds at the test pres-
sure value ➔ Repair.
• Radiator
• Radiator hose connections
Coolant leaks ➔ Repair or replace.
• Radiator hose
Bulges ➔ Replace.
EWA i:9000

A WARNING
When the radiator cap tester is removed,
coolant will spout; therefore, cover it with a
cloth beforehand.

6-6
 OIL COOLER

...,..,..
OIL COOLER
Removing the oil cooler

>

,.. ~~
J

·:.327,4
.- -I
((_,,,F -
2
1
rr- \"., 10 ~m (1,0 kgfm, 7,4 lb-It)

I 9'
\"'
11-3

...~~ - ,

Order Job/Parts to remove

a
Q'ty Remarks
Coolant reservoir Refer to "RADIATOR" on page 6-3.
Drain.
Coolant Refer to "CHANGING THE COOLANT" on
page 3-31.
Drain.
Engine oil Refer to "CHANGING THE ENGINE OIL" on
page 3-28.
1 Radiator inlet hose
2 Oil cooler inlet hose
3 Oil cooler outlet hose
4 Oil cooler
5 Water jacket joint

6-7
 OIL COOLER

EAS30l41
5. Measure:
CHECKING THE OIL COOLER
• Radiator cap valve opening pressure
1. Check:
Below the specified pressure ➔ Replace the
• Oil cooler
radiator cap.
Cracks/damage ➔ Replace. Refer to "CHECKING THE RADIATOR" on
2. Check:
page 6-5.
• Oil cooler inlet hose
• Oil cooler outlet hose
Cracks/damage/wear ➔ Replace.
EAS30442
INSTALLING THE OIL COOLER
1. Clean:
• Mating surfaces of the oil cooler and the
crankcase
(with a cloth dampened with lacquer thinner)
2. Install:
• 0 -ring ml!)
• Oil cooler
• Oil cooler bolt "1"

Oil cooler bolt

10 N-m (1.0 kgf•m, 7.4 lb•ft)

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Before installing the oil cooler, apply lithium-
soap-based grease to the 0-ring.
• Make sure the 0 -ring is positioned properly.

3. Fill:
• Cooling system
(with the specified amount of the recom-
mended coolant)
Refer to "CHANGING THE COOLANT' on
page 3-31.
• Crankcase
(with the specified amount of the recom-
mended engine oil)
Refer to "CHANGING THE ENGINE OIL" on
page 3-28.
4. Check:
• Cooling system
Leaks ➔ Repair or replace any faulty part.
Refer to "INSTALLING THE RADIATOR" on
page 6-5.

6-8
 THERMOSTAT
..THERMOSTAT
.,..,,.

Removing the thermostat assembly

--

2
" • 10 N-m (1.0 kgf-m, 7.4 lb-It)

Order Job/Parts to remove Q'ty Remarks

Drain.
Coolant Refer to "CHANGING THE COOLANT" on
page 3-31.
Radiator Refer to "RADIATOR" on page 6-3.
Muffler assembly Refer to "ENGINE REMOVAL" on page 5-:9.
Oil cooler outlet hose
2 Radiator outlet hose
3 Water pump inlet hose
4 Thermostat housing
5 Thermostat cover
6 Thermostat

6-9
 THERMOSTAT
EAS30l43
4. Measure:
CHECKING THE THERMOSTAT
• Radiator cap valve opening pressure
1. Check:
Below the specified pressure ➔ Replace the
• Themiostat
radiator cap.
When the water temperature in the specified
Refer to "CHECKING THE RADIATOR" on
value, the thermostat does not fully open. ➔
page 6-5.
Replace.

Valve full open temperature

95.0 oc (203.00 Of)

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-
mostat and thermometer's indicated tem-
perature.

G089032

TIP_ _ _ _ _ _ _ _ _ _ _ _ __
If the accuracy of the thermostat is in doubt, re-
place it. A faulty thermostat could cause serious
overheating or overcooling.

2. Check:
• Themiostat cover
• Themiostat housing
Cracks/damage ➔ Replace.
EAS301415
INSTALLING THE THERMOSTAT
ASSEMBLY
1. Install:
• Themiostat
2. Fill:
• Cooling system
(with the specified amount of the recom-
mended coolant)
Refer to "CHANGING THE COOLANT' on
page 3-31.
3. Check:
• Cooling system
Leaks ➔ Repair or replace any faulty part.
Refer to "INSTALLING THE RADIATOR" on
page 6-5.

6-10
 WATER PUMP

...,..,..
W.A TER PUMP
Removing the water pump

Order Job/Parts to remove Q'ty Remarks

Drain.
Coolant Refer to "CHANGING THE COOLANT" on
page 3-31.
Water pump inlet hose Disconnect.
2 Water pump assembly

6-11
 WATER PUMP

Disassembling the water pump

amm
5
s mm
I·.J
·,{:::·
mm
8

4
mm 2

,, 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Order Job/Parts to remove Q'ty Remarks

1 Water pump housing cover
2 0 -ring
3 Circlip
4 Water pump driven gear
5 Pin
6 Washer
7 Impeller shaft
8 Mechanical seal
9 Bearing
10 Oil seal

6-12
 WATER PUMP

...,....
DISASSEMBLING THE WATER PUMP
• Water pump housing cover "1"
• Impeller shaft "2"
1. Remove:
Cracks/damage/wear ➔ Replace.
• Mechanical seal (housing side) " 1"
• Water pump housing ''3"
TIP_ _ _ _ _ _ _ _ _ _ _ __ Cracks/damage/wear ➔ Replace the water
Remove the mechanical seal (housing side) pump assembly.
from the inside of the water pump housing "2".
3
1

1 2
2. Check:
2. Remove: • Bearing
Rough movement ➔ Replace.
• Bearing "1"
• Oil seal "2" 3. Check:
TIP_ _ _ _ _ _ _ _ _ _ _ __ • Water pump inlet hose
Cracks/damage/wear ➔ Replace.
Remove the oil seal and bearing from the out-
side of the water pump housing "3". EAS30448
ASSEMBLIIIIG THE WATER PUMP
1. Install:
• Oil seal "1" ml')
• Bearing "2" ml')
(into the water pump housing "3")

Installed depth "a"

0.5-1.0 mm (0.02--0.04 in)
3 TIP_ _ _ _ _ _ _ _ _ _ _ __
3. Remove: Install the oil seal with a socket that matches iits
outside diameter.
• Mechanical seal (impeller side) " 1"
(from the impeller, with a thin, flat-head
screwdriver)
TIP_ _ _ _ _ _ _ _ _ _ _ __
Do not scratch the impeller shaft.

1
2 . Install:
• Mechanical seal (housing side) "1" el'l!I
Ec.<20330

NOTICE
G089034 -::;--::--::-;-::---:--..,......,----
~eve~ lubricate the mechanical seal (hous-
........, ing side) surface with oil or grease.
CHECKING THE WATER PUMP
1. Check:

6-13
 WATER PUMP

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Use the special tools and a press to press the
mechanical seal (housing side) straight in until it
touches the water pump housing.

Mechanical seal installer

90890-04078
Water pump seal installer
YM-33221-A G089035
Middle driven shaft bearing driv-
er
90890-04058
Middle drive bearing i1n staller 40
&SO mm
YM-04058

2. Water pump housing

3. Mechanical seal installer
4. Middle driven shaft bearing driver
A. Push down
3. Install:
• Mechanical seal (impeller side) "1" ml!!I
NOTICE
-------------
Make sure the mechanical seal (impeller
side) is flush with the impeller.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Before installing the mechanical seal (impeller
si de), apply tap water or coolant onto its outer
surface.
• If the top of the mechanical seal is dirty, clean
it.

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 SOLENOID
(for MT09MC/MT09SPMC) ....................................................................... 7-4
INSTALLING THE FUEL PUMP ................................................................ 7-4
INSTALLING THE FUEL TANK ................................................................. 7-4

THROTTLE BODIES ....................................................................................... 7-5

CHECKING THE INJECTORS (BEFORE REMOVING) ........................... 7-7
REMOVING THE FUEL HOSE (FUEL RAIL SIDE) .................................. 7-7
REMOVING THE INJECTORS ................................ ................................. 7-7
CHECKING THE INJECTORS .................................................................. 7-7
CHECKING AN D CLEANING THE THROTTLE BODIES ......................... 7-7
REPLACING THE THROTTLE BODIES ................................................... 7-9
INSTALLING THE INJECTORS ................................................................ 7-9
CHECKING THE INJECTOR PRESSURE .............................................. 7-10
CHECKING THE FUEL PRESSURE ...................................................... 7-10
INSTALLING THE FUEL HOSE (FUEL RAIL SIDE) ............................... 7-11
ADJUSTING THE THROTTLE POSITION SENSOR .............................. 7-11
 FUEL TANK

EA""""7

FUEL TANK
Removing the fuel tank
<s>r 1 ... 1s N-m (0.6 kgf-m, 4.4 lb•"> 1
N-m (0. 7 kgf-m, 5.2 lb-It) -'1 1
~. N-m (0.7 kgf,m, 5.2 11>11}
1/ .
_/ '

5 2
,:. 11 N-m (1.1 kgl-m, 8.1 lb•lt)

Order Job/Parts to remove Q'ty Remarks

Refer to "GENERAL CHASSIS (1)" on
Rider seat
page 4-1.
Refer to "GENERAL CHASSIS (1)" on
Fuel tank side cover/Fuel tank center cover
page4-1 .
Fuel tank bracket bolt 4
2 Fuel hose connector Disconnect.
3 Fuel pump coupler Disconnect.
4 Fuel tank breather hose Disconnect.
5 Fuel tank drain hose Disconnect.
6 Fuel tank
7 Fuel pump bracket
8 Fuel pump
9 Fuel pump gasket
10 Fuel tank cap

7-1
 FUEL TANK

Removing the canister (for MT09MC/MT09SPMC)

Order Job/Parts to remove Q'ty Remarks

Fuel tank Refer to "FUEL TANK" on page 7-1.
Fuel tank breather hose (fuel tank to canister)
Canister purge hose (purge cut valve solenoid
2
to canister)
3 Canister breather hose
4 Canister
5 Purge cut valve solenoid coupler Disconnect.
Canister purge hose (purge cut valve solenoid
6 to hose joint)
7 Purge cut valve solenoid

7-2
 FUEL TANK

REMOVING THE FUEL TANK

1. Extract the fuel in the fuel tank through the 1
fuel tank cap with a pump.
2. Remove:
• Rider seat
• Fuel tank side cover
• Fuel tank center cover
Refer to "GENERAL CHASSIS (1 )" on
page 4-1.
• Bracket bolt
3. Disconnect:
• Fuel hose (fuel tank side) "1"
• Fuel pump coupler "2"
• Fuel tank breather hose "3"
• Fuel tank drain hose "4"

4. Remove:
• Fuel tank
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Do not set the fuel tank down so that the instal-
lation surface of the fuel pump is directly under
E\VA t!133:J the tank. Be sure to lean the fuel tank in an up-
A WARNING right position.
Cover fuel hose connections with a cloth
when disconnecting them. Residual pres-
sure in the fuel lines could cause fuel to REMOVING THE FUEL PUMP
spurt out when removing the hose. 1. Remove:
• Fuel pump
ECA17490

NOTICE NOTICE
-------------
Be sure to disconnect the fuel hose by hand. -------------
• Do not drop the fuel pump or give it a
Do not forcefully disconnect the hose with strong shock.
tools. • Do not touch the base section of the fuel
sender.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• While pushing the ends "a" of the fuel hose
connector cover "1" in direction "b", slide the CHECKING THE FUEL PUMP BODY
fuel hose connector cover in direction "c", and 1. Check:
then remove the hose from the fuel pump. • Fuel pump body
• Before removing the hose, place a few rags in Obstruction ➔ Clean.
the area under where it will be removed. Cracks/damage ➔ Replace fuel pump as-
• It is prohibited to wear the cotton work gloves sembly.
or equivalent coverings.
CHECKING THE FUEL PUMP OPERATION
1. Check:
• Fuel pump operation
Refer to "CHECKING THE FUEL PRES-
SURE" on page 7-10.

7-3
 FUEL TANK

EA"""'42 EAS3007
CHECKING THE PURGE CUT VALVE INSTALLING THE FUEL TANK
SOLENOID (for MT09MC/MT09SPMC) 1. Connect:
1. Check: • Fuel hose (fuel tank side)
ECA1MOO
• Canister purge hose
Loose connection ➔ Connect property. NOTICE
-------------
When installing the fuel hose, make sure that
Cracks/damage/wear ➔ Replace.
2. Check: it is securely connected, and that the fuel
• Purge cut valve solenoid resistance hose connector cover on the fuel hose is in
Refer to "CHECKING THE PURGE CUT the correct position, otherwise the fuel hose
VALVE SOLENOID (for MT09MC/MT09SP- will not be properly installed.
MC)" on page 8-65.
...,..,.
INSTALLING THE FUEL PUMP
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Install the fuel hose onto the fuel pump secure-
ly, and slide the fuel hose connector cover "1"
1. Install: in the direction shown in the illustration.
• Fuel pump gasket Gm • It is prohibited to wear the cotton work gloves
• Fuel pump or equivalent coverings.
• Fuel pump bracket
• Fuel pump bolt

Fuel pump bolt

1
4.0 N-m (0.40 kgf-m, 3.0 lb-ft)

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Do not damage the installation surfaces of the
fuel tank when installing the fuel pump.
• Always use a new fuel pump gasket.
• Install the fuel pump gasket so that the lip side
turns to the inside of the fuel tank:. 2. Connect:
• Install the fuel pump as shown in the illustra- • Fuel tank drain hose
tion. • Fuel tank breather hose
• Install the fuel pump projection "a" toward the • Fuel pump coupler
fuel tank slot "b".
• Align the projection "a" on the fuel pump with
the slot in the fuel pump bracket.
• Tighten the fuel pump bolts in the proper tight-
ening sequence as shown.

A. Forward

7-4
 THROTTLE BODIES

EA"""'70

THROTTLE BODIES
Removing the throttle bodies

Order Job/Parts to remove Q'ty Remarks

Refer to "GENERAL CHASSIS (2)" on
Air filter case
page 4-10.
Fuel hose
2 Intake air pressure sensor 1 coupler Disconnect.
3 Intake air pressure sensor 2 coupler Disconnect.
4 Injector coupler 3 Disconnect.
5 Throttle servo motor coupler Disconnect.
6 Throttle position sensor coupler Disconnect.
Canister purge hose (purge cut valve solenoid Disconnecl.
7 to hose joint) For MT09MC/MT09SPMC.
8 Throttle body joint clamp screw 3 Loosen.
9 Throttle body assembly
10 Throttle body joint
11 Throttle body joint

7-5
 THROTTLE BODIES

Removing the injectors

, 3.5 N-m (0.35 kgf-m, 2.6 lb-fl)

Order Job/Parts to remove Q'ty Remarks

1 Fuel rail
2 lnjeclor 3
3 Intake air pressure sensor 2
4 Intake air pressure sensor 1
5 Throttle position sensor
6 Negative pressure hose 6
7 Hose joint 2
8 Canister purge hose 4 For MT09MC/MT09SPMC.
9 Hose joint 2 For MT09MC/MT09SPMC.

7-6
 THROTTLE BODIES

EAS304n,
CH ECKING THE INJECTORS (BEFORE
...,..,.
REMOVING THE INJECTORS
E\VA17'3:J:)
REMOVING)
1. Check: ~ WARNING
• Injector • Check the injectors in a well-ventilated area
Use the diagnostic code numbers "36"- "38". free of combustible materials. Make sure
Refer to "DIAGNOSTIC CODE: ACTUATOR that there is no smoking or use of electri'c
OPERATION TABLE" on page 9-66. tools in the vicinity of the injectors.
• Be careful when disconnecting the fuel
£AS3i1!iB
hose. Any remaining pressure in the fuel
REMOVING THE FUEL HOSE (FUEL RAIL
hose may cause the fuel to spray out. Place
SIDE)
a container or rag under the hose to catch
1. Remove:
any fuel that spills. Always clean up any
• Fuel tank
spilt fuel immediately.
Refer to "REMOVING THE FUEL TANK" on
• Tum the main switch to "OFF" and discon-
page 7-3.
nect the negative battery lead from the bat•
2. Remove:
tery terminal before removing the injectors.
• Fuel hose (fuel rail side)
ECA17490
1. Remove:
NOTICE
-------------
Be sure to disconnect the fuel hose by hand.
• Fuel rail
a. Remove the fuel rail bolts.
Do not forcefully disconnect the hose with
tools. EAS30477
CHECKING THE INJECTORS
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ 1. Check:
• While pushing the ends "a" of the fuel hose • Injector
co nnector cover "1" in direction "b", slide the Obstruction ➔ Replace and check the fuel
fuel hose connector cover in direction "c", and pump/fuel supply system.
then remove the hose from the fuel pump. Deposit ➔ Replace.
• Before removing the hose, place a few rags in Damage ➔ Replace.
the area under where it will be removed. 2. Check:
• It is prohibited to wear the cotton work gloves • Injector resistance
or equivalent coverings. Refer to "CHECKING THE FUEL INJEC-
TORS" on page 8-64.

1
...,.,..
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
• Air filter element
• Throttle body joint
b Gf.i • Fuel hose
• Exhaust system
• Cylinder head breather hose

b c...=l:!::tL.J.- .J./':U-'-'---

7-7
 THROTTLE BODIES

EWAl17340

A WARNING
If the throttle bodies are subjected to strong
shocks or dropped during cleaning, replace
them as a set.
1. Check:
• Throttle bodies
Cracks/damage ➔ Replace the throttle bod-
ies as a set.
2. Clean:
• Throttle bodies ffil
NOTICE
-------------
• Observe the following precautions; other-
wise, the throttle bodies may not operate
properly.
• Do not subject the throttle bodies to exces-
sive force.
• Clean the thrott.le bodies in the recom- a
mended cleaning solvent.
A. For MT09M/MT09SPM
• Do not use any caustic carburetor cleaning B. For MT09MC/MT09SPMC
solution.
• Do not apply cleaning solvent directly to c. Hold the throttle valves in the open position.
E\VA1!!940
any plastic parts, sensors, or seals.
• Be careful not to remove the white paint
A WARNING
mark that identifies the standard throttle When cleaning the throttle bodies, be careful
body. not to injure yourself on the throttle valves or
• Do not turn the bypass air screws "a" ; oth- other components of the throttle bodies.
erwise, the throttle body synchronizat ion
will be affected. NOTICE
-------------
• Do not open the throttle valves by supply-
ing electrical power to the throttle bodies.
Recommended cleani1n g solvent
• Do not use tools to open the throttle valves
Yamaha Oil & Brake Cleaner
or to keep them in the open position.
• Do not open the throttle valves quickly.

a . Place the throttle bodies on a flat surface

with the air filter case side facing up. d. Apply the recommended cleaning solvent
b. Install the caps (895-14169-00) onto the to the throttle valves and the inside of the
hose fittings "a". throttle bodies to remove any carbon de-
posits.

7-8
 THROTTLE BODIES

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ 5. Adjust:
• Do not allow any cleaning solvent to enter the • Throttle bodies synchronizing
opening for the injectors. Out of specification ➔ Replace the throttle
• Do not apply any cleaning solvent to the por- bodies.
tions of the throttle valve shafts between the Refer to "SYNCHRONIZING THE THROT-
throttle bodies. TLE BODI ES" on page 3-8.
EAS31 180
e. Remove the carbon deposits from the in-
REPLACING THE THROTTLE BODIES
side of each throttle body in a downward di- 1. Remove the throttle bodies from the vehicle.
rection, from the air filter case side of the
2. Install a new throttle bodies to the vehicle.
throttle body to the engine side.
ECA17990
3. Reset:
NOTICE • ISC (idle speed control) learning values
-------------
• Do not use a tool, such as a wire brush, to Use the diagnostic code number "67".
Refer to "DIAGNOSTIC CODE: SENSOR
remove the carbon deposits; otherwise, the
inside of the throttle bodies may be dam- OPERATION TABLE" on page 9-62.
aged. • A/F control learning value
Use the diagnostic code number "87''.
• Do not allow carbon deposits or other for-
Refer to "DIAGNOSTIC CODE: SENSOR
eign materials to enter any of the passages
in each throttle body or in the space be· OPERATION TABLE" on page 9-62.
4. Adjust:
tween the throttle valve shaft and the throt•
• Throttle bodies synchronizing
tie body.
Refer to "SYNCHRONIZING THE THROT-
f. After removing the carbon deposits, clean TLE BODI ES" on page 3-8.
the inside of the throttle bodies with the rec- 5. Place the vehicle on a maintenance stand so
ommended cleaning solvent, and then dry that the rear wheel is elevated.
the throttle bodies using compressed air. 6. Check:
g. Make sure that there are no carbon depos- • Engine idling speed
its or other foreign materials in any of the Start the engine, warm it up, and then mea-
passages "a" in each throttle body or in the sure the engine idling speed.
space "b" between the throttle valve shaft
and the throttle body. Engine idling speed
1200-1400 r/min

~ -~~ EAS30480
INSTALLING THE INJECTORS
ECA19'00

... . ... ..
NOTICE
-------------
• Always use new O-rings.
• When installing the injectors, do not allow

A. Air filter case side

J_ any foreign material to enter or adhere to
the injectors, fuel rails, or 0-rings.
• Be careful not to twist or pinch the O-rings
when installing the injectors.
B. Throttle body joint side • When installing the injector, install it at tlhe
same position as the removed cylinder.
3. Install the throttle bodies. • If an injector is subject to strong shocks or
4. Reset: excessive force, replace it.
• ISC (idle speed control) learning values
Use the diagnostic code number "67". 1. Install a new seal onto the end of each injec-
Refer to "DIAGNOSTIC CODE: SENSOR tor.
OPERATION TABLE" on page 9-62. 2. Install the injectors to the fuel rail, making
sure to install them in the correct direction.
3. Install the injector assemblies to the throttle
bodies.

7-9
 THROTTLE BODIES

ECA17600

NOTICE
Fuel rail bolt
3.5 N-m (0.35 kgf-m, 2 .6 lb-ft)
-------------
Never exceed the specified air pressure or
damage could occur.
4. Check the injector pressure after the injectors
are installed. f. Close the valve on the fuel injector pressure
Refer to "CHECKING THE INJECTOR adapter.
PRESSURE" on page 7-10. g. Check that the specified air pressure is held

...,....,
CHECKING THE INJECTOR PRESSURE
at least one minute.
Pressure drops ➔ Check the pressure
gauge and adapter.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ Check the seals and O-rings and then rein-
• After installing the injectors, perform the follow- stall.
ing steps to check the injector pressure. Out of specification ➔ Replace the fuel in-
• Do not allow any foreign materials to enter the jectors.
fuel lines.
1. Check: CHECKING THE FUEL PRESSURE
• Injector pressure 1. Check:
• Fuel pressure
a. Connect the fuel injector pressure adapter
"1" to the fuel rail joint "2", and then connect a. Remove the rider seat, fuel tank side cover
an air compressor "3" to the adapter. and fuel tank center cover.
b. Connect the pressure gauge "4" to the fuel Refer to "GENERAL CHASSIS (1)" on
injector pressure adapter "1 ". page 4-1.
b. Remove the fuel bracket bolt and hold up
Pressure gauge the fuel tank.
90890-03153 c. Disconnect the fuel hose "1" from the fuel
Pressure gauge pump.
YU-03153 Refer to "REMOVING THE FUEL TANK"
Fuel injector pressure adapter on page 7-3.
90890-03210 EWA17'320

Fuel injector pressure adapter ~ WARNING

YU-03210 Cover fuel hose connections with a cloth
when disconnecting them. Residual pres-
sure in the fiuel lines could cause fuel to
spurt out when removing the hose.
ECA17490

NOTICE
-------------
Be sure to disconnect the fuel hose by hand.
Do not forcefully disconnect the hose with
tools.

G089041 2
c. Close the valve on the fuel injector pressure
adapter.
d . Apply air pressure with the air compressor.
e . Open the valve on the fuel injector pressure
adapter until the specified air pressure is
reached.

Specified air pressure

490 kPa (5.0 kgf/cm2, 71.1 psi)
d. Connect the pressure gauge "2" and fuel
pressure adapter "3" to the fuel hose.

7-10
 THROTTLE BODIES

Pressure gauge
90890-03153
Pressure gauge 1
YU-03153
Fuel pressure adapter
90890-03176
Fuel pressure adapter
YM-00176

...,..,.
ADJUSTING THE THROTTLE POSITION
SENSOR
ECA1~

NOTICE
------------
• Handle the throttle position sensor with
special care.
• Never subject the throttle position sensor
to strong shocks. If the throttle position
sensor is dropped, replace it.
e. Start the engine.
I. Measure the fuel line pressure. 1. Check:
Faulty ➔ Replace the fuel pump. • Throttle position sensor
Refer to "DIAGNOSTIC CODE: SENSOR
Fuel line pressure (at idle) OPERATION TABLE" on page 9-62.
300-390 kPa (3.0-3.9 kgf/cm 2, 2. Adjust:
43.5--56.6 psi) • Throttle position sensor angle
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
EAS311159
Before adjusting the throttle position sensor, the
INSTALLING THE FUEL HOSE (FUEL RAIL
throttle bodies must be removed.
SIDE)
1. Connect: a. Temporary tighten the throttle position sen-
• Fuel hose (fuel rail side) sor screws "1".
ECA1'MOO
b. Check that the throttle valves are fully
NOTICE
------------
When installing the fuel hose, make sure that
closed.
c. Connect the throttle position sensor to the
it is securely connected, and that the fuel
wire harness.
hose connector cover on the fuel hose is in
d. Remove the protective cap, and then con-
the correct position, otherwise the fuel hose
nect the VDT to coupler.
will not be properly installed.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ Yamaha diagnostic tool USB
(US)
• Install the fuel hose onto the fuel pump secure-
90890-03269
ly, and slide the fuel hose connector cover "1"
Yamaha diagnostic tool (A/1)
in the direction shown in the illustration. 90890-03264
• It is prohibited to wear the cotton work gloves
or equivalent coverings. TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
• Yamaha diagnostic tool (A/1) (90890-03264) in-
cludes VDT sub harness (6P) (90890-03266).
• If you already have Yamaha diagnostic tool (A/
I) (90890-03262), VDT sub harness (6P)
(90890-03266) is separately required.

7-11
 THROTTLE BODIES

e . Diagnostic code number "01" fis selected.

I. Adjust the position of the throttle position
sensor angle so that 11- 21 can appear in
the VDT screen.
g . After adjusting the throttle position sensor
angle, tighten the throttle position sensor
screws.

Throttle position sensor screw

3.5 N-m (0.35 kgf•m, 2.6 lb•ft)

7-12
 THROTTLE BODIES

7-13
 ELECTRICAL SYSTEM

IGNITION SYSTEM ......................................................................................... 8-1

CIRCUIT DIAGRAM .................................................................................. 8-1
ENGINE STOPPING DUE TO SIDESTAND OPERATION ....................... 8-5
TROUBLESHOOTING .............................................................................. 8-6

ELECTRIC STARTING SYSTEM .................................................................... 8-9

CIRCUIT DIAGRAM .................................................................................. 8-9
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ........................ 8-13
TROUBLESHOOTING ............................................. ............................... 8-14

CHARGING SYSTEM .....................................................•.............................. 8-17

CIRCUIT DIAGRAM ................................................ ................................. 8-17
TROUBLESHOOTING ............................................. ............................... 8-21

L.IGHTING SYSTEM ......................................................................................8-23

CIRCUIT DIAGRAM ................................................................................ 8-23
TROUBLESHOOTING ....... ................... ................... ............................... 8-27

SIGNALING SYSTEM ....................................................•.............................. 8-29

CIRCUIT DIAGRAM ................................... ................... .......................... 8-29
TROUBLESHOOTING ............................................. ............................... 8-33

COOLING SYSTEM ....................................................................................... 8-39

CIRCUIT DIAGRAM ................................................................................. 8-39
TROUBLESHOOTING ............................................. ............................... 8-43

FUEL PUMP SYSTEM....................................................•.............................. 8-45

CIRCUIT DIAGRAM ................................................................................ 8-45
TROUBLESHOOTING ............................................. ........................ ....... 8-49

ELECTRICAL COMPONENTS.......................................•.............................. 8-51

CHECKING THE SWITCHES .................................. ............................... 8-53
CHECKING THE FUSES ......................................... ............................... 8-55
REPLACING THE ECU (Engine Control Unit) ........................................ 8-55
CHECKING AND CHARGING THE BATTERY ....................................... 8-56
CHECKING THE RELAYS ...................................................................... 8-56
CHECKING THE RELAY UNIT (DIODE) ................................................ 8-58
CHECKING THE IGNITION COILS ............ ............................................. 8-59
CHECKING THE IGNITION SPARK GAP .................. .............................. 8-59
CHECKING THE CRANKSHAFT POSITION SENSOR. ......................... 8-60
I
CHECKING THE STARTER MOTOR OPERATION ............................... 8-60
CHECKING THE STATOR COIL ............................................................ 8-61
CHECKING THE RECTIFIER/REGULATOR .......................................... 8-61
CHECKING THE HORN ................................................ .......................... 8-62
CHECKING THE FUEL SENDER ........................................................... 8-62
CHECKING THE FUEL LEVEL WARNING LIGHT .. ............................... 8-62
CHECKING THE RADIATOR FAN MOTOR ........................................... 8-63
CHECKING THE COOLANT TEMPERATURE SENSOR. ...................... 8-63
CHECKING THE THROTTLE SERVO MOTOR ........ .............................. 8-63
CHECKING THE INT AKE AIR TEMPERATURE SENSOR .................... 8-64
CHECKING THE FUEL INJECTORS ...................................................... 8-64
CHECKING THE PURGE CUT VALVE SOLENOID
(for MT09MC/MT09SPMC) ..................................................................... 8-65
CHECKING THE WHEEL SWITCH ........................ ................................ 8-65
 IGNITION SYSTEM

EA""""2

IGNITION SYSTEM
EA"'°"°
CIRCUIT DIAGRAM
MT09M/MT09MC

8-1
 IGNITION SYSTEM

3. Fuse box
4. Main fuse
5. Main switch
9. Backup fuse 2
11. Ignition fuse 2
12. Ignition fuse 1
21. Battery
22. Engine ground
25. Handlebar switch (right)
28. Stop/run/start switch
30. Relay unit
31. Starting circuit cut-off relay
33. Neutral switch
34. Sidestand switch
41. Crankshaft position sensor
44. ECU (Engine Control Unit)
45. Ignition coil # 1
46. Spark plug
47. Ignition coil #2
48. Ignition coil #3
59. IMU (Inertial Measurement Unit)

8-2
 IGNITION SYSTEM

MT09SPM/MT09SPMC

IJ

.
' . ... .
.
~ w'Hiifai,

8-3
 IGNITION SYSTEM

3. Fuse box
4. Main fuse
5. Main switch
9. Backup fuse 2
11. Ignition fuse 2
12. Ignition fuse 1
23. Battery
24. Engine ground
30. Handlebar switch (right)
32. Stop/run/start switch
34. Relay unit
35. Starting circuit cut-off relay
37. Neutral switch
38. Sidestand switch
45. Crankshaft position sensor
48. ECU (Engine Control Unit)
49. Ignition coil #1
50. Spark plug
51. Ignition coil #2
52. Ignition coil #3
63. IMU (Inertial Measurement Unit)

8-4
 IGNITION SYSTEM

...,....,
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
8

1. Battery
2. Main fuse
3. Main switch
4. Ignition fuse 1
5. Stop/run/start switch
6. Ignition coil
7. Spark plug
8. ECU (Engine Control Unit)
9. Relay unit (diode)
10. Sidestand switch
11. Neutral switch

8-5
 IGNITION SYSTEM

TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Before troubleshooting, remove the following part(s):
1. Rider seat
2. Fuel tank side cover
3. Fuel tank center cover
4. Fuel tank
5. Air filter case

1. Check the fuses.

(Main, backup 2, ignition 1, and ig-
nition 2) Replace the fuse(s).
Refer to "CHECKING THE FUS-
ES" on page 8-55.

OK.I,

2 . Check the battery.

Refer to "CHECKING AND • Clean the battery tenninals.
NG➔
CHARGING THE BATTERY" on • Recharge or replace the battery.
page 8-56.

OK.I,

3 . Check the spark plugs.

Refer to "CHECKING THE SPARK Re-gap or replace the spark plugs.
PLUGS" on page 3-5.

OK.I,

4 . Check the ignition spark gap.

Refer to "CHECKING THE IGNI- Ignition system is OK.
TION SPARK GAP" on page 8-59.
NG.I,

5 . Check the ignition coils.

Refer to "CHECKING THE IGNI- Replace the ignition coils.
TION COILS" on page 8-59.

OK.I,

6 . Check the crankshaft position sen-

sor.
Refer to "CHECKING THE Replace the crankshaft position sensor.
CRANKSHAFT POSITION SEN-
SOR" on page 8-60.

OK.I,

7 . Check the main switch.

Refer to "CHECKING THE Replace the main switch.
SWITCHES" on page 8-53.

OK.I,

8-6
 IGNITION SYSTEM

8 . Check the stop/run/start switch.

Refer to "CHECKING THE Replace the handlebar switch (right).
SWITCHES" on page 8-53.

OK.I,

9 . Check the neutral switch.

Refer to "CHECKING THE Replace the neutral switch.
SWITCHES" on page 8-53.

OK.I,

10.Check the sidestand switch.

Refer to "CHECKING THE Replace the sidestand switch.
SWITCHES" on page 8-53.

OK.I,

11.Check the relay unit (diode).

Refer to "CHECKING THE RELAY Replace the relay unit.
UNIT (DIODE)" on page 8-58.

OK.I,

12.Check the entire ignition system's

wiring. Properly connect or repair the ignition sys-
Refer to "CIRCUIT DIAGRAM" on tem's wiring.
page 8-1 .

OK.I,

Replace the ECU.

Refer to "REPLACING THE ECU (En-
g ine Control Unit)" on page 8-55.

8-7
 IGNITION SYSTEM

8-8
 ELECTRIC STARTING SYSTEM

EA""""3

ELECTRIC STARTING SYSTEM

.........
CIRCUIT DIAGRAM
MT09M/MT09MC

®:
~ ~-11-----+---+--+---------+-t_--=-.--=-.--=---=t-~---+---'
['·
i~fi:r·~
©
u~-~ w · r
--e-=---t=-!:::'==,'
'-'=========;i~ ,uilmJ: :· ;
~'-···' fffiID> ~

8-9
 ELECTRIC STARTING SYSTEM

3. Fuse box
4. Main fuse
5. Main switch
9. Backup fuse 2
11. Ignition fuse 2
12. Ignition fuse 1
21. Battery
22. Engine ground
23. S1arter relay
24. Starter motor
25. Handlebar switch (right)
28. Stop/run/start switch
30. Relay unit
31. Starting circuit cut-off relay
33. Neutral switch
34. Sidestand switch
44. ECU (Engine Control Unit)
59. IMU (Inertial Measurement Unit)
89. Handlebar switch (left)
90. Clutch switch

8-10
 ELECTRIC STARTING SYSTEM

MT09SPM/MT09SPMC

f!
I
'
,.

:······'l'l"P" ···················~ ·· ·····r············· ~ --·1rn-········ - ·····r ....TT ~

:I ...... ··- ·... ······-
®
··- -··· ······················· ······~---·!

I· ffl·
-
:@: ,....Y:
I· -...... ~

,~~w1rI··=,"
11

I @ r=
. . .~ l i
:_ij'!
") iij~ I

,~ -
(:':'.""' ~~ :~
iii•
···· ~-

~,
~

~ ' -
~--------~-
~J~(f fl1-ti=-~·
~ ffli
··········-····

~
!~
l::-i I -wm!..
,l,
... _,
'®'
i.::_~:w
r®· ~-
,_
I
I

~qd.~-;f
L .! . !

f .~.at.
i(3iij: -
!@ j
i m:t l
·0 ·
,<i!mu
1~ 1.H,
l
.ailmJ. ,.1bmJI,
1:~~:M:?;;> ~

8-11
 ELECTRIC STARTING SYSTEM

3. Fuse box
4. Main fuse
5. Main switch
9. Backup fuse 2
11. Ignition fuse 2
12. Ignition fuse 1
23. Battery
24. Engine ground
25. S1arter relay
26. Starter motor
27. Clutch switch
30. Handlebar switch (right)
32. Stop/run/start switch
34. Relay unit
35. Starting circuit cut-off relay
37. Neutral switch
38. Sidestand switch
48. ECU (Engine Control Unit)
63. IMU (Inertial Measurement Unit)

8-12
 ELECTRIC STARTING SYSTEM

STARTING CIRCUIT CUT-OFF SYSTEM OPERATION

If the main switch is turned to "ON" and the "(<)" side of the stop/run/start 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
si destand 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 c losed and the engine can be started by pressing the"(<)" side off the stop/run/start switch.

10

6
b 8 19110
l = =
a. WHEN THE TRANSMISSION IS IN NEU- 1. Battery
TRAL 2. Main fuse
b. WHEN THE SIDESTAND IS UP AND THE 3. Main switch
CLUTCH LEVER IS PULLED TO THE HAN-
DLEBAR 4. Ignition fuse 1
5. Starting circuit cut-off relay
6. Relay unit (diode)
7. Clutch switch
8. Sidestand switch
9. Neutral switch
10. Stop/run/start switch
11 . Starter relay
12. Starter motor

8-13
 ELECTRIC STARTING SYSTEM

...,.....
TROUBLESHOOTING
The starter motor fails to turn.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Before troubleshooting, remove the following part(s):
1. Rider seat
2. Fuel tank side cover
3. Fuel tank center cover
4. Fuel tank
5. Air filter case
6. Canister (for MT09MC/MT09SPMC)

1. Check the fuses.

(Main, backup 2, ignition 1, and ig-
nition 2) Replace the fuse(s).
Refer to "CHECKING THE FUS-
ES" on page 8-55.

OK.I,

2. Check the battery.

Refer to "CHECKING AND • Clean the battery tenninals.
CHARGING THE BATTERY" on • Recharge or replace the battery.
page 8-56.

3 . Check the starter motor operation.

Starter motor is OK. Perform the electric
Refer to "CHECKING THE START-
starting system troubleshooting, starting
ER MOTOR OPERATION" on
with step (5).
page 8-60.

NG.I,

4. Check the starter motor.

Refer to "CHECKING THE ST ART- Repair or replace the starter motor.
ER MOTOR" on page 5-43.

5. Check the relay unit (starting circuit

cut-off relay). Replace the relay unit.
Refer to "CHECKING THE RE-
LAYS" on page 8-56.

6. Check the relay unit (diode).

Refer to "CHECKING THE RELAY Replace the relay unit.
UNIT (DIODE)" on page 8-58.

7 . Check the starter relay.

Refer to "CHECKING THE RE- Replace the starter relay.
LAYS" on page 8-56.

OK.I,

8-14
 ELECTRIC STARTING SYSTEM

8 . Check the main switch.

Refer to "CHECKING THE Replace the main switch.
SWITCHES" on page 8-53.

OK.I,

9 . Check the neutral switch.

Refer to "CHECKING THE Replace the neutral switch.
SWITCHES" on page 8-53.

OK.I,
1O.Check the sidestand switch.
Refer to "CHECKING THE Replace the sidestand switch.
SWITCHES" on page 8-53.

OK.I,
11.Check the clutch switch.
Refer to "CHECKING THE Replace the clutch switch.
SWITCHES" on page 8-53.

OK.I,

12.Check the stop/run/start switch.

Refer to "CHECKING THE Replace the handlebar switch (right).
SWITCHES" on page 8-53.

OK.I,

13.Check the entire starting system's

wiring. Properly connect or repair the starting sys-
Refer to "CIRCUIT DIAGRAM" on tem's wiring.
page 8-9.

OK.I,

Replace the ECU.

Refer to "REPLACING THE ECU (En-
g ine Control Unit)" on page 8-55.

8-15
 ELECTRIC STARTING SYSTEM

8-16
 CHARGING SYSTEM

..CHARGING
.,..,,,
SYSTEM
.........
CIRCUIT DIAGRAM
MT09M/MT09MC

8-17
 CHARGING SYSTEM

1. AC magneto
2. Rectifier/regulator
3. Fuse box
4. Main fuse
21. Battery
22. Engine ground

8-18
 CHARGING SYSTEM

MT09SPM/MT09SPMC

8-19
 CHARGING SYSTEM

1. AC magneto
2. Rectifier/regulator
3. Fuse box
4. Main fuse
23. Battery
24. Engine ground

8-20
 CHARGING SYSTEM

TROUBLESHOOTING
The battery is not being charged.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Before troubleshooting, remove the following part(s):
1. Rider seat
2. Fuel tank side cover
3. Fuel tank center cover
4. Fuel tank
5. Air filter case

1. Check the fuse.

(Main)
Replace the fuse.
Refer to "CHECKING THE FUS-
ES" on page 8-55.

2 . Check the battery.

Refer to "CHECKING AND • Clean th e battery tenninals.
CHARGING THE BATTERY" on • Recharge or replace the battery.
page 8-56.

OK.I,

3. Check the stator coil.

Refer to "CHECKING THE STA- Replace the stator coil assembly.
TOR COIL" on page 8-61.

OK.I,

4 . Check the rectifier/regulator.

Refer to "CHECKING THE RECTI-
Replace the rectifier/regulator.
FIER/REGULATOR" on page 8-
61.

OK.I,

5 . Check the entire charging system's

wiring. Properly connect or repair the charging
Refer to "CIRCUIT DIAGRAM" on system's wiring.
page 8-17.

OK.I,

T he charging system circuit is OK.

8-21
 CHARGING SYSTEM

8-22
 LIGHTING SYSTEM

..LIGHTING
.,.,.,,.
SYSTEM
.........
CIRCUIT DIAGRAM
MT09M/MT09MC

i ,iJatii

•.tld:iiccr.
ri . .., 1 .
+

i¼»,;;:i, tk:ii\~$~

8-23
 LIGHTING SYSTEM

3. Fuse box
4. Main fuse
5. Main switch
9. Backup fuse 2
10. Signaling system fuse
11. Ignition fuse 2
13. Headlight fuse
18. Backup fuse 1
21. Battery
22. Engine ground
44. ECU (Engine Control Unit)
63. Meter assembly
64. Multi-function meter
67. Auxiliary system warning light
73. Meter light
75. High beam indicator light
81 . Headlight control unit
82. Headlight (low)
83. Headlight (high)
84. Tail/brake light
85. License plate light
86. Auxiliary light
89. Handlebar switch (left)
92. Pass switch
93. Dimmer switch

8-24
 LIGHTING SYSTEM

MT09SPM/MT09SPMC

: :

i . ~

~
'Tff---1-L

:ill· · 1r
@, ••••••••.... l

l'!!'-' : .i
~ ■
t QI

r~·--•_
~·· : )
0
L==~======l-
1 ·· -···:..,_r,.__J
_:;,:'©·_j

~lll,- -~~-+
:.........:::~

........
_J 1

8-25
 LIGHTING SYSTEM

3. Fuse box
4. Main fuse
5. Main switch
9. Backup fuse 2
10. Signaling system fuse
11. Ignition fuse 2
13. Headlight fuse
20. Backup fuse 1
23. Battery
24. Engine ground
48. ECU (Engine Control Unit)
67. Meter assembly
68. Multi-function meter
71 . Auxiliary system warning light
79. Meter light
81 . High beam indicator light
87. Headlight control unit
88. Headlight (low)
89. Headlight (high)
90. Tail/brake light
91 . License plate light
92. Auxiliary light
95. Handlebar switch (left)
98. Dimmer/pass switch

8-26
 LIGHTING SYSTEM

TROUBLESHOOTING
Any of the following fail to light: headlight, auxiliary light, high beam indicator light, taillight, license light
or meter light.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Before troubleshooting, remove the following part(s):
1. Rider seat
2. Fuel tank side cover
3. Fuel tank center cover
4. Fuel tank
5. Air filter case
6. Headlight assembly

1. Check the fuses.

(Main, headlight, ignition 1, ignition
2, backup 1, backup 2, and signal-
Replace the fuse(s).
ing system)
Refer to "CHECKING THE FUS-
ES" on page 8-55.

2 . Check the battery.

Refer to "CHECKING AND • Clean the battery tenninals.
CHARGING THE BATTERY" on • Recharge or replace the battery.
page 8-56.

OK.I,

3. Check the main switch.

Refer to "CHECKING THE Replace the main switch.
SWITCHES" on page 8-53.

OK.I,

4. Check the dimmer switch.

The dimmer switch is faulty. Replace the
Refer to "CHECKING THE
handlebar switch (left).
SWITCHES" on page 8-53.

OK.I,

5. Check the pass switch.

The pass switch is faulty. Replace the
Refer to "CHECKING THE
handlebar switch (left).
SWITCHES" on page 8-53.

OK.I,

6. Check the entire lighting system's

wiring. Properly connect or repair the lighting sys-
Refer to "CIRCUIT DIAGRAM" on tem's wiring.
page 8-23.

OK.I,

8-27
 LIGHTING SYSTEM

Replace the ECU, meter assembly,

headlight assembly, tail/brake light, li-
cense plate light or auxiliary light.
Refer to "REPLACING THE ECU (En-
g ine Control Unit)" on page 8-55.

8-28
 SIGNALING SYSTEM

...,..,,.
SIGNALING SYSTEM
EAS""100
CIRCUIT DIAGRAM
MT09M/MT09MC

@I••··
l ~i~:@
1· I i . ;g:c I·
i """==
f
; ••····- · · · · · · · · · · · · ·. . · · · · - · · · · ·, ············• - •
0
1T~1T···················r···....···:
!I @
··· - ······.. -·- · .. - ··- ·- ·····- ··1-·························•······r ···

•
: ®il
·t;

I '' -----+ >-+ --

#
~----+-----+-----+ ~-

r ruh
; n.1.1.r
~~~ ;u ~. :·m :
~@.; ~ @W:it:lio

8-29
 SIGNALING SYSTEM

3. Fuse box
4. Main fuse
5. Main switch
9. Backup fuse 2
10. Signaling system fuse
11 . Ignition fuse 2
12. Ignition fuse 1
14. ABS ECU fuse
18. Backup fuse 1
21. Battery
22. Engine ground
25. Handlebar switch (right)
26. Front brake light switch
30. Relay unit
33. Neutral switch
36. Fuel sender
37. Gear position sensor
42. Coolant temperature sensor
44. ECU (Engine Control Unit)
56. ABS ECU (Electronic Control Unit)
58. Rear wheel sensor
61. Shift sensor
63. Meter assembly
64. Multi-function meter
65. Neutral indicator light
66. Oil pressure and coolant temperature warn-
ing light
69. Fuel level warning light
71 . Turn signal indicator light (left)
72. Turn signal indicator light (right)
76. Oil pressure switch
77. Rear turn signal light (left)
78. Rear turn signal light (right)
79. Front turn signal/position light (ri ght)
80. Front turn signal/position light (left)
84. Tail/brake light
88. Rear brake light switch
89. Handlebar switch (left)
94. Hom switch
95. Hazard switch
96. Turn signal switch
97.Horn

8-30
 SIGNALING SYSTEM

MT09SPM/MT09SPMC

--

8-31
 SIGNALING SYSTEM

3. Fuse box
4. Main fuse
5. Main switch
9. Backup fuse 2
10. Signaling system fuse
11. Ignition fuse 2
12. Ignition fuse 1
14. ABS ECU fuse
1B. Brake light fuse
20. Backup fuse 1
23. Battery
24. Engine ground
28. Front brake light switch
29. Rear brake light switch
34. Relay unit
37. Neutral switch
40. Fuel sender
41. Gear position sensor
46. Coolant temperature sensor
48. ECU (Engine Control Unit)
60. ABS ECU (Electronic Control Unit)
62. Rear wheel sensor
65. Shift sensor
67. Meter assembly
68. Multi-function meter
69. Neutral indicator light
70. Oil pressure and coolant temperature warn-
ing light
73. Fuel level warning light
75. Turn signal indicator light (left)
76. Turn signal indicator light (right)
82. Oil pressure switch
83. Rear turn signal light (left)
84. Rear turn signal light (right)
85. Front turn signal/position light (ri ght)
86. Front turn signal/position light (left)
90. Tail/brake light
94. Brake light relay
95. Handlebar switch (left)
99. Hom switch
102.Hazard switch
103.Turn signal switch
104.Horn

8-32
 SIGNALING SYSTEM

EAS3Co01
TROUBLESHOOTING
• Any of the following fail to light: tum signal light, brake light or an indicator light.
• The horn tails to sound.
• The fuel meter fails to come on.
• The speedometer fails to operate.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Before troubleshooting, remove the following part(s):
1. Rider seat
2. Fuel tank side cover
3. Fuel tank center cover
4. Fuel tank
5. Air filter case

1. Check the fuses.

(Main, ignition 1, ignition 2, ABS
ECU signaling system, backup 1,
Replace the fuse(s).
backup 2, and brake light.)
Refer to "CHECKING THE FU S-
ES" on page 8-55.

OKi

2 . Check the battery.

Refer to "CHECKING AND • Clean the battery tenninals.
CHARGING THE BATTERY" on • Recharge or replace the battery.
page 8-56.

OKi

3. Check the main switch.

Refer to "CHECKING THE Replace the main switch.
SWITCHES" on page 8-53.

OKi

4 . Check the entire signaling sys-

tem's wiring. Properly connect or repair the signaling
Refer to "CIRCUIT DIAGRAM" on system's wiring.
page 8-29.

OKi

Check the condition of each of the sig-

naling system circuits. Refer to
"Checking the signaling system" on
page 8-34.

8-33
 SIGNALING SYSTEM

Checking the signaling system

The horn fails to sound.

1. Check the horn switch.

Refer to "CHECKING THE Replace the handlebar switch (left).
SWITCHES" on page 8-53.

OKi

2 . Check the horn.

Refer to "CHECKING THE HORN" Replace the horn.
on page 8-62.

OKi

3. Check the entire signaling sys-

tem's wiring. Properly connect or repair the signaling
Refer to "CIRCUIT DIAGRAM" on system's wiring.
page 8-29.

OKi

This circuit is OK.

The tail/brake light fails to come on.

1. Check the front brake light switch.

Refer to "CHECKING THE Replace the front brake light switch.
SWITCHES" on page 8-53.

OKi

2 . Check the rear brake light switch.

Refer to "CHECKING THE Replace the rear brake light switch.
SWITCHES" on page 8-53.

OKi

3. Check the entire signaling sys-

tem's wiring. Properly connect or repair the signaling
Refer to "CIRCUIT DIAGRAM" on system's wiring.
page 8-29.

OKi

This circuit is OK.

The turn signal light turn signal indicator light or both fail to blink.
1. Check the turn signal switch.
Refer to "CHECKING THE Replace the handlebar switch (left).
SWITCHES" on page 8-53.

OKi

2. Check the hazard switch.

Refer to "CHECKING THE Replace the handlebar switch (left).
SWITCHES" on page 8-53.

8-34
 SIGNALING SYSTEM

OKt

3. Check the entire signaling sys-

tem's wiring. Properly connect or repair the signaling
NG ➔
Refer to "CIRCUIT DIAGRAM" on system's wiring.
page 8-29.

OK-I,

Replace the meter assembly or turn

s ignal light.

T he neutral indicator light fails to come on.

1. Check the neutral switch.

Refer to "CHECKING THE Replace the neutral switch.
SWITCHES" on page 8-53.

OK-I,

2. Check the relay unit (diode).

Refer to "CHECKING THE RELAY Replace the relay unit.
UNIT (DIODE)" on page 8-58.

OKt

3. Check the entire signaling sys-

tem's wiring. Properly connect or repair the signaling
Refer to "CIRCUIT DIAGRAM " on system's wiring.
page 8-29.

OKt

Replace the meter assembly.

T he 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"
1. Check the entire signaling sys-
tem's wiring. Properly connect or replace the wiring har-
Refer to "CIRCUIT DIAGRAM " on ness.
page 8-29

OKt

2. Disconnect the oil pressure s.witch

lead from the oil pressure switch,
and then check whether the oil
pressure and coolant temperature Replace the meter assembly.
warning light comes on when the
lead is connected to the engine
ground.

OK-I,

Replace the oil pressure switch.

8-35
 SIGNALING SYSTEM

l"he oil pressure and coolant temperature warning light remains on after the engine is started.

1. Check the entire signaling sys-

tem's wiring. Properly connect or replace the wiring har-
Refer to "CIRCUIT DIAGRAM" on ness.
page 8-29.

OKi

2 . Measure the engine oil pressure.

Refer to "MEASURING THE EN- Check the engine oil leakage, oil viscosity,
GINE OIL PRESSURE" on page 3- oil seal, oil filter, or oil pump.
29.

OKi

Replace the oil pressure switch.

l"he fuel level warning light fails to come on.

1. Check the fuel sender.

Refer to "CHECKING THE FUEL NG➔ Replace the fuel pump assembly.
SENDER" on page 8-62.

OKi

2 . Check the entire signaling sys-

tem's wiring. Properly connect or repair the signaling
Refer to "CIRCUIT DIAGRAM" on system's wiring.
page 8-29.

OKi

Replace the meter assembly.

l"he oil pressure and coolant temperature warning light fails to come on.

1. Check the coolant temperature

sensor.
Refer to "CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR"
on page 8-63.

OKi

2. Check the entire signaling sys-

tem's wiring. Properly connect or replace the wiring har-
Refer to "CIRCUIT DIAGRAM'' on ness.
page 8-29.

OKi

Replace the ECU or meter assembly.

Refer to "REPLACING THE ECU (En-
gine Control Unit)" on page 8-55.

8-36
 SIGNALING SYSTEM

ass (Quick Shift System) does not operate.

1. Check that the M IL does not come
Repair the faulty parts.
on.

OKi
2 . Check that the QSS is working un- Check the OSS operating conditions ex-
der normal QSS operating condi- plained in the owner's manual and operate
tions. the OSS accordingly .

OKi
3 . Make sure that the OSS is effec-
tive.
Activate the OSS. (Set the OSS to a set-
(Check whether the "OS A,.. " icon
ting other than "OFP'.)
is displayed at the top of the me-
ter.)

OKi
4 . Are you operating while the
Operate while the "QS A,.. " icon is lit.
"OS A ,.. " icon is lit?

OKi
5 . Is the transmission gear display
Repair the gear position sensor.
normal?

OKi
6 . Check the connection of the cou-
pler between the gear position sen- Connect the gear position sensor coupler.
sor and the ECU.

OKi
7 . Are the clutch and neutral swrtches
Repair the switch if it is not normal.
normal?

OKi
8 . Check the shift sensor value in the
diagnostic mode.
2.5 V when the shift pedal is not be-
ing operated.
Replace the shift sensor.
4.5 V when the shift pedal is
pressed fully in.
0.5 V when the shift pedal is
pushed fully up.

OKi
9 . Check the entire signaling sys-
tem's wiring. Properly connect or repair the signaling
Refer to "CIRCUIT DIAGRAM" on system's wiring.
page 8-29.

OK.I,

8-37
 SIGNALING SYSTEM

Replace the ECU.

Refer to "REPLACING THE ECU (En-
g ine Control Unit)" on page 8-55.

T he speedometer fails to operate.

1. Check the rear wheel sensor.

Refer to "MAINTENANCE OF THE
Replace the rear wheel sensor.
REAR WHEEL SENSOR AND
SENSOR ROTOR" on page 4-2.2.

OKi
2. Check the entire wheel sensor wir-
Properly connect or repair the wheel sen-
ing.
sor wiring.
Refer to TIP.

OKi
Replace the hydraulic unit assembly,
ECU, meter assembly.
Refer to "REPLACING THE ECU (En-
g ine Control Unit)" on page 8-55.
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.
(white/green- white/green)
(white/yellow-white/yellow)
• Between joint coupler and meter assembly coupler.
(blue/white- blue/white)
(blue/black- blue/black)

8-38
 COOLING SYSTEM

EA""""7

COOLING SYSTEM
.,..,_
CIRCUIT DIAGRAM
MT09M/MT09MC

IL

8-39
 COOLING SYSTEM

3. Fuse box
4. Main fuse
5. Main switch
6. Radiator fan motor relay
9. Backup fuse 2
12. Ignition fuse 1
19. Radiator fan motor fuse
21. Battery
22. Engine ground
42. Coolant temperature sensor
44. ECU (Engine Control Unit)
87. Radiator fan motor

8-40
 COOLING SYSTEM

MT09SPM/MT09SPMC

................

[f@!
@·;

I LiEL-.. . 1

8-41
 COOLING SYSTEM

3. Fuse box
4. Main fuse
5. Main switch
6. Radiator fan motor relay
9. Backup fuse 2
12. Ignition fuse 1
21. Radiator fan motor fuse
23. Battery
24. Engine ground
46. Coolant temperature sensor
48. ECU (Engine Control Unit)
93. Radiator fan motor

8-42
 COOLING SYSTEM

EAS3CGOO
TROUBLESHOOTING
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Before troubleshooting, remove the following part(s):
1. Rider seat
2. Fuel tank side cover
3. Fuel tank center cover
4. Fuel tank
5. Air filler case

1. Check the fuses.

(Main, ignition 1, backup 2, and ra-
diator fan motor) Replace the fuse(s).
Refer to "CHECKING THE FUS-
ES" on page 8-55.

OKi

2 . Check the battery.

Refer to "CHECKING AND • Clean the battery tenninals.
CHARGING THE BATTERY" on • Recharge or replace the battery.
page 8-56.

OKi

3. Check the main switch.

Refer to "CHECKING THE Replace the main switch.
SWITCHES" on page 8-53.

OKi

4 . Check the radiator fan motor.

Refer to "CHECKING THE RADIA- Replace the radiator fan motor(s).
TOR FAN MOTOR" on page 8-63.

OKi

5 . Check the radiator fan motor relay.

Refer to "CHECKING THE RE- Replace the radiator fan motor relay.
LAYS" on page 8-56.

OKi

6 . Check the coolant temperature

sensor.
Refer to "CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR"
on page 8·63.
OKi

7 . Check the entire cooling system's

wiring. Property connect or repair the cooling sys-
NG ➔
Refer to "CIRCUIT DIAGRAM" on tem's wiring.
page 8-39.

OK.I,

8-43
 COOLING SYSTEM

Replace the ECU.

Refer to "REPLACING THE ECU (En-
g ine Control Unit)" on page 8-55.

8-44
 FUEL PUMP SYSTEM

EA""""'1

FUEL PUMP SYSTEM

EA"""'13
CIRCUIT DIAGRAM
MT09M/MT09MC

11; ·····-
! ffl!~
!....... ~

8-45
 FUEL PUMP SYSTEM

3. Fuse box
4. Main fuse
5. Main switch
7. Fuel injection system fuse
9. Backup fuse 2
12. Ignition fuse 1
21. Battery
22. Engine ground
25. Handlebar switch (right)
28. Stop/run/start switch
30. Relay unit
32. Fuel pump relay
35. Fuel pump
44. ECU (Engine Control Unit)

8-46
 FUEL PUMP SYSTEM

MT09SPM/MT09SPMC

~f· m
: fflii}
...............

Jbm.
~

8-47
 FUEL PUMP SYSTEM

3. Fuse box
4. Main fuse
5. Main switch
7. Fuel injection system fuse
9. Backup fuse 2
12. Ignition fuse 1
23. Battery
24. Engine ground
30. Handlebar switch (right)
32. Stop/run/start switch
34. Relay unit
36. Fuel pump relay
39. Fuel pump
48. ECU (Engine Control Unit)

8-48
 FUEL PUMP SYSTEM

EAS30614

TROUBLESHOOTING
If the fuel pump fails to operate.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Before troubleshooting, remove the following part(s):
1. Rider seat
2. Fuel tank side cover
3. Fuel tank center cover
4. Fuel tank

1. Check the fuses.

(Main, ignition 1, backup 2, and
fuel injection system) Replace the fuse(s).
Refer to "CHECKING THE FUS-
ES" on page 8-55.

OKi

2 . Check the battery.

Refer to "CHECKING AND • Clean the battery tenninals.
CHARGING THE BATTERY" on • Recharge or replace the battery.
page 8-56.

OKi

3. Check the main switch.

Refer to "CHECKING THE Replace the main switch.
SWITCHES" on page 8-53.

OKi

4 . Check the stop/run/start switch.

Refer to "CHECKING THE Replace the handlebar switch (right).
SWITCHES" on page 8-53.

OKi

5 . Check the relay unit (fuel pump re-

lay).
Replace the relay unit.
Refer to "CHECKING THE RE-
LAYS" on page 8-56.

OKi

6 . Check the fuel pump.

Refer to "CHECKING THE FUEL Replace the fuel pump.
PUMP OPERATION" on page 7-3.

OKi

7 . Check the entire fuel pump sys-

tem's wiring. Properly connect or repair the fuel pump
Refer to "CIRCUIT DIAGRAM" on system's wiring.
page 8-45.

OK.I,

8-49
 FUEL PUMP SYSTEM

Replace the ECU.

Refer to "REPLACING THE ECU (En-
g ine Control Unit)" on page 8-55.

8-50
 ELECTRICAL COMPONENTS

..ELECTRICAL
.,.,.,..
COMPONENTS

15

~ 14
13
9

10

1. ECU (Engine Control Unit) 18. Intake air temperature sensor

2. Fuel pump 19. Clutch switch
3. Relay unit
4. Radiator fan motor relay
5. Fuse box
6. Brake light relay (for MT09SPM/ MT09SPMC)
7. Starter relay
8. Gear position sensor
9. Shift sensor
10. Sidestand switch
11. AC magneto
12. Crankshaft position sensor
13. 0 2 sensor
14. Purge cut valve solenoid (for MT09MC/
MT09SPMC)
15. Front wheel sensor
16.Hom
17. Headlight control unit

8-51
 ELECTRICAL COMPONENTS

1. ABS ECU (Electronic Control Unit)

2. Throttle servo motor
3. Intake air pressure sensor 2
4. Intake air pressure sensor 1
5. Throttle position sensor
6. Injector
7. Accelerator position sensor
8. Front brake light switch
9. Main switch
10. Ignition coil
11. Radiator fan motor
12. Coolant temperature sensor
13. Starter motor
14. Oil pressure switch
15. Neutral switch
16. Rear brake light switch
17. Rear wheel sensor
18. Rectifier/regulator
19. IMU (Inertial Measurement Unit)
20. Battery

8-52
 ELECTRICAL COMPONENTS

CHECKING THE SWITCHES

Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the
wiring connections and if necessary, replace the switch.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Refer to "CHECKING THE SWITCIHES" in "BASIC INFORMATION" (separate volume).

MT 09M/MT09MC

1 lllB WX B VO
' 9
FREE
-------
DOWN
SET ~

UP IC ,..,

2 ~,a y
ON
OFF

3 ~
ON , a
OFF
y 10

----
OFF
RUN
..,, UII B

4~
ON a
OFF

:6mv
'
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.:---------------------------~
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tlR.....
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-- ---- --.
Br Y
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• 8 y
• I
L-------------------------- ' '
1--------------------------
1. Mode switch
2. Dimmer switch
3. Pass switch
4. Hom switch
5. Hazard switch
6. Turn signal switch
7. Clutch switch
8. Sidestand switch
9. Front brake light switch
10. Stop/run/start switch
11 . Main switch
12. Neutral switch
13. Rear brake light switch

8-53
 ELECTRICAL COMPONENTS

MT 09SPM/MT09SPMC

: 10 :
'' ~~=== ''
,,, : 1?1§9%1 ,~~~j i
2
---- ""-'"'
SET
FREE
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1-------------------------~' '
AES
: 11,..,,,.~=== :
3 ----
HI
LO
PASS
Y YIB Y
: 1?1¥1¥11~ 1
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•-------------------------J
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: 12 :
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---- •t IJII B ..•
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.:
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AUN
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UP

DOWN

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l 14 I :
8 i ,tSb; :
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····················------J ' :1:
... ...
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: __________ : ••• -♦ _ _ _ _ _ _ _ _ _ _ :

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: -----------' --------------' : ••••••••••••••••••••••••_ I

1. Cruise control power switch

2. Cruise control setting switch
3. Dimmer/pass switch
4. Hom switch
5. Mode switch
6. Select switch
7. Hazard switch
8. Turn signal switch
9. Sidestand switch
10. Clutch switch
11. Front brake light switch
12. Stop/run/start switch
13. Main switch
14. Neutral switch
15. Rear brake light switch

8-54
 ELECTRICAL COMPONENTS

EA""""1
CHECKING THE FUSES Amper-
Fuses Q 'ty
The following procedure applies to all of the fus- age rating
es. Term inal 1 2A 1
ECA13ti80

NOTICE Backup 1 7.5A 1

-------------
To avoid a short circuit, always set the main Backup 2 15 A 1
switch to "OFF" when checking or replacing Electronic throttle valve 7.5A 1
a fuse.
ABS motor 30A 1
1. Remove: ABS ECU 7.5A 1
• Rider seat
ABS solenoid 15 A 1
Refer to "GENERAL CHASSIS (1 )" on
page 4-1. Cruise co ntrol (for 1
2A
• Fuse box cover MT09SPM/MT09SPMC)
2. Check: Spare fuse 30A 1
• Fuse
Spare fuse 15 A 1
a. Connect the digital circuit tester to the fuse
Spare fuse 10 A 1
and check the continuity.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ Spare fuse 7.5A 1
Set the digital circuit tester selector to "0 ", Spare fuse 2A 1

EWAt3310

Digital circuit tester (CD732) A WARNING

90890-03243 Never use a fuse with an amperage rating
Model 88 Multimeter with ta- other than that specified. Improvising or us-
chometer ing a fuse with the wrong amperage rating
YU-A1927 may cause extensive damage to the electri-
cal system, cause the lighting and ignition
b. If the digital circuit test er indica tes "O.L", re-
systems to malfunction and could possibly
place the fuse.
cause a fire.
3. Replace:
• Blown fuse 4. Install:
a. Set the main switch to "OFP'. • Fuse box cover
b. Install a new fuse of the correct amperage • Rider seat
rating. Refer to "GENERAL CHASSIS (1 )" on
c. Set on the switches to verify if the electrical page 4-1.
circuit is operational.
NOTICE
d . If the fuse immediately blows again, check
the electrical circuit.
-------------
• Be careful not to lose or damage the fuse
box cover. If the fuse box cover is lost or
Amper- damaged, replace it with a new one.
Fuses Q'ty
age ra1ing • Be sure to install the fuse box cover. Water
Main 50A 1 may get inside the fuse box and cause mal-
function.
Headlight 7 .S A 1
Signaling system 7.5A 1 EAS31006

Ignition 1 10A 1 REPLACING THE ECU (Engine Control Unit)

1. Tum the main switch to "OFP'.
Ignition 2 7.5A 1
2. Replace th e ECU (Engine Control Unit).
Radiator fan motor 15A 1 TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
Brake light (for 1 Fix the ECU " 1" with the claw of air filter case•
2A
MT09SPM/MT09SPMC) cover "2" prop erty.
!F uel injection system 7.5A 1

8-55
 ELECTRICAL COMPONENTS

7 . Connect:
• Battery lead
(to the battery terminals)
Ec.<20980

NOTICE _ _ _ _ _ _ _ _ _ _ __
First, connect the positive battery lead, and
then the negative battery lead.
8. Check:
• Battery terminal
l!!!!!!!~~!!!!!!!illll._
3. Clean the throttle bodies and reset the ISC Dirt ➔ Clean with a wire brush.
(idle speed control) learning valu e. Loose connection ➔ Connect p roperty.
Refer to "CHECKING AND CLEANING THE 9. Lubricate:
THROTTLE BODIES" on pa ge 7 -7 . • Battery terminal
4. Check:
Recommended lubricant
• Engine idling speed
Dielectric grease
Start the engine, warn, it up, and then mea-
su re the engine idling speed. 10.lnstall:
• Rider seat
Engine idling speed Refer to "GENERAL CHASSIS (1)" on
1200-1400 r/min page 4-1.

""""""'
CHECKING AND CHARGING THE BATTERY CHECKING THE RELAVS
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ Check each switch for continuity with the digital
Refer to "CHECKING AND CHARGING THE circuit tester. If t he continuity reading is incor-
BATTERY" in "BASIC INFORM ATION" (sepa- rect, replace the relay.
rate volume).
Digital circuit tester (CD732)
1. Remove: 90890-03243
• Rider seat Model 88 Multimeter with ta-
Refer to "GENERAL CHASSIS ( 1)" on chometer
page 4- 1. YU·A1927
2. Disconnect:
• Battery lead 1. Disconnect t he relay from the wire harness.
(from the battery terminals) 2. Connect th e digital circuit tester (Q) and bat-
ECA13700 tery (12 V) to the relay terminal a s shown.
NOTICE Check the relay operation.
------------
First, disconnect the negative battery lead, Out of specification ➔ Replace.
and then the positive battery lead.
3. Remove:
• Battery
Refer to "GENERAL CHASSIS ( 1)" on
page 4- 1.
4. Check:
• Battery charge
5. Charg e:
• Battery
6. Install:
• Battery
Refer to "GENERAL CHASSIS ( 1)" on
page 4- 1.

8-56
 ELECTRICAL COMPONENTS

Starter relay Relay unit (fuel pump relay)

3
&,-:. ............. ····~
2 1 4

mer
,: •. •. G .......•...........
1, 1
1 ,: 2
4
1. Positive battery terminal 1. Positive b attery 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

~
Relay operation Result
Continuity Continuity
(between "3" and "4") (between "3" and "4")

Relay unit (starting circuit cut-off relay) Radiator fan motor relay

1 2 4

1. Positive battery terminal 1. Positive b attery 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")

8-57
 ELECTRICAL COMPONENTS

Brake light relay (for MT09SPM/MT09SPMC)

Continuity
Positive tester probe
sky blue "1 "
Negative tester probe
black "2"
No continuity
Positive tester probe
black "2"
Negative tester probe
sky blue "1 "
Continuity
1. Positive battery terminal Positive tester probe
2. Negative battery terminal sky blue "1 "
3. Positive tester probe Negative tester probe
4. Negative tester probe blue "3"
No continuity
Positive tester probe
Result blue "3"
No continuity Negative tester probe
(between "3" and "4") sky blue "1"
...,.,,.
CHECKING THE RELAY UNIT (DIODE)
Continuity
Positive tester probe
sky blue "1"
1. Check: Negative tester probe
• Relay unit (diode) sky blue/white "4"
Out of specification ➔ Replace. No continuity
Positive tester probe
Digital circuit tester (CD732) sky blue/white "4"
90890-03243 Negative tester probe
Model 88 Multimeter with ta- sky blue "1"
chometer Continuity
YU-A1927 Positive tester probe
blue/black "5"
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ Negative tester probe
The digital circuit tester readings are shown in blue "3"
the following table. No continuity
Positive tester probe
blue "3"
Negative tester probe
blue/black "5"

a. Disconnect the relay unit coupler from the

wire harness.
b. Connect the digital circuit tester (l.1) to the
relay unit terminal as shown.

8-58
 ELECTRICAL COMPONENTS

c . Check the relay unit (diode) for continuity.

d . Check the relay unit (diode) for no continui- Digital circuit tester (CD732)
ty. 90890-03243
Model 88 Multimeter with ta-
chometer
CHECKING THE IGNITION COILS
VU-A1927
The following procedure applies to a ll of the igni-
tion coils.
• Negative tester probe
1. Check:
Ignition co il terminal "1"
• Primary coil resistance • Positive tester probe
Out of specification ➔ Replace. Spark plug term inal "2"

Primary coil resistance

1.19-1.&1 n
1
a . Disconnect the ignition coil coupler from the
ignition coil.
b. Connect the digital circuit tester (0) to the
ignition coil as shown.

Digital circuit tester (CD732)

90890-03243
Model 88 Multimeter with ta- b. Measure the secondary coil resistance.
chometer
YU-A1927
CHECKING THE IGNITION SPARK GAP
• Positive tester probe 1. Check:
Ignition coil terminal " 1" • Ignition spark gap
• N egative tester probe Out of specification ➔ Perform the ignition
Ignition coil terminal "2" system troubleshooting, starting with step (5).
Refer to "TROUBLESHOOTING" on page 8-
6.

Minimum ignition spark gap

D
~
6.0 mm (0.24 in)

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
If the ignition spark gap is within specification,
the ignition system circuit is operating normally.

G089046 a. Remove the ignition coil from the spark

c . Measure the primary coil resistance. plug.
b. Connect the ignition checker "1 " as shown.
2. Check:
• Secondary coil resistance Ignition checker
Out of specification ➔ Replace. 90890-06754
Oppama pet-4000 spark checker
Secondary coil resistance VM-34487
8.50-11.50 kQ

a . Connect the digital circuit tester (0) to the

ignition coil as shown.

8-59
 ELECTRICAL COMPONENTS

1 2

G089048

2. Ignition coil b. Measure the crankshaft position sensor re-

sistance.
c. Tum the main switch to "ON".
d. Measure the ignition spark gap "a". ...,_
e. Crank the engine by pushing the "<il" side of CHECKING THE STARTER MOTOR
the stop/run/start switch and gradually in- OPERATION
crease the spark gap until a misfire occurs. 1. Check:
..
.,._
CHECKING THE CRANKSHAFT POSITION
• Starter motor operation
Does not operate ➔ Perform the electric
starting system troubleshooting, starting with
SENSOR
st ep (4).
1. Disconnect:
Refer to "TROUBLESHOOTING" on page 8-
• Crankshaft position sensor coupler
14.
(from the wire harness)
2. Check: a. Connect the positive battery terminal "1"
• Crankshaft position sensor resistance and starter motor lead "2" with a jumper
lead "3".
Out of specification ➔ Replace the crank- EWAt3810
shaft position sensor. & WARNING
• A wire that is used as a jumper lead must
Crankshaft position sensor re•
have at least the same capacity of the bat•
sistance
22s-342 n tery lead, otherwise the jumper lead may
bum.
a. Connect the digital circuit tester (Q) to the • This check is likely to produce sparks,
therefore, make sure no flammable gas or
crankshaft position sensor coupler as
shown. fluid is in the vicinity.

Digital circuit tester (CD732)

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

• Positive tester probe

black "1 "
• Negative tester probe
gray "2"
G089054
1
b. Check the starter motor operation.

8-60
 ELECTRICAL COMPONENTS

EAS30<80
CHECKING THE STATOR COIL CHECKING THE RECTIFIER/REGULATOR
1. Disconnect: 1. Check:
• Stator coil coupler • Rectifier/regulator input voltage
(from the wire harness) Out of specification ➔ Correct the stator coil
2. Check: condition.
• Stator coil resistance Refer to "CHECKING THE STATOR COIL"
Out of specification ➔ Replace the stator coil. on page 8-61.

Stator coil resistance Rectifier/regulator input voltage

0.152-0.228 n above 14 V at 5000 r/min

a. Connect the digital circuit tester to the stator a. Connect the digital circuit tester (AC V) to
coil coupler as shown. the rectifier/regulator coupler as shown.

Digital circuit tester (CD732) Digital circuit tester (CD732)

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

• Positive tester probe • Positive tester probe

white "1" white "1"
• N egative tester probe • Negative tester probe
white "2" white "2"

• Positive tester probe • Positive tester probe

white "1" white "1"
• N egative tester probe • Negative tester probe
white "3" white "3"

• Positive tester probe • Positive tester probe

white "2" white "2"
• N egative tester probe • Negative tester probe
white "3" white "3"

1 2 3

b. Measure the stator coil resistance. b. Start the engine and let it run at approxi-
mately 5000 r/min.
c. Measure the rectifier/regulator input volt-
age.
2. Check:
• Rectifier/regulator output voltage
Out of specification ➔ Replace the rectifie r/
regulator.

8-61
 ELECTRICAL COMPONENTS

Regulated voltage (DC) Dmgital circuit tester (CD732)

14.3-14.7 V 90890-03243
Model 88 Multimeter with ta•
a. Connect the digital circuit tester (DC V) to chometer
the battery as shown. VU-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"
VU-A1927

• Positive tester probe ➔

Positive battery terminal
• Negative tester probe ➔
Negative battery terminal
2
b. Start the engine and let it run at approxi-
mately 5000 r/min.
c. Measure the charging voltage.
b. Move the fuel sender float to maximum "3"
CHECKING THE HORN
and minimum "4" level position.
1. Check:
• Hom sound
Faulty sound ➔ Replace.
EAS3Clo'3
CHECKING THE FUEL SENDER
1. Disconnect:
• Fuel pump coupler
(from the fuel pump)
2. Remove:
• Fuel tank
3. Remove:
EAS30<57•
• Fuel pump CHECKING THE FUEL LEVEL WARNING
(from the fuel tank) LIGHT
4. Check: This model is equipped with a self-diagnosis de-
• Fuel sender resistance vice for the fuel level detection circuit.
Out of specification ➔ Replace the fuel pump 1. Check:
assembly. • Fuel level warning light "1"
(Turn the main switch to "ON".)
Sender unit resistance (full) Warning light comes on for a few seconds,
9.0-11.0 n then goes off ➔ Warning light is OK.
Sender unit resistance (empty) Warning light does not come on ➔ Replace
213.0-219.o n the meter assembly.
Warning light flashes eight times, then goes
a. Connect the digital circuit tester (Q) to the
off for 3 seconds in a repeated cycle (mal-·
fuel sender terminals as shown.
function detected in fuel sender) ➔ Replace
the fuel pump assembly.

8-62
 ELECTRICAL COMPONENTS

Coolant temperature sensor re-

sistance
n
2513-2TT7 at 20 °c (2513-
n
21n at 68 °F)
Coolant temperature sensor re-
sistance
210-221 n at 100 °c (210-221 n
1
St 212 °F)

a. Connect the digital circuit tester (0) to the

"""""'"
CHECKING THE RADIATOR FAN MOTOR
coolant temperature sensor as shown.
1. Check:
• Radiator fan motor Digital circuit tester (CD732)
90890-03243
Faulty/rough movement ➔ Replace.
Model 88 Multimeter with ta-
a. Disconnect the radiator fan motor coupler chometer
from the wire harness. VU-A1927
b. Connect the battery (DC 12 V) as shown.
b. Immerse the coolant temperature sensor
• Positive tester probe
"1" in a container filled with coolant "2".
blue "1"
• Negative tester probe TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __
black "2" Make sure the coolant temperature sensor ter-
minals do not get wet.
c. Place a thermometer "3" in the coolant.

D
~

12v

c. Measure the radiator fan motor movement.

...,..,.
G089056

d. Heat the coolant or let it cool down to the

CHECKING THE COOLANT TEMPERATURE specified temperatures.
SENSOR e. Measure the coolant temperature sensor
1. Remove: resistance.
• Coolant temperature sensor 3. Install:
Refer to "CYLINDER HEAD" on page 5-26. • Coolant temperature sensor
EWA1!4130

A WARNING
Coolant temperature sensor
• Handle the coolant temperature sensor 15 N,m (1.5 kgf,m, 11 lb,ft)
with special care.
• Never subject the coolant temperature sen-
sor to strong shocks. If the coolant tem- CHECKING THE THROTTLE SERVO MOTOR
perature sensor is dropped, replace it. 1. Remove:
• Air filter case
2. Check: Refer to "GENERAL CHASSIS (1)" on
• Coolant temperature sensor resistance page 4-1.
Out of specification ➔ Replace.

8-63
 ELECTRICAL COMPONENTS

2. Check:
• Throttle valve operation lnitake air temperature sensor re-
Throttle valves do not fully close ➔ Replace sistance
the throttle bodies. n
5400-6600 at o 0 c (540~600
O at 32 °F)
a. Connect two C-size batteries t o the throttle
lnitake air temperature sensor re-
servo motor terminals "1" as shown.
ECA17600
sistance
NOTICE 289-391 n at 80 °c (289-391 n
-------------
Do not use a 12 V battery to operate the throt•
St 176 °F)
tie servo motor.
a. Connect the digital circuit tester (0) to the
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ __ intake air temperature sensor terminal as
shown.
Do not use old batteries to operate the throttle
servo motor.
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
chometer
VU-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. Place a thermometer "3" in the water.

A. Check that the throttle valves "2" open.

B. Check that the throttle valves "2'' fully close. G089057

...,_
CHECKING THE INTAKE AIR
d. Slowly heat the water, then let it cool down
to the specified temperature .
e. Measure the intake air temperature sensor
TEMPERATURE SENSOR resistance.
1. Remove:
• Intake air temperature sensor 3. Install:
EWAT!4110 • Intake air temperature sensor
A WARNING EAS30<81
• Handle the intake air temperature sensor CHECKING THE FUEL INJECTORS
with special care. The following procedure applies to all of the fuel
• Never subject the intake air temperature injectors.
sensor to strong shocks. If the intake air 1. Remove:
temperature sensor is dropped, replace it. • Fuel inject or
2. Check: Refer to ''THROTTLE BODIES" on page 7-5.
2. Check:
• Intake air temperature sensor resistance
• Fuel inject or resistance
Out of specification ➔ Replace.
Out of specification ➔ Replace the fuel injeo-
tor.

8-64
 ELECTRICAL COMPONENTS

• Positive tester probe ➔

Resistance Purge cut valve solenoid terminal "1"
12.0 0 • Negative tester probe ➔
Purge cut valve solenoid terminal ''2"
a . Disconnect the fuel injector coupler from
the fuel injector.
b. Connect the digital circuit tester (0) to the 1
fuel injector coupler as shown.

~
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927

• Positive tester probe ➔ c. Measure the purge cut valve solenoid resis-
Injector terminal "1" tance.
• N egative tester probe ➔
Injector terminal "2" EAS31ffl
CHECKING THE WHEEL SWITCH
1. Check:
• Wheel switch "1" output voltage
1 2 Out of specification ➔ Replace the right han-
dlebar switch.
a. Connect the digital circuit tester (DC V) to
the handlebar switch coupler (right) as
shown.

~
Di gital circuit tester (CD732)
90890-03243
c. Measure the fuel injector resistance.
...,_
CHECKING THE PURGE CUT VALVE
Model 88 Multimeter with ta-
chometer
YU·A1927
SOLENOID (for MT09MC/MT09SPMC)
1. Check: • Positive tester probe
white/green "2"
• Purge cut valve solenoid resistance
• Negative te ster probe
Out of specification ➔ Replace. black/white "3"

Solenoid resistance b. Tum the main switch to "ON".

22- 26 0
c. When turning the wheel switch in direction
"a" and "b", check that the output voltage is
a . Disconnect the purge cut valve solenoid
within the specified values.
coupler from the wire harness.
b. Connect the digital circuit tester to the
purge cut valve solenoid terminals as
shown. ili Output voltage reading cycle
More than 5 V to less than 0.5 V
then back to more than 5 V to
l,e ss than 0.5 V
Digital circuit tester (CD732)
90890-03243 d. Connect the digital circuit tester (DC V) to
Model 88 Multimeter with ta- the hand lebar switch coupler (right) as
chometer shown.
YU-A1927

8-65
 ELECTRICAL COMPONENTS

Digital circuit tester (CD732)

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

• Positive tester probe

white/black "4"
• Negative tester probe
black/white "3"

e. When turning the wheel switclh in direction

"a", check that the output voltage is within
the specified values.

Output voltage
More than 5 V

I. When turning the wheel switclh in direction

"b", check that the output voltage is within
the specified values.

Output voltage
Less than 0.5 V

3 2 4

8-66
 ELECTRICAL COMPONENTS

8-67
 SELF DIAGNOSTIC

SELF-DIAGNOSTIC FUNCTION..................................................................... 9-1

GLOSSARY .. ............................................................................................. 9-1
OUTLINE ............................ ................... ................................................... . 9-1
CHECKING THE WARNING LIGHT ......................................................... 9-2
VDT .................................... ................................................... .................... 9-3
PARTS CONNECTED TO THE ECU ........................................................ 9-3
PARTS CONNECTED TO THE ABS ECU ................................................ 9-4
PRECAUTIONS FOR ROAD TEST ...... .................................................... 9-4

SYSTEM DIAGRAM ........................................................................................ 9-5

ECU CIRCUIT DIAGRAM .......................................................................... 9-5
ECU COUPLER LAYOUT ......................................................................... 9-8

FUEL INJECTION SYSTEM ........................................................................... 9-12

CIRCUIT DIAGRAM ................................................................................ 9-12
BASIC PROCESS FOR TROUBLESHOOTING ..................................... 9· 16
[A) THE MIL COMES ON/FLASHES AND ENGINE OPERATION
IS NOT NORMAL ................................................................................... 9- 17
[BJ THE MIL DOES NOT COME ON, BUT THE ENGINE
OPERATION IS NOT NORMAL ............................................................. 9- 17

CRUISE CONTROL SYSTEM (for MT09SPM/MT09SPMC) ........................ 9-18

CIRCUIT DIAGRAM ................... ............................................................. 9-18
CRUISE CONTROL CIRCUIT OPERATION ............ ............................... 9-20
BASIC INSTRUCTIONS FOR TROUBLESHOOTING ............................ 9-21
BASIC PROCESS FOR TROUBLESHOOTING ..................................... 9-22
[A) CHECKING THE CRUISE CONTROL SYSTEM INDICATOR
LIGHT ........................................................................... .......................... 9-23
[B-1] DIAGNOSIS USING THE DTC ........................ ............................... 9-23
[B-2] DIAGNOSIS USING THE MALFUNCTION HISTORY CODES ...... 9-23
[B-3] MALFUNCTION HISTORY IS NOT DISPLAYED ........................... 9-23
[C-1] ERASING THE DTC ....................................................................... 9-24
[C-2] FINAL CHECK ................................................................................ 9-24

ABS (Anti-lock Brake System) .................................................................... 9-26

CIRCUIT DIAGRAM ................................................................................ 9-26
ABS COMPONENTS CHART ....................................... .......................... 9-30
ABS COUPLER LOCATION CHART ....................... ............................... 9-31
MAINTENANCE OF THE ABS ECU ....................................................... 9-32
ABS TROUBLESHOOTING OUTLINE .................................................... 9-32
BASIC INSTRUCTIONS FOR TROUBLESHOOTING ............................ 9-33

I
[A) CHECKING THE ABS WARNING LIGHT .......................................... 9-35
[A-1) ONLY THE ABS WARNING LIGHT FAILS TO COME ON ............. 9-35
[A-2] ALL INDICATOR LIGHTS FAIL TO COME ON .............................. 9-35
[A-3] THE ABS WARNING LIGHT COMES ON ...................................... 9-35
 [A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE ........................ 9-36
[A-5] ABS ECU AND Fl ECU FAIL TO COMMUNICATE ........................ 9-36
[B-1] MALFUNCTION ARE CURRENTLY DETECTED .......................... 9-36
[B-2] DIAGNOSIS USING THE DTC ....................................................... 9-36
[B-3] DELETING THE DTC ........................ ................... .......................... 9-37
[C-1] FINAL CHECK ................................................................................ 9-37

SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE .......... 9-39

DTC TABLE ............................................................................................. 9-39
SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION
SYSTEM) ................................................................................................ 9-43
SELF-DIAGNOSTIC FUNCTION TABLE (FOR ABS
(Anti-lock Brake System)) ....................................................................... 9-57
COMMUNICATION ERROR WITH THE METER ................................... 9-61
DIAGNOSTIC CODE: SENSOR OPERATION TABLE ........................... 9-62
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE ...................... 9-66

EVENT CODE TABLE ................................................................................... 9-68

30_EVENT ..................................................................................................... 9-71

TROUBLESHOOTING ....... ................... .................................................. 9-71

70_EVENT ..................................................................................................... 9-73

TROUBLESHOOTING ............................................................................ 9-73

C0520 .............................................................................•.............................. 9-74

TROUBLESHOOTING ............................................................................ 9-74

P0030 ............................................................................................................. 9-78

TROUBLESHOOTING ............................................................................ 9-78

P00D1, P2195 ................................................................................................ 9-82

TROUBLESHOOTING ............................................................................ 9-82

P0107, P0108 .................................................................•.............................. 9-86

TROUBLESHOOTING ............................................. ........................ ....... 9-86

P0112, P0113 ................................................................................................. 9-90

TROUBLESHOOTING ............................................. ............................... 9-90

P0117, P0118 ................................................................................................ 9-94

TROUBLESHOOTING ............................................. ............................... 9-94

P01 22, P0123, P0222, P0223, P2 135 ........................................................... 9-98

TROUBLESHOOTING ............................................. ............................... 9-98
P0132 ............................•..............................................................................9-103
TROUBLESHOOTING ....................................... ................................... 9-1 03

P0201 ...........................................................................................................9-107
TROUBLESHOOTING .......................................................................... 9-1 07

P0202 ...........................................................................................................9-110
TROUBLESHOOTING .......................................................................... 9-1 10

P0203 ........................................................................................................... 9-113

TROUBLESHOOTING .......................................................................... 9-113

P0335 ...........................................................................................................9-116
TROUBLESHOOTING .......................................................................... 9-116

P0351 ...........................................................................................................9·120
TROUBLESHOOTING ....................................... ................................... 9· 120

P0352 ...........................................................................................................9-124
TROUBLESHOOTING ............ .............................................................. 9-124

P0353 ...........................................................................................................9-128
TROUBLESHOOTING .......................................................................... 9-128

P0458 ...........................................................................................................9-132
TROUBLESHOOTING ............ .............................................................. 9-132

P0480 ...........................................................................................................9-136
TROUBLESHOOTING .......................................................................... 9-136

P0500, P1500 ..............................................................................................9-139

TROUBLESHOOTING ............................................ .............................. 9-139

P0560, P0563 .................................................................•............................ 9-152

TROUBLESHOOTING .......................................................................... 9-152

P0564 ........................................................................................................... 9-153

TROUBLESHOOTING ............................................ .............................. 9-153

P056C .......................................................................................................... 9·159

TROUBLESHOOTING .......................................................................... 9-159
P0601 ..............................................................................•............................9-166
TROUBLESHOOTING ............................................. ............................. 9· 166

P0606 ..............................................................................•............................9-167
TROUBLESHOOTING ..........................................................................9· 167

P062F ........................................................................................................... 9-168

TROUBLESHOOTING .......................................................................... 9· 168

P0638 ..............................................................................•............................ 9-169

TROUBLESHOOTING .......................................................................... 9· 169

P0657 ..............................................................................•............................9-173
TROUBLESHOOTING ............................................. ............................. 9· 173

P0916, P0917 .............................................................................................. 9-177

TROUBLESHOOTING ............................................. ............................. 9·177

P1004 ..............................................................................•............................9-181
TROUBLESHOOTING .......................................................................... 9· 181

P1600 ..............................................................................•............................9-183
TROUBLESHOOTING .......................................................................... 9· 183

P1601 ..............................................................................•............................9-187
TROUBLESHOOTING .......................................................................... 9· 187

P1602 ...........................................................................................................9-191
TROUBLESHOOTING ............................................. ............................. 9· 191

P1606, P1607 ............................................................................................... 9-195

TROUBLESHOOTIN G .......................................................................... 9· 195

P1806, P1807 .................................................................•............................ 9-199

TROUBLESHOOTING .......................................................................... 9· 199

P2122, P2123, P2127, P2128, P2138 ......................................................... 9-203

TROUBLESHOOTIN G .......................................................................... 9·203

P2158 ........................................................................................................... 9-207

TROUBLESHOOTING .......................................................................... 9-207
U0125 .............................................................................•............................ 9-212
TROUBLESHOOTING ....................................... ................................... 9-212

U0155 or Err ................................................................................................ 9-216

TROUBLESHOOTING .......................................................................... 9-21 6

11_ABS ....................................................................................................... 9-220

TROUBLESHOOTING .................................................. ........................ 9-220

12_ABS ..........................................................................•............................ 9-221

TROUBLESHOOTING .......................................................................... 9-221

13, 26_ABS ................................................................................................. 9-222

TROUBLESHOOTING .......................................................................... 9-222

14, 27_ABS ................................................................................................. 9-223

TROUBLESHOOTING ....................................... ................................... 9·223

15_ABS ....................................................................................................... 9-224

TROUBLESHOOTING ............ .............................................................. 9-224

16_ABS ....................................................................................................... 9-226

TROUBLESHOOTING .......................................................................... 9-226

21 _ABS ..........................................................................•............................ 9-228

TROUBLESHOOTING ............ .............................................................. 9-228

31_ABS ....................................................................................................... 9-229

TROUBLESHOOTING .......................................................................... 9-229

33_ABS ....................................................................................................... 9-231

TROUBLESHOOTING ............................................ .............................. 9-231

34_ABS ....................................................................................................... 9-233

TROUBLESHOOTING ............................... ................... ........................ 9-233

41_ABS ....................................................................................................... 9-234

TROUBLESHOOTING .......................................................................... 9-234

42_ABS ....................................................................................................... 9-235

TROUBLESHOOTING .......................................................................... 9-235
43, 45_ABS ....................................................................•............................ 9-236
TROUBLESHOOTING ............................................. ............................. 9·236

44, 46_ABS ....................................................................•............................ 9-237

TROUBLESHOOTING .......................................................................... 9·237

51_ABS ........................................................................................................ 9-238

TROUBLESHOOTING ............................................. ............................. 9·238

53_ABS ..........................................................................•............................ 9-239

TROUBLESHOOTING .......................................................................... 9·239

55_ABS ........................................................................................................ 9-241

TROUBLESHOOTING ............................................. ............................. 9-241

56_ABS ..........................................................................•............................ 9-242

TROUBLESHOOTING ............................................. ............................. 9·242

57_ABS ........................................................................................................ 9-243

TROUBLESHOOTING .......................... ................... ............................. 9-243

62_ABS ....................................................................................................... 9-247

TROUBLESHOOTING ............................................. ............................. 9-247

68_ABS ........................................................................................................ 9-248

TROUBLESHOOTING .......................................................................... 9-248

89_ABS ........................................................................................................ 9-249

TROUBLESHOOTING ............................................. ............................. 9-249

90_ABS ........................................................................................................ 9-252

TROUBLESHOOTING .......................................................................... 9-252

91_ABS ..........................................................................•............................ 9-255

TROUBLESHOOTING .................................................. ........................ 9-255
 SELF-DIAGNOSTIC FUNCTION

..SELF-DIAGNOSTIC
.,.,..,
FUNCTION
EAS33t42

GLOSSARY
Word Description
MIL
MIL is an indicator light that comes on when a control unit detennines 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)
Pending DTC Pending DTC is a code that is saved within a control unit's memory when
(Pending diagnostic the control unit detects an abnormal condition. It the abnonnal condition
trouble code) continues, a malfunction may be determined.
Driving cycle is the duration from the main switch being turned on, OBD re-
Driving cycle
quirements are met, and until the main switch is turned off.
FFD FFD is the data of all signal sensors saved at the moment a malfunction is
(Freeze frame data) determined.
Current malfunction A OTC for an unrecovered, current malfunction.
Recovered malfunc-
A DTC for a previously determined but now recovered malfunction.
lion
Abnormal condition that is detected but not yet detennined to be a malfunc-
Pending abnormality
tion.
Threshold is a point set to detect it the output from sensors are abnormal or
Threshold
not.
O:SD
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)
VDT
(Yamaha diagnostic Diagnostic tool developed especially for Yamaha vehicles.
tool)

OUTLINE
The control unit is equipped with a self-diagnostic function in order to ensure that the system is operat-
ing nonnally. 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
corntrol unit.

9-1
 SELF-DIAGNOSTIC FUNCTION

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 0 2 sensor, the exhaust system part (catalyst, 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.

System Lighting up warning light Lighting time

FUEL INJECTION SYSTEM MIL"1" 2.0 seconds
ABS (Anti-lock Brake Sys-
ABS warning light "2" ·1
tern)
CRUISE CONTROL SYS-
TEM (for MT09SPM/ MIL"1" 2.0 seconds
MT09SPMC)

9-2
 SELF-DIAGNOSTIC FUNCTION

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
•1: The ABS warning light goes off when the vehicle is judged to normal with running .

...,,,...
VDT
This model uses the VDT to identify malfunctions.
For information about using the VDT, refer to the operation manual that is included with the tool.

Yamaha diagnostic to,ol use

(US)
90890-03269
Yamaha diagnostic tool (A/1)
90890-03264
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Yamaha diagnostic tool (A/I) (90890-03264) includes VDT 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 VDT

Remove the protective cap, and then connect the VDT to the coupller "1".

PARTS CONNECTED TO THE ECU

The following parts are connected tto the ECU.
When checking for a power short circuit, the couplers must be disconnected from all of the following
parts beforehand.
• Crankshaft position sensor • Intake air temperature sensor
• Injector # 1 • Fuel pump
• Injector #2 • 0 2 sensor
• Injector #3 • ABS ECU (Electronic Control Unit)
• Clutch switch (for MT09SPM/MT09SPMC) • Throttle servo motor
• Ignition coil #1 • Relay unit
• Ignition coil #2 • Starter relay
• Ignition coil #3 • Purge cut valve solenoid (for MT09MC/
MT09SPMC)
• Throttle position sensor • Brake light relay (for MT09SPM/MT09SPMC)
• Intake air pressure sensor 1 • Radiator fan motor relay
• Intake air pressure sensor 2 • Meter assembly

9-3
 SELF-DIAGNOSTIC FUNCTION

• Coolant temperature sensor • Headlight control unit

• Gear position sensor • Handlebar switch (left and right)
• Shift sensor • IMU (Inertial Measurement Unit)

EAS32918
PARTS CONNECTED TO THE ABS ECU
The following parts are connected to the hydraulic unit assembly (ABS ECU).
When checking for a power short circuit, the couplers must be disconnected from all of the following
parts beforehand.
• Meter assembly • Handlebar switch (left)
• IMU (Inertial Measurement Unit) • Rear brake light switch (for MT09SPM/
MT09SPMC)
• ECU (Engine Control Unit) • Tail/brake light
• Front wheel sensor • Brake light relay (for MT09SPM/MT09SPMC)
• Rear wheel sensor

EAS33137
PRECAUTIONS FOR ROAD TEST
EIVWOGO

A WARNING
When test riding the vehicle, always comply with local traffic regulations.

9-4
 SYSTEM DIAGRAM

EA"""87

SYSTEM DIAGRAM
EAS3mo
ECU CIRCUIT DIAGRAM
IA]
- rn:J
8. Fuel ,.P~".'P relay
t
~. 41. Injector #1
•➔

\1
14. Engine stop
- _..,. - 42. Injector #2
20. Fuel< l
"' switch pump {1
j ' ~ 43. Injector #3
Q
:, 6. Ignition
7?,:9. Starter 22. Neutral
~4~
t'-•
-"' fuse 2
[I! 1)
~ Indicator light
11. Main
"'.,; switch
21. Starter
3.Main
fuse
motor ):,,_:: cut-off
7. Starting circuit
relay

l 16. Clutch
2. Battery

,J,
sw_!!ch Fi I
15. Stop/run/start
switch 12. Sidestand , 13. Neutral
switch switch
j 19. Rectifier/regulator ,.,. I 1. ECU (Engine
Control Unit)
,i,
·1
- --- ----- ----- --- ---- ----- ---- ------- ----- ----- --- ---- -------- ------
' 35. Cruise con_!Tol power switch
.
7. Front brake
light switch
rII 36. Cruise control setting switch (SET-)

37. Cruise control setting switch (SET+)

6~ ~

44. Throttte ~ervo motor

8. Rear brake 38. Clutch 39. Front brake 40. Rear brake 1
light switch I switch light switch light switch
6~ I
0,
§~
10 Brake ¼ :

······l
.......... -........:
"
23. Tail/brake light

45. Ignition coil #1

rnJc- r· . . ,
24. Crankshaft position senso{ Q~ ~ ,1, :
I ,_ -. ·'
46. lgn_tti~~. coil #2
25. Intake air pressure sensor 2 f~ -
~~- _, -:- ,1, :
9
----
26. Intake air pressure sensor 1 [Sf:
~~- - _, 47. Ignition coil #3
27. Coolant temperature sensor
--- -,
. iw:
8'
28. Intake air temperature sensor ----

29. Shift sensor

~,
30. Gear position sensor
,,
31. O, sensor

~ f l-, ' <f

):'-

9-5
 SYSTEM DIAGRAM

48.Grip 49. Grip

wanner (left) warmer (right)
4Th--i181------CEsJ--,

32. Throttle 50. Purge cut

position sensor valve solenoid

51. Radiator
fan motor

°§
-~- ii
~
.; ! :54. Headlight
-~ ~ gj jcontrol unit
0 . •
33. Accelerator . <? •
N Ul '
position sensor "' :
.......... ·-·
.. --------- - ---- ---·
:-~~. ~.':t?~.8:S.s:8.~~!~:

56. CAN communication

34. ABS ECU (Electronic Control Unit)
circuit

9-6
 SYSTEM DIAGRAM

1. ECU (Engine Control Unit) 49. Grip warmer (right)

2. Battery 50. Purge cut valve solenoid (for MT09MC/
3. Main fuse MT09SPMC)
4. Electronic throttle valve fuse 51. Radiator fan motor
5. Backup fuse 2 52. Dimmer switch
6. Ignition fuse 53. Pass switch
7. Starting circuit cu1-off relay 54. Headlight control unit
8. Fuel pump relay 55. Meter assembly
9. S1arter relay 56. CAN communication circuit
10. Brake light relay (for MT09SPM/ MT09SPMC) • 1. For MT09SPM/MT09SPMC
11 . Main switch
12. Sidestand switch
13. Neutral switch
14. Engine stop switch
15. ON/start switch
16. Clutch switch
17. Front brake light switch (for MT09SPM/
MT09SPMC)
18. Rear brake light switch (for MT0:9SPM/
MT09SPMC)
19. Rectifier/regulator
20. Fuel pump
21. Starter motor
22. Neutral indicator light
23. Tail/brake light (for MT09SPM/MT09SPMC)
24. Crankshaft position sensor
25. Intake air pressure sensor 2
26. Intake air pressure sensor 1
27. Coolant temperature sensor
28. Intake air temperature sensor
29. Shift sensor
30. Gear position sensor
31. 0 2 sensor
32. Throttle position sensor
33. Accelerator position sensor
34. ABS ECU (Electronic Control Unit)
35. Cruise control power switch (for MT09SPM/
MT09SPMC)
36. Cruise control setting switch (SET- )
(for MT09SPM/MT09SPMC)
37. Cruise control setting switch (RES+)
(for MT09SPM/MT09SPMC)
38. Clutch switch (for MT09SPM/MT09SPMC)
39. Front brake light switch (for MT09SPM/
MT09SPMC)
40. Rear brake light switch (for MT0:9SPM/
MT09SPMC)
41. Injector #1
42. Injector #2
43. Injector #3
44. Throttle servo motor
45. Ignition coil #1
46. Ignition coil #2
47. Ignition coil #3
48. Grip warmer (left)

9-7
 SYSTEM DIAGRAM

EAS""'9
ECU COUPLER LAYOUT

Wire harness Wire harness

No. Connected parts No. Connected parts
color color
1 Throttle servo motor Y/R Dimmer/pass
2 - - 28 switch, Headlight Y/B
control unit
3 - -
29 Fuel pump relay 1../W
4 - -
30 - -
5 0 2 sensor P/B
31 - -
6 - -
Fuel pump relay,
7 Ignition coil #1 0
32 R/L
Fuel pump
8 Ignition coil #3 O/G 33 Ground B/W
9 Ignition coil #2 Gy/R 34 Ground B/W
10 Throttle servo motor Lg/A Accelerator position
35 W/R
11 - - sensor

12 - - ABS ECU (Electron-

36 ic Control Unit)
G
13 - -
Throttle position
14 Injector #1 RIB 37 L
sensor
15 Injector #3 UB 38 - -
16 Injector #2 G/B 39 - -
17 Ground B Grip warmer (left),
40 Grip warmer (right)
Br/Y
Electronic throttle
18 R/L
valve fuse 41 Ignition fuse 2 R/W
Radiator fan motor Accelerator position
19 relay
G/Y 42 y
sensor
20 - - Throttle position
43
sensor
w
21 - -
22 - - 44 - -
23 - - Accelerator position
45 sensor
Y/R
24 - -
46 - -
25 Ground B
47 - -
26 Backup fuse 2 RIG
48 - -
27 Purge cut valve so-
Y/R Throttle position
("2) lenoid 49 B/L
sensor

9-8
 SYSTEM DIAGRAM

Wire harness Wire harness

No. Connected parts No. Connected parts
color color
50 - - 78 - -
Accelerator position 79 - -
51 sensor
Br
Start ing circuit cut-
52 - - 80 off relay, Clutch B/Y
53 - - swrtch

Accelerator position 81 - -
54 W/B Cruise control set-
sensor 82
Br/L
55 - - (*1) ting switch (RES+)
83 Cruise control set-
Throttle position GIL
56 B (*1) ting switch (SET- )
sensor
Accelerator position 84 0 2 sensor Gy/G
57 Y/B
sensor 85 - -
58 - - Intake air tempera-
86 Br/W
59 - - ture sensor

60 - - 87 - -
CAN communica- Crankshaft position
61 tion circuit UB sensor, Intake air
pressure sensor 1,
62 - - Intake air pressure
63 - - 88 sensor 2, Coolant BIL
temperature sensor,
64 - - Intake air tempera-
65 - - ture sensor, Shift
66 Cruise control pow- sensor, 0 2 sensor
er switch 0/W
(*1) Gear position sen-
89 BIL
67 Rear brake light sor
Lg/L
(*1) switch 90 = =

68
Intake air pressure
P/W 91 - -
sensor1 - -
92
Intake air pressure p 93 - -
69
sensor2
94 - -
70 - -
95 Clutch switch L/Y
71 Shift sensor V
Starting circuit cut-
Intake air pressure 96
off relay
uw
72 sensor 1, Intake air
L 97 - -
pressure sensor 2,
Shift sensor Brake light relay,
98
Gear position sen- (*1) Rear brake light Lg/B
73 L switch
sor
74 - - 99 - -
75 - - 100 - -
Crankshaft position 101 - -
76 Gy
sensor Coolant tempera-
102 G/W
CAN communica- ture sensor
77
tion circuit uw

9-9
 SYSTEM DIAGRAM

Wir•e harness
No. Connected parts
color
Gear position sen-
103
sor
GJW
104 - -
ABS ECU (Electron-
105
ic Control Unit)
WIG

106 - -
ABS ECU (Electron-
107
ic Control Unit)
WN

108 - -

*1. For MT09SPM/MT09SPMC

*2. For MT09MC/MT09SPMC

9-10
 SYSTEM DIAGRAM

9-11
 FUEL INJECTION SYSTEM

EA"""40

FUEL INJECTION SYSTEM

EAS32871
CIRCUIT DIAGRAM
MT09M/MT09MC

!,..
..·· · ~ .
~ :
rr

9-12
 FUEL INJECTION SYSTEM

1. AC magneto 87. Radiator fan motor

2. Rectifier/regulator 89. Handlebar switch (left)
3. Fuse box 90. Clutch switch
4. Main fuse
5. Main switch
6. Radiator fan motor relay
7. Fuel injection system fuse
8. Electronic throttle valve fuse
9. Backup fuse 2
11. Ignition fuse 2
12. Ignition fuse 1
14. ABS ECU fuse
18. Backup fuse 1
19. Radiator fan motor fuse
21. Battery
22. Engine ground
23. Starter relay
25. Handlebar switch (right)
28. Stop/run/start switch
29. Accelerator position sensor
30. Relay unit
31. Starting circuit cut-off relay
32. Fuel pump relay
33. Neutral switch
34. Sidestand switch
35. Fuel pump
37. Gear position sensor
38. Intake air pressure sensor 1
39. Intake air pressure sensor 2
40. 0 2 sensor
41. Crankshaft position sensor
42. Coolant temperature sensor
43. Intake air temperature sensor
44. ECU (Engine Control Unit)
45. Ignition coil #1
46. Spark plug
47. Ignition coil #2
48. Ignition coil #3
49. Injector #1
50. Injector #2
51. Injector #3
54. Throttle position sensor
55. Throttle servo motor
56. ABS ECU (Electronic Control Unit)
57. Front wheel sensor
58. Rear wheel sensor
59. IMU (Inertial Measurement Unit)
60. Purge cut valve solenoid (for MT09MC)
61. Shift sensor
62. YDT coupler
63. Meter assembly
64. Multi-function meter
70. MIL (Malfunction indicator light)

9-13
 FUEL INJECTION SYSTEM

MT09SPM/MT09SPMC

i_~r::I•
rll-lR~•-!:-;:e:ir
-• :m•
0'.J.7 {ii!ilt

~
1~
l:

!~~
··{3ii··,t _m _, :·11_ m_:

9-14
 FUEL INJECTION SYSTEM

1. AC magneto 74. MIL (Malfunction indicator light)

2. Rectifier/regulator 93. Radiator fan motor
3. Fuse box
4. Main fuse
5. Main switch
6. Radiator fan motor relay
7. Fuel injection system fuse
8. Electronic throttle valve fuse
9. Backup fuse 2
11. Ignition fuse 2
12. Ignition fuse 1
14. ABS ECU fuse
20. Backup fuse 1
21. Radiator fan motor fuse
23. Battery
24. Engine ground
25. Starter relay
27. Clutch switch
30. Handlebar switch (right)
32. Stop/run/start switch
33. Accelerator position sensor
34. Relay unit
35. Starting circuit cut-off relay
36. Fuel pump relay
37. Neutral switch
38. Sidestand switch
39. Fuel pump
41. Gear position sensor
42. Intake air pressure sensor 1
43. Intake air pressure sensor 2
44. 0 2 sensor
45. Crankshaft position sensor
46. Coolant temperature sensor
47. Intake air temperature sensor
48. ECU (Engine Control Unit)
49. Ignition coil #1
50. Spark plug
51. Ignition coil #2
52. Ignition coil #3
53. Injector #1
54. Injector #2
55. Injector #3
58. Throttle position sensor
59. Throttle servo motor
60. ABS ECU (Electronic Control Unit)
61. Front wheel sensor
62. Rear wheel sensor
63. IMU (Inertial Measurement Unit)
64. Purge cut valve solenoid (for MT09SPMC)
65. Shift sensor
66. YDT coupler
67. Meter assembly
68. Multi-function meter

9-15
 FUEL INJECTION SYSTEM

EAS32917

BASIC PROCESS FOR TROUBLESHOOTING

This section describes the basic process about fuel injection system troubleshooting.
But because a work procedure varies depending to symptom and OTC, check and repair it according
to applicable troubleshooting.

When turning the main switch to No Does the MIL (LED) work No
Check Ille MIL (lED).
"ON", doos the Mil oome on? properly?

Yes Yes
,, •
Yes (BJPertonn the checking wtth the
TOO MIL goes off after 2 seconds?
diagnostic mode.

No

Sdll on/!lash.
[A] Check Ille OTC.

'
Do the troubleshooting according
to the OTCs of "malfunction".

Check the DTCs of "malfuncdon"

are not displayed on the screen.

,,
Flnlshed.

9-16
 FUEL INJECTION SYSTEM

EAS33t 47

[A] THE MIL COMES ON/FLASHES AND ENGINE OPERATI ON IS NOT NORMAL
1. Check the OTC of "malfunction" using the VDT.
2. Check and repair the malfunction according to applicable OTC troubleshooting.
3. Tum the main switch from "OFP' to "ON", and then check the OTC of "malfunction" is not displayed.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• If another OTC is displayed, repeat steps (1) to (3) until no OTC is displayed.
• Turning the main switch to "OFP' will not erase the malfunction history.

EAS33t 48

[BJ 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 VDT in the diagnostic mode.
Refer to "DIAGNOSTIC CODE: SENSOR OPERATION TABLE" on page 9-62 and "DIAGNOSTilC
CODE: ACTUATOR OPERATION TABLE" on page 9-66.
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
31 : Cylinder-#2 ignition coil
32: Cylinder-#3 ignition coil
36: Injector # 1
37: Injector #2
38: Injector #3

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.

9-17
 CRUISE CONTROL SYSTEM (for MT09SPM/MT09SPMC)

EA"'°'41

CRUISE CONTROL SYSTEM (for MT09SPM/MT09SPMC)

...,,,.,.
CIRCUIT DIAGRAM

~ -- =-=-====----==----====---~
~---_____.• 'I,.
I •
I..
rltt-=-=~~~~;t..::::..::::..::::::::::::41-1--.
1
;••····- ·················· - ······ r············ - ·· ff ff •······.!. •····r·•-ll•-;·,
!I @

~ I
1~-
I """ I

9-18
 CRUISE CONTROL SYSTEM (for MT09SPM/MT09SPMC)

3. Fuse box
4. Main fuse
5. Main switch
9. Backup fuse 2
10. Signaling system fuse
11 . Ignition fuse 2
12. Ignition fuse 1
16. Brake light fuse
17. Cruise control fuse
20. Backup fuse 1
23. Battery
24. Engine ground
27. Clutch switch
28. Front brake light switch
29. Rear brake light switch
30. Handlebar switch (right)
33. Accelerator position sensor
41. Gear position sensor
48. ECU (Engine Control Unit)
65. Shift sensor
66. VDT coupler
67. Meter assembly
68. Multi-function meter
74. MIL (Malfunction indicator light)
77. Cruise control system indicator Iight
78. Cruise control setting indicator light
94. Brake light relay
95. Handlebar switch (left)
96. Cruise control power switch
97. Cruise control setting switch

9-19
 CRUISE CONTROL SYSTEM (for MT09SPM/MT09SPMC)

...,,,.,.
CRUISE CONTROL CIRCUIT OPERATION

7. Ignition 8. Crui,se control 9. Cruise control

fuse 1 system fuse powe!Jwilch
- - - - 10.Cruise control
setting switch
' '
-,
:
........
11.Front brake
light switch 12.Rea r brake
5. Signaling 6. Brake light switch 16.ECU (Engine
system light Control Unit)

-.
fuse fuse
- 14.Brake light relay
. 13. Accelerator
position sensor D----
. . Q I
;-a ~
r
..-- ---.
-=
15.Fuel pump relay
- . ---- .
,
4. Fuel injection
~
system fuse
- - .. ----:-- ..
... ---..
(__ /'-... l.)
3. Ignition <>
fuse2 l

-~
18. Cruise control system indicator light
17.Multi-function
ii.. meter
19. Cruise controlsetting Indicator light
)
2. Main
tl
fuse l ~

-..:- t- ---v -)
1. Battery
--

1. Battery
l --= --=
18. Cruise control system indicator light
2. Main fuse 19. Cruise control setting indicator light
3. Ignition fuse 2
4. Fuel injection system fuse
5. Signaling system fuse
6. Brake light fuse
7. Ignition fuse 1
8. Cruise control system fuse
9. Cruise control power switch
10. Cruise control setting switch
11. Front brake light switch
12. Rear brake light switch
13. Accelerator position sensor
14. Brake light relay
15. Fuel pump relay
16. ECU (Engine Control Unit)
17. Multi-function meter

9-20
 CRUISE CONTROL SYSTEM (for MT09SPM/MT09SPMC)

EAS32877
BASIC INSTRUCTIONS FOR TROUBLESHOOTING
1. Check the OTC of "malfunction" using the VDT.
2. Check and repair the malfunction according to applicable OTC troubleshooting.
3. Tum the main switch from "OFP' to "ON", and then check the OTC of "malfunction" is not displayed.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• If another OTC is displayed, repeat steps (1) to (3) until no OTC is displayed.
• Turning the main switch to "OFP' will not erase the malfunction history.

4. Do the final check.

EWA1!7420

A WARNING
• Perform the troubleshooting [A]➔[B]➔[C] in order. Be sure to follow the order since a wrong
d iagnosis could result if the steps are followed in a different order or omitted.
• Use sufficiently charged regular batteries only.

9-21
 CRUISE CONTROL SYSTEM (for MT09SPM/MT09SPMC)

EAsm,,
BASIC PROCESS FOR TROUBLESHOOTING
When turning the main switch to No I Chock Iha MIL (lED).
"ON", doos the MIL oome on? ·1 I
Yes
,,
Th& Mil goes off after 2 Vas
seconds?

No
,,
(A) Push the cruise control Falls to come on ;. • The cruise control power swftch Is
power swltch, and check defecttva.
the cruise control system
-
-
• The cruise control system fuse is
Indicator light. Flashes
blown.
- ( Return to (Al)
• The ECU Is dafectlva.

Comes on

-.i [B-1) Diagnosis using tile OTC. [C-1 ) Delete tile OTC.
I- - ( Return to [Al)

,,
(S-21 Check tho malfunction
history using Iha malfunction Vas
mode of tile VDT.
Is there any malfuncdon
history?

No

(S-31 Is lhere automatic Yes Explain the conditions for

deactivation history for the automatically deact!vadng the
cruise control system? crulse control system to the
customer.
No
OK
•• I
(C-2) Final check.
I.

..
OTC No. ls not displayed.

,,
Finished. .
1·

9-22
 CRUISE CONTROL SYSTEM (for MT09SPM/MT09SPMC)

EAS3:1879
[A] CHECKING THE CRUISE CONTROL SYSTEM INDICATOR LIGHT
Turn the main switch, and then push the cruise control power switch.
1. The cruise control system indicator light does not come on.
• Check the control power switch for continuity. Refer to "CHECKING THE SWITCHES" on page 8-
53. If there is no continuity, replace the handlebar switch (left).
• Check the fuse for continuity. Refer to "CHECKING THE FUSES" on page 8-55. If the cruise con-
trol system fuse is blown, replace the fuse.
• Check for continuity between the orange/white tem,inal of the handlebar switch coupler (left) and
orange/white tem,inal 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)
EAS3"'80
[B-1] DIAGNOSIS USING THE DliC
1. lnfom,ation 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 No normal signals from the switch are • Wire harness (ECU coupler and front or rear
received by the ECU. brake light switch coupler)
• Signaling system fuse and brake light fuses
• Connection of the ECU coupler, 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 No normal signals from the switch are • Wire harness (ECU coupler and handlebar
received by the ECU. switch coupler (left))
• Ignition fuse 1 and cruise control system
fuse
• Cruise control setting switch

EAS3""'1
[B-2] DIAGNOSIS USING THE MALFUNCTION HISTORY CODES
Check the malfunction history using the malfunction mode of the VDT.
• Malfunction history is displayed on the VDT. [B-1)
• Malfunction history is not displayed on the VDT. [B-3)
EAS3"'82
[B-3] MALFUNCTION HISTORY IS NOT DISPLAYED
Use the VDT 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.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
If you do not have a VDT, the automatic deactivation history cannot be checked. Therefore, explain tlhe
automatic deactivation function of the cruise control system to the customer and explain that this is not
a malfunction.

9-23
 CRUISE CONTROL SYSTEM (for MT09SPM/MT09SPMC)

EAS3"'83
[C-1] ERASING THE DTC
1. Delete the OTC using the malfunction of the VDT, and check that the MIL goes off.
...,,,,..
[C-2] FINAL CHECK
EWA1l7441

A 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 front brake lever and rear brake pedal operation.
2. Check the rear brake light switch.
Refer to "CHECKING THE SWITCHES" on page 8-53.
3. Execute the diagnostic mode (No. 82 and 83) to check the operation of the front brake light switch,
rear brake light switch, and accelerator position sensor.
Refer to "DIAGNOSTIC CODE: SENSOR OPERATION TABLE" on page 9-62.
4. Execute the diagnostic mode (No. 80 and 81) to check the operation of the cruise control settingr
switch.
Refer to "DIAGNOSTIC CODE: SENSOR OPERATION TABLE" on page 9-62.
5. Delete the DTCs.
Refer to "OTC 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 nomially.

9-24
CRUISE CONTROL SYSTEM (for MT09SPM/MT09SPMC)

9-25
 ABS (Anti-lock Brake System)

.........
ABS (Anti-lock Brake System)
EAS3""°
CIRCUIT DIAGRAM
MT09M/MT09MC

I I, .~,·
I· ~

..
I

'
':il. l
~ ; ~;

9-26
 ABS (Anti-lock Brake System)

3. Fuse box
4. Main fuse
5. Main switch
9. Backup fuse 2
10. Signaling system fuse
11 . Ignition fuse 2
12. Ignition fuse 1
14. ABS ECU fuse
18. ABS solenoid fuse
17. ABS motor fuse
18. Backup fuse 1
21. Battery
22. Engine ground
25. Handlebar switch (right)
26. Front brake light switch
44. ECU (Engine Control Unit)
56. ABS ECU (Electronic Control Unit)
57. Front wheel sensor
58. Rear wheel sensor
59. IMU (Inertial Measurement Unit)
62. VDT coupler
63. Meter assembly
64. Multi-function meter
70. MIL (Malfunction indicator light)
74. ABS warning light
84. Tail/brake light
88. Rear brake light switch

9-27
 ABS (Anti-lock Brake System)

MT09SPM/MT09SPMC

······- ····················~ ·······t··············- ···.,,.,..········..l····· ....Yjl:::;

®

I It.. :1 '
•:

I
: ...... •:
[i';=====:==:==i===/ ~b.;=; ~

®tlG In='·~·········· ········j

i 1 1. l ll'!J
i 1 ~ e ,,. ,..oq TT
I JI, '"'
r i I p:
]
.. ,

.-lf-t-;::::'....~:=···:.:.:!·.:.;t
.:· ·JO.lllt1. 11 10$- ........ '•
I I ;

~I
,~-
I ..
.......
I

- ~--+-'I

9-28
 ABS (Anti-lock Brake System)

3. Fuse box
4. Main fuse
5. Main switch
9. Backup fuse 2
10. Signaling system fuse
11 . Ignition fuse 2
12. Ignition fuse 1
14. ABS ECU fuse
1B. Brake light fuse
17. Cruise control fuse
18. ABS solenoid fuse
19. ABS motor fuse
20. Backup fuse 1
23. Battery
24. Engine ground
27. Clutch switch
28. Front brake light switch
29. Rear brake light switch
48. ECU (Engine Control Unit)
60. ABS ECU (Electronic Control Unit)
61 . Front wheel sensor
62. Rear wheel sensor
63. IMU (Inertial Measurement Unit)
66. VDT coupler
67. Meter assembly
68. Multi-function meter
74. MIL (Malfunction indicator light)
80. ABS warning light
90. Tail/brake light
94. Brake light relay

9-29
 ABS (Anti-lock Brake System)

EAS32881

ABS COMPONENTS CHART

11

7
10
-a
- g

1. Meter assembly
2. Hydraulic unit assembly (ABS ECU)
3. Fuse box (ABS motor fuse, ABS ECU fuse,
ABS solenoid fuse)
4. VDT coupler
5. Rear wheel sensor
6. Rear wheel sensor rotor
7. Rear brake caliper
8. Front brake caliper (left)
9. Front wheel sensor
10. Front wheel sensor rotor
11. Front brake caliper (right)

9-30
 ABS (Anti-lock Brake System)

...,,,,..
ABS COUPLER LOCATION CHART

----- -- ------ ---- ------,

5 '

3
4

(BJ
---- ---- ---- ---- ---- --- ----- - ----- ---- -------- ---- ----- ---- --- -----
1. Meter assembly coupler
2. VDT coupler
3. ABS ECU coupler
4. Rear wheel sensor coupler
5. Front wheel sensor coupler

9-31
 ABS (Anti-lock Brake System)

...,,,,.,
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.

2
...,,,,..
ABS TROUBLESHOOTING OUTLINE
EWA t:87'10

A 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 9-37.

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 "[C-1 ] FINAL CHECK" on page 9-37.

9-32
 ABS (Anti-lock Brake System)

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 utiliz.ing the VDT 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 nnalfunction.

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.)

BASIC INSTRUCTIONS FOR TROUBLESHOOTING

1. Check the DTC of "malfunction" using the VDT.
2. Check and repair the malfunction according to applicable DTC troubleshooting.
3. Tum the main switch from "OFP' 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 "OFP' will not erase the malfunction history.

4. Do the final check.

EWA ti143'l

A 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.

9-33
 ABS (Anti-lock Brake System)

Falls to
[A) Turn the main switch to "ON', [A· I ) Does only the ABS • The ABS warning light (LEO) Is
~
come on
and chook the ABS wamlng warning light fall to defective. -.J Return to [AJ. I
light come on? • The wtre harnG&s Is grounded
between the ABS ECU and the
Comes on meter assembly.
• The meter assembly Is detecctve.
• The hydraulic unit assembly Is
defective.

• No
• The main switch ls defective.

~ -1
[A·2) Do all Indicator lights • The b.attery voltage ls low.
fall to come on? • The main fuse Is blown. Return to (A).I
• The meter assembly Is detecctve.

• cannot
• The ABS ECU fuse Is blown.

~
[A-3) The ABS warning light comes communlcata [A-4) Only the ABS ECU
on.
Connect the VDT, and then
- falls to communicate.
• The ABS ECU coupler Is
dlsconoocted.
- I Return to [A). I
execute function.al diagnosis. • The wire harness Is defecttve.
Can the VDT communicate • The hydraulic unit assembly
with the ABS ECU? Is defective.

can communicate
• No

[A-5) ABS ECU and Fl ECU ~ • The connection with the VDT Is
-1 Return to (A). I
fall to communicate. defective.
• The wire harooss Is defective .

•
[B -1) Checkfor ABSDTCln the
screen for the YOT.
Execute diagnosis of
Yes
-
[B-2) Diagnose by the OTC. [B-3) Delete the OTC.
I Return to (A). I
malfunctlon.
Are OTC displayed on
the screen?
The reaction force generated
No du~ng brake line routing
confirmation Is fncorr9Ct. Refer to
"(C-1) FINAL CHECK".
[C· 1J Perform the final cllecl<s. • The brake hoses and brake
Were all of the flnal checks
completed nonnany?
No pipes are not connected
correctty.
I Return to (A). I
The ABS warning light does
Yes not go off when the Ught Is
(The ABS warning light cllecl<ed. Refer to "[C-1)
goes off when the light Is FINAL CHECK".
checked.) • The malfunction Is not
corrected.
• There ls a break In the wire
hamess between the ABS ECU
and the meter assembly.
• The meter assembly Is defective.
• The ABS wamlng Ught circuit In
the hydraulic unh assembly ls
defective.

•
Finished.

9-34
 ABS (Anti-lock Brake System)

EAS3""'7
[A] CHEC KING 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)
EAS3""8
[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.
EAS32ll00
[A-2] ALL INDICATOR LIGHTS FAIL TO COME ON
1. Main switch
• Check the main switch for continuity.
Refer to "CHECKING THE SWITCHES" on page 8-53.
• 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 8-56.
• 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 8-55.
• If the main fuse is blown, replace the fuse.
4. Circuit
• Check the meter assembly circuit.
Refer to "CIRCUIT DIAGRAM" on page 9-26.
• If the meter assembly circuit is open, replace the wire harness.
EAS32000
[A-3] THE ABS WARNING LIGHT COMES ON
Connect the VDT to the VDT 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 Fl ECU fail to communicate. [A-5)
• Communication is possible with the ABS ECU. [B-1) (The ABS is displayed on the select unit screen.)

9-35
 ABS (Anti-lock Brake System)

EAS3""'1
[A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE
1. ABS ECU fuse
• Check the ABS ECU fuse for continuity.
Refer to "CHECKING THE FUSES" on page 8-55.
• 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 ASSEMBLV" on page 4-52.
3. Wire harness
• Open circuit between the main switch and the ABS ECU, or between the ABS ECU and the ground.
Check for continuity between brown/blue terminal of the main switch coupler and red/black terminal
of the ABS ECU coupler.
Check for continuity between black terminal of the ABS ECU coupler and the ground.
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 VDT coupler.
Check for continuity between blue/while terminal of the ABS ECU coupler and blue/white terminal of
the VDT coupler. (CANH)
Check for continuity between bl1.11e/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.
EAS320CQ
[A-5] ABS ECU AND Fl ECU FAIL TO COMMUNICATE
1. VDT
Check that the VDT is properly connected.
2. Wire harness
• Open circuit in the wire harness between the ABS ECU coupler and the VDT coupler.
Check for continuity between blue/while terminal of the ABS ECU coupler and blue/white terminal of
the VDT coupler. (CANH)
Check for continuity between bl1.11e/black terminal of the ABS ECU coupler and blue/black terminal of
the VDT coupler. (CANL)
EAS3""°
[B-1] MALFUNCTION ARE CURRENTLY DETECTED
When the VDT is connected to the VDT coupler, the OTC will be di.splayed on the computer screen.
• A OTC is displayed. [B-2]
• A OTC is not displayed. [C-1]
EAS32""
[B-2] DIAGNOSIS USING THE DliC
This model uses the VDT to identify malfunctions.
For information about using the VDT, refer to the operation manual that is included with the tool.

Yamaha diagnostic tool USB

(US)
90890-03269
Yamaha diagnostic tool (A/1)
90890-03264

9-36
 ABS (Anti-lock Brake System)

TIP _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Yamaha diagnostic tool (A/1) (90890-03264) includes VDT sub harness (6P) (90890-03266).
• If you already have Yamaha diagnostic tool (A/1) (90890-03262), YDT sub harness (6P) (90890-
03266) is separately required.
Details about the displayed DTCs are shown in the following chart. Refer to this chart and check the ve-
hicle.
Once all the work is complete, delete the DTCs. [B-3]
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Do the final check after terminating the connection with the VDT and turning the main switch off. [C- 1]

EAS3:l339
[B-3] DELETING THE DTC
To delete the DTCs, use the VDT. For information about deleting the DTCs, refer to the operation man-
ual of the VDT.
Check that all the displayed DTCs are deleted.

Yamaha diagnostic tool use

(US)
90890-03269
Yamaha diagnostic tool (A/1)
90890-03264
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• Yamaha diagnostic tool (A/1) (90890-03264) includes VDT sub harness (6P) (90890-03266).
• If you already have Yamaha diagnostic tool (A/1) (90890-03262), YDT sub harness (6P) (90890-
03266) is separately required.

EAS3:lll<l5
[C-1] FINAL CHECK
EWAt:8710

A WARNING
When maintenance or checks ha.ve 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 3-13.
2. Check the wheel sensors for proper installation.
Refer to "INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS)" on page 4-16 and "IN-
STALLING THE REAR WHEEL (REAR BRAKE DISC)" on page 4-23.
3. Perform brake line routing confirmation.
Refer to "HYDRAULIC UNIT OPERATION TESTS" on page 4-53.
If it does not have reaction-force property, the brake hose is not properly routed or connected.
4. Delete the DTCs.
Refer to "[B-3] DELETING THE DTC" on page 9-37.

9-37
 ABS (Anti-lock Brake System)

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 9-35.
If the ABS warning light does not tum 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.

9-38
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EA""""1

SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EAS33t49

DTCTABLE
Fail-safe system
Diagnos-
DTC Symptom Starting the Driving the tic code
engine vehicle

"11_ABS" Front wheel sensor (intermittent pulses - - -

or no pulses)

"12_ABS" Rear wheel sensor (intennittent pulses or - - -

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 detected. Unablle Unable 17
r·
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- - - -
lion)
Rear wheel ABS (in1ennittent wheel
"42_ABS" speed pulses or incorrect depressuriza- - - -
lion)
"43,
Front wheel sensor (missing pulses) - - -
45_ABS"
"44,
46_ABS"
Rear wheel sensor (missing pulses) - - -
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 commu nication line or pow-
"57_ABS"
er source of vehicle system
- - -

9-39
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Fail-safe system
Diagnos-
DTC Symptom Starting the Driving the tic code
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
Able/Unable Able/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 commun ication (between IMU and
"91_ABS" - - -
hydraulic unit assembly)
ECU: no normal signals or malfunction
"C0520" Able/Unable Able/Unable -
signals are received from the IMU.
0 2 sensor heater: defective heater con•
"P0030" Able Able -
!roller detected.
[P00D1] 0 2 sensor: heater performance
"P00D1 ,
deterioration Able Able -
P2195"
[P2195] 0 2 sensor: open circuit detected.
[P0107] Intake air pressure sensor 1:
"P0107, ground short circuit detected.
Able Able 03
P0108" [P0108] Intake air pressure sensor 1:
open or power short circuit detected.
[P0112] Intake air temperature sensor:
"P0112, ground short circuit detected.
Able Able 05
P0113" [P0113] Intake air temperature sensor:
open or power short circuit detected.
[P0117] Coolant temperature sensor:
"P0117, ground short circuit detected.
Able Able 06
P0118" [P0118] Coolant temperature sensor:
open or power short circuit detected.
[P0122] Throttle position sensor: ground
short circuit detected.
[P0123] Throttle position sensor: open or
"P0122,
power short circuit detected.
P0123,
[P0222] Throttle position sensor: open or
P0222, Able/Unable Able/Unable 01 , 13
ground short circuit detected.
P0223,
[P0223] Throttle position sensor: power
P2135"
short circuit detected.
[P2135] Throttle position sensor: output
voltage deviation error.
0 2 sensor: short circuit detected (power
"P0132" Able Able -
short circuit) .

9-40
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Fail-safe system
Diagnos-
DTC Symptom Starting the Driving the tic code
engine vehicle
Able Able
(depending (depending
"P0201" Injector #1: malfunction in injector # 1. on the num- on the num- 36
ber of faulty ber of faulty
cylinders) cylinders)
Able Able
(depending (depending
"P0202" Injector #2: malfunction in injector #2. on the n um- on the num- 37
ber of faulty ber of faulty
cylinders) cylinders)
Able Able
(depending (depending
"P0203" Injector #3: malfunction in injector #3. on the n um- on the num- 38
ber of faulty ber of faulty
cylinders) cylinders)
Crankshaft position sensor: no normal
"P0335" signals are received from the crankshaft Unable Unable -
position sensor.
Able Able
Cylinder-#1 ignition coil: open or short (depending (depending
"P0351" circuit detected in the primary lead of the on the num- on the num- 30
cylinder-#1 ignition coil. ber of faulty ber of faulty
cylinders) cylinders)
Able Able
Cylinder-#2 ignition coil: open or short (depending (depending
"P0352" circuit detected in the primary lead of the on the num- on the num- 31
cylinder-#2 ignition coil. ber of faulty ber of faulty
cylinders) cylinders)
Able Able
Cylinder-#3 ignition coil: open or short (depending (depending
"P0353" circuit detected in the primary lead of the on the num- on the num- 32
cylinder-#3 ignition coil. ber of faulty ber of faulty
cylinders) cylinders)
Purge cut valve solenoid: open circuit de-
"P0458"
tected.
Able Able -
Radiator fan motor relay: open or short Able,
"P0480" Able 51
circuit detected.
Rear wheel sensor: no normal signals
are received from the rear wheel sensor.
"P0S00, Neutral switch: open or short circuit is de-
Able Able 07,21
P1500" tected.
Clutch switch: open or short circuit is de-
tected.
[P0560) Charging voltage is abnormal.
"P0560,
[P0563) Vehicle system power voltage Able Able -
P0563"
out of range

9-41
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Fail-safe system
Diagnos-
DTC Symptom Starting the Driving the tic code
engine vehicle
Cruise control setting switch "RES+":
open or short circuit is detected.
"P0564" Able Able 80, 81
Cruise control setting switch "SET- ":
open or short circuit is detected.
Front brake light switch: open or short cir-
cuit is detected.
"P056C" Able Able 82, 83
Rear brake light switch: open or short cir-
cuit is detected.
Internal malfunction in ECU. (When this
malfunction is detected in the ECU, the -
"P0601" Unable Unable
DTC might not appear on the tool dis-
play.)
Internal malfunction in ECU. (When this
malfunction is detected in the ECU, the
"P0606" Able/Unable Able/Unable -
DTC might not appear on the tool dis-
play.)
EEPROM OTC: an error is detected
MP062F" Able/Unable Able/Unable 60
while reading or writing on EEPROM.
YCC-T drive system: malfunction detect-
"P0638" Able/Unable Able/Unable -
ed.
Fuel system voltage: incorrect voltage
"P0657' supplied to the fuel finjector and fuel Able Able 09, 50
pump.
[P0916] Gear position sensor: open or
"P0916, ground short circuit detected.
P0917"
Able Able -
[P0917] Gear position sensor: power
short circuit detected.
Intake air pressure sensor 1 and intake
"P1004" air pressure sensor 2: output voltage de- Able Able 03, 04
viation error.
Lean angle sensor: open or short circuit
"P1600" Unable Unable 17
detected.
Sidestand switch: open or short circuit of
"P1601" the blue/yellow lead of the ECU is detect- Unable Unable 20
ed.
Malfunction in ECU internal circuit (mal- Able/Unable -
"P1602" Able/Unable
function of ECU power cut-off function).
[P1606] Intake air pressure sensor 2:
"P1606, ground short circuit detected.
Able Able 04
P160T' [P1607] Intake air pressure sensor 2:
open or power short circuit detected.
[P1806] Shift sensor : open or ground
"P1806, short circuit detected.
Able Able 95
P1807' [P1807] Shift sensor : power short circuit
detected.

9-42
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Fail-safe system
Diagnos-
DTC Symptom Starting the Driving the tic code
engine vehicle
[P2122] Accelerator position sensor:
open or ground short circuit detected.
"P2122, [P2123] Accelerator position sensor:
P2123, power short circuit detected.
P2127, [P2127] Accelerator position sensor; Able/Unable Able/Unable 14, 15
P2128, open or ground short circuit detected.
P2138" [P2128] Accelerator position sensor:
power short circuit detected.
[P2138] Deviation error
Front wheel sensor: no normal signals
'"P2158" Able Able 16
are received from the front wheel sensor.
Signals cannot be transmitted between
"U0125" Unabl'.e Able/Unable -
the ECU and the IMU.
Multi-function meter: signals cannot be
"U0155 or
transmitted between the ECU and the Able Able -
Err''
multi-function meter.

"'"'""""
SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM)
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
For details of the OTC, refer to "BASIC PROCESS FOR TROUBLESHOOTING" on page 9-16.

Probable cause of Fail-safe system

DTC Item Vehicle symptom
malfunction operation
30_ Overturn detected. • The vehicle has
EVENT overturned.
• Installed condition
of IMU. ·- -
• Defective IMU.
• Malfunction in
ECU.
70_ Engine forcibly • Allow to idle for a
EVENT stops when the ve- long period of time.
·- -
hicle is left idling for • Malfunction in
a long period. ECU.
C0520 ECU: no nomial sig- • Defective IMU Engine cannot be Engine cannot be
nals or malfunction coupler or ECU started (depending started (depending
signals are received coupler. on the circumstanc- on the circumstanc-
from the IMU. • Open or short cir- es). es).
cuit in wire har-
ness between IMU
and ECU.
• Improperly in-
stalled IMU.
• Malfunction in
IMU.
• Malfunction in
ECU.

9-43
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system

DTC Item Vehicle symptom
malfunction operation
P0030 0 2 sensor heater: • Open circuit in wire (When the 0 2 sen- Display only (If the
defective heater harness. sor does not oper- 0 2 sensor does not
controller detected. • Disconnected cou- ate because the operate, 0 2 feed-
pier. exhaust tempera- back is not carried
• Defective ~ sen- ture is low) out.)
sor heater control- Increased exhaust Cruise control sys-
ler (Malfunction in emissions. tern cannot be oper-
ECU). Fuel learning cannot ated. (for
• Broken or discon- be carried out. MT09SPM/
nected lead in 0 2 MT09SPMC)
sensor heater.
PO0D1 0 2 sensor: heater • Improperly in- Increased exhaust 0 2 feedback is not
performance deteri- stalled 0 2 sensor. emissions. carried out.
oration • Defective coupler 0 2 learning is not
between 0 2 sen- carried out.
sor and ECU. QSS is not carried
• Open or short cir- out.
cuit in wire har- Cruise control sys-
ness between 0 2 tern cannot be oper-
sensor and ECU. ated. (for
• Incorrect fuel pres- MT09SPM/
sure. MT09SPMC)
• Defective 0 2 sen-
sor.
• Malfunction in
ECU.
P0107 [P0107] Intake air [P0107] Low voltage Engine idling speed Intake air pressure
P0108 pressure sensor 1: of the intake air is unstable. is fixed to 101.3
ground short circuit pressure sensor 1 Engine response is [kPa].
detected. circuit (0.5 V or less) poor. Intake air pressure
[P0108] Intake air [P0108] High volt- Loss of engine pow- difference is fixed to
pressure sensor 1: age of the intake air er. 0 [kPa].
open or power short pressure sensor 1 Increased exhaust a-N is fixed.
circuit detected. circuit (4.8 V or emissions. Fuel is not cut off
more) due to the intake air
• Defective coupler pressure difference.
between intake air 0 2 feedback is not
pressure sensor 1 carried out.
and ECU. ISC feedback is not
• Open or short cir- carried out.
cuit in wire har- ISC learning is not
ness between carried out.
intake air pressure QSS is not carried
sensor 1 and ECU. out.
• Defective intake Cruise control sys-
air pressure sen- tern cannot be oper-
sor 1. ated. (for
• Malfunction in MT09SPM/
ECU. MT09SPMC)

9-44
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system

DTC Item
malfunction
Vehicle symptom
operation
P0112 [P0112] Intake air [P0112] Low voltage Engine is difficult to The intake air tern-
P0113 temperature sensor: of the intake air tern- start. perature is fixed to
ground short circuit perature sensor cir- Increased exhaust 20 [°C].
detected. cuit (0.1 V or less) emissions. O:? sensor heater
[P0113] Intake air [P0113] High volt- Engine id ling speed driving is not carried
temperature sensor: age of the intake air is unstable. out.
open or power short temperature sensor 0 2 feedback is not
circuit detected. circuit (4.8 V or carried out.
more) ISC feedback is not
• Defective coupler carried out.
between intake air ISC learning is not
temperature sen- carried out.
sor and ECU. QSS is not carried
• Open or short cir- out.
cuit in wire har- Cruise control sys-
ness between tern cannot be oper-
intake air tempera- ated. (for
ture sensor and MT09SPM/
ECU. MT09SPMC)
• Improperly in-
stalled intake air
temperature sen-
sor.
• Defective intake
air temperature
sensor.
• Malfunction in
ECU.

9-45
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system

DTC Item
malfunction
Vehicle symptom
operation
P0117 [P0117] Coolant [P0117] Low voltage Engine is difficult to The radiator fan mo-
P0118 temperature sensor: of the coolant tern- start. tor relay is on only·
ground short circuit perature sensor cir- Increased exhaust when the vehicle is
detected. cuit (0.1 V or less) emissions. traveling at low
[P0118] Coolant [P0118] High volt- Engine id ling speed speeds.
temperature sensor: age of the coolant is unstable. 0.? feedback is not
open or power short temperature sensor carried out.
circuit detected. circuit (4.9 V or ISC feedback is not
more) carried out.
• Defective coupler ISC learning is not
between coolant carried out.
temperature sen- The coolant tern-
sor and ECU. perature is fixed to
• Open or short cir- 60 [°C].
cuit in wire har- QSS is not carried
ness between out.
coolant tempera- Cruise control sys-
ture sensor and tern cannot be oper-
ECU. ated. (for
• Improperly in- MT09SPM/
stalled coolant MT09SPMC)
temperature sen-
sor.
• Defective coolant
temperature sen-
sor.
• Malfunction in
ECU.

9-46
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system

DTC Item
malfunction
Vehicle symptom
operation
P0122 [P0122] Throttle po- [P0122, P0222] Low Engine id ling speed Change in the throt-
P0123 sition sensor: voltage of the throt- is high. tie opening is 0
P02.2 2 ground short circuit tie position sensor Engine id ling speed (transient control is
P0223 detected. circuit (0.25 V or is unstable. not carried out).
P2135 [P0123] Throttle po- less) Engine response is D-j is fixed.
sition sensor: open [P0123, P0223] poor. Throttle opening is
or power short cir- High voltage of the Loss of engine pow- fixed to 125 [ 0 ] .
cuit detected. throttle position sen- er. O:! feedback is not
[P0222] Throttle po- sor circuit (4.75 V or Deceleration is carried out.
sition sensor: open more) poor. Fuel is not cut off
or ground short cir- [P2135] Difference Increased exhaust due to the throttle
cuit detected. in output voltage 1 emissions. opening.
[P0223] Throttle po- and output voltage 2 Vehicle cannot be Output is restricted.
sition sensor: power of the throttle posi- driven. ISC feedback is not
short circuit detect- tion sensor carried out.
ed. • Defective coupler ISC learning is not
[P2135] Throttle po- between throttle carried out.
sition sensor: output position sensor 0 2 sensor heater
voltage deviation er- and ECU. driving is not carried
ror. • Open or short cir- out.
cuit in wire har- ass is not carried
ness between out.
throttle position Cruise control sys-
sensor and ECU. tern cannot be oper-
• Improperly in- ated. (for
stalled throttle po- MT09SPM/
sition sensor. MT09SPMC)
• Defective throttle
position sensor.
• Malfunction in
ECU.
P0132 0 2 sensor: deterio- High voltage of the Increased exhaust 0 2 feedback is not
ration detected O:? sensor circuit emissions. carried out.
(4.8 V or more) 0 2 feedback learn-
• Improperly in- ing is not carried
stalled 0 2 sensor. out.
• Defective coupler ass is not carried
between 0 2 sen- out.
sor and ECU. Cruise control sys-
• Open or short cir- tern cannot be oper-
cuit in wire har- ated. (for
ness between 0 2 MT09SPM/
sensor and ECU. MT09SPMC)
• Incorrect fuel pres-
sure.
• Defective 0 2 sen-
sor.
• Malfunction in
ECU.

9-47
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system

DTC Item
malfunction
Vehicle symptom
operation
P0201 [P0201] Injector #1: • Defective coupler Loss of engine pow- O:! feedback is not
P0202 malfunction in injec- between injector er. carried out.
P0203 tor # 1. and ECU. Engine is difficult to ISC feedback is not
[P0202] Injector #2: • Open or short cir- start. carried out.
malfunction in injec- cuit in wire har- Engine cannot be ISC learning is not
tor #2. ness between started. carried out.
[P0203] Injector #3: injector and ECU. Engine stops. QSS is not carried
malfunction in injec- • Defective injector. Engine id ling speed out.
tor #3. • Malfunction in is unstable. Cruise control sys-
ECU. Increased exhaust tern cannot be oper-
• Improperly in- emissions. ated. (for
stalled injector. MT09SPM/
MT09SPMC)
P0335 Crankshaft position • Defective coupler Engine cannot be Does not operate.
sensor: no normal between crank- started. ISC feedback is not
signals are received shaft position sen- carried out.
from the crankshaft sor and ECU. ISC learning is not
position sensor. • Open or short cir- carried out.
cuit in wire har- Cruise control sys-
ness between tern cannot be oper-
crankshaft position ated. (for
sensor and ECU. MT09SPM/
• Improperly in- MT09SPMC)
stalled crankshaft
position sensor.
• Malfunction in
generator rotor.
• Defective crank-
shaft position sen-
sor.
• Malfunction in
ECU.
P0351 [P0351] Cylinder-#1 • Defective coupler Engine stops. 0 2 feedback is not
P0352 ignition coil: open or between ignition Loss of engine pow- carried out.
P0353 short circuit detect- coil and ECU. er. ISC feedback is not
ed in the primary • Open or short cir- Engine is difficult to carried out.
lead of the cylinder- cuit in wire har- start. ISC learning is not
#1 ignition coil. ness between Engine cannot be carried out.
[P0352] Cylinder-#2 ignition coil and started. QSS is not carried
ignition coil: open or ECU. Engine idling speed out.
short circuit detect- • Improperly in- is unstable. Cruise control sys-
ed in the primary stalled ignition coil. Increased exhaust tern cannot be oper-
lead of the cylinder- • Defective ignition emissions. ated. (for
#2 ignition coil. coil. MT09SPM/
[P0353] Cylinder-#3 • Malfunction in MT09SPMC)
ignition coil: open or ECU.
short circuit detect-
ed in the primary
lead of the cylinder-
#3 ignition coil.

9-48
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system

DTC Item
malfunction
Vehicle symptom
operation
P0458 Purge cut valve so- • Open or short cir- Vapor gas cannot Closing side on
lenoid: open circuit cuit in wire har- be purged from can- purge cut valve so -
detected. ness. ister. lenoid is fixed .
• Defective purge
cut valve solenoid.
• 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 detected. ness. Loss of engine pow- time.
• Disconnected cou- er. ◊.! feedback is not
pier. Engine overheats. carried out.
• Defective radiator Increased exhaust ISC feedback is not
fan motor relay. emissions. carried out.
• Defective radiator ISC learning is not
fan motor relay carried out.
controller (Mal- Cruise control sys-
function in ECU). tern cannot be oper-
ated. (for
MT09SPM/
MT09SPMC)
P0500 [P0500] Rear wheel • Open or short cir- Vehicles.peed is not Vehicle speed dis-
P1500 sensor: no normal cuit in wire har- displayed on the played on the meter
signals are received ness between rear meter. = 0 [km/h]
from the rear wheel wheel sensor and [P1500] Indication 0 2 feedback is not
sensor. ABS unit. of the neutral indica- carried out.
[P1500] Neutral • Open or short cir- tor light is incorrect. Fuel cut-off control
switch: open or cuit in wire har- Engine id ling speed when the rear wheel
short circuit is de- ness between is unstable. sensor or neutral
tected. ABS unit and ECU. Traction control switch malfunctions
[P1500] Clutch • [P1500] Open or does not work. is carried out.
switch: open or short circuit in wire ISC feedback is not
short circuit is de- harness between carried out.
tected. neutral switch and ISC learning is not
ECU. carried out.
• [P1500] Open or Traction control
short circuit in wire does not work.
harness between [P0500] QSS is not
clutch switch and carried out.
ECU. Cruise control sys-
• Defective rear tern cannot be oper-
wheel sensor. ated. (for
• [P1500] Defective MT09SPM/
neutral switch. MT09SPMC)
• [P1500] Defective
clutch switch.
• [P1500] Improper
adjustment of
clutch lever.
• Malfunction in
ECU.

9-49
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system

DTC Item
malfunction
Vehicle symptom
operation
P0560 Charging voltage is • Battery over-dis- Engine is difficult to O:! feedback is not
abnormal. charging (broken start. carried out.
or disconnected Increased exhaust
lead in charging emissions.
system). Battery perfor-
• Battery over-dis- mance has deterio-
charging (defec- rated or battery is
live rectifier/ defective.
regulator) .
P0563 Vehicle system • Battery overcharg- Engine is difficult to 0 2 feedback is not
power voltage out of ing (defective rec- start. carried out.
range lifier/regulator). Increased exhaust
• Battery overcharg- emissions.
ing (broken or dis- Battery perfor-
connected lead in mance has deterio-
rectifier/regulator rated or battery is
wire harness). defective.
P0564 Cruise control set- • Open or short cir- Cruise control sys- Cruise control sys-
ting switch "RES+": cuit in wire har- tern cannot be oper- tern cannot be oper-
open or short circuit ness. ated. ated. (for
is detected. • Defective cruise MT09SPM/
Cruise control set- control setting MT09SPMC)
ting switch "SET-": switch.
open or short circuit • Malfunction in
is detected. ECU.
P056C Front brake light
switch: open or
short circuit is de-
tected.
Rear brake light
switch: open or
short circuit is de-
tected.
P0601 Internal malfunction • Malfunction in Engine cannot be Engine cannot be
in ECU. (When this ECU. started. started.
malfunction is de- Cruise control sys-
tected in the ECU, tern cannot be oper-
the OTC might not ated. (for
appear on the tool MT09SPM/
display.) MT09SPMC)

9-50
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system

DTC Item
malfunction
Vehicle symptom
operation
P0606 Internal malfunction • Malfunction in Engine cannot be Engine cannot be
in ECU. (When this ECU. started. started.
malfunction is de- Engine response is Ignition and injec-
tected in the ECU, poor. lion are not carried
the OTC might not Loss of engine pow- out.
appear on the tool er. Judgment for other
display.) DTCs is not carried
out.
Load control is not
carried out. (The re-
lay unit, radiator fan
motor relay, and
other relays are all
turned off.)
The CO adjustment
mode and diagnos-
tic mode cannot be
activated.
Output is restricted.
Cruise control sys-
tern cannot be oper-
ated. (for
MT09SPM/
MT09SPMC)
P062F EEPROM OTC: 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.
• 0 2 feedback learn- is unstable. OBD memory value
ing value is not OBD memory value is initialized.
properly written. is not correct. Initialization of 0 2
• OBD memory val- feedback learning
ue is not properly value.
written. Cruise control sys-
• Malfunction in tem cannot be oper-
ECU. ated. (for
MT09SPM/
MT09SPMC)

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SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system

DTC Item
malfunction
Vehicle symptom
operation
P0638 YCC-T drive sys- • Defective coupler Engine response is O:! feedback is not
tern: 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 id ling 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 QSS is not carried
servo motor. out.
• Throttle servo mo- Cruise control sys-
tor is stuck (mech- tern cannot be oper-
anism or motor). ated. (for
• Malfunction in MT09SPM/
ECU. MT09SPMC)
• Blown electric
throttle valve fuse.
P0657 Fuel system volt- • Open or short cir- Engine is difficult to Monitor voltage= 1 2
age: incorrect volt- cuit in wire har- start. [V)
age supplied to the ness between Increased exhaust 0 2 feedback is not
fuel injector and fuel relay unit and emissions. carried out.
pump. ECU. Cruise control sys-
• Open circuit in wire tern cannot be oper-
harness between ated. (for
battery and ECU. MT09SPM/
• Defective relay MT09SPMC)
unit.
• Malfunction in
ECU.
P0916 [P0916] Gear posi- [P0916] Low voltage Improper display for Maintains the gear
P0917 lion sensor: open or of the gear position position. position value at the
ground short circuit sensor circuit (0.2 V Engine response is previous value.
detected. or less) poor. QSS is not carried
[P0917] Gear posi- [P0917] High volt- out.
lion sensor: power age of the gear posi- Engine brake man-
short circuit detect- tion sensor circuit agement: control
ed. (4.8 V or more) mode is fixed.
• Defective coupler Engine brake man-
between gear po- agement: control
sition sensor and value is fixed.
ECU. Cruise control sys-
• Open or power tern cannot be oper-
short circuit in wire ated. (for
harness between MT09SPM/
gear position sen- MT09SPMC)
sor and ECU.
• Improperly in-
stalled gear posi-
lion sensor.
• Defective gear po-
sition sensor.
• Malfunction in
ECU.

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SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system

DTC Item
malfunction
Vehicle symptom
operation
P1004 Intake air pressure • Intake pressure Engine is difficult to Intake air pressure
sensor 1 and intake sensor 1 hose or start. is fixed to 101.3
air pressure sensor intake pressure Engine id ling speed [kPa].
2: output voltage de- sensor 2 hose is is unstable. Intake air pressure
viation error. detached, Increased exhaust difference is fixed to
clogged, kinked or emissions. 0 [kPa].
bent. Loss of engine pow- Atmospheric pres-
• Defective intake er. sure is fixed to
air pressure sen- 101.3 [kPa].
sor 1 or intake air a- N is fixed.
pressure sensor 2. Fuel is not cut off
• Malfunction in due to the intake air
ECU. pressure difference.
0 2 feedback is not
carried out.
ISC feedback is not
carried out.
ISC learning is not
carried out.
Cruise control sys-
tern cannot be oper-
ated. (for
MT09SPM/
MT09SPMC)
P1600 Lean angle sensor: • Open or short cir- Engine cannot be Engine cannot be
open or short circuit cuit in wire har- started. started.
detected. ness. Cruise control sys-
• Malfunction in tern cannot be oper-
IMU. ated. (for
• Malfunction in MT09SPM/
ECU. MT09SPMC)
P1601 Sidestand switch: • Defective coupler Engine cannot be Engine is forcefully
open or short circuit between relay unit started. stopped (the injector
of the blue/yellow and ECU. output is stopped).
lead of the ECU is • Open or short cir- Cruise control sys-
detected. cuit in wire har- tern cannot be oper-
ness between ated. (for
relay unit and MT09SPM/
ECU. MT09SPMC)
• 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.

9-53
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system

DTC Item
malfunction
Vehicle symptom
operation
P1602 Malfunction in ECU • Open or short cir- Engine id ling speed O:! feedback learn-
internal circuit (mal- cuit in wire har- is unstable. ing is not carried
function of ECU ness between Engine id ling speed out.
power cut-off tune- ECU and battery. is high. 0 2 feedback learn-
lion). • 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 sys-
ECU and main start. tern cannot be oper-
switch. ated. (for
• Blown backup MT09SPM/
fuse. MT09SPMC)
• Malfunction in
ECU.
P1606 [P1606] Intake air • Defective coupler Engine is difficult to a-N is fixed.
P1607 pressure sensor 2: between intake air start. Intake air pressure
ground short circuit pressure sensor 2 Increased exhaust difference is fixed to
detected. and ECU. emissions. 0 [kPa].
[P1607] Intake air • Open or short cir- Insufficient power at Atmospheric pres-
pressure sensor 2: cuit in wire har- high altitudes. sure is fixed to
open or power short ness between Engine id ling speed 101.3 [kPa].
circuit detected. intake air pressure is unstable. Fuel is not cut off
sensor 2 and ECU. due to the intake air
• Improperly in- pressure difference.
stalled intake air 0 2 feedback is not
pressure sensor 2. carried out.
• Defective intake ISC feedback is not
air pressure sen- carried out.
sor 2. ISC learning is not
• Malfunction in carried out.
ECU.
P1806 [P1806] Shift sen- • Defective coupler Unable to carry out QSS is not carried
P1807 sor: open or ground between shift sen- QSS. out.
short circuit detect- sor and ECU. (If this abnormality
ed. • Open or power occurs during actual
[P1807] Shift sen- short circuit in wire shifting, the opera-
sor: power short cir- harness between lion will be carried
cuit detected. shift sensor and out until the process
ECU. is completed.)
• Improperly in-
stalled shift sen-
sor.
• Defective shift
sensor.
• Malfunction in
ECU.

9-54
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system

DTC Item
malfunction
Vehicle symptom
operation
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 ground erator position sen- Loss of engine pow- (transient control is
P2128 short circuit detect- sor circuit (0.25 V or er. not carried out).
P2138 ed. less) Engine id ling speed Accelerator open-
[P2123] Accelerator [P2123, P2128] is unstable. ing is fixed to 0[0 ].
position sensor: High voltage of the ~ feedback is not
power short circuit accelerator position carried out.
detected. sensor circuit (4.75 YCC-T evacuation
[P2127] Accelerator V or more) is activated.
position sensor: [P2138] Difference Fuel cut is prohibit-
open or ground in output voltage 1 ed by accelerator
short circuit detect- and output voltage 2 opening.
ed. of the accelerator Output is restricted.
[P2128] Accelerator position sensor ISC feedback is not
position sensor: • Defective coupler carried out.
power short circuit between accelera- ISC learning is not
detected. tor position sensor carried out.
(P2138) Deviation and ECU. QSS is not carried
error • Open or short cir- out.
cuit in wire har- Cruise control sys-
ness between tern cannot be oper-
accelerator posi- ated. (for
tion sensor and MT09SPM/
ECU. MT09SPMC)
• Improperly in-
stalled accelerator
position sensor.
• Defective acceler-
ator position sen-
sor.
• Malfunction in
ECU.
P2158 Front wheel sensor: • Open or short cir- Traction control Traction control
no normal signals cuit in wire har- does not work. does not work.
are received from ness between Traction control sys- Cruise control sys-
the front wheel sen- front wheel sensor tern indicator on the tern cannot be oper-
sor. and ABS ECU. meter comes on. ated. (for
• Defective front Traction control sys- MT09SPM/
wheel sensor. tern switch is dis- MT09SPMC)
• Malfunction in abled. (Traction
ABS ECU. control system indi-
• Malfunction in cater on tthe meter
ECU. goes OFF.)

9-55
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Probable cause of Fail-safe system

DTC Item
malfunction
Vehicle symptom
operation
P2195 0 2 sensor: open cir- • Low voltage of the Increased exhaust 0 2 feedback is not
cuit detected. ~ sensor circuit emissions. carried out.
(0.18--0.49 V). 0 2 feedback learn-
• Improperly in- ing is not carried
stalled 0 2 sensor. out.
• Defective coupler QSS is not carried
between 0 2 sen- out.
sor and ECU. Cruise control sys-
• Open or short cir- tern cannot be oper-
cuit in wire har- ated. (for
ness between 0 2 MT09SPM/
sensor and ECU. MT09SPMC)
• Incorrect fuel pres-
sure.
• Defective 0 2 sen-
sor.
• 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 sys-
IMU. • Open or short cir- tern cannot be oper-
cuit in wire har- ated. (for
ness between IMU MT09SPM/
and ECU. MT09SPMC)
• Malfunction in
IMU.
• Malfunction in
ECU.

9-56
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EA"""95
SELF-DIAGNOSTIC FUNCTION T ABLE (FOR ABS (Ant.i-lock Brake System))
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
For details of the OTC, refer to "BASIC INSTRUCTIONS FOR TROUBLESHOOTING" on page 9-33.

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
incorrect installation of
the rotor
• Defective rear wheel
sensor or incorrect in-
stallation of the sensor
13• Front wheel sensor (ab- Front wheel sensor signal • Foreign material ad-
2e· 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
incorrect installation of
the rotor
• Defective front wheel
sensor or incorrect in-
stallation of the sensor
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
• Defective sensor rotor or
incorrect installation of
the rotor
• Defective rear wheel
sensor or incorrect in-
stallation of the sensor

9-57
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

DTC Item Symptom Check point

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
• Defective front wheel
sensor or hydraulic unit
assembly
16 Rear wheel sensor (open Open or short circu it is de- • Defective coupler be-
or short circuit) tected in the rear wheel tween the rear wheel
sensor. sensor and the hydraulic
unit assembly
• Open or short circuit in
the wire harness be-
tween the rear wheel
sensor and the hydraulic
unit assembly
• Defective rear wheel
sensor or hydraulic unit
assembly
21 Hydraulic unit assembly Solenoid drive circuit in • Defective hyd raulic 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
• Open or short circuit in
the wire harness be-
tween the battery and the
hydraulic unit assembly
• 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
hydraulic unit assembly
• Open or short circuit in
the wire harness be-
tween the battery and the
hydraulic unit assembly
• Defective hydraulic unit
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.

9-58
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

DTC Item Symptom Check point

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 intemiittently • Incorrect rotation of the
tion) while the veh icle 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 p res-
sure.
42 Rear wheel ABS (intermit- • Pulses from the rear • Incorrect installation of
tent wheel speed pu lses or wheel sensor are re- the rear wheel sensor
incorrect depressuriza- ceived intemiittently • Incorrect rotation of the
tion) while the veh icle 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 p res-
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
• Defective sensor rotor or
incorrect installation of
the rotor
• Defective front wheel
sensor or incorrect in-
stallation of the sensor
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
• Defective sensor rotor o r
incorrect installation of
the rotor
• Defective rear wheel
sensor or incorrect in-
stallation of the sensor
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-
tern

9-59
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

DTC Item Symptom Check point

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
• Open or short circuit in
the wire harness be-
tween the battery and the
hydraulic unit assembly
• Defective charging sys-
tern
55 Hydraulic unit assembly Abnormal data is detected • Defective hyd raulic unit
(defective ABS ECU) in the hydraulic unit as- assembly
sembly.
56 Hydraulic unit assembly Abnormality detected in of • Defective hyd raulic unit
(abnormal internal circuit) hydraulic unit assembly. assembly
57 Vehicle CAN comrnunica- Short-circuit in CAN com- • Short-circuit in CAN
lion 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-
tern
62 Power supply voltage fail- Abnormality detected in • Defective hydraulic unit
ure in pressure sensor pressure sensor power assembly
supply circu it 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
• Defective hydraulic unit
assembly

9-60
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

DTC Item Symptom Check point

90 CAN communication (be- Transmitted data from the • Defective coupler be-
tween ECU and hydraulic Fl ECU cannot be normal- tween Fl ECU and hy-
unit assembly) ly received. draulic unit assembly
• Harness is broken or
short-circuit between Fl
ECU and hydraulic unit
assembly
• Detective Fl ECU
• Defective hydraulic unit
assembly
91 CAN communication (be- Transmitted data from the • Defective coupler be-
tween IMU and hydraulic IMU cannot be normally tween IMU and hydraulic
unit assembly) received. unit assembly
• Harness is broken or
short-circuit between
IMU and hydraulic unit
assembly
• Defective IMU
• Defective hydraulic unit
assembly

• The OTC number varies according to the vehicle conditions.

"""""""'
COMMUNICATION ERROR WITH THE METER
Probable cause of Fail-safe system
DTC It em Vehicle symptom
malfunction operation
U0155 [U0155 (Fl)] Multi- Communication be- Defective meter dis- MAP changeover:
(YDT) function meter: sig- tween the ECU and play. State is fixed.
Err (multi- nals cannot be 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 OFF is fixed.
ter. coupler QSS is not carried
• Open or short cir- out.
cuit in the wire har- Cruise control sys-
ness between the tern cannot be oper-
meter and the ated. (for
ECU MT09SPM/
• Defective meter MT09SPMC)
• Defective ECU

9-61
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EA""""'1
DIAGNOSTIC CODE: SENSOR OPERATION TABLE
Diagnostic
Item Tool display Procedure
code No.
01 Throttle position sensor
signal 1
• Fully closed position 11-21 Check with throttle valves
fully closed.
• Fully open position 96-107 Check with throttle valves
fully open.
03 Intake air pressure Displays the intake air Operate the throttle while
pressure. pushing the" CiJ" side of the
stop/run/start switch. (If
the display value changes,
the performance is OK.)
04 Intake air pressure 2 Displays the intake air Operate the throttle while
pressure. pushing the"@" side of the
stop/run/start switch. (If
the display value changes,
the performance is OK.)
05 Intake air temperature Displays the intake air Compare the actually
temperature. measured air temperatur,e
with the tool display value .
06 Coolant temperature When engine is cold: Dis- Compare the actually
plays temperature closer measured coolant tern-
to air temperature. perature with the tool dis-
When engine is hot: Dis- play value.
plays current coolant tern-
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 Fuel system voltage Set the stop/run/start
(battery voltage) Approximately 12.0 switch to "n ", and then
compare the actually mea-
sured battery voltage with
the tool display value. (If
the actually measured bat-
tery voltage is low, re-
charge the battery.)
13 Throttle position sensor
signal 2
• Fully closed position 9-23 Check with throttle valves
fully closed.
• Fully open position 93-109 Check with throttle valves
fully open.

9-62
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Diagnostic
Item Tool display Procedure
code No.
14 Accelerator position sen-
sor signal 1
• Fully closed position 14-18 Check with throttle grip ful-
ly closed position.
• Fully open position 82- 92 Check with throttle grip ful-
ly open position.
[For MT09SPM/MT09SP- 7- 12
MC] Turn the throttle grip
past the closed position in
the deceleration direction.
15 Accelerator position sen-
sor signal 2
• Fully closed position 14-18 Check with throttle grip ful-
ly closed position.
• Fully open position 82-92 Check with throttle grip ful-
ly open position.
[For MT09SPM/MT09SP- 7- 12
MC] Turn the throttle grip
past the closed position in
the deceleration direction.
16 Front wheel vehicle speed Front wheel speed pulse Check that the number in-
pulses 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 (with the trans-
mission in gear).
• Sidestand extended OFF

9-63
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Diagnostic
Item Tool display Procedure
code No.
21 Neutral switch and clutch Operate the transmission,
switch clutch lever, and side-
stand.
• Transmission is iin neu- ON
tral
• Transmission is iin gear OFF
or 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
60 EEPROM DTC display -
• No history 00
• No malfunctions detect-
ed (If the DTC P062 F is
indicated, the ECU is de-
fective.)
• History exists 01-03 (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 00-03 (EEPROM
data error for correspond-
ing learning/memory val-
ues)
67 ISC (Idle Speed Control) 00 To erase the ISC (Idle
learning condition d isplay 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 in 5 sec-
01 onds.
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 Control number 0-254 [-] -

9-64
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Diagnostic
Item Tool display Procedure
code No.
80 Cruise control setting Push and release the
switch "RES+" "RES+" side of the cruise
control setting switch.
• Switch is pushed ON
• 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

82 Cruise control cancel cir- Operate the clutch lever,
cuit brake lever, brake pedal,
• Clutch lever is squeezed ON and throttle grip.

• Clutch lever is relleased OFF

• Brake lever is squeezed ON
• Brake lever is released OFF
• Brake pedal is depressed ON
• Brake pedal is released OFF
• Throttle grip is turned ON
past the closed position
in the deceleration direc-
tion
• Throttle grip is re leased 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 depressed ON
• Brake pedal is released OFF
87 0 2 feedback learning data 00 To erase the 0 2 feedback
erasure 0 2 feedback learning data learning data, push the
has been erased. "Operation" button 3 times
01 in 5 seconds.
0 2 feedback learning data
has not been erased.
95 Shift sensor Check the sensor condi-
• Shift sensor output volt- 0.2-4.8 [VJ tion by operating the shift
pedal.
age display
• With no shift weighting Approx. 2.5 [VJ
input
• Shift up weighting Changes to the low side
• Shift down weighting Changes to the high s ide

9-65
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EAS3:!002
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 come on
each time the ignition coil
is actuated.
31 Cylinder-#2 ignition coil Actuates the cylinder-#2 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 come on
each time the ignition coil
is actuated.
32 Cylinder-#3 ignition coil Actuates the cylinder-#3 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 come on
each time the ignition coil
is actuated.
36 Injector #1 Actuates the injector #1 Disconnect the fuel pump
five times at one-second coupler before doing this
intervals. procedure.
The "check" indicator on Check that injector #1 is
the VDT screen come on actuated five times by lis.-
each time the fuel injector tening for the operating
is actuated. sound.
37 Injector #2 Actuates the injector #2 Disconnect the fuel pump
five times at one-second coupler before doing this
intervals. procedure.
The "check" indicator on Check that injector #2 is
the VDT screen come on actuated five times by lis.-
each time the fuel injector tening for the operating
is actuated. sound.
38 Injector #3 Actuates the injector #3 Disconnect the fuel pump
five times at one-second coupler before doing this
intervals. procedure.
The "check" indicator on Check that injector #3 is
the VDT screen come on actuated five times by lis-
each time the fuel injector tening for the operating
is actuated. sound.
46 Purge cut valve solenoid Actuates the purge cut Check that the purge cut
valve solenoid five times valve solenoid is actuated
at one-second intervals. five times by listening for
The "check" indicator on the operating sound.
the VDT screen come on
each time the intake sole-
noid is actuated.

9-66
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Diagnostic
code No. Item Actuation Procedure

50 Main relay Actuates the relay unit five Check that the relay unit i s
times at one-second inter- actuated five times by lis-
vals. tening for the operating
The "check" indicator on sound.
the VDT screen come 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.
the VDT screen come on
each time the relay is actu-
ated.
52 Headlight relay Actuates the headlight five Check that the headlight
times at five-seconds in- comes on five times.
tervals.
The "check" indicator on
the VDT screen come on
each time the headlight is
actuated.
57 Grip warmer Turns on the grip warmers Check that the grip warm-
for 2 minutes. ers become warm.

9-67
 EVENT CODE TABLE

EA"'°'°7

EVENT CODE TABLE

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
The event code numbers listed below cannot be displayed on the meter. To display the event code
numbers, use the VDT.

No. Item Symptom Possible causes Note

192 Intake air pres- Brief abnormality Same as for OTC num- Perform the inspection
sure sensor detected in the in- ber P0107 and P0108 items listed for OTC nunn-
take air pressure ber P0107 and P0108.
sensor
193 Throttle position Brief abnormality Same as for OTC num- Perform the inspection
sensor detected in the ber P0122, P0123, items listed for OTC nunn-
throttle, position P0222 and P0223 ber P0122, P0123,
sensor P0222 and P0223.
195 Sidestand Brief abnormality Same as for OTC num- Perform the inspection
switch detected in the ECU ber P1601 items listed for OTC nunn-
(blue/y,ellow) input ber P1601.
line
196 Coolant tem- Brief abnormality Same as for OTC num- Perform the inspection
perature sensor detected a in the ber P0117 and P0118 items listed for OTC nunn-
coolant tempera- ber P0117 and P0118.
ture sensor
197 Intake air tern- Brief abnormality Same as for OTC num- Perform the inspection
perature sensor detected in the in- ber P0112 and P0113 items listed for OTC nunn-
take air temperature ber P0112 and P0113.
sensor
199 Intake air pres- Brief abnormality Same as for OTC No. Perform the inspection
sure sensor 2 detected in the in- P1606 and P1607 items listed for OTC No.
take air pressure P1606 and P1607.
sensor 2
207 Accelerator po- Brief abnormality Same as for OTC num- Perform the inspection
sition sensor detected in the ac- ber P2122, P2123, items listed for OTC nunn-
celerat-or position P2127 and P2128 ber P2122, P2123,
sensor P2127 and P2128.
220 Gear position Brief abnormality Same as for OTC num- Perform the inspection
sensor detected in the gear ber P0916 and P0917 items listed for OTC nunn-
position sensor ber P0916 and P0917.
240 0 2 sensor During 0 2 feed- • Open or short circuit • If a OTC 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-
j ustment) at the upper limit and ECU curs even when the sys-
• Drop in fuel pressure tern is functioning
• Clogged fuel injector properly.
• Fault in sensor
• Malfunction in ECU
• Malfunction in the
fuel injection system

9-68
 EVENT CODE TABLE

No. Item Symptom Possible causes Note

241 0 2 sensor During 0 2 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 tern is functioning
• Clogged fuel injector properly.
• Fault in sensor
• Malfunction in ECU
• Malfunction in the
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 tern is functioning
• Malfunction in the properly.
battery
• Malfunction in ECU
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 tern is functioning
fuel injection system properly.
• Dirty or worn spark
plug
• Malfunction in the
battery
• Malfunction in ECU
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 tern is functioning
• Malfunction in the properly.
battery
• Malfunction in ECU
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 tern is functioning
• Dirty or worn spark properly.
plug
• Malfunction in the
battery
• Malfunction in ECU

9-69
 EVENT CODE TABLE

No. Item Symptom Possible causes Note

246 Cruise control Automatic turning The cruise control sys- The automatic turning off
off of the cruise con- tern will automatically of the cruise control sys-
trol system detected turn off under the fol- tern does not indicate a
lowing conditions: malfunction in the sys-
• Unable to maintain tern.
the set cruising
speed when traveling
up a steep slope
• Wheel slip detected
• Engine stalls
• Sidestand is extend-
ed
• Engine stop switch is
set to the position
251 Shift sensor Brief abnormality Same as for OTC num- Perform the inspection
detected in the shift ber P1806 and P1807 items listed for OTC num-
sensor ber P1806 and P1807.

9-70
 30_EVENT

EA""""'

30_EVENT
EAS3:l000
TROUBLESHOOTING
Item
Overturn detected.
Fa'il-safe system
• Unable to start engine
• Unable to drive vehicle

Procedure
1. The vehicle has overturned.
• Raise the overturned vehicle vertically and check again.
• Tum 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.
Refer to "GENERAL CHASSIS (1)" on page 4-1.
• Check the grommet for cracks.

Is check result OK?

YES
➔ Go to step 3.
NO
a. Fix the IMU installation condition.
b. Turn the main switch to "ON", then to "OFF", and then back to "ON".

Is the MIL on?

YES
➔ Go to step 3.
NO
➔ Service is completed.

3. Defective IMU.
• Execute the diagnostic mode. (Code 17)
• Check that 0°-5° is displayed wlnen the vehicle is vertical and that the displayed value increases as
the vehicle continues to incline.

Is check result OK?

YES
➔ Go to step 4.
NO
a. Replace the IMU.
Refer to "GENERAL CHASSIS (1)" on page 4-1.
b. Tum the main switch to "ON", then to "OFF", and then back to "ON".

9-71
 30_EVENT

Is the MIL on?

YES
➔ Go to step 4.
NO
➔ Service is completed.

4. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.

9-72
 70_EVENT

..70_EVENT
.,_

EA"""°'
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.
• Tum the main switch to "OFP'.
• Check whether it is possible to start the engine.

Can the engine starting?

YES
➔ Service is completed.
NO
➔ Go to step 2.

2. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.

9-73
 C0520

........
C0520
...,,..,.
TROUBLESHOOTING
Item
ECU: no normal signals or malfunction signals are received from the IMU.
Fa'il-safe system
• Able/Unable to start engine
• Able/Unable to drive vehicle

Procedure
1. Connection of IMU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals 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. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 2.

2. Connection of ECU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Tum the main switch to "ON", and then check the condition o f the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 3.

3. Wire harness continuity.

• Disconnect the ECU coupler "1", IMU coupler ''3" and ignition fuse 1 "4".
• Remove the joint coupler cap "2".
• Open circuit check

9-74
 C0520

Between ignition fuse 1 "4" coupler and IMU red/white-red/white

coupler"3"
blue/white-blue/white
Between IMU coupler "3" and joint coupler "2" blue/black-blue/black
blue/white-blue/white
Between IMU coupler "3" and joint coupler "2" blue/black-blue/black
Between IMU coupler "3" and ground black/white- ground

* MT09M/MT09MC
~ amm rm'jl fntil I
•• MT09SPM/MT09SPMC

Is resistance O n?
YES
➔ Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Turn the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service .
NO
➔ Go to "Short circuit check".
• Short circuit check
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.
Ground short circuit check "A"
blue/black-ground
Between ECU coupler "1" and ground
blue/white-ground
blue/black-ground
Between IMU coupler "3" and ground blue/white-ground
red/white-ground

9-75
 C0520

Lines short circuit check "B"

blue/black- any other coupler terminal
ECU coupler "1"
blue/white-any other coupler terminal
blue/black- any other coupler terminal
IMU coupler "3" blue/white-any other coupler terminal
red/white- any other coupler terminal
blue/black- any other coupler terminal
Joint coupler "2"
blue/white-any other coupler terminal

[BJ

p•-------~
' ''
Q :
''
''
''
''
''
----------4'' ''.. -······•--4''
* MT09M/MT09MC
•• MT09SPM/MT09SPMC

Is resistance ~ n?
YES
➔ Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" c ondition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 4.
4. Installed condition of IMU.
• Check the installed direction and condition of the sensor.
Refer to "GENERAL CHASSIS (1)" on page 4-1 .
• Check the grommet for cracks.

9-76
 C0520

Is check result OK?

YES
➔ Go to step 5.
NO
a. Fix the IMU installation condition.
b. Tum the main switch to "ON", and then check the condition o f the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 5.

5. Defective IMU.
• Replace the IMU.
Refer to "GENERAL CHASSIS (1)" on page 4-1.
• Tum the main switch to "ON", and then check the condition of the OTC using the malfunction mode
of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 6.

6. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
7. Delete the OTC and check that the MIL goes off.
• Confirm that the OTC has a condition of "Recovered" using the VDT, and then delete the OTC.

9-n
 P0030

EA"""'7

P0030
EAS331M
TROUBLESHOOTING
Item
0 2 sensor heater: defective heater controller detected.
Fail-safe system
• Able to start engine
• Able to drive vehicle

Procedure
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
If more than one OTC is detected at the same time, perform troubleshooting of OTC listed below first.
• P011 2, P0113, P0122, P0123, P0222, P0223, P2135
1. Connection of 0 2 sensor couple r.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals 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. Tum the main switch to "O N", and then check the condition o f the DTC using the malfunction
mode of the VDT .

Is it in the "Recovered" condition?

YES
➔ Go to step 6, and complete the service.
NO
➔ Start the engine, and then check the condition of the DTC.

Is it in the "Recove red" condition?

YES
➔ Go to step 6, and complete the service.
NO
➔ Go to step 2.

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
For this check, also set the stop/run/start switch to "ON".
2. Connection of ECU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

9-78
 P0030

Is the coupler condition normal?

YES
➔ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Tum the main switch to "ON", and then check the condition o f the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 6, and complete the service.
NO
➔ Start the engine, and then check the condition of the DTC.

Is it in the "Recovered" condition?

YES
➔ Go to step 6, and complete the service.
NO
➔ Go to step 3.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
For this check, also set the stop/run/start switch to "ON".

3. Wire harness continuity.

• Disconnect the 0 2 sensor coupler "1", ECU coupler "2"and ignition fuse 1 "3".
• Open circuit check
Between 0 2 sensor coupler "1" and ECU cou-
pink/black-pink/black
pier "2"
Between 0 2 sensor coupler "1" and ignition fuse
red-red
holder "3"

3 1
B --·-------{@------•ti)

Is resistance 0 '2?
YES
➔ Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Tum the main switch to "ON", and then check the condition o f the DTC using the malfunction
mode of the VDT.

9-79
 P0030

Is it in the "Recovered" condition?

YES
➔ Go to step 6, and complete the service.
NO
➔ Start the engine, and then check the condition of the DTC.

Is it in the "Recovered" condition?

YES
➔ Go to step 6, and complete the service.
NO
➔ Go to "Short c ircuit check''.

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
For this check, also set the stop/run/start switch to "ON".
• Short circuit check
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.

Ground short circuit check "A"

red-ground
Between 0 2 sensor coupler "1" and ground
pink/black-ground

Lines short ci rcuit check "B"

red-any other coupler terminal
0 2 sensor coupler "1"
pink/black-any other coupler terminal
ECU coupler "2" pink/black-any other coupler terminal

IA! rn:J
1
2

' -------------------

Is resistance ~ n?
YES
➔ Go to step 4.
NO
a. Replace the wire harness.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 6, and complete the service.
NO
➔ Start the engine, and then check the condition of the DTC.

9-80
 P0030

Is it in the "Recovered" condition?

YES
➔ Go to step 6, and complete the service.
NO
➔ Go to step 4.

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
For this check, also set the stop/run/start switch to "ON".
4. Defective 0 2 sensor.
• Replace the 0 2 sensor.
Refer to "ENGINE REMOVAL" on page 5-9.
• Turn the main switch to "ON", and then check the condition of the OTC using the malfunction mode
of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 6, and complete the service.
NO
➔ Start the engine, and then check the condition of the DTC.

Is it in the "Recovered" condition?

YES
➔ Go to step 6, and complete the service.
NO
➔ Go to step 5.

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
For this check, also set the stop/run/start switch to "ON".
5. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
6. Delete the OTC and check that the MIL goes off.
• Confirm that the OTC has a condition of "Recovered" using the YDT, and then delete the OTC.

9-81
 POOD1,P2195
..POOD1,P2195
......,

EAS33115
TROUBLESHOOTING
Item
• [P00D1] 0 2 sensor: heater performance deterioration
• [P2195] 0 2 sensor: open circuit detected.
Fail-safe system
• Able to start engine
• Able to drive vehicle

Procedure
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first.
• P0030
1. Installed condition of 0 2 sensor ..
• Check for looseness or pinching.

Is check result OK?

YES
➔ Go to step 2.
NO
a. Reinstall or replace the 0 2 sensor.
Refer to "ENGINE REMOVAL" on page 5-9.
b. Start the engine and let it idle for approximately 1 minute.
c. Check the condition of the DTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 8, and complete the service.
NO
➔ Go to step 2.
2 . Connection of 0 2 sensor coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and let it idle for approximately 1 minute.
c. Check the condition of the DTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 8, and complete the service.
NO
➔ Go to step 3.

9-82
 POOD1,P2195

3. Connection of ECU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and let it idle for approximately 1 minute.
c. Check the condition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 8, and complete the service.
NO
➔ Go to step 4.

4. Wire harness continuity.

• Disconnect the 0 2 sensor coupler "1", ECU coupler "2" and ignition fuse 1 "3".
• Open circuit check
gray/green-gray/green
Between 0 2 sensor coupler "1" and ECU cou-
pink/black-pink/black
pier "2" black/blue-black/blue
Between 0 2 sensor coupler "1" and ignition fuse
red-red
1 holder "3"

• MT09M/MT09MC
•• MT09SPM/MT09SPMC

Is resistance 0 n?
YES
➔ Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Start the engine and let it idle for approximately 1 minute.
c. Check the condition of the OTC using the malfunction mode of the VDT.

9-83
 POOD1,P2195

Is it in the "Recovered" condition?

YES
➔ Go to step 8, and complete the service.
NO
➔ Go to "Short circuit check".

• Short circuit check

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.
Ground short circuit check "A"
gray/green-ground
pink/black-ground
Between 0 2 sensor coupler "1" and ground
black/blue-ground
red-ground

Lines short circuit check "B"

gray/green- any other coupler terminal
pink/black-any other coupler tenninal
0 2 sensor coupler "1 "
black/blue-any other coupler terminal
red-any other coupler tenninal
gray/green- any other coupler terminal
ECU coupler "2" pink/black-any other coupler tenninal
black/blue-any other coupler terminal

ml
2~-----··------
1 : LI 'a Gf'
: li" Bit
: u i ==;;,1, \'A l
,__ ------+----- ---------
·,
·-----
'
2 ' 2**
-- -- -------------- -- --------------- - --
-
:t.~;;;;;:;.;;;;;;;~:;;~~
'
' . .
--------- -- ------ -- -

• MT09M/MT09MC
•• MT09SPM/MT09SPMC

Is resistance ~ n?
YES
➔ Go to step 5.
NO
a. Replace the wire harness.
b. Start the engine and let it idle for approximately 1 minute.
c. Check the condition of the DTC using the malfunction mode of the YDT.

9-84
 POOD1 , P2195

Is it in the "Recovered" condition ?

YES
➔ Go to step 8, and complete the service.
NO
➔ Go to step 5.

5. Check fuel pressure.

• Check the fuel pressure.
Refer to "CHECKING THE FUEL PRESSURE" on page 7-10.

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.
b. Start the engine and let it i die for approximately 1 minute.
c. Check the condition of the DTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 8, and complete the service.
NO
➔ Go to step 6.

6. Defective 0 2 sensor.
a. Replace the 0 2 sensor.
Refer to "ENGINE REMOVAL" on page 5-9.
b. Start the engine and let it idle for approximately 1 minute.
c. Check the condition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 8, and complete the service.
NO
➔ Go to step 7.

7. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
8. Delete the OTC and check that 1he MIL goes off.
• Confirm that the OTC has a condition of "Recovered" using the VDT, and then delete the OTC.

9-85
 P0107,P0108
..P0107,P0108
.....,

EAS3:l047
TROUBLESHOOTING
Item
• [P0107] Intake air pressure sensor 1: ground short circuit detected.
• [P0108] Intake air pressure sensor 1: open or power short circuit detected.
Fa'il-safe system
• Able to start engine
• Able to drive vehicle

Procedure
1. Connection of intake air pressure sensor 1 coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals 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. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 2.

2. Connection of ECU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 3.

3. Wire hamess continuity.

• Disconnect the intake air pressure sensor 1 coupler "1" and ECU coupler "3".
• Remove the joint coupler cap "2".
• Open circuit check

9-86
 P0107,P0108

Between ECU coupler "3" and joint coupler cap

[P0108) black/blue-black/blue
"2"
Between ECU coupler "3" and intake air pres- [P0108) blue-bl ue
sure sensor 1 coupler "1" [P0107, P0108) pink/white-pink/white
Between intake air pressure sensor 1 coupler
[P0108) black-black
"1 " and joint coupler "2"

- - - - - - - --I.Qi----------------------
a**
1

'----------n-----'----1------------'

•
~ ri
MT09M/MT09MC
fjT(j f LlIJ ....@.
•• MT09SPM/MT09SPMC

Is resistance O 11?
YES
➔ Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Turn the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the YDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to "Short circuit check".
• Short circuit check
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.

9-87
 P0107, P0108

Ground short circuit check "A"

Between intake air pressure sensor 1 coupler blue- ground
"1 " and ground pink/white-ground

Lines short circuit check "B"

[P0108) blue- an y other coupler terminal
[P0108) black/blue-any other coupler terminal
ECU coupler "3"
[P0107, P0108) pink/white- any other coupler
terminal
[P0108) blue- an y other coupler terminal
[P0108) black- any other coupler terminal
Intake air pressure sensor 1 coupler "1"
[P0107, P0108) pink/white- any other coupler
terminal
[P0108) black/blue-any other coupler terminal
Joint coupler "2" [P0108) black- any other coupler terminal

~ [ID

---·-----························
' '
: 1• •••••••••••••••••• I :
I I ., • • • • •• • • ._ I I
2 : : I : : :

y.
..' ..
: :
..
: a**
.. .
'--___L._.._
.""'··®-l i
'••••••• I

• MT09M/MT09MC
•• MT09SPM/MT09SPMC

Is resistance ~ n?
YES
➔ Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the YDT.

Is it in the "Recovered" c ondition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 4.
4. Installed condition of intake air pressure sensor 1.
• Check for looseness or pinching.

9-88
 P0107, P0108

Is check result OK?

YES
➔ Go to step 5.
NO
a. Reinstall or replace the sensor.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 5.

5. Defective intake air pressure sensor 1.

• Execute the diagnostic mode. (Code 03)
• When engine is stopped: Atmospheric pressure at the current altitude and weather conditions is in -
dicated.
Approx. 101 kPa (757.6 mmHg, 29.8 inHg), ap-
At sea level
prox. 3.64 V
Approx. 90 kPa (675.1 mmHg, 26.6 inHg), ap-
1000 m (3300 ft) above sea level
prox. 3.30 V
Approx. 80 kPa (600.0 mmHg, 23.6 inHg), ap-
2000 m (6700 ft) above sea level
prox. 3.00 V
Approx. 70 kPa (525.0 mmHg, 20.7 inHg), ap-
3000 m (9800 ft) above sea level
prox. 2.70 V

• 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 1.
Refer to "THROTTLE BODIES" on page 7-5.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 6.

6. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
7. Delete the OTC and check that t he MIL goes off.
• Confirm that the OTC has a condition of "Recovered" using the YDT, and then delete the OTC.

9-89
 P0112,P0113
........
P0112, P0113
EAS3:l048
TROUBLESHOOTING
Item
• [P0112] Intake air temperature sensor: ground short circuit detected.
• [P0113] Intake air temperature sensor: open or power short circuit detected.
Fa'il-safe system
• Able to start engine
• Able to drive vehicle

Procedure
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Perform this procedure when the engine is cold.
1. Connection of intake air temperature sensor coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals 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. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 2.

2. Connection of ECU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Tum the main switch to "ON", and then check the condition o f the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 3.

9-90
 P0112,P0113

3. Wire harness continuity.

• Disconnect the intake air temperature sensor coupler "1" and ECU coupler "3".
• Remove the joint coupler cap "2".
• Open circuit check
Between ECU coupler "3" and intake air tern-
[P0113) brown/white-brown/white
perature sensor coupler "1"
Between ECU coupler "3" and joint coupler "2" [P0112, P0113] black/blue-black/blue
Between intake air temperatu re sensor coupler
[P0113) black-black
"1 " and joint coupler "2"

~ - - - - - - ----i.Q,-- - - - ~ - - - - - - - - - - - - ~

3* a**
1

•
~
MT09M/MT09MC
fffffiT~@ w:i..l
...•

•• MT09SPM/MT09SPMC

Is resistance O .O?
YES
➔ Go to "Short circuit check"_
NO
a. Replace the wire harness.
b. Turn the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the YDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to "Short circuit check''.
• Short circuit check
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.

9-91
 P0112, P0113

Ground short circuit check "A"

Between intake air temperature sensor coupler [Po 112, p 01131 brown/white- ground
"1 " and ground

Lines short circuit check "B"

[P0112, P0113] brown/white-any other coupler
int ake air temperature sensor coupler "1" terminal
[P0113) black- any other coupler terminal
[P0113) black/blue-any other coupler terminal
Joint coupler "2"
[P0113) black- a ny other coupler terminal
[P0112, P0113] brown/white-any other coupler
ECU coupler "3" terminal
[P0113) black/blue-any other coupler terminal

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Is resistance ~ n?
YES
➔ Go to step 5.
NO
a. Replace the wire harness.
b. Turn the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the YDT.

Is it in the "Recovered" c ondition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 4.

4. Installed condition of intake air te mperature sensor.

• Check for looseness or pinching.
Refer to "GENERAL CHASSIS (2)" on page 4·10.

9-92
 P0112,P0113

Is check result OK?

YES
➔ Go to step 5.
NO
a. Reinstall the sensor.
b. Tum the main switch to "ON" , and then check the condition o f the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 5.

5. Defective intake air temperature sensor.

• Execute the diagnostic mode. (Code 05)
• When engine is cold: Displayed temperature is close to the ambient temperature.
• The displayed temperature is not close to the ambient temperatUJre ➔ Check the intake air tempera-
ture sensor.
Refer to "DIAGNOSTIC CODE: SENSOR OPERATION TABLE" on page 9-62.

Is check result OK?

YES
➔ Go to step 6.
NO
a. Replace the intake air temperature sensor.
Refer to "GENERAL CHASSIS (2)" on page 4-10.
b. Tum the main switch to "ON", and then check the condition o f the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 6.

6. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
7. Delete the OTC and check that t he MIL goes off.
• Confirm that the OTC has a condition of "Recovered" using the YDT, and then delete the OTC.

9-93
 P0117,P0118
........
P0117, P0118
EAS3:l040
TROUBLESHOOTING
Item
• [P0117] Coolant temperature sensor: ground short circuit detected.
• [P0118] Coolant temperature sensor: open or power short circuit detected.
Fa'il-safe system
• Able to start engine
• Able to drive vehicle

Procedure
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Perform this procedure when the engine is cold.
1. Connection of coolant temperature sensor coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals 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. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 2.

2. Connection of ECU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Tum the main switch to "ON", and then check the condition o f the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 3.

9-94
 P0117,P0118

3. Wire harness continuity.

• Disconnect the coolant temperature sensor coupler "1" and ECU coupler "3".
• Remove the joint coupler cap "2".
• Open circuit check
Between coolant temperature sensor coupler
[P0117, P0118) green/white-green/white
"1" and ECU coupler "3"
Between coolant temperature sensor coupler
[P0118) black-black
"1 " and joint coupler "2"
Between joint coupler "2" and ECU coupler "3" [P0118) black/blue-black/blue

~ - - - - - - -----i.Q,-- - - - ~ - - - - - - - - - - - - - ~

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Is resistance O .O?
YES
➔ Go to step "Short circuit check''.
NO
a. Replace the wire harness.
b. Turn the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the YDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Goto step "Short circuit check".
• Short circuit check
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.

9-95
 P0117,P0118

Ground short circuit check "A"

Between coolant temperature sensor coupler
[P0117, P0118] green/ white-ground
"1 " and ground

Lines short circuit check "B"

[P0117, P0118] green/white-any other coupler
Coolant temperature sensor coupler "1 " terminal
[P0118) black-any other coupler terminal
[P0118) black/blue-any other coupler terminal
Joint coupler "2"
[P0118) black-any other coupler terminal
[P0117, P0118] green/white-any other coupler
ECU coupler "3" terminal
[P0118) black/blue-any other coupler terminal

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Is resistance ~ n?
YES
➔ Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the YDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 4.
4. Installed condition of coolant temperature sensor.
• Check for looseness or pinching.
Refer to "CYLINDER HEAD" on page 5-26.

9-96
 P0117,P0118

Is check result OK?

YES
➔ Go to step 5.
NO
a. Reinstall the sensor.
b. Tum the main switch to "ON" , and then check the condition o f the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 5.

5. Defective coolant temperature sensor.

• Execute the diagnostic mode. (Code 06)
• 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 8-63.

Is check result OK?

YES
➔ Go to step 6.
NO
a. Replace the coolant temperature sensor.
Refer to "CYLINDER HEAD" on page 5-26.
b. Tum the main switch to "ON", and then check the condition o f the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 6.

6. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
7. Delete the OTC and check that t he MIL goes off.
• Confirm that the OTC has a condition of "Recovered" using the YDT, and then delete the OTC.

9-97
 P0122,P0123,P0222,P0223,P2135

P0122, P0123, P0222, P0223, P2135

"""""""
TROUBLESHOOTING
Item
• [P0122] Throttle position sensor: ground short circuit detected.
• [P0123] Throttle position sensor: open or power short circuit detected.
• [P0222] Throttle position sensor: open or ground short circuit detected.
• [P0223] Throttle position sensor: [Power short circuit detected.
• [P2135] Throttle position sensor: output voltage deviation error.
Fa'il-safe system
• Able/Unable to start engine
• Able/Unable to drive vehicle

Procedure
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
If a OTC other than P2135 (P0122, P0123, P0222, P0223) is detected, perform troubleshooting first
1. Connection of throttle position sensor coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals 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. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT .

Is it in the "Recovered" condition?

YES
➔ Go to step 8, and complete the service.
NO
➔ Go to step 2.

2. Connection of ECU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Tum the main switch to "ON", and then check the condition o f the DTC using the malfunction
mode of the VDT.

9-98
 P0122, P0123, P0222, P0223, P2135

Is it in th e "Recovered" condition?
YES
➔ Go to step 8, and complete the service.
NO
➔ Go to step 3.
3. Wire harness continuity.
• Disconnect the throttle position sensor coupler "1" and ECU coupler "2".
• Open circuit check
[P0122, P0123, P0222, P0223, P2135] white-
white
Between throttle position sensor coupler "1" and [P0123, P0223) black/blue- black/blue
ECU coupler "2" [P0122, P0222) blue-blue
[P0122, P0123, P0222, P0223, P2135] black-
black

n
n
1

~r -

Is resistance 0 n?
YES
➔ Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 8, and complete the service.
NO
➔ Go to "Short circuit check".
• Short circuit check
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.

9-99
 P0122,P0123,P0222,P0223,P2135

Ground short circuit check "A"

[P0122, P0123, P0222, P0223, P2135] white-
Between throttle position sensor coupler "1" and ground
[P0122, P0222)] blue-ground
ground
[P0122, P0123, P0222, P0223, P2135] black-
ground

Lines short circuit check "B"

[P0122, P0123, P0222, P0223, P2135] white=
any other coupler terminal
[P0123, P0223]I black/blue- any other coupler
Throttle position sensor coupler "1" terminal
[P0122, P0222) blue-any other coupler terminal
[P0122, P0123, P0222, P0223, P2135] black-
any other coupler terminal
[P0122, P0123, P0222, P0223, P2135] white-
any other coupler terminal
[P0123, P02.2 3)I black/blue- any other coupler
ECU coupler "2" terminal
[P0122, P0222) blue-any other coupler terminal
[P0122, P0123, P0222, P0223, P2135] black-
any other coupler terminal

ml

1 1 2
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Is resistance ~ n?
YES
➔ Go to step 4.
NO
a. Replace the wire harness.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

9-100
 P0122,P0123,P0222,P0223,P2135

Is it in the "Recovered" condition?

YES
➔ Go to step 8, and complete the service.
NO
➔ Go to step 4.
4. Installed condition of throttle posrtion sensor.
• Check for looseness or pinching.
Refer to "ADJUSTING THE THROTTLE POSITION SENSOR" on page 7-11.

Is check result OK?

YES
➔ Go to step 5.
NO
a. Reinstall or adjust the sensor.
b. Turn the main switch to "ON", and then check the condition of the OTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 8, and complete the service.
NO
➔ Go to step 5.
5. Defective throttle position sensor.
• Check throttle position sensor signal 1.
• Execute the diagnostic mode. (Code 01)
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.
Refer to "ADJUSTING THE THROTTLE POSITION SENSOR" on page 7-11.
b. Tum the main switch to "ON", and then check the condition o f the OTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 8, and complete the service.
NO
➔ Go to step 6.
6. Defective throttle position sensor.
• Check throttle position sensor signal 2.
• Execute the diagnostic mode. (Code 13)
When the throttle valves are fully closed 9-23
When throttle valves are fully open 93-109

9-101
 P0122,P0123,P0222,P0223,P2135

Is check result OK?

YES
➔ Go to step 7.
NO
a. Replace the throttle position sensor.
Refer to "ADJUSTING THE THROTTLE POSITION SENSOR" on page 7-11.
b. Tum the main switch to "ON", and then check the condition of the OTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 8, and complete the service.
NO
➔ Go to step 7.
7. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
8. Delete the OTC and check that the MIL goes off.
• Confirm that the OTC has a condition of "Recovered" using the YDT, and then delete the OTC.

9-102
 P0132

P0132
EA""""1
TROUBLESHOOTING
Item
0 2 sensor: short circuit detected (power short circuit).
Fail-safe system
• Able to start engine
• Able to drive vehicle

Procedure
1. Installed condition of 0 2 sensor ..
• Check for looseness or pinching.
Refer to "ENGINE REMOVAL" on page 5-9.

Is check result OK?

YES
➔ Go to step 2.
NO
a. Reinstall or replace the sensor.
b. Tum the main switch to "ON", and then check the condition o f the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 2.

2. Connection of 0 2 sensor coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Tum the main switch to "ON", and then check the condition o f the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 3.

3. Connection of ECU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

9-103
 P0132

Is the coupler condition normal?

YES
➔ Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 4.

4. Wire harness continuity.

• Disconnect the 0 2 sensor coupler "1" and ECU coupler "3".
• Remove the joint coupler cap "2".
• Open circuit check
Between 0 2 sensor coupler "1" and ECU cou-
gray/green-gray/green
pier "3"
Between 0 2 sensor coupler "1" and joint coupler
black/blue-black/blue
"2"
Between joint coupler "2" and ECU coupler "3" black/blue-black/blue

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Is resistance 0 n?
YES
➔ Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the YDT.

9-104
 P0132

Is it in th e "Recovered" condition ?
YES
➔ Go to step 7, and complete the service.
NO
➔ Go to "Short circuit check".
• Short circuit check
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.
Ground short circuit check "A"
I Between 0 2 sensor coupler "1" and ground I gray/green-ground
Lines short circuit check "B"
0 sensor coupler "1" gray/green- any other coupler terminal
2
black/blue-any other coupler terminal
Joint coupler "2" black/blue-any other coupler terminal
gray/green- any other coupler terminal
ECU coupler "3"
black/blue-any other coupler terminal

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Is resistance ~ n?
YES
➔ Go to step 5.
NO
a. Replace the wire harness.
b. Turn the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the YDT.

9-105
 P0132

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 5.

5. Defective 0 2 sensor.
a. Replace the 0 2 sensor.
Refer to "ENGINE REMOVAL" on page 5-9.
b. Turn the main switch to "ON", and then check the condition of the OTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 6.

6. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
7. Delete the OTC and check that 1he MIL goes off.
• Confirm that the OTC has a condition of "Recovered" using the YDT, and then delete the OTC.

9-106
 P0201

P0201
""""""'
TROUBLESHOOTING
Item
Injector #1: malfunction in injector #1.
Fa'il-safe system
• Able to start engine (depending on the number of faulty cylinders)
• Able to drive vehicle (depending on the number of faulty cylinders)

Procedure
1. Connection of injector #1 coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code 36)

Is it hear operating sound?

YES
➔ Go to step 6.
NO
➔ Go to step 2.

2. Defective injector #1.

• Measure the injector resistance.
Refer to "CHECKING THE FUEL INJECTORS" on page 8-64.

Is check result OK?

YES
➔ Go to step 3.
NO
a. Replace the injector #1.
Refer to "THROTTLE BODIES" on page 7-5.
b. Execute the diagnostic mode. (Code 36)

Is it hear operating sound?

YES
➔ Go to step 6.
NO
➔ Go to step 3.

3. Connection of ECU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

9-107
 P0201

Is the coupler condition normal?

YES
➔ Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code 36)

Is it hear operating sound?

YES
➔ Go to step 6.
NO
➔ Go to step 4.

4. Wire harness continuity.

• Disconnect the injector #1 coupler "1", ECU coupler "2" and relay unit coupler "3".
• Open circurt check
Between injector #1 coupler "1 " and ECU cou-
red/black-red/black
pier "2"
Between injector #1 coupler "1 " and relay unit
red/blue-red
coupler "3"

Is resistance 0 O?
YES
➔ Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code 36)

Is it hear operating sound?

YES
➔ Go to step 6.
NO
➔ Go to "Short circuit check".

• Short circuit check

9-108
 P0201

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.
Ground short circuit check "A"
red/black-ground
Between injector #1 coupler "1" and ground
red/blue-ground

Lines short circuit check "B"

red/black-any other coupler terminal
Injector #1 coupler "1"
red/blue-any other coupler tenninal
ECU coupler "2" red/black-any other coupler terminal
Relay unit coupler "3" reel-any other coupler terminal

ffil

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e
!
Is resistance ~ O?
YES
➔ Go to step 5.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code 36)

Is it hear operating sound?

YES
➔ Go to step 6.
NO
➔ Go to step 5.

5. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
6. Delete the OTC and check that t he MIL goes off.
• Start the engine and let it idle for approximately 5 seconds.
• Confinn that the OTC has a condition of "Recovered" using the malfunction mode of the VDT, and
then delete the OTC.

9-109
 P0202

PO202
EA""""5
TROUBLESHOOTING
Item
Injector #2: malfunction in injector #2.
Fa'il-safe system
• Able to start engine (depending on the number of faulty cylinders)
• Able to drive vehicle (depending on the number of faulty cylinders)

Procedure
1. Connection of injector #2 coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

Is the coupler condition norma l?

YES
➔ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code 37)

Is it hear operating sound?

YES
➔ Go to step 6.
NO
➔ Go to step 2.

2. Defective injector #2.

• Measure the injector resistance.
Refer to "CHECKING THE FUEL INJECTORS" on page 8-64.

Is check result OK?

YES
➔ Go to step 3.
NO
a. Replace the injector #2.
Refer to "THROTTLE BODIES" on page 7-5.
b. Execute the diagnostic mode. (Code 37)

Is it hear operating sound?

YES
➔ Go to step 6.
NO
➔ Go to step 3.

3. Connection of ECU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

9-110
 P0202

Is the coupler condition normal?

YES
➔ Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code 37)

Is it hear operating sound?

YES
➔ Go to step 6.
NO
➔ Go to step 4.

4. Wire harness continuity.

• Disconnect the injector #2 coupler "1", ECU coupler "2" and relay unit coupler "3".
• Open circuit check
Between injector #2 coupler "1" and ECU cou-
green/black-green/black
pier "2"
Between injector #2 coupler "1" and relay unit
red/blue-red
coupler "3"

Is resistance 0 O?
YES
➔ Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code 37)

Is it hear operating sound?

YES
➔ Go to step 6.
NO
➔ Go to "Short circuit check''.

• Short circuit check

9-111
 P0202

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.
Ground short circuit check "A"
green/black-ground
Between injector #2 coupler "1" and ground
red/blue-ground

Lines short circuit check "B"

green/black-any other coupler tem,inal
Injector #2 coupler "1"
red/blue-any other coupler tem,inal
ECU coupler "2" green/black-any other coupler tem,inal
Relay unit coupler "3" red-any other coupler terminal

(ID

1 1

t
Is resistance ~ O?
YES
➔ Go to step 5.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code 37)

Is it hear operating sound?

YES
➔ Go to step 6.
NO
➔ Go to step 5.

5. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
6. Delete the OTC and check that t he MIL goes off.
• Start the engine and let it idle for approximately 5 seconds.
• Confim, that the OTC has a condition of "Recovered" using the malfunction mode of the VDT, and
then delete the OTC.

9-112
 P0203

P0203
"""""""
TROUBLESHOOTING
Item
Injector #3: malfunction in injector #3.
Fa'il-safe system
• Able to start engine (depending on the number of faulty cylinders)
• Able to drive vehicle (depending on the number of faulty cylinders)

Procedure
1. Connection of injector #3 coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code 38)

Is it hear operating sound?

YES
➔ Go to step 6.
NO
➔ Go to step 2.

2. Defective injector #3.

• Measure the injector resistance.
Refer to "CHECKING THE FUEL INJECTORS" on page 8-64.

Is check result OK?

YES
➔ Go to step 3.
NO
a. Replace the injector #3.
Refer to "THROTTLE BODIES" on page 7-5.
b. Execute the diagnostic mode. (Code 38)

Is it hear operating sound?

YES
➔ Go to step 6.
NO
➔ Go to step 3.

3. Connection of ECU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

9-113
 P0203

Is the coupler condition normal?

YES
➔ Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code 38)

Is it hear operating sound?

YES
➔ Go to step 6.
NO
➔ Go to step 4.

4. Wire harness continuity.

• Disconnect the injector #3 coupler "1", ECU coupler "2" and relay unit coupler "3"
• Open circurt check
Between injector #3 coupler "1 " and ECU cou-
blue/black-blue/black
pier "2"
Between injector #3 coupler "1 " and relay unit
red/blue-red
coupler "3"

Is resistance 0 O?
YES
➔ Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code 38)

Is it hear operating sound?

YES
➔ Go to step 6.
NO
➔ Go to "Short circuit check".

• Short circuit check

9-114
 P0203

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.
Ground short circuit check "A"
blue/black-ground
Between injector #3 coupler "1" and ground
red/blue-ground

Lines short circuit check "B"

blue/black-any other coupler terminal
Injector #3 coupler "1"
red/blue-any other coupler tenninal
ECU coupler "2" blue/black-any other coupler terminal
Relay unit coupler "3" reel-any other coupler terminal

[ID

1 1

t
Is resistance ~ O?
YES
➔ Go to step 5.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code 38)

Is it hear operating sound?

YES
➔ Go to step 6.
NO
➔ Go to step 5.

5. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
6. Delete the OTC and check that t he MIL goes off.
• Start the engine and let it idle for approximately 5 seconds.
• Confinn that the OTC has a condition of "Recovered" using the malfunction mode of the VDT, and
then delete the OTC.

9-115
 P0335

P0335
"""""""
TROUBLESHOOTING
Item
Crankshaft position sensor: no normal signals are received from the crankshaft position sensor.
Fa'il-safe system
• Unable to start engine
• Unable to drive vehicle

Procedure
1. Connection of crankshaft position sensor coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

Is the coupler condition norma l?

YES
➔ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Crank the engine, and then check the condition of the DTC using the malfunction mode of the
YDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 2.

2. Connection of wire harness ECU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition norma l?

YES
➔ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Crank the engine, and then check the condition of the DTC using the malfunction mode of the
YDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 3.

3. Wire harness continuity.

• Disconnect the crankshaft positi on sensor coupler "1" and ECU coupler "3".
• Remove the joint coupler cap "2".
• Open circuit check

9-116
 P0335

Between crankshaft position sensor coupler "1"

gray- gray
and ECU coupler "3"
Between crankshaft position sensor coupler "1"
black-black
and joint coupler "2"
Between joint coupler "2" and ECU coupler "3" black/blue-black/blue

• MT09M/MT09MC
~ nrnrn rm ...oo.l
•• MT09SPM/MT09SPMC

Is resistance O11?
YES
➔ Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Crank the engine, and then check the condition of the DTC using the malfunction mode of the
VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to "Short circuit check".

• Short circuit check

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.
Ground short circuit check "A"
Between crankshaft position sensor coupler "1" gray- ground
and ground

Lines short circuit check "B"

black/blue-any other coupler terminal
Clrankshaft position sensor coupler "1"
gray- any other coupler terminal
black- any othe:r coupler terminal
Joint coupler "2"
black/blue-any other coupler terminal
black/blue-any other coupler terminal
ECU coupler "3"
gray- any other coupler terminal

9-117
 P0335

[ID
1
3*--- -------------- -- -- ------------ --- -

~
---------------------·······----
'
' ••••••••••• • • • • • • • • • I

2 :' I ~••• • • • • • ~ I
: ' : :
'' ''
3**
------------ --- --------------- -- -----
''' ''
''
'' ''' '
'' ,.--.,'
'·······rn , .!'

~ .

~ ijTfjTjT~OIJ ....@.!
• MT09M/MT09MC
•• MT09SPM/MT09SPMC

Is resistance ~ n?
YES
➔ Go to step 4.
NO
a. Replace the wire harness.
b. Crank the engine, and then check the condition of the DTC using the malfunction mode of the
VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 4.
4. Installed condition of crankshaft position sensor.
• Check for looseness or pinching.
• Check the gap (0.85 mm (0.03 in)) between the crankshaft posit ion sensor and the generator rotor.

Is check result OK?

YES
➔ Go to step 5.
NO
a. Reinstall or replace the sensor.
b. Crank the engine, and then check the condition of the DTC using the malfunction mode of the
VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 5.

9-118
 P0335

5. Defective crankshaft position sensor.

• Check the crankshaft position sensor.
Refer to "CHECKING THE CRANKSHAFT POSITION SENSOR" on page 8-60.

Is check result OK?

YES
➔ Go to step 6.
NO
a. Replace the crankshaft position sensor.
b. Crank the engine, and then check the condition of the DTC using the malfunction mode of the
YDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 6.

6. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
7. Delete the OTC and check that the MIL goes off.
• Confirm that the OTC has a condition of "Recovered" using the YDT, and then delete the OTC.

9-11 9
 P0351

........
P0351
EAS3:JCOO
TROUBLESHOOTING
Item
Cy1inder-#1 ignition coil: open or short circuit detected in the primary lead of the cylinder-#1 ignition coil.
Fa'il-safe system
• Able to start engine (depending on the number of faulty cylinders)
• Able to drive vehicle (depending on the number of faulty cylinders)

Procedure
1. Connection of cylinder-#1 ignition coil coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 2.

2. Connection of ECU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and chock the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 3.

3. Wire hamess continuity.

• Disconnect the cylinder-#1 ignition coil coupler "1" and ECU coupler "2".
• Open circuit check
Between cylinder-#1 ignition coil coupler "1" and
ECU coupler "2" orange-orange

9-120
 P0351

,--------,@.--~

~
Is resistance 0 n?
YES
➔ Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to "Short circuit check".
• Short circuit check
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.
Ground short circuit check "A"
Between cylinder-#1 ignition coil coupler "1" and orange-ground
ground

Lines short circuit check "B"

Cylinder-#1 ignition coil coupler "1" orange-any other coupler terminal
ECU coupler "2" orange-any other coupler terminal

[Al ml

1 1

9-121
 P0351

Is resistance ~ O?
YES
➔ Go to step 4.
NO
a. Replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 4.
4. Installed condition of cylinder-#1 ignition coil.
• Check for looseness or pinching.

Is check result OK?

YES
➔ Go to step 5.
NO
a. Reinstall or replace the ignition coil.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 5.
5. Defective cylinder-#1 ignition co il.
• Measure the primary coil resistance of the cylinder-# 1 ignition coil.
Refer to "CHECKING THE IGNITION COILS" on page 8-59.

Is check result OK?

YES
➔ Go to step 6.
NO
a. Replace the cylinder-#1 ignition coil.
Refer to "CAMSHAFTS" on page 5-16.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the OTC using the malfunction mode of the YDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 6.

9-122
 P0351

6. Malfunction in ECU.
• Execute the diagnostic mode. (Code 30)
• Confirm that spark plug does not sparking.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
7. Delete the OTC and check that the MIL goes off.
• Confirm that the OTC has a condition of "Recovered" using the YDT, and then delete the OTC.

9-123
 P0352

EA""""'1

P0352
EAS"""1
TROUBLESHOOTING
Item
Cy1inder-#2 ignition coil: open or short circuit detected in the primary lead of the cylinder-#2 ignition coil.
Fa'il-safe system
• Able to start engine (depending on the number of faulty cylinders)
• Able to drive vehicle (depending on the number of faulty cylinders)

Procedure
1. Connection of cylinder-#2 ignition coil coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 2.

2. Connection of ECU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and chock the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 3.

3. Wire hamess continuity.

• Disconnect the cylinder-#2 ignition coil coupler "1" and ECU coupler "2".
• Open circuit check
Between cylinder-#2 ignition coil coupler "1" and gray/re~ray/red
ECU coupler "2" u7:1

9-124
 P0352

Is resistance 0 n?
YES
➔ Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to "Short circuit check''.
• Short circuit check
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.
Ground short circuit check "A"
Between cylinder-#2 ignition coil coupler "1" and gray/red-ground
ground

Lines short circuit check "B"

Cylinder-#2 ignition coil coupler "1" gray/red-any other coupler terminal
ECU coupler "2" gray/red-any other coupler terminal

mi

1 1
2 r-··-- .§)
! t i
j ===JCsl.'.=,:::J 1
'········--·-··················'

'
9-125
 P0352

Is resistance ~ O?
YES
➔ Go to step 4.
NO
a. Replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 4.
4. Installed condition of cylinder-#2 ignition coil.
• Check for looseness or pinching.

Is check result OK?

YES
➔ Go to step 5.
NO
a. Reinstall or replace the ignition coil.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 5.
5. Defective cylinder-#2 ignition co il.
• Measure the primary coil resistance of the cylinder-#2 ignition coil.
Refer to "CHECKING THE IGNITION COILS" on page 8-59.

Is check result OK?

YES
➔ Go to step 6.
NO
a. Replace the cylinder-#2 ignition coil.
Refer to "CAMSHAFTS" on page 5-16.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the OTC using the malfunction mode of the YDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 6.

9-126
 P0352

6. Malfunction in ECU.
• Execute the diagnostic mode. (Code 31)
• Confirm that spark plug does not sparking.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
7. Delete the OTC and check that the MIL goes off.
• Confirm that the OTC has a condition of "Recovered" using the YDT, and then delete the OTC.

9-127
 P0353

EA""""2

P0353
EAS3:JC«>
TROUBLESHOOTING
Item
Cy1inder-#3 ignition coil: open or short circuit detected in the primary lead of the cylinder-#3 ignition coil.
Fa'il-safe system
• Able to start engine (depending on the number of faulty cylinders)
• Able to drive vehicle (depending on the number of faulty cylinders)

Procedure
1. Connection of cylinder-#3 ignition coil coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 2.

2. Connection of ECU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and chock the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Goto step 3
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 3.

3. Wire hamess continuity.

• Disconnect the cylinder-#3 ignition coil coupler "1" and ECU coupler "2".
• Open circuit check
Between cylinder-#3 ignition coil coupler "1" and orange/green-orange/green
ECU coupler "2"

9-128
 P0353

Is resistance 0 n?
YES
➔ Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to "Short circuit check''.
• Short circuit check
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.
Ground short circuit check "A"
Between cylinder-#3 ignition coil coupler "1" and orange/green-ground
ground

Lines short circuit check "B"

Cylinder-#3 ignition coil coupler "1" orange/green-any other coupler tenninal
ECU coupler "2" orange/green-any other coupler tenninal

mi
i··-
2 :

!............................. ·:

9-129
 P0353

Is resistance ~ O?
YES
➔ Go to step 4.
NO
a. Replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 4.
4. Installed condition of cylinder-#3 ignition coil.
• Check for looseness or pinching.

Is check result OK?

YES
➔ Go to step 5.
NO
a. Reinstall or replace the ignition coil.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 5.
5. Defective cylinder-#3 ignition co il.
• Measure the primary coil resistance of the cylinder-#3 ignition coil.
Refer to "CHECKING THE IGNITION COILS" on page 8-59.

Is check result OK?

YES
➔ Go to step 6.
NO
a. Replace the cylinder-#3 ignition coil.
Refer to "CAMSHAFTS" on page 5-16.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the OTC using the malfunction mode of the YDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 6.

9-130
 P0353

6. Malfunction in ECU.
• Execute the diagnostic mode. (Code 32)
• Confirm that spark plug does not sparking.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
7. Delete the OTC and check that the MIL goes off.
• Confirm that the OTC has a condition of "Recovered" using the YDT, and then delete the OTC.

9-131
 P0458
..P0458
.,.,,.

"'"""""
TROUBLESHOOTING
Item
Purge cut valve solenoid: open circuit detected.
Fa'il-safe system
• Able to start engine
• Able to drive vehicle

Procedure
1. Connection of purge cut valve solenoid coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals 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. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 2.

2. Connection of ECU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and chock the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 3.

3. Wire hamess continuity.

• Disconnect the ignition fuse 1 "1 ", purge cut valve solenoid coupler "2", ECM coupler "3" and main
switch coupler "4".
• Open circuit check

9-132
 P0458

Between ignition fuse 1 holder "1" and purge cut

red-red/white
valve solenoid coupler "2"
Between purge cut valve solenoid coupler "2"
yellow/red-yellow/red
and ECU coupler "3"
Between main switch coupler "4" and ignition
brown/blue- brown/blue
fuse 1 holder "1"

4 1 2

~ -4\_0~1--4- --1@1---+(I)-----{

Is resistance 0 n?
YES
➔ Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT .

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to "Short circuit check''.

• Short circuit check

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
Ground short circuit check "A"
Between purge cut valve solenoid coupler "2" red/white-ground
and ground yellow/red-ground
Between main switch coupler "4" and ground brown/blue-ground

Lines short circuit check "B"

red/white-any other coupler terminal
Purge cut valve solenoid coupler "2"
yellow/red-any other coupler terminal
ECU coupler "3" yellow/red-any other coupler terminal
Main switch coupler "4" brown/blue- any other coupler terminal

9-133
 P0458

4 4

3
□

Is resistance ~ O?
YES
➔Go to step 4.
NO
a. Replace the wire harness.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 4.

4. Installed condition of purge cut valve solenoid.

• Check for looseness or pinching.
Refer to "FUEL TANK" on page 7-1 .

Is check result OK?

YES
➔ Go to step 5.
NO
a. Replace the purge cut valve solenoid.
Refer to "FUEL TANK" on page 7-1 .
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 5.

5. Defective purge cut valve solenoid.

• Execu1e the diagnostic mode. (Code 46)

9-134
 P0458

Is it hear operationg sound?

YES
➔ Go to step 7, and complete the service.
NO
➔ Check the purge cut valve solenoid.
Refer to "CHECKING THE PURGE CUT VALVE SOLENOID (for MT09MC/MT09SPMC)" on
page 8-65.

Is check result OK?

YES
➔ Go to step 6.
NO
a. Replace the purge cut valve solenoid.
b. Turn the main switch to "ON", and then check the condition of the OTC using the malfunc-
tion mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 6.
6. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
7. Delete the OTC and check that the MIL goes off.
• Start the engine and let it idle for approximately 5 seconds.
• Confirm that the OTC has a condition of "Recovered" using the malfunction mode of the YDT, and
then delete the OTC.

9-135
 P0480

........
P0480
"'""""'
TROUBLESHOOTING
Item
Radiator fan motor relay: open or short circuit detected.
Fa'il-safe system
• Able to start engine
• Able to drive vehicle
Procedure
1. Connection of radiator fan motor relay coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals 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. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 6, and complete the service.
NO
➔ Go to step 2.
2. Connection of ECU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and chock the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Tum the main switch to "ON", and then check the condition o f the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 6, and complete the service.
NO
➔ Go to step 3.
3. Wire harness continuity.
• Disconnect the radiator fan motor relay "1 ", ECU coupler "2" and ignition fuse 1 "3".
• Open circuit check

9-136
 P0480

Between radiator fan motor relay "1" and igni-

red-red
lion fuse 1 holder "3"
Between radiator fan motor relay "1" and ECU
green/yellow-green/yellow
coupler"2"

Is resistance 0 n?
YES
➔ Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT .

Is it in the "Recovered" condition?

YES
➔ Go to step 6, and complete the service.
NO
➔ Go to "Short circuit check''.

• Short circuit check

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.
Ground short circuit check "A"
Between radiator fan motor relay "1" and ground green/yellow- ground
red-ground

Lines short circuit check "B"

Radiator fan motor relay "1" green/yellow- an y other coupler terminal
red-any other coupler terminal
ECU coupler "2" green/yellow-an y other coupler terminal

9-137
 P0480

(ID
1 1

Is resistance ~ O?
YES
➔ Go to step 4.
NO
a. Replace the wire harness.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 6, and complete the service.
NO
➔ Go to step 4.

4. Defective radiator fan motor relay.

• Replace the radiator fan motor relay.
• Tum the main switch to "ON", and then check the condition of the OTC using the malfunction mode
of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 6, and complete the service.
NO
➔ Go to step 5.

5. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
6. Delete the OTC and check that t he MIL goes off.
• Confirm that the OTC has a condition of "Recovered" using the VDT, and then delete the OTC.

9-138
 P0500, P1500

P0500, P1500
EA""""3
TROUBLESHOOTING
Item
• Rear wheel sensor: no normal signals are received from the rear wheel sensor.
• Neutral switch: open or short circuit is detected.
• Clutch switch: open or short circu it is detected.
Fa'il-safe system
• Able to start engine
• Able to drive vehicle

Procedure
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• In case P0S00 is detected, or both P0SOO 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 P0S00 or P0S00 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
➔ Go to step 21 .
NO
➔ Go to step 2.

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Perform the procedure from step 2 to step 7 and step 21.

• DTC P1500 detected.

a . Execute the diagnostic mode. (Code 21)

When the transmission is in neutral ON

When the transmission is in gear with the clutch lever released OFF

Is check result OK?

YES
➔ Go to step b.
NO
➔ Go to step 8.

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Perform the procedure from step 8 to step 14 and step 21.

b. Execute the diagnostic mode. (Code 21)

When the transmission is in gear with the clutch lever squeezed and the ON
sidestand retracted

9-139
 P0500,P1500

Is check result OK?

YES
➔ Go to step 21.
NO
➔ Goto step 15.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Perform the procedure from step 15 to step 21 .

2. Connection of rear wheel sensor coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code 07)
c. Rotate the rear wheel by hand and check that the indicated value increases.

Is that value increased?

YES
➔ Go to step 21.
NO
➔ Go to step 3.
3. Connection of ABS ECU couple r.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code 07)
c. Rotate the rear wheel by hand and check that the indicated value increases.

Is that value increased?

YES
➔ Go to step 21.
NO
➔ Go to step 4.
4. Connection of ECU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

9-140
 P0500, P1500

Is the coupler condition norma l?

YES
➔ Go to step 5.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code 07)
c. Rotate the rear wheel by hand and check that the indicated value increases.

Is that value increased?

YES
➔ Go to step 21.
NO
➔ Go to step 5.

5. Wire harness continuity.

• Disconnect the rear wheel sensor coupler "1", ABS ECU coupler "2" and ECU coupler "3".
• Open circuit check
Between rear wheel sensor coupler "1" and black-black
ABS ECU coupler ''2" white-white
Between ABS ECU coupler "2" and ECU COLI-
white/yellow-white/yellow
pier "3"

~---n---~
1 2-~ ~~~:;;;J
a**

• MT09M/MT09MC
•• MT09SPM/MT09SPMC

Is resistance 0 .O?
YES
➔ Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code 07)
c. Rotate the rear wheel by hand and check that the indicated value increases.

Is that value increased?

YES
➔ Goto step 21.
NO
➔ Goto "Short circuit check".

9-141
 P0500,P1500

• Short circuit check

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.
Ground short circuit check "A"
black-ground
Between ABS ECU coupler "2" and ground white-ground
white/yellow-ground

Lines short circuit check "B"

black-any other coupler terminal
Rear wheel sensor coupler "1"
white-any other coupler terminal
black-any other coupler terminal
ABS ECU coupler "2" white-any other coupler terminal
white/yellow-any other coupler terminal
ECU coupler "3" white/yellow-any other coupler terminal

IN
1 2

t
a*----- -- -- ------- --- --- ---------- ---- ...
:?::::::i~;=:;u;;;;;;;u:~;=::i=~ .
: LI

a**
.
•
~~==
.
\'I._

. - - . -- --
·---------
'

• MT09M/MT09MC
•• MT09SPM/MT09SPMC

Is resistance ~ n?
YES
➔ Go to step 6.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code 07)
c. Rotate the rear wheel by hand and check that the indicated value increases.

9-142
 P0500, P1500

Is that value increased?

YES
➔ Go to step 21.
NO
➔ Go to step 6.
6. Malfunction in ECU.
• Replace the ECU.
Refer to "REPLACING THE ECU (Engine Control Unrt)" on page 8-55.
• Execute the diagnostic mode. (Code 07)
• Rotate the rear wheel by hand and check that the indicated value increases.

Is that value increased?

YES
➔ Goto step 21 .
NO
➔ Go to step 7.
7. Malfunction in ABS ECU.
• Replace the ABS ECU and go to step 21.
8. Connection of neutral switch coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condrtion of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 9.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code 21)

When the transmission is in neutral ON

When the transmission is in gear with the clutch lever released OFF

Is it correct indication?
YES
➔ Go to step 21.
NO
➔ Go to step 9.
9. Connection of ECU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 10.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code 21)

9-143
 P0500, P1500

When the transmission is in neutral ON

When the transmission is in gear with the clutch lever released OFF

Is it correct indication?
YES
➔ Go to step 21.
NO
➔ Goto step 10.
10.Wire harness continuity.
• Disconnect the relay unit coupler "1", ECU coupler "2" and neutral switch coupler "3".
• Remove the joint coupler cap "4".
• Open circuit check
Between relay unit coupler "1" and joint coupler
black-black/yellow
"4"
Between joint coupler "4" and ECU coupler "2" black/yellow-black/yellow
Between relay unit coupler "1" and neutral
sky blue-sky blue
switch coupler "3"

1- - - ----,'Q',____ __.
~=~

• MT09M/MT09MC
•• MT09SPM/MT09SPMC

Is resistance 0 .O?
YES
➔ Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code 21)

W hen the transmission is in neutr al ON

When the transmission is in gear with the clutch lever released OFF

9-144
 P0500, P1500

Is it correct indication?
YES
➔ Go to step 21.
NO
➔ Go to "Short circuit check".

• Short circuit check

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.
Ground short circuit check "A"
black-ground
Between relay unit coupler "1" and ground
sky blue-ground

Lines short circuit check "B"

black- any othe:r coupler terminal
Relay unit coupler "1"
sky blue-any other coupler terminal
ECU coupler "2" black/yellow- any other coupler terminal

[ID

• MT09M/MT09MC
•• MT09SPM/MT09SPMC

Is resistance = n?
YES
➔ Gotostep11.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code 21)

When the transmission is in neutral ON

When the transmission is in gear with the clutch lever released OFF

9-145
 P0500, P1500

Is it correct indication?
YES
➔ Go to step 21.
NO
➔ Go to step 11 .
11 . Defective relay unit.
• Check the relay unit.
Refer to "CHECKING THE RELAY UNIT (DIODE)" on page 8-58.

Is check result O K?
YES
➔ Go to step 12.
NO
a. Replace the relay unit.
b. Execute the diagnostic mode. (Code 21)

When the transmission is in neutral ON

When the transmission is in gear with the clutch lever released OFF

Is it correct indication?
YES
➔ Go to step 21.
NO
➔ Goto step 12.
12. Defective neutral switch.
• Check the neutral switch.
• Refer to "CHECKING THE SWITCHES" on page 8-53.

Is check result OK?

YES
➔ Go to step 13.
NO
a. Replace the neutral switch.
Refer to "CRANKCASE" on page 5-63.
b. Execute the diagnostic mode. (Code 21)

When the transmission is in neutral ON

When the transmission is in gear with the clutch lever released OFF

Is it correct indication?
YES
➔ Go to step 21.
NO
➔ Goto step 13.
13. Faulty shift drum (neutral detection area).
• Check the shift drum.
Refer to "CHECKING THE SHIFT DRUM ASSEMBLY" on page 5-92.

9-146
 P0500, P1500

Is check result OK?

YES
➔ Goto step 14.
NO
➔ Replace the shift drum and go to step 21 .
Refer to "TRANSMISSION" on page 5-86.
14. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
15.Clutch lever adjustment.
• Refer to "ADJUSTING THE CLUTCH LEVER FREE PLAY" on page 3-12.
• Execute the diagnostic mode. (Code 21)

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
the sidestand is retracted

Is it correct indication?
YES
➔ Go to step 21 .
NO
➔ Goto step 16.

16.Connection of clutch switch coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition norma l?

YES
➔ Goto step 17.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code 21)

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
the sidestand is retracted

Is it correct indication?
YES
➔ Go to step 21.
NO
➔ Goto step 17.

9-147
 P0500, P1500

17.Connection of ECU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

Is the coupler condition norma l?

YES
➔ Goto step 18.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code 21)

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
the sidestand is retracted

Is it correct indication?
YES
➔ Go to step 21.
NO
➔ Goto step 18.
18.Wire harness continuity.
• Disconnect the ECU coupler "2", relay unit coupler "1" and clutch switch coupler "3".
• Remove the joint coupler cap "4" and joint coupler cap "5".
• Open circuit check
Between ECU coupler "2" and joint coupler "4" black/yellow-black/yellow
Between relay unit coupler "1" and joint coupler
black-black
"4"
Between clutch switch coupler "3" and joint cou-
black/yellow-black/yellow
pier "4"
Between clutch switch coupler "3" and joint cou-
blue/yellow- blue/yellow
pi er "5"
Between relay unit coupler "1" and joint coupler
blue- blue
"5"

9-148
 P0500, P1500

Q
4
' ........
.
' .. -~~~
=i

, ............
'.i;;;Q.'
.. ..

* MT09M/MT09MC
•• MT09SPM/MT09SPMC

Is resistance 0 O?
YES
➔ Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code 21)

When the clutch lever is released with the transmission in gear and when
th:e sidestand is retracted
OFF

When the clutch lever is squeezed with the transmission in gear and when
ON
th:e sidestand is retracted

Is it correct indication?
YES
➔ Go to step 21.
NO
➔ Go to "Short circuit check".

• Short circuit check

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9·3.
Ground short circuit check "A"
black-ground
Between relay unit coupler "1" and ground
blue- ground

9-149
 P0500, P1500

Lines short circuit check "B"

black- any other coupler terminal
Relay unit coupler "1"
blue- any other coupler terminal
ECU coupler "2" black/yellow- any other coupler terminal
black/yellow- any other coupler terminal
Cl utch switch coupler "3"
blue/yellow- any other coupler terminal

, ...........................................................
a**
1 1~;~2~~~;~;;~;;~~~:~;;;,~
' llt~~ ~ ~;;:":,;,-P.tt:1-r.:'i~~:
I
f
L... • ___ i
;
l~!~t!i!~~~~~~~l:
:~ · · · -· · · · · · · ·· · 1
............. ~

3*
2 ** -·
,...........................................................
' ,?::::ii;;;;;;;=;~ ===-~ '
®=@)
iw~~;~~~=~~~r-=-IC~A~~;,?.~'~~ ~ !
1 ':a.?)(-:>'i." ~~~~~ ~ !
L. ••...••.•....•••••...•1

• MT09M/MT09MC
•• MT09SPM/MT09SPMC

Is resistance ~ n?
YES
➔ Go to step 19.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code 21)

When the clutch lever is released w ith the transmission in gear and when
OFF
the sidestand is retracted
When the clutch lever is squeezed w ith the transmission in gear and when
ON
the sidestand is retracted

Is it correct indication?
YES
➔ Go to step 21.
NO
➔ Go to step 19.

19. Defective clutch switch.

• Check the clutch switch.
Refer to "CHECKING THE SWITCHES" on page 8-53.

9-150
 P0500, P1500

Is check result OK?

YES
➔ Go to step 20.
NO
a. Replace the clutch switch.
Refer to "HANDLEBAR" on page 4-57.
b. Execute the diagnostic mode. (Code 21)

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
the sidestand is retracted

Is it correct indication?
YES
➔ Go to step 21.
NO
➔ Go to step 20.

20. Malfunction in ECU.

• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
21.Delete the OTC and check that the MIL goes off.
• Tum the main switch to "ON", and then rotate the rear wheel by hand.
• Start the engine, and inpu1 the vehicle speed signals by operating the vehicle at 20 to 30 km/h (12
to 19 mph).
• Confirm that the OTC has a condition of "Recovered" using the malfunction mode of the YDT, and
then delete the OTC. Delete this OTC even if it has a condition of "Detected".

9-151
 P0560, P0563
...,.,.,.
P0560, P0563
EAS3:l30<
TROUBLESHOOTING
Item
• [P0560] Charging voltage is abnormal.
• [P0563] Vehicle system power voltage out of range
Fa'il-safe system
• Able to start engine
• Able to drive vehicle

Procedure
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
If more than one OTC is detected at the same time, perform troubleshooting of OTC listed below first.
• P0335
1. Malfunction in charging system.
• Check the charging system.
Refer to "CHARGING SYSTEM" on page 8-17.

Is check result OK?

YES
➔ Repeat step 1.
NO
a. Defective rectifier/regulator or AC magneto ➔ Replace.
b. Defective connection in the charging system circuit ➔ Properly connect or replace the wire har-
ness.
c. Start the engine and let it idle for approximately 5 seconds.
d. Check the condition of the DTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 2, and complete the service.
NO
➔ Repeat step 1.

2. Delete the OTC and check that t he MIL goes off.

• Confirm that the OTC has a condition of "Recovered" using the YDT, and then delete the OTC.

9-152
 P0564

..P0564
.,_

..
._,
TROUBLESHOOTING
Item
• Cruise control setting switch "RES+": open or short circuit is detected.
• Cruise control setting switch "SET-": open or short circuit is detected.
Fa'il-safe system
• Able to start engine
• Able to drive vehicle

Procedure
1. Connection of ECU coupler, handlebar switch coupler (left) and main switch coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals 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. Tum the main switch to "ON", and then push the "RES+" side and "SET-''side of the cruise con-
trol setting switch.
c. Check the condition of the DTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔Go to step 10, and complete the service.
NO
➔Go to step 2.
2. Locate the malfunction.
a. Execute the diagnostic mode. (Code 80)
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.
b. Execute the diagnostic mode. (Code 81)
When the cruise control setting switch "SET-" is pushed ON
When the cruise control setting switch is released OFF

c. Confirm that it is defective.

d. Go to step 6.

9-153
 P0564

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Perform the procedure from step 6 to step 10.

3. Check the fuse.

• Check the ignition fuse 1 and cruise control fuse.

Is check result OK?

YES
➔Go to step 4.
NO
a. Replace the fuse.
b. Turn the main switch to "ON".
c. Push and release the "RES+" side of the cruise control setting switch, and then check the condi-
tion of the DTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔Go to step 10, and complete the service.
NO
➔Go to step 4.
4. Wire harness continuity
• Disconnect the ignition fuse 1 "4", cruise control fuse "1 ", handlebar switch coupler (left) "2" and ECU
coupler "3".
• Open circuit check
Between ignition fuse 1 holder "4" and cruise
red/white-red
control fuse holder "1"
Between cruise control fuse holder "1 " and han-
yellow/white-yellow/white
di ebar switch coupler (left) "2"
Between handlebar switch coupler (left) "2" and
brown/blue-brown/blue
ECU coupler "3"

4 1
E3----@------E3

Is resistance O O?
YES
➔Go to "Short circuit check".
NO

9-154
 P0564

a. Replace the wire harness.

b. Turn the main switch to "ON".
c. Push and release the "RES+" side of the cruise control setting switch, and then check the condi-
tion of the DTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔Go to step 10, and complete the service.
NO
➔Go to "Short circuit check".
• Short circuit check
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.

Ground short circuit check "A"

Between handlebar switch coupler (left) "2" and brown/blue-grou nd
ground yellow/white-ground

Lines short circuit check "B"

brown/blue-any other coupler terminal
Handlebar switch coupler (left) "2"
yellow/white-any other coupler terminal
ECU coupler "3" brown/blue-any other coupler terminal

ffil

2 2
:.·c .~~=o=';;.12~~~E2
..•
.
'. ~====s===s==l======e===e=====sa==e,Y-)

Is resistance ~ n?
YES
➔Go to step 5.
NO
a. Replace the wire harness.
b. Turn the main switch to "ON".
c. Push and release the "RES+" side of the cruise control setting switch, and then check the condi-
tion of the DTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔Go to step 10, and complete the service.
NO
➔Go to step 5.

9-155
 P0564

5. Defective cruise control setting switch.

• Replace the handlebar switch (left).
• Tum the main switch to "ON".
• Push the "RES+" side and "SET- " side of the cruise control setting switch, and then check the con-
dition of the OTC using the malfunction mode of the YDT.

Is it in the "Recovered" condition?

YES
➔Go to step 10, and complete the service.
NO
➔Go to step 9.
6. Check the fuse. (main fuse, cruise control fuse)

Is check result OK?

YES
➔Go to step 7.
NO
a. Replace the fuse.
b. Tum the main switch to "ON".
c. Push and release the "SET-" side of the cruise control setting switch, and then check the condi-
tion of the DTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔Go to step 10, and complete the service.
NO
➔Go to step 7.
7. Wire harness continuity.
• Open circuit check
• Disconnect the main fuse "4", ignition fuse 1 "5", main switch coupler "6", cruise control fuse "1 ", han-
dlebar switch coupler (left) "2" and ECU coupler "3".
Between main fuse holder "4" and main switch
reel-red
coupler"6"
Between main switch coupler "6" and ignition
brown/blue- brown/blue
fUJse 1 holder "5"
Between ignition fuse 1 holder "5" and cruise
red-red/white
control fuse holder "1"
Between cruise control fuse holder "1 " and han-
yellow/white-yellow/white
di ebar switch coupler (left) "2"
Between handlebar switch coupler (left) "2" and
green/blue-green/blue
ECU coupler "3"

9-156
 P0564

Is resistance 0 n?
YES
➔Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Tum the main switch to "ON".
c. Push and "SET-" side of the cruise control setting switch, and then check the condition of the
DTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔Go to step 10, and complete the service.
NO
➔Go to "Short circuit check".
• Short circuit check
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.

Ground short circuit check "A"

Between handlebar switch coupler (left) "2" and green/blue-ground
ground yellow/white-ground
re~round
Between main switch coupler "6" and ground
brown/blue-ground

Lines short circuit check "B"

green/blue-any other coupler terminal
Handlebar switch coupler (left) "2"
yellow/white-any other coupler terminal
ECU coupler "3" green/blue-any other coupler terminal
reel-any other coupler terminal
Mlain switch coupler "6"
brown/blue- any other coupler terminal

9-157
 P0564

[a] Im
2 2

Is resistance ~ O?
YES
➔Go to step 8.
NO
a. Replace the wire harness.
b. Tum the main switch to "ON".
c. Push and "SET-" side of the cruise control setting switch, and then check the condition of the
DTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔Go to step 10, and complete the service.
NO
➔Go to step 8.
8. Defective cruise control setting switch.
• Replace the handlebar switch (left).
• Tum the main switch to "ON".
• Push the "RES+• side and "SET-" side of the cruise control setting switch, and then check the con-
dition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔Go to step 10, and complet,e the service.
NO
➔Go to step 9.
9. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
10.Delete the OTC and check that t he MIL goes off.
• Confirm that the OTC has a condition of "Recovered" using the YDT, and then delete the OTC.

9-158
 P056C

........
P056C
EA""""'5
TROUBLESHOOTING
Item
• Front brake light switch: open or short circuit is detected.
• Rear brake light switch: open or short circuit is detected.
Fa'il-safe system
• Able to start engine
• Able to drive vehicle

Procedure
1. Locate the malfunction.
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 1Oto 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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Perform the procedure from step 6 to step 11.

2. Connection of ECU coupler, front brake light switch coupler, bra.ke light relay coupler and main
switch coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

Is the coupler condition norma l?

YES
➔Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to "ON".
c. Operate the front brake lever, and then check the condition o f the OTC using the malfunction
mode of the VDT.

9-159
 P056C

Is it in the "Recovered" condition?

YES
➔Go to step 11, and complete the service.
NO
➔Go to step 3.
3. Check the fuse. (signaling system fuse and brake light fuse)

Is check result OK?

YES
➔Go to step 4.
NO
a. Replace the fuse.
b. Turn the main switch to "ON".
c. Operate the front brake lever, and then check the condition of the OTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔Go to step 11 , and complete the service.
NO
➔Go to step 4.
4. Wire harness continuity.
• Disconnect the brake light fuse "1 ", front brake light switch coupler "2", rear brake light switch coupler
"3", brake light relay coupler "4" and ECU coupler "5".
• Open circuit check
Between brake light fuse holder " 1" and front
green/white-green/white
brake light switch coupler "2"
Between front brake light switch coupler "2" and
green/yellow-green/yellow
rear brake light switch coupler "3"
Between rear brake light switch coupler "3" and
light green/black-light green/black
brake light relay coupler "4"
Between brake light relay coupler "4" and
black-ground
ground
Between brake light relay coupler "4" and ECU
light green/black-light green/black
coupler"5"

9-160
 P056C

Is resistance 0 O?
YES
➔Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Turn the main switch to "ON".
c. Operate the front brake lever, and then check the condition of the OTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔Go to step 11, and complete the service.
NO
➔Go to "Short circuit check".
• Short circuit check
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.

Ground short circuit check "A"

Between brake light relay coupler "4" and
light green/black- ground
ground
Between front brake light switch coupler "2" and green/white-ground
ground green/yellow- ground

Lines short circuit check "B"

Brake light relay coupler "4" light green/black-any other coupler terminal
green/white-any other coupler terminal
Front brake light switch coupler "2"
green/yellow- ainy other coupler terminal
green/yellow- ainy other coupler terminal
Rear brake light switch coupler "3"
light green/black-any other coupler terminal
ECU coupler "5" light green/black- any other coupler terminal

IA] ffil
2 5

~ i --- ►·---- J

9-161
 P056C

Is resistance ~ O?
YES
➔Go to step 5.
NO
a. Replace the wire harness.
b. Turn the main switch to "ON".
c. Operate the front brake lever, and then check the condition of the OTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔Go to step 11, and complete the service.
NO
➔Go to step 5.
5. Defective front brake light switch.
• Replace the front brake light switch.
Refer to "FRONT BRAKE" on page 4-25.
• Tum the main switch to "ON".
• Operate the front brake lever, and then check the condition of the OTC using the malfunction mode
of the VDT.

Is it in the "Recovered" condition?

YES
➔Go to step 11, and complet-e the service.
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.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔Go to step 7.
NO
a. Connect the coupler securely or replace the wire harness.
b. Tum the main switch to "ON".
c. Operate the rear brake pedal, and then check the condition of the OTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔Go to step 11, and complete the service.
NO
➔Go to step 7.

9-162
 P056C

7. Check the fuse. (signaling system fuse and brake light fuse)

Is check result OK?

YES
➔Go to step 8.
NO
a. Replace the fuse.
b. Turn the main switch to "ON".
c. Operate the rear brake pedal, and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔Go to step 11, and complete the service.
NO
➔Go to step 8.
8. Wire harness continuity.
• Disconnect the brake lightfuse "1 ", front brake light switch coupler ''2", rear brake light switch coupler
"3", brake light relay coupler "4" and ECU coupler "5".
• Open circuit check
Between brake light fuse holder "1" and front
green/white-green/white
brake light switch coupler "2"
Between front brake light switch coupler "2" and
green/yellow- green/yellow
rear brake light switch coupler "3"
Between rear brake light switch coupler "3" and
light green/black-light green/black
brake light relay coupler "4"
Between brake light relay coupler "4" and
black-ground
ground
Between brake light relay coupler "4" and ECU
light green/black-light green/black
coupler"5"

9-163
 P056C

Is resistance 0 O?
YES
➔Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Turn the main switch to "ON".
c. Operate the rear brake pedal, and then check the condition of the DTC using the malfunction
mode of the VDT .

Is it in the "Recovered" condition?

YES
➔Go to step 11, and complete the service.
NO
➔Go to "Short circuit c heck".

• Short circuit check

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.

Ground short circuit check "A"

Between brake light relay coupler "4" and
light green/black- ground
ground
Between front brake light switch coupler "2" and green/white-ground
ground green/yellow- ground

Lines short circuit check "B"

Brake light relay coupler "4" light green/black-any other coupler terminal
green/white-any other coupler terminal
Front brake light switch coupler "2"
green/yellow- an y other coupler terminal
green/yellow- an y other coupler terminal
Rear brake light switch coupler "3"
light green/black-any other coupler terminal
ECU coupler "5" light green/black- any other coupler terminal

IA] ffil
2 5

~ i--- ►·---- J

9-164
 P056C

Is resistance ~ O?
YES
➔Go to step 9.
NO
a. Replace the wire harness.
b. Turn the main switch to "ON".
c. Operate the rear brake pedal, and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔Go to step 11, and complete the service.
NO
➔Go to step 9.
9. Defective rear brake light switch.
• Replace the rear brake light switch.
Refer to "REAR BRAKE" on page 4-37.

Is check result OK?

YES
➔Go to step 10.
NO
a. Turn the main switch to "ON".
b. Operate the rear brake pedal, and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔Go to step 11, and complete the service.
NO
➔Go to step 10.
10.Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
11 . Delete the OTC and check that 1he MIL goes off.
• Confirm that the OTC has a condition of "Recovered" using the YDT, and then delete the OTC.

9-165
 P0601

..P0601
.,.,.,.

...,_
TROUBLESHOOTING
Item
Internal malfunction in ECU. (When this malfunction is detected in the ECU, the OTC might not appear
on the tool display.)
Fa'il-safe system
• Unable to start engine
• Unable to drive vehicle

Procedure
1. Malfunction in ECU.
• Replace the ECU.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
• Tum the main switch to "ON".
• Check that the MIL does not come on.

9-166
 P0606

..P0606
.,.,.,,

EAS3:!300
TROUBLESHOOTING
Item
Internal malfunction in ECU. (When this malfunction is detected in the ECU, the OTC might not appear
on the tool display.)
Fa'il-safe system
• Able/Unable to start engine
• Able/Unable to drive vehicle

Procedure
1. Check and repair for simultaneous malfunction.
• Check the items of DTCs P0122, P0123, P0222, P0223 and P2135, if they are detected at the same
time, correct the P0122, P0123, P0222, P0223 and P2135 first.
• Tum the main switch to "ON", and then check the condition of the OTC using the malfunction mode
of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 3, and complete the service.
NO
➔ Go to step 2.

2. Malfunction in ECU.
• Replace the ECU.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
• Tum the main switch to "ON".
• Check that the MIL does not come on.
3. Delete the OTC and check that the MIL goes off.
• Confirm that the OTC has a condition of "Recovered" using the YDT, and then delete the OTC.

9-167
 P062F

........
P062F
EAS3:!0nl
TROUBLESHOOTING
Item
EEPROM OTC: an error is detected while reading or writing on EEPROM.
Fa'il-safe system
• Able/Unable to start engine
• Able/Unable to drive vehicle

Procedure
1. Locate the malfunction.
• Execute the diagnostic mode (Code 60)
2. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
3. Delete the OTC and check that the MIL goes off.
• Confirm that the OTC has a condition of "Recovered" using the YDT, and then delete the OTC.

9-168
 P0638

........
P0638
EAS300'9
TROUBLESHOOTING
Item
YCC-T drive system: malfunction detected.
Fa'il-safe system
• Able/Unable to start engine
• Able/Unable to drive vehicle

Procedure
1. Connection of throttle servo motor coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals 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. Tum the main switch to "ON", and then check the condition o f the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 2.

2. Connection of ECU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and chock the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Tum the main switch to "ON", and then check the condition o f the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 3.

9-169
 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.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the YDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 4.

4. Wire harness continuity.

• Disconnect the throttle servo motor coupler "1", ECU coupler "2" and electronic throttle valve fuse
"3".
• Open circuit check
Between throttle servo motor coupler "1'' and yellow/red-yellow/red
ECU coupler "2" light green/red-light green/red
Between ECU coupler "2" and electronic throttle
red/blue-red/blue
valve fuse holder "3"

..---- Q >-- - - ,

Is resistance O n?
YES
➔ Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to "Short circuit check''.

• Short circuit check

9-170
 P0638

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.
Ground short circuit check "A"
yellow/red-ground
Between ECU coupler "2" and ground light green/red-ground
red/blue-ground

Lines short circuit check "B"

yellow/red-any other coupler terminal
Throttle servo motor coupler "1"
light green/red-any other coupler terminal
yellow/red-any other coupler terminal
ECU coupler "2" light green/red-any other coupler terminal
red/blue-any other coupler terminal

IN [gJ 1
2

'
···········--·--····· ·
'

Is resistance ~ O?
YES
➔ Go to step 5.
NO
a. Replace the wire harness.
b. Tum the main switch to "ON", and then check the condition o f the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 5.

5. Defective throttle bodies.

• Check the throttle bodies.
Refer to "CHECKING THE THROTTLE SERVO MOTOR" on page 8-63.

Is check result OK?

YES
➔ Go to step 6.
NO
a. Replace the throttle bodies.
Refer to "REPLACING THE THROTTLE BODIES" on page 7-9.
b. Tum the main switch to "ON", and then check the condition o f the DTC using the malfunction
mode of the VDT.

9-171
 P0638

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 6.

6. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
7. Delete the OTC and check that t he MIL goes off.
• Confirm that the OTC has a condition of "Recovered" using the YDT, and then delete the OTC.

9-172
 P0657

..P0657
.,.,..,,

EAS3:l081
TROUBLESHOOTING
Item
Fuel system voltage: incorrect voltage supplied to the fuel injector and fuel pump.
Fa'il-safe system
• Able to start engine
• Able to drive vehicle

Procedure
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first.
• P0335
1. Connection of relay unit coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 8, and complete the service.
NO
➔ Go to step 2.

2. Connection of handlebar switch coupler (right).

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).
Refer to "HANDLEBAR" on page 4-57.

Is the coupler condition normal?

YES
➔ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 8, and complete the service.
NO
➔ Go to step 3.

9-173
 P0657

3. Connection of ECU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

Is the coupler condition norma l?

YES
➔ Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 8, and complete the service.
NO
➔ Go to step 4.
4. Wire harness continuity.
• Disconnect the fuel injection system fuse "1", relay unit coupler "2", ignition fuse 1 "3", handlebar
switch (right) coupler "4" and ECU coupler "5".
• Open circuit check
Between fuel injection system fuse holder "1"
brown- brown
and relay unit coupler "2"
Between ignition fuse 1 holder "3" and handle-
red-red/white
bar switch (right) coupler "4"
Between handlebar switch (right) coupler "4"
red/white- red
and relay unit coupler "2"
Between relay unit coupler "2" and ECU coupler red-red/blue
"5" blue/white-blue/white

~ - - - - --<Q>--- - - - - ~
1 2
EJ-4- @f--~ ~~~~e:r-=~p...e.!¥j+- ---<n

3
E3------<

9-174
 P0657

Is resistance 0 O?
YES
➔ Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 8, and complete the service.
NO
➔ Go to "Short circuit check''.
• Short circuit check
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.

Ground short circuit check "A"

brown- ground
Between relay unit coupler ''2" and ground blue/white-ground
re~round
Between handlebar switch (right) coupler "4" red/white-ground
and ground red/white-ground

Lines short circuit check "B"

brown- any other coupler terminal
Relay unit coupler "2" blue/white-any other coupler terminal
reel-any other coupler terminal
red/white-any other coupler terminal
Handlebar switch (right) coupler "4"
red/white-any other coupler terminal
red/blue-any other coupler terminal
ECU coupler "5"
blue/white-any other coupler terminal

2 ml 2 5

''
4 4 '
'''
''
·-------····

9-175
 P0657

Is resistance ~ O?
YES
➔ Go to step 5.
NO
a. Replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 8, and complete the service.
NO
➔ Go to step 5.
5. Defective relay unit.
• Execute the diagnostic mode. (Code 50)
• Check the operating sound of the relay.

Is check result OK?

YES
➔ Go to step 6.
NO
a. Replace the relay unit.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 8, and complete the service.
NO
➔ Go to step 6.
6. Defective relay unit.
• Execute the diagnostic mode. (Code 09)

Is the fuel system voltage less than 3V?

YES
a. Replace the relay unit.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 8, and complete the service.
NO
➔ Go to step 7.
NO
➔ Goto step 7.
7. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
8. Delete the OTC and check that the MIL goes off.
• Confirm that the DTC has a condition of "Recovered" using the YDT, and then delete the OTC.

9-176
 P0916, P0917

EA"""'11

P0916, P0917
EAS3:l001
TROUBLESHOOTING
Item
• [P0916] Gear position sensor: open or ground short circuit detected.
• [P0917] Gear position sensor: power short circuit detected.
Fa'il-safe system
• Able to start engine
• Able to drive vehicle

Procedure
1. Connection of gear position sensor coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

Is the coupler condition norma l?

YES
➔ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 2.

2. Connection of ECU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

Is the coupler condition norma l?

YES
➔ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 3.

3. Wire hamess continuity.

• Disconnect the gear position sensor coupler "1" and ECU coupler ''2".
• Open circuit check

9-177
 P0916, P0917

black/blue-black/blue
Between gear position sensor coupler "1" and
green/white-green/ white
ECU coupler "2"
blue- blue

L-----------{1i'l-----'----------------'
• MT09M/MT09MC
•• MT09SPM/MT09SPMC

Is resistance O n?
YES
➔ Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Turn the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to "Short circuit check''.

• Short circuit check

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.

Ground short circuit check "A"

Between gear position sensor coupler "1 " and green/white-ground
ground blue- ground

Lines short circuit check "B"

black/blue-any other coupler terminal
Gear position sensor coupler "1" green/white-any other coupler terminal
blue- any other coupler terminal
black/blue-any other coupler terminal
ECU coupler "2" green/white-any other coupler terminal
blue- any other coupler terminal

9-178
 P0916,P0917

IA!
1 1

r
MT09M/MT09MC
•• MT09SPM/MT09SPMC

Is resistance ~ n?
YES
➔ Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the YDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 4.

4. Installed condition of gear positio n sensor.

• Check for looseness or pinching.

Is check result OK?

YES
➔ Go to step 5.
NO
a. Reinstall or replace the sensor.
Refer to "CRANKCASE" on page 5-63.
b. Turn the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the YDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 5.

9-179
 P0916, P0917

5. Defective gear position sensor.

• Make sure that the position of each gear is correctly displayed on the meter.

Is check result OK?

YES
➔ Go to step 6.
NO
a. Replace the gear position sensor.
Refer to "CRANKCASE" o:n page 5-63.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 6.

6. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
7. Delete the OTC and check that the MIL goes off.
• Confirm that the OTC has a condition of "Recovered" using the YDT, and then delete the OTC.

9-180
 P1004

..P1004
.,.,..

EA""""9
TROUBLESHOOTING
Item
Intake air pressure sensor 1 and intake air pressure sensor 2: output voltage deviation error.
Fa'il-safe system
• Able to start engine
• Able to drive vehicle

Procedure
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first.
• P0105, P0106, P0108, P0335, P0606
1. Defective intake air pressure sensor 1.
• Execute the diagnostic mode. (Code 03)
• When engine is stopped: Atmospheric pressure at the current altitude and weather conditions is in-
dicated.
Approx. 101 kPa (757.6 mmHg, 29.8 inHg), ap-
At sea level
prox. 3.64 V
Approx. 90 kPa (675.1 mmHg, 26.6 inHg), ap-
1000 m (3300 ft) above sea level
prox. 3.30 V
Approx. 80 kPa (600.0 mmHg, 23.6 inHg), ap-
2000 m (6700 ft) above sea level
prox. 3.00 V
Approx. 70 kPa (525.0 mmHg, 20.7 inHg), ap-
3000 m (9800 ft) above sea level
prox. 2.70 V

Is check result OK?

VE$
➔ Go to step 2.
NO
a. Replace the intake air pressure sensor 1.
Refer to "THROTTLE BODIES" on page 7-5.
b. Tum the main switch to "ON", and then check the condition o f the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 4, and complete the service.
NO
➔ Go to step 2.

2. Defective intake air pressure sensor 2.

• Execute the diagnostic mode. (Code 04)
• When engine is stopped: Atmospheric pressure at the current altitude and weather conditions is in-
dicated.

9-181
 P1004

Approx. 101 kPa (757.6 mmHg, 29.8 inHg), ap-

At sea level prox. 3.64 V
Approx. 90 kPa (675.1 mmHg, 26.6 inHg), ap-
1000 m (3300 ft) above sea level
prox. 3.30 V
Approx. 80 kPa (600.0 mmHg, 23.6 inHg), ap-
2000 m (6700 ft) above sea level
prox. 3.00 V
Approx. 70 kPa (525.0 mmHg, 20.7 inHg), ap-
3000 m (9800 ft) above sea level
prox. 2.70 V

Is check result OK?

YES
➔ Go to step 3.
NO
a. Replace the intake air pressure sensor 2.
Refer to "THROTTLE BODIES" on page 7-5.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 4, and complete the service.
NO
➔ Go to step 3.

3. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
4. Delete the DTC and check that t he MIL goes off.
• Confirm that the OTC has a condition of "Recovered" using the YDT, and then delete the DTC.

9-182
 P1600

EA"""'13

P1600
EAS33000
TROUBLESHOOTING
Item
Lean angle sensor: open or short circuit detected.
Fa'il-safe system
• Unable to start engine
• Unable to drive vehicle

Procedure
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first.
• U0125
1. Connection of IMU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to "ON", then to "OFF", and back to "ON".
c. Check the condition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 2.

2. Connection of ECU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Tum the main switch to "ON", then to "OFF", and back to "ON".
c. Check the condition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 3.

9-183
 P1600

3. Wire harness continuity.

• Disconnect the ECU coupler "1", IMU coupler ''3" and ignition fuse 2 "4".
• Remove the joint coupler cap "2".
• Open circuit check
blue/white-blue/white
Between ECU coupler "1" and joint coupler "2"
blue/black-blue/black
blue/white-blue/white
Between joint coupler "2" and IMU coupler "3"
blue/black-blue/black
Between ECU coupler "1" and ground black/white-ground
Between ignition fuse 2 holder "4" and IMU cou-
red/white-red/white
pier "3"

* MT09M/MT09MC
~ rn:m:n:-m'i .rcrn:I
• • MT09SPM/MT09SPMC

Is resistance O n?
VE$
➔ Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Tum the main switch to "ON", then to "OFP', and back to "ON".
c. Check the condition of the OTC using the malfunction mode of the YDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to "Short circuit check".
• Short circuit check
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU and IMU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.

9-184
 P1600

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

Lines short circuit check "B"

blue/white-any other coupler terminal
ECU coupler "1" black/black- any other coupler terminal
blue/white-any other coupler terminal
Joint coupler "2" blue/black- any other coupler terminal
blue/white-any other coupler terminal
IMU coupler "3" blue/black- any other coupler terminal
red/white-any other coupler terminal

(q) !
''
----------~
i~
''.. -·······--~
''
11111111 ri:tfil _rrm:I
• MT09M/MT09MC
•• MT09SPM/MT09SPMC

Is resistance ~ n?
YES
➔ Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to "ON", then to "OFP', and back to "ON".
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 4.

9-185
 P1600

4. Installed condition of IMU.

• Check the installed direction and condition of the sensor.
Refer to "GENERAL CHASSIS (1)" on page 4-1 .
• Check the grommet for cracks.

Is check result OK?

YES
➔ Go to step 5.
NO
a. Fix the IMU installation condition.
b. Turn the main switch to "ON .
c. Check the condition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 5.

5. Defective IMU .
• Replace the IMU.
Refer to "GENERAL CHASSIS (1)" on page 4-1.
• Tum the main switch to "ON", then to "OFF", and back to "ON".
• Check the condition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 6.

6. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
7. Delete the OTC and check that the MIL goes off.
• Confirm that the OTC has a condition of "Recovered" using the YDT, and then delete the OTC.

9-186
 P1601

P1601

"""""""
TROUBLESHOOTING
Item
Sidestand switch: open or short circuit of the blue/yellow lead of the ECU is detected.
Fa'il-safe system
• Unable to start engine
• Unable to drive vehicle

Procedure
1. Connection of sidestand switch coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals 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. Tum the main switch to "ON", and then extend and retract the sidestand.
c. Check the condition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 2.

2. Connection of ECU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and chock the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Tum the main switch to "ON", and then extend and retract the sidestand.
c. Check the condition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 3.

3. Connection of relay unit coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

9-187
 P1601

Is the coupler condition normal?

YES
➔ Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Tum the main switch to "ON", and then extend and retract the sidestand.
c. Check the condition of the OTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 4.

4. Wire harness continuity.

• Disconnect the relay unit coupler "1", ECU coupler "2" and sidestand switch coupler "3".
• Remove the joint coupler cap "4".
• Open ci rcuit check
Between relay unit coupler "1" and joint coupler
blue-blue
cap "4"
Between joint coupler "4" and ECU coupler "2" blue/yellow-blue/yellow
Between relay unit coupler "1" and sidestand
blue/black-blue/black
switch coupler "3"

3 1

...'J;J;;;;J_'...

• MT09M/MT09MC
•• MT09SPM/MT09SPMC

Is resistance O11?
YES
➔ Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Tum the main switch to "ON", and then extend and retract the sidestand.
c. Check the condition of the OTC using the malfunction mode of the VDT.

9-188
 P1601

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to "Short circuit check".
• Short circuit check
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.
Ground short circuit check "A"
blue-ground
Between relay unit coupler "1" and ground
blue/black-ground

Lines short ci rcuit check "B"

blue-any other coupler terminal
Relay unit coupler "1"
blue/black-any other coupler terminal
ECU coupler "2" blue/yellow-any other coupler terminal
Sidestand switch coupler "3" blue/black-any other coupler terminal

IA! [el
1 ------. ---- -- -. ---.. -..
1 2~ -------------------- ------------

: LI Y.t.

,''__ : L"
:~
,______ _ --------- ---
''
-- ---- ------- ----- ---- -- ------ ----- --

• MT09M/MT09MC
•• MT09SPM/MT09SPMC

Is resistance ~ n?
YES
➔ Go to step 5.
NO
a. Replace the wire harness.
b. Turn the main switch to "ON", and then extend and retract the sidestand.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 5.

9-189
 P1601

5. Defective sidestand switch.

• Execute the diagnostic mode. (Code 20)
• Shift the transmission into gear.
Sfdestand retracted ON
Sfdestand extended OFF

Is check result OK?

YES
➔ Go to step 6.
NO
a. Replace the sidestand switch.
b. Tum the main switch to "ON", and then extend and retract the sidestand.
c. Check the condition of the DTC using the malfunction mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 6.

6. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
7. Delete the OTC and check that the MIL goes off.
• Confirm that the OTC has a condition of "Recovered" using the YDT, and then delete the OTC.

9-190
 P1602

P1602
"""""""
TROUBLESHOOTING
Item
Malfunction in ECU internal circuit (malfunction of ECU power cut-off function).
Fa'il-safe system
• Able/Unable to start engine
• Able/Unable to drive vehicle

Procedure
1. Installed condition of battery leads.
• Check the installed condition of the battery and battery leads (loose bolts).

Is check result OK?

YES
➔ Go to step 2.
NO
a. Reinstall or replace the battery leads.
b. Tum the main switch to "ON", and then check the condition o f the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 2.

2. Connection of starter relay coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Tum the main switch to "ON", and then check the condition o f the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 3.

3. Connection of main switch coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

9-191
 P1602

Is the coupler condition normal?

YES
➔ Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 4.

4. Check the backup fuse.

Is check result OK?

YES
➔ Go to step 5.
NO
a. Replace the fuse.
b. Tum the main switch to "ON", and then check the condition o f the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 5.

5. Wire harness continuity.

• Disconnect the battery "1", backup fuse 1 "2", ECU coupler "3", main switch coupler "4" and ignition
fuse 1 "5".
• Open circuit check
Between battery "1" and backup fuse 2 holder
red-red
"2"
Between backup fuse 2 holder "2" and ECU
red/green-red/green
coupler"3"
Between main switch coupler "4" and ignition brown/blue-brown/blue
fUJse 1 holder "5"
Between ignition fuse 1 holder "5" and ECU cou- red/white-red
pier "3"

9-192
 P1602

1
·r
1t 2

~- ·B5
@
4
@ •B n

Is resistance 0 n?
YES
➔ Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Tum the main switch to "ON", and then check the conc;lition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to "Short circuit check".

• Short circuit check

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.

Ground short circuit check "A"

Between battery "1 • and ground red-ground
recl/green- grou nd
Between ECU coupler "3" and ground
red/white-ground
Between main switch coupler "4" and ground brown/blue-ground

Lines short circuit check "B"

red/green- any other coupler terminal
ECU coupler "3"
red/white-any other coupler terminal
Main switch coupler "4" brown/blue- any other coupler terminal

9-1 93
 P1602

~
1
·r·1 3 .. -............... . 3 . --. -. . . . ..... .

IJ
~
4~ 4 ~

Is resistance ~ O?
YES
➔ Go to step 6.
NO
a. Replace the wire harness.
b. Tum the main switch to "ON", anc;I then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 6.

6. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
7. Delete the OTC and check that t he MIL goes off.
• Confirm that the OTC has a condition of "Recovered" using the YDT, and then delete the OTC.

9-194
 P1606,P1607
..P1606,P1607
.,.,.,

EA"""'30
TROUBLESHOOTING
Item
• [P1606] Intake air pressure sensor 2: ground short circuit detected.
• [P1607] Intake air pressure sensor 2: open or power short circuit detected.
Fa'il-safe system
• Able to start engine
• Able to drive vehicle

Procedure
1. Connection of intake air pressure sensor 2 coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals 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. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 2.

2. Connection of ECU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 3.

3. Wire hamess continuity.

• Disconnect the intake air pressure sensor 2 coupler "1" and ECU coupler "3".
• Remove the joint coupler cap "2".
• Open circuit check

9-195
 P1606,P1607

Between ECU coupler "3" and joint coupler "2" [P1607] black/blue-black/blue
Between ECU coupler "3" and intake air pres- [P1607) blue-bl ue
sure sensor 2 coupler "1" [P1606, P1607) pink-pink
Between intake air pressure sensor 2 coupler
[P 1607) black-black
"1 " and joint coupler "2"

a*
1 ~~=~~~%~~ L
at
'I.G VA

* MT09M/MT09MC
•• MT09SPM/MT09SPMC

Is resistance O n?
YES
➔ Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the YDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to "Short circuit check".
• Short circuit check
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
Ground short circuit check "A"
Between intake air pressure sensor 2 coupler [P1607) blue-ground
"1 " and ground [P1606, P1607) pink-ground

9-196
 P1606, P1607

Lines short circuit check "B"

[P1607) blue- any other coupler terminal
ECU coupler "3" [P1607) black/blue-any other coupler terminal
[P1606, P1607) pink- any other coupler tenninaJ
[P1607) blue- any other coupler terminal
Intake air pressure sensor 2 coupler "1" [P1607) black- any other coupler terminal
[P1606, P1607) pink- any other coupler terminal
[P1607) black/blue-any other coupler terminal
Joint coupler "2"
[P1607) black- any other coupler terminal

!Al rn.l ~

''
......................... ~

1
2* :
-?:::::J~~ru~3.J~;;::='2:::::::::::.

• ..............~
1I
': '• '
I ''
''' "' :''
'''
'
''
''
'
I; fflT(Trn ITJJ ...@ ., ' " ' = = = = = = l = = = ,I===,:,,- ''
~

''
"
------·
'
'

''I.,.,,.,.,..,.,..,,.,.,.,. .. .,,.,.,. I

* MT09M/MT09MC
•• MT09SPM/MT09SPMC

Is resistance = n?
YES
➔ Go to step 4.
NO
a. Replace the wire harness.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the YDT.

Is it in the "Recovered" c ondition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 4.
4. Installed condition of intake air pressure sensor 2.
• Check for looseness or pinching.

9-197
 P1606, P1607

Is check result OK?

YES
➔ Go to step 5.
NO
a. Reinstall or replace the sensor.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 5.

5. Defective intake air pressure sensor 2.

• Execute the diagnostic mode. (Code 04)
• When engine is stopped: Atmospheric pressure at the current altitude and weather conditions is in -
dicated.
Approx. 101 kPa (757.6 mmHg, 29.8 inHg), ap-
At sea level
prox. 3.64 V
Approx. 90 kPa (675.1 mmHg, 26.6 inHg), ap-
1000 m (3300 ft) above sea level
prox. 3.30 V
Approx. 80 kPa (600.0 mmHg, 23.6 inHg), ap-
2000 m (6700 ft) above sea level
prox. 3.00 V
Approx. 70 kPa (525.0 mmHg, 20.7 inHg), ap-
3000 m (9800 ft) above sea level
prox. 2.70 V

• 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 2.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 6.

6. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to ''THROTTLE BODIES" on page 7-5.
7. Delete the OTC and check that the MIL goes off.
• Confirm that the OTC has a condition of "Recovered" using the YDT, and then delete the DTC.

9-1 98
 P1806,P1807
..P1806,P1807
.....,

EAS33103
TROUBLESHOOTING
Item
• [P1806] Shift sensor: open or ground short circuit detected.
• [P1807] Shift sensor: power shorti circuit detected.
Fa'il-safe system
• Able to start engine
• Able to drive vehicle

Procedure
1. Connection of shift sensor coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals 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. Tum the main switch to "ON", and then check the condition o f the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 2.

2. Connection of ECU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Tum the main switch to "ON", and then check the condition o f the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 3.

3. Wire harness continuity

• Disconnect the shift sensor coupler "1" and ECU coupler "2".
• Remove the joint coupler cap "3".
• Open circuit check

9-199
 P1806,P1807

Between shift sensor coupler "1" and ECU cou- blue-blue

pier "2" violet-violet
Between shift sensor coupler "1" and joint cou-
black-black
pier "3"
Between joint coupler "3" and ECU coupler "2" black/blue-black/blue

* MT09M/MT09MC
~ fff)TITi: ill) -- Jill.I
•• MT09SPM/MT09SPMC

Is resistance O n?
YES
➔ Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the YDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to "Short circuit check".
• Short circuit check
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.
Ground short circuit check "A"
violet-ground
Between shift sensor coupler "1" and ground
blue- ground

9-200
 P1806, P1807

Lines short circuit check "B"

black- any othe:r coupler terminal
Shift sensor coupler "1" violet- any other coupler terminal
blue- any other coupler terminal
black/blue-any other coupler terminal
ECU coupler "2" violet- any other coupler terminal
blue- any other coupler terminal
black/blue-any other coupler terminal
Joint coupler "3"
black- any othe:r coupler terminal

ffil

.. -------·
.. .--------·'
.
----- - - -- - - - - - - ------- - - ---- - - - 1
3

... .. ....
•••••••••••••••••••• I
I ~ • • • • .... ••<> I
: I : :
'

.·------- n-..: ...

'
. ''
'''
'
.
, __ _____
..
~ fffiTrTi:an .. [email protected]
................'
* MT09M/MT09MC
•• MT09SPM/MT09SPMC

Is resistance = n?
YES
➔ Go to step 4.
NO
a. Replace the wire harness.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the YDT.

Is it in the "Recovered" c ondition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 4.
4. Installed condition of shift sensor.
• Check for looseness or pinching.

9-201
 P1806, P1807

Is check result OK?

YES
➔ Go to step 5.
NO
a. Reinstall or replace the sensor.
Refer to "CHAIN DRIVE" on page 4-86.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Goto step 7, and complete the service.
NO
➔ Go to step 5.

5. Defective shift sensor.

• Execute the diagnostic mode. (Code D95)
Shift sensor output voltage display 0.2-4.8 [V]
With no shift weighting input Approx. 2.5 M
Shift up weighting Changes to the low side
Shift down weighting Changes to the high side

Is check result OK?

YES
➔ Go to step 6.
NO
a. Replace the shift sensor.
Refer to "CHAIN DRIVE" on page 4-86.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 7, and complete the service.
NO
➔ Go to step 6.

6. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
7. Delete the OTC and check that the MIL goes off.
• Confirm that the OTC has a condition of "Recovered" using the YDT, and then delete the OTC.

9-202
 P2122,P2123,P2127,P2128,P2138
........
P2122,P2123, P2127, P2128,P2138
EAS33112
TROUBLESHOOTING
Item
• [P2122] Accelerator position sensor: open or ground short circuit detected.
• [P2123] Accelerator position sensor: power short circuit detected.
• [P2127] Accelerator position sensor: open or ground short circuit detected.
• [P2128] Accelerator position sensor: power short circuit detected.
• [P2138] Deviation error
Fa'il-safe system
• Able/unable to start engine
• Able/unable to drive vehicle

Procedure
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
If a OTC other than P2138 (P2122, P2123, P2127, or P2128) is indicated, perform troubleshooting first.
1. Connection of accelerator position sensor coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 6, and complete the service.
NO
➔ Go to step 2.

2. Connection of ECU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

9-203
 P2122,P2123,P2127,P2128,P2138

Is it in the "Recovered" condition?

YES
➔ Go to step 6, and complete the service.
NO
➔ Go to step 3.

3. Wire harness continuity.

• Disconnect the accelerator position sensor coupler "1" and ECU coupler "2".
• Open circurt check
[P2122, P2127] yellow/red-yellow/red
[P2122, P2127] white/red-white/red
[P2122, P2123, P2127, P2128, P2138) yellow-
Between accelerator position sensor coupler "1" yellow
and ECU coupler "2" [P2123, P2128] white/black-whrte/black
[P2123, P2128] yellow/black-yellow/black
[P2122, P2123, P2127, P2128, P2138) brown-
brown

Is resistance 0 n?
YES
➔ Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 6, and complete the service.
NO
➔ Go to "Short circuit check''.

• Short circuit check

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.

9-204
 P2122, P2123, P2127, P2128, P2138

Ground short circuit check "A"

[P2122, P2123, P2127, P2128, P2138) brown--
ground
Between accelerator position sensor coupler "1" [P2122, P2127) white/red-ground
and ground (P2122, P2127)[ yellow/red- ground
[P2122, P2123, P2127, P2128, P2138) yellow-
ground

Lines short circuit check "B"

[P2122, P2123, P2127, P2128, P2138) brown-
any other coupler terminal
[P2122, P2127)[ white/red-any other coupler
terminal
[P2122, P2127] yellow/red- any other coupler
terminal
Accelerator position sensor coupler "1"
[P2122, P2123, P2127, P2128, P2138) yellow-
any other coupler terminal
[P2123, P2128) yellow/black- any other coupler
terminal
[P2123, P2128)[ white/black- any other coupler
terminal
[P2122, P2123, P2127, P2128, P2138) brown-
any other coupler terminal
[P2122, P2127)[ white/red-any other coupler
terminal
[P2122, P2127) yellow/red- any other coupler
terminal
ECU coupler "2"
[P2122, P2123, P2127, P2128, P2138) yellow-
any other coupler terminal
[P2123, P2128) yellow/black- any other coupler
terminal
[P2123, P2128)[ white/black- any other coupler
terminal

IA] llil
1 1 2
~-------------~'
' '
'

9-205
 P2122,P2123,P2127,P2128,P2138

Is resistance ~ O?
YES
➔ Go to step 4.
NO
a. Replace the wire harness.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 6, and complete the service.
NO
➔ Go to step 4.

4. Defective accelerator position sensor.

• Execute the diagnostic mode. (Code 14) (Accelerator position sensor signal 1.)
W hen the throttle valves are fully closed 14-1 8
W hen the throttle valves are fully open 82- 92
*Turn the throttle grip past the closed position in the deceleration direc-
7- 12
lion.

•: For MT09SPM/MT09SPMC
• Execute the diagnostic mode. (Code 15) (Accelerator position sensor signal 2.)
W hen the throttle valves are fully closed 14-1 8
W hen the throttle valves are fully open 82- 92
*Turn the throttle grip past the closed position in the deceleration direc-
7- 12
lion.

•: For MT09SPM/MT09SPMC

Is check result OK?

YES
➔ Go to step 5.
NO
➔ Replace the handlebar switch (right).
Refer to "HANDLEBAR" on page 4-57.

Is it in the "Recovered" condition?

YES
➔ Go to step 6, and complete the service.
NO
➔ Go to step 5.

5. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
6. Delete the OTC and check that t he MIL goes off.
• Confirm that the OTC has a condition of "Recovered" using the YDT, and then delete the OTC.

9-206
 P2158

........
P2158
EAS33113
TROUBLESHOOTING
Item
Front wheel sensor: no normal signals are received from the front wheel sensor.
Fa'il-safe system
• Able to start engine
• Able to drive vehicle

Procedure
1. Locate the malfunction.
• Check the ABS warning light.

Is the ABS warning light on?

YES
➔ Refer to "BASIC INSTRUCTIONS FOR TROUBLESHOOTING" on page 9-33.
NO
➔ Go to step 2.

2. Execute the diagnostic mode.

• Execute the diagnostic mode. (Code 16)
• Rotate the front wheel by hand and check that the indicated value increases.

Is that value increased?

YES
➔ Go to step 10, and complete the service.
NO
➔ Go to step 3.

3. Connection of front wheel sensor coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

Is the coupler condition norma l?

YES
➔ Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code 16)
c. Rotate the front wheel by hand and check that the indicated value increases.

Is that value increased?

YES
➔ Goto step 10, and complete the service.
NO
➔ Go to step 4.

4. Connection of ABS ECU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

9-207
 P2158

Is the coupler condition normal?

YES
➔ Go to step 5.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code 16)
c. Rotate the front wheel by hand and check that the indicated value increases.

Is that value increased?

YES
➔ Go to step 10, and complete the service.
NO
➔ Go to step 5.

5. Connection of ECU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken term inals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 6.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code 16)
c. Rotate the front wheel by hand and check that the indicated value increases.

Is that value increased?

YES
➔ Go to step 10, and complete the service.
NO
➔ Go to step 6.

6. Wire harness continuity.

• Disconnect the front wheel sensor coupler "1", ABS ECU coupler "2" and ECU coupler "3".
• Open circuit check
Between front wheel sensor coupler "1" and brown-brown
ABS ECU coupler ''2" yellow-yellow
Between ABS ECU coupler "2" and ECU cou-
white/green-white/green
pier "3"

9-208
 P2158

a*

• MT09M/MT09MC
•• MT09SPM/MT09SPMC

Is resistance O 11?
YES
➔ Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code 16)
c. Rotate the front wheel by hand and check that the indicated value increases.

Is that value increased?

YES
➔ Go to step 10, and complete the service.
NO
➔ Go to "Short circuit check''.

• Short circuit check

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU and ABS ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3 and "PARTS CONNECTED TO THE ABS
ECU" on page 9-4.
Ground short circuit check "A"
brown- ground
Between ABS ECU coupler "2" and ground yellow- ground
white/green-ground

Lines short circuit check "B"

brown- any other coupler terminal
Front wheel sensor coupler "1"
yellow- any other coupler terminal
brown- any other coupler terminal
ABS ECU coupler ''2" yellow- any other coupler terminal
white/green-any other coupler terminal
ECU coupler "3" white/green-any other coupler terminal

9-209
 P2158

IA) [ID
1 3*

MT09M/MT09MC
•• MT09SPM/MT09SPMC

Is resistance ~ n?
YES
➔ Go to step 7.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code 16)
c. Rotate the front wheel by hand and chec k that the indicated value increases.

Is that value increased?

YES
➔ Go to step 10, and complete the service.
NO
➔ Goto step 7.
7. Defective front wheel sensor.
• Check the front wheel sensor.
Refer to "FRONT WHEEL" on page 4-11.

Is check result OK?

YES
➔ Go to step 8.
NO
a. Reinstall or replace the fro nt wheel sensor.
Refer to "FRONT WHEEL" on page 4-11.
b. Execute the diagnostic mode. (Code 16)
c. Rotate the front wheel by hand and chec k that the indicated value increases.

Is that value increased?

YES
➔ Go to step 10, and complete the service.
NO
➔ Go to step 8.

9-210
 P2158

8. Malfunction in ECU.
• Replace the ECU.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
• Execute the diagnostic mode. (Code 16)
• Rotate the front wheel by hand and check that the indicated value increases.

Is that value increased?

YES
➔ Goto step 10, and complete the service.
NO
➔ Go to step 9.

9. Malfunction in ABS ECU.

• Replace the ABS ECU.
Refer to "REMOVING THE HYDRAULIC UNIT ASSEMBLY" on page 4-51.
• Go to step 10, and complete the service.
10. Delete the OTC and check that 1he MIL goes off.
• Tum the main switch to "ON", and then rotate the front wheel by hand.
• Start the engine, and input the vehicle speed signals by operating the vehicle at 20 to 30 km/h (12
to 19 mph).
• Confirm that the OTC has a condition of "Recovered" using the malfunction mode of the YDT, and
then delete the OTC.
• Delete this OTC even if it has a condition of "Detected".

9-211
 U0125

..U0125
.,.,.,.

EAS33127
TROUBLESHOOTING
Item
Signals cannot be transmitted between the ECU and the IMU.
Fa'il-safe system
• Unable to start engine
• Able/Unable to drive vehicle

Procedure
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first.
• P1600
1. Connection of IMU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 2.
NO
a. Connect the coupler securely or replace the wi re harness.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT .

Is it in the "Recovered" condition?

YES
➔ Go to step 6, and complete the service.
NO
➔ Go to step 2.

2. Connection of ECU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Tum the main switch to "ON", and then check the condition o f the DTC using the malfunction
mode of the VDT .

Is it in the "Recovered" condition?

YES
➔ Go to step 6, and complete the service.
NO
➔ Go to step 3.

9-212
 U0125

3. Wire harness continuity.

• Disconnect the ECU coupler "1", IMU coupler "3" and ignition fuse 2 "4".
• Remove the joint coupler cap "2".
• Open circuit check
blue/white-blue/white
Between ECU coupler "1" and joint coupler "2"
blue/black-blue/black
blue/white-blue/white
Between joint coupler "2" and IMU coupler "3"
blue/black-blue/black
Between IMU coupler "3" and ignition fuse 2
red/white-red/white
holder "4"
Between IMU coupler "3" and ground black/white- ground

~, ,,,, ,r1rtttn__ remU

* MT09M/MT09MC
•• MT09SPM/MT09SPMC

Is resistance O n?
VE$
➔ Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 6, and complete the service.
NO
➔ Go to "Short circuit check".
• Short circuit check
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU and IMU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.

9-213
 U0125

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

Lines short circuit check "B"

blue/white-any other coupler terminal
ECU coupler "1 "
blue/black- any other coupler terminal
blue/white-any other coupler terminal
Joint coupler "2"
blue/black- any other coupler terminal
blue/white-any other coupler terminal
IMU coupler "3" blue/black- any other coupler terminal
red/white-any other coupler terminal

[BJ

(q) !
''
----------~
i~
''.. -·······--~
''
11111111 ri:tfil _rrm:I
• MT09M/MT09MC
•• MT09SPM/MT09SPMC

Is resistance ~ n?
YES
➔ Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the YDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 6, and complete the service.
NO
➔ Go to step 4.

9-214
 U0125

4. Malfunction in IMU.
• Replace the IMU.
Refer to "GENERAL CHASSIS (1)" on page 4-1.
• Tum the main switch to "ON", and then check the condition of the DTC using the malfunction mode
of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 6, and complete the service.
NO
➔ Go to step 5.

5. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
6. Delete the DTC and check that the MIL goes off.
• Confinm that the DTC has a condition of "Recovered" using the VDT, and then delete the DTC.

9-215
 U0155 or Err

........
U0155 or Err
EAS33129
TROUBLESHOOTING
Item
M1.11lti-function meter: signals cannot be transmitted between the ECU and the multi-function meter.
Fa'il-safe system
• Able to start engine
• Able to drive vehicle

Procedure
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
"Err" is displayed on the clock display of the multi-function meter, but the MIL does not come on.
1. Connection of meter assembly coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 2.
NO
a. Connect the coupler securely or replace the wi re harness.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT .

Is it in the "Recovered" condition?

YES
➔ Go to step 6, and complete the service.
NO
➔ Go to step 2.

2. Connection of ECU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
➔ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Tum the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT .

Is it in the "Recovered" condition?

YES
➔ Go to step 6, and complete the service.
NO
➔ Go to step 3.

9-216
 U0155 or Err

3. Wire harness continuity.

• Disconnect the meter assembly coupler "1" and ECU coupler "4".
• Remove the joint coupler cap ''2" and joint coupler cap "3".
• Open circuit check
Between meter assembly coupler "1" and joint
blue/black-blue/black
coupler"2"
Between meter assembly coupler "1" and joint
blue/white-blue/white
coupler"3"
Between joint coupler "2" and ECU coupler "4" blue/black-blue/black
Between joint coupler "3" and ECU coupler "4" blue/white-blue/white

* MT09M/MT09MC
•• MT09SPM/MT09SPMC

Is resistance O n?
YES
➔ Go to "Short circuit check".
NO
a. Replace the wire harness.
b. Turn the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the YDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 8, and complete the service.
NO
➔ Go to "Short circuit check''.
• Short circuit check
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3.

9-217
 U0155 or Err

Ground short circuit check "A"

Between meter assembly coupler "1" and blue/white-ground
ground blue/black-ground
blue/white-ground
Between ECU coupler "4" and ground
blue/black-ground

Lines short circuit check "B"

blue/white-any other coupler terminal
Meter assembly coupler "1"
blue/black-any other coupler terminal
blue/white-any other coupler terminal
ECU coupler "4"
blue/black-any other coupler terminal

IA] [ID
1 .········---------------·-·-- .
'
•fr.::15:~~~&.~~,:;;i:~~· '
'' '
'
'

* MT09M/MT09MC
u MT09SPM/MT09SPMC

Is resistance ~ n?
YES
➔ Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to "ON", and then check the condition of the DTC using the malfunction
mode of the VDT.

Is it in the "Recovered" condition?

YES
➔ Go to step 6, and complete the service.
NO
➔ Go to step 4.
4. Defective meter assembly.
• Replace the meter assembly.
Refer to "GENERAL CHASSIS (2)" on page 4-10.
• Tum the main switch to "ON", and then check the condition of the OTC using the malfunction mode
of the VDT.

9-218
 U0155 or Err

Is it in the "Recovered" condition?

YES
➔ Go to step 6, and complete the service.
NO
➔ Go to step 5.

5. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to "REPLACING THE ECU (Engine Control Unit)" on page 8-55.
6. Delete the OTC and check that the MIL goes off.
• Confirm that the OTC has a condition of "Recovered" using the YDT, and then delete the OTC.

9-21 9
 11 _ABS

........
11 _ABS
EAS3:l>t•
TROUBLESHOOTING
Item
Front wheel sensor (intermittent pulses or no pulses)

Procedure
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
If the rear wheel continues to tum 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 4-13.

Is check result OK?

YES
➔ Go to step 3.
NO
➔ Replace the wheel axle, tire, front wheel, wheel bearings or oil seals.

3. Defective sensor rotor or incorrect installation of the rotor

• Check the surface of the sensor rotor for damage.
Refer to "MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR" on page 4-
15.

Is check result OK?

YES
➔ Go to step 4.
NO
➔ Replace the sensor rotor.

4. Defective front wheel sensor or incorrect installation of the sensor

• Check the wheel sensor for damage and the installed condition of the sensor.
Refer to "MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR" on page 4-
15.

Is check result OK?

YES
➔ Replace the hydraulic unit assembly (ABS ECU).
NO
➔ Repair or replace the wheel sensor.

9-220
 12_ABS

........
12_ABS
...,,..,.
TROUBLESHOOTING
Item
Rear wheel sensor (intermittent pulses or no pulses)

Procedure
1. Foreign material adhered around the rear wheel sensor
• Check the surface of the sensor rotor and wheel sensor for foreign material, such as metal particles.

Is check result OK?

YES
➔ Go to step 2.
NO
➔ Clean the sensor rotor and wheel sensor.

2. Incorrect installation of the rear wheel

• Check the components for looseness, distortion, and bends.
Refer to "CHECKING THE REAR WHEEL" on page 4-21.

Is check result OK?

YES
➔ Go to step 3.
NO
➔ Replace the wheel axle, tire, rear wheel, wheel bearings or oil seals.

3. Defective sensor rotor or incorrect installation of the rotor

• Check the surface of the sensor rotor for damage.
Refer to "MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR" on page 4-
22.

Is check result OK?

YES
➔ Go to step 4.
NO
➔ Replace the sensor rotor.

4. Defective rear wheel sensor or incorrect installation of the sensor

• Check the wheel sensor for damage and the installed condition of the sensor.
Refer to "MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR" on page 4-
22.

Is check result OK?

YES
➔ Replace the hydraulic unit assembly (ABS ECU).
NO
➔ Repair or replace the wheel sensor.

9-221
 13, 26_ABS

..13,.....,26_ABS
...,,..,.
TROUBLESHOOTING
Item
Front wheel sensor (abnomial pulse period)

Procedure
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• If the front brake ABS operates continuously for 20 seconds or more, OTC No. 26 will be recorded. If
the front brake ABS operates continuously for 36 seconds or more, OTC No. 13 will be recorded.
• Vehicle possibly ridden on uneven roads.
1. Foreign material adhered around the front wheel sensor
• Check the surface of the sensor rotor and wheel sensor for foreign material, such as metal particles.

Is check result OK?

YES
➔ Go to step 2.
NO
➔ Clean the sensor rotor and wheel sensor.

2. Incorrect installation of the front wheel

• Check the components for looseness, distortion, and bends.
Refer to "CHECKING THE FRONT WHEEL" on page 4-13.

Is check result OK?

YES
➔ Go to step 3.
NO
➔ Replace the wheel axle, tire, rear wheel, wheel bearings or oi l seals.

3. Defective sensor rotor or incorrect installation of the rotor

• Check the surface of the sensor rotor for damage.
Refer to "MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR" on page 4-
15.

Is check result OK?

YES
➔ Go to step 4.
NO
➔ Replace the sensor rotor.

4. Defective front wheel sensor or incorrect installation of the sensor

• Check the wheel sensor for damage and the installed condition of the sensor.
Refer to "MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR" on page 4-
15.

Is check result OK?

YES
➔ Replace the hydraulic unit assembly (ABS ECU).
NO
➔ Repair or replace the wheel sensor.

9-222
 14, 27_ABS

........
14, 27_ABS
EAS3:l>l7
TROUBLESHOOTING
Item
Rear wheel sensor (abnormal pulse period)

Procedure
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
• If the rear brake ABS operates continuously for 20 seconds or more, OTC No. 27 will be recorded. If
the rear brake ABS operates continuously for 36 seconds or more, OTC No. 14 will be recorded.
• Vehicle possibly ridden on uneven roads.
1. Foreign material adhered around the rear wheel sensor
• Check the surface of the sensor rotor and wheel sensor for foreign material, such as metal particles.

Is check result OK?

YES
➔ Go to step 2.
NO
➔ Clean the sensor rotor and wheel sensor.

2. Incorrect installation of the rear wheel

• Check the components for looseness, distortion, and bends.
Refer to "CHECKING THE REAR WHEEL" on page 4-2 1.

Is check result OK?

YES
➔ Go to step 3.
NO
➔ Replace the wheel axle, tire, rear wheel, wheel bearings or oi l seals.

3. Defective sensor rotor or incorrect installation of the rotor

• Check the surface of the sensor rotor for damage.
Refer to "MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR" on page 4-
22.

Is check result OK?

YES
➔ Go to step 4.
NO
➔ Replace the sensor rotor.

4. Defective rear wheel sensor or incorrect installation of the sensor

• Check the wheel sensor for damage and the installed condition of the sensor.
Refer to "MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR" on page 4-
22.

Is check result OK?

YES
➔ Replace the hydraulic unit assembly (ABS ECU).
NO
➔ Repair or replace the wheel sensor.

9-223
 15_ABS

........
15_ABS
EAS3:l040
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.
• Check the locking condition of the coupler.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Turn the main switch to "OFF" before disconnecting or connecting a coupler.

Is check result OK?

YES
➔ Go to step 2.
NO
➔ If there is a malfunction, re pair it and connect the coupler securely.

2. Wire harness continuity

• Disconnect the ABS ECU coupler "1" and front wheel sensor coupler "2".
• Open circuit check
Between ABS ECU coupler "1" and front wheel brown-brown
sensor coupler "2" yellow-yellow

,-----1 Q - - - - ,

Is resistance O O?
YES
➔ Go to "Short circuit check".
NO
➔ Replace the wire harness.

• Short circuit check

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ABS ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ABS ECU" on page 9-4.

9-224
 15_ABS

Ground short circuit check "A"

yellow- ground
Between ABS ECU coupler "1" and ground
brown-ground

Lines short circuit check "B"

yellow- any other coupler terminal
ABS ECU coupler "1"
brown- any other coupler terminal

(ID
1 .......... .............. .

~ • L\ ~
..... . .....
!.' ............

Is resistance ~ O?
YES
➔ Go to step 3.
NO
➔ Replace the wire harness.
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 4-11 and "ABS (ANTI-LOCK BRAKE SYSTEM)" on page 4-49.

9-225
 16_ABS

........
16_ABS
...,,,,..
TROUBLESHOOTING
Item
Rear wheel sensor (open or short c ircuit)

Procedure
1. Defective coupler between the rear wheel sensor and the hydraulic unit assembly
• Check the coupler for any pins that may be pulled out.
• Check the locking condition of the coupler.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Turn the main switch to "OFF" before disconnecting or connecting a coupler.

Is check result OK?

YES
➔ Go to step 2.
NO
➔ If there is a malfunction, repair it and connect the coupler securely.

2. Wire harness continuity

• Disconnect the ABS ECU coupler "1" and rear wheel sensor coupler "2".
• Open circuit check
Between ABS ECU coupler "1" and rear wheel white-white
sensor coupler "2" black-black

Is resistance O O?
YES
➔ Go to "Short circuit check".
NO
➔ Replace the wire harness.

• Short circuit check

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ABS ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ABS ECU" on page 9-4.

9-226
 16_ABS

Ground short circuit check "A"

white-ground
Between ABS ECU coupler "1" and ground
black-ground

Lines short circuit check "B"

white-any other coupler terminal
ABS ECU coupler "1"
black-any other coupler terminal

(ID
1 --- ------ -------- -- ------

Is resistance ~ O?
YES
➔ Go to step 3.
NO
➔ Replace the wire harness.
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 hyd raulic unit assembly.
Refer to "REAR WHEEL" on page 4-18 and "ABS (ANTI-LOCK BRAKE SYSTEM)" on page 4-49.

9-227
 21_ABS

..21......,_ABS
EA"""'1>
TROUBLESHOOTING
Item
Hydraulic unit assembly (defective solenoid drive circuit)

Procedure
1. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to "ABS (ANTI -LOCK BRAKE SYSTEM)" on page 4-49.

9-228
 31_ABS

.......,
31 _ABS
EA""""1
TROUBLESHOOTING
Hydraulic unit assembly (defective ABS solenoid power circuit)

Procedure
1. Blown ABS solenoid fuse
• Check the ABS solenoid fuse.
Refer to "CHECKING THE FUSES" on page 8-55.

Is check result OK?

YES
➔ Go to step 2.
NO
➔ Replace the fuse and check the wire harness.

2. Defective coupler between the battery and the hydraulic unit assembly
• Check the coupler for any pins that may be pulled out.
• Check the locking condition of the coupler.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Turn the main switch to "OFF" before disconnecting or connecting a coupler.

Is check result OK?

YES
➔ Go to step 3.
NO
➔ If there is a malfunction, repair it and connect the coupler securely.

3. Wire harness continuity

• Disconnect the ABS solenoid fuse "1" and ABS ECU coupler "2".
• Open circuit check
Between ABS solenoid fuse holder "1" and ABS blue/white-blue/white
ECU coupler "2"

Is resistance O '2?
YES
➔ Go to "Short circuit check".
NO
➔ Replace the wire harness.

• Short circuit check

9-229
 31_ABS

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ABS ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ABS ECU" on page 9-4.
Ground short circuit check "A"
I Between ABS ECU coupler "2" and ground I blue/white-ground
Lines short circuit check "B"
I ABS ECU coupler "2" I blue/white-any other coupler term inal
IA) rn:J
2 r;;;::::';::;:~~~::=,;::;i 2

Is resistance ~ n?
YES
➔ Go to step 4.
NO
➔ Replace the wire harness.
4. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to "ABS (ANTI-LOCK BRAKE SYSTEM)" on page 4-49.

9-230
 33_ABS

........
33_ABS
EA"""'2
TROUBLESHOOTING
Item
Hydraulic unit assembly (abnormal ABS motor power supply)

Procedure
1. Blown ABS motor fuse
• Check the ABS motor fuse.
Refer to "CHECKING THE FUSES" on page 8-55.

Is check result OK?

YES
➔ Go to step 2.
NO
➔ Replace the fuse and check the wire harness.

2. Defective coupler between the battery and the hydraulic unit assembly
• Check the coupler for any pins that may be pulled out.
• Check the locking condition of the coupler.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Turn the main switch to "OFF" before disconnecting or connecting a coupler.

Is check result OK?

YES
➔ Go to step 3.
NO
➔ If there is a malfunction, repair it and connect the coupler securely.

3. Wire harness continuity

• Disconnect the ABS motor fuse "1" and ABS ECU coupler "2".
• Open circuit check
Between ABS motor fuse "1" and ABS ECU
red-red/white
coupler"2"

Is resistance O n?
YES
➔ Go to "Short circuit check".
NO
➔ Replace the wire harness.

9-231
 33_ABS

• Short circuit check

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ABS ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ABS ECU" on page 9-4.
Ground short circuit check "A"
I Between ABS ECU coupler "2" and ground I red-ground
Lines short circuit check "B"
I ABS ECU coupler "2" I red-any other coupler tenninal
IA] rn:J
2 IZ';::;:~~2~ 2 .......... .............. .

Is resistance ~ O?
YES
➔ Go to step 4.
NO
➔ Replace the wire harness.
4. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to "ABS (ANTI -LOCK BRAKE SYSTEM)" on page 4-49.

9-232
 34_ABS

........
34_ABS
EA""'3"3
TROUBLESHOOTING
Item
Hydraulic unit assembly (short circuit in ABS motor power supply circuit)

Procedure
1. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to "ABS (ANTI -LOCK BRAKE SYSTEM)" on page 4-49.

9-233
 41_ABS

........
41 _ABS
EAS3:l331
TROUBLESHOOTING
Item
Front wheel ABS (intermittent wheel speed pulses or incorrect depressurization)

Procedure
1. Incorrect installation of the front wheel sensor
• Check the components for looseness, distortion, and bends.
Refer to "MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR" on page 4-
15.

Is check result OK?

YES
➔ Go to step 2.
NO
➔ Repair or replace the defective part.

2. Incorrect rotation of the front wheel

• Check that there is no brake disc drag on the wheel and make sure that it rotates smoothly.
Refer to "CHECKING THE FRONT WHEEL" on page 4-13 and "CHECKING THE FRONT BRAKE
DISCS" on page 4-31.

Is check result OK?

YES
➔ Go to step 3.
NO
➔ Repair or replace the defective part.

3. Front brake dragging

• Check that the brake fluid pressure is correctly transmitted to the brake caliper when the brake lever
is operated and that the pressure decreases when the lever is released.
Refer to "CHECKING THE FRONT BRAKE DISCS" on page 4-31.

Is check result OK?

YES
➔ Go to step 4.
NO
➔ Repair or replace the defective part.

4. Defective hydraulic unit assembly

• Replace the hydraulic unit assembly.
Refer to "ABS (ANTI-LOCK BRAKE SYSTEM)" on page 4-49.

9-234
 42_ABS

........
42_ABS
EAS3'!304
TROUBLESHOOTING
Item
Rear wheel ABS (intemiittent wheel speed pulses or incorrect depressu rization)

Procedure
1. Incorrect installation of the rear wheel sensor
• Check the components for looseness, distortion, and bends.
Refer to "MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR" on page 4-
22.

Is check result OK?

YES
➔ Go to step 2.
NO
➔ Repair or replace the defective part.

2. Incorrect rotation of the rear wheel

• Check that there is no brake disc drag on the wheel and make sure that it rotates smoothly.
Refer to "CHECKING THE REAR WHEEL" on page 4-21 and "CHECKING THE REAR BRAKE
DISC" on page 4-43.

Is check result OK?

YES
➔ Go to step 3.
NO
➔ Repair or replace the defective part.

3. Rear brake dragging

• Check that the brake fluid pressure is correctly transmitted to the brake caliper when the brake pedal
is operated and that the pressure decreases when the pedal is released.
Refer to "CHECKING THE REAR BRAKE DISC" on page 4-43.

Is check result OK?

YES
➔ Go to step 4.
NO
➔ Repair or replace the defective part.

4. Defective hydraulic unit assembly

• Replace the hydraulic unit assembly.
Refer to "ABS (ANTI-LOCK BRAKE SYSTEM)" on page 4-49.

9-235
 43, 45_ABS

........
43, 45_ABS
EAS3:l330
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.
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 4-13.

Is check result OK?

YES
➔ Go to step 3.
NO
➔ Replace the wheel axle, tire, front wheel, wheel bearings or oil seals.

3. Defective sensor rotor or incorrect installation of the rotor

• Check the surface of the sensor rotor for damage.
Refer to "MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR" on page 4-
15.

Is check result OK?

YES
➔ Go to step 4.
NO
➔ Replace the sensor rotor.

4. Defective front wheel sensor or incorrect installation of the sensor

• Check the wheel sensor for damage and the installed condition of the sensor.
Refer to "MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR" on page 4-
15.

Is check result OK?

YES
➔ Replace the hydraulic unit assembly (ABS ECU).
NO
➔ Repair or replace the wheel sensor.

9-236
 44, 46_ABS

..44,.,.,..,46_ABS
EA""""5
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 lime are exceeded.
1. Foreign material adhered around the rear wheel sensor
• Check the surface of the sensor rotor and wheel sensor for foreign material, such as metal particles.

Is check result OK?

YES
➔ Go to step 2.
NO
➔ Clean the sensor rotor and wheel sensor.

2. Incorrect installation of the rear wheel

• Check the components for looseness, distortion, and bends.
Refer to "CHECKING THE REAR WHEEL" on page 4-21.

Is check result OK?

YES
➔ Go to step 3.
NO
➔ Replace the wheel axle, tire, rear wheel, wheel bearings or oil seals.

3. Defective sensor rotor or incorrect installation of the rotor

• Check the surface of the sensor rotor for damage.
Refer to "MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR" on page 4-
22.

Is check result OK?

YES
➔ Go to step 4.
NO
➔ Replace the sensor rotor.

4. Defective rear wheel sensor or incorrect installation of the sensor

• Check the wheel sensor for damage and the installed condition of the sensor.
Refer to "MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR" on page 4-
22.

Is check result OK?

YES
➔ Replace the hydraulic unit assembly (ABS ECU).
NO
➔ Repair or replace the wheel sensor.

9-237
 51_ABS

........
51 _ABS
...,,,,.
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.
Refer to "CHECKING AND CHARGING THE BATTERY" on page 8-56.
2. Disconnected battery terminal
• Check the connection.

Is check result OK?

YES
➔ Go to step 3.
NO
➔ Replace or reconnect the terminal.

3. Defective charging system

• Check the charging system.
Refer to "CHARGING SYSTEM" on page 8-17.

Is check result OK?

YES
➔ Replace the hydraulic unit assembly (ABS ECU).
NO
➔ Confirm the cause of the problem and repair it, and check again.

9-238
 53_ABS

........
53_ABS
EA""""7
TROUBLESHOOTING
Item
Vehicle system power supply (voltage of ABS ECU power supply is low)

Procedure
1. Defective battery
• Recharge or replace the battery, and check again.
Refer to "CHECKING AND CHARGING THE BATTERY" on page 8-56.
2. Defective coupler between the battery and the hydraulic unit assembly
• Check the coupler for any pins that may be pulled out.
• Check the locking condition of the coupler.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Turn the main switch to "OFF" before disconnecting or connecting a coupler.

Is check result OK?

YES
➔ Go to step 3.
NO
➔ If there is a malfunction, repair it and connect the coupler securely.
3. Wire harness continuity
• Disconnect the ABS ECU fuse " 1" and ABS ECU coupler "2".
• Open circuit check
Between ABS ECU fuse holder "1" and ABS
red/black-red/black
ECU coupler "2"

1
B -:----n----~

Is resistance O!l?
YES
➔ Go to "Short circuit check".
NO
➔ Replace the wire harness.
• Short circuit check
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ABS ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ABS ECU" on page 9-4.

9-239
 53_ABS

Ground short circuit check "A"

I
Between ABS ECU coupler "2" and ground I red/black-ground
Lines short circuit check "B"
I ABS ECU coupler "2" I red/black-any other coupler terminal
IA) [ID

2 ~~~~~~ 2 -------------------------

Is resistance ~ O?
YES
➔ Go to step 4_
NO
➔ Replace the wire harness.
4_ Defective charging system
• Check the charging system.
Refer to "CHARGING SYSTEM" on page 8-17.

Is check result OK?

YES
➔ Replace the hydraulic unit assembly (ABS ECU).
NO
➔ Confirm the cause of the problem and repair it, and check again.

9-240
 SS_ABS

..55_ABS
.,.,..

EA"""'9
TROUBLESHOOTING
Item
Hydraulic unit assembly (defective ABS ECU)

Procedure
1. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to "ABS (ANTI -LOCK BRAKE SYSTEM)" on page 4-49.

9-241
 56_ABS

EA""""1

56_ABS
EA"""'9
TROUBLESHOOTING
Item
Hydraulic unit assembly (abnormal internal circuit)

Procedure
1. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to "ABS (ANTI -LOCK BRAKE SYSTEM)" on page 4-49.

9-242
 57_ABS

........
57_ABS
EAs=
TROUBLESHOOTING
Item
Vehicle CAN communication line or power source of vehicle system

Procedure
1. Wire harness continuity.
• Disconnect the ECU coupler "1" and ABS ECU coupler "5".
• Remove the joint coupler cap "2", joint coupler cap "3" and joint coupler cap "4".
• Open circuit check
Between ECM coupler "1" and joint coupler "3" blue/black-blue/black
Between ECM coupler "1" and joint coupler "4" blue/white-blue/white
Between joint coupler "2" and joint coupler "3" yellow/black- yellow/black
Between joint coupler "2" and joint coupler "4" white-white
Between joint coupler "2" and ABS ECU coupler blue/black-blue/black
"5" blue/white-blue/white

~ - - - - - - - - - -----<Q>--- - - - - - - ~
2
/ ,
\.--.;:~==;==~~)

~ .
Q ~ I ! I 1111 Iq'ff;Yl rtmt1

• MT09M/MT09MC
•• MT09SPM/MT09SPMC

Is resistance O O?
YES
➔ Go to "Short circuit check"
NO
➔ Replace the wire harness.

• Short circuit check

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU and ABS ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3 and "PARTS CONNECTED TO THE ABS
ECU" on page 9-4.

9-243
 57_ABS

Ground short circuit check "A"

blue/white-ground
Between ECU coupler "1" and ground
blue/black-ground
blue/white-ground
Between ABS ECU coupler "5" and ground
blue/black-ground

Lines short circuit check "B"

blue/white-any other coupler terminal
ECU coupler "1 "
blue/black- any other coupler terminal
yellow/black- any other coupler terminal
Joint coupler "2"
white-any othe:r coupler terminal
blue/white-any other coupler terminal
ABS ECU coupler "5"
blue/black- any other coupler terminal

ffil

~~~;~t~L(;
===•JI•
~-- ~------------------------------ ;
1**- -- - - - ;
'
~~'i?.'ii:'li."'~~,l~,
--
' .''
5 ---
'
\' :'
·~-- ~~==::5~~·
'
'
~
'
,'

'
~--------~
I o
''
''

................ ''
~
'
I •••••••••• f
I~ I ft rt t fl ;°ffjj"; Jfjff!
• MT09M/MT09MC
•• MT09SPM/MT09SPMC

Is resistance = n?
YES
➔ Go to step 2.
NO
➔ Replace the wire harness.

2. Defective battery
• Recharge or replace the battery, and check again.
Refer to "CHECKING AND CHARGING THE BATTERY" on page 8-56.
3. Defective coupler between the battery and the hydraulic unit assembly
• Check the coupler for any pins that may be pulled out.
• Check the locking condition of the coupler.

9-244
 57_ABS

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Turn the main switch to "OFF" before disconnecting or connecting a coupler.

Is check result OK?

YES
➔ Go to step 4.
NO
➔ If there is a malfunction, repair it and connect the coupler securely.

4. Wire harness continuity

• Disconnect the ABS ECU fuse "1 ", ABS solenoid fuse "2" and ABS ECU coupler "3".
• Open circuit check
Between ABS ECU fuse holder "1" and ABS
red/black-red/black
ECU coupler "3"
Between ABS solenoid fuse holder "2" and ABS
blue/white-blue/white
ECU coupler "3"

1
B --------<n,_____~

Is resistance O '2?
YES
➔ Go to "Short circuit check"
NO
➔ Replace the wire harness.

• Short circuit check

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ABS ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ABS ECU" on page 9-4.

Ground short circuit check "A"

red/black-ground
Between ABS ECU coupler "3" and ground
blue/white-ground

Lines short circuit check "B"

red/black-any other coupler terminal
ABS ECU coupler "3"
blue/white-any other coupler terminal

9-245
 57_ABS

IA) [ID
3 ···········-·············

Is resistance ~ O?
YES
➔ Go to step 5.
NO
➔ Replace the wire harness.

5. Defective charging system

• Check the charging system.
Refer to "CHARGING SYSTEM" on page 8-17.

Is resistance ~ O?
YES
➔ Replace the hydraulic unit assembly (ABS ECU).
NO
➔ Confirm the cause of the problem and repair it, and check again.

9-246
 62_ABS

..62_ABS
.,.,.,,

EAS3:l300
TROUBLESHOOTING
Item
Power supply voltage failure in pressure sensor

Procedure
1. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to "ABS (ANTI -LOCK BRAKE SYSTEM)" on page 4-49.

9-247
 68_ABS

EA"'°"'5

68_ABS
EAS3:l336
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.

2. Defective hydraulic unit assembly

• Replace the hydraulic unit assembly.
Refer to "ABS (ANTI -LOCK BRAKE SYSTEM)" on page 4-49.

9-248
 89_ABS

........
89_ABS
...,,,,..
TROUBLESHOOTING
Item
CAN communication (between meter assembly and hydraulic unit assembly)

Procedure
1. Defective coupler between the meter assembly and the hydraulic unit assembly
• Check the coupler for any pins that may be pulled out.
• Check the locking condition of the coupler.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Turn the main switch to "OFF" before disconnecting or connecting a coupler.

Is check result OK?

YES
➔ Go to step 2.
NO
➔ If there is a malfunction, repair it and connect the coupler securely.

2. Wire harness continuity.

• Disconnect the meter assembly coupler "1" and ABS ECU coupler "3".
• Remove the joint coupler cap "2", joint coupler cap "4" and joint coupler cap "5".
• Open circuit check
Between meter assembly coupler "1" and joint
blue/black-blue/black
coupler"4"
Between meter assembly coupler "1" and joint
blue/white-blue/white
coupler"5"
Between joint coupler "2" and joint coupler "4" yellow/black- yellow/black
Between joint coupler "2" and joint coupler "5" white-white
Between joint coupler "2" and ABS ECU coupler blue/black-blue/black
"3" blue/white-blue/white

9-249
 89_ABS

Is resistance 0 O?
YES
➔ Go to "Short circuit check".
NO
➔ Replace the wire harness.
• Short circuit check
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ABS ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ABS ECU" on page 9-4.
Ground short circuit check "A"
Between meter assembly coupler "1" and blue/white-ground
ground blue/black-ground
blue/white-ground
Between ABS ECU coupler "3" and ground
blue/black-ground

Lines short circuit check "B"

blue/white-any other coupler terminal
Meter assembly coupler "1"
blue/black- any other coupler terminal
blue/white-any other coupler terminal
Joint coupler "2"
blue/black- any other coupler terminal
blue/white-any other coupler terminal
ABS ECU coupler "3"
blue/black- any other coupler terminal

[ID

1 3
'
:
''
~
~~~~~
'' ~~~~~~~~
.
&\'
'
:
''
''
--- ..
,'__

~ I
~ 11II!I I( ftfj] i"crfj] ~

Is resistance ~ O?
YES
➔ Go to step 3.
NO
➔ Replace the wire harness.
3. Defective meter assembly
• Replace the meter assembly, and check again.

9-250
 89_ABS

4. Defective hydraulic unit assembly

• Replace the hydraulic unit assembly.

9-251
 90_ABS

..90_ABS
.,.,.,.,

EAS3:l300
TROUBLESHOOTING
Item
CAN communication (between ECU and hydraulic unit assembly)

Procedure
1. Defective coupler between the ECU and the hydraulic unit assembly
• Check the coupler for any pins that may be pulled out.
• Check the locking condition of the coupler.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Turn the main switch to "OFF" before disconnecting or connecting a coupler.

Is check result OK?

YES
➔ Go to step 2.
NO
➔ If there is a malfunction, repair it and connect the coupler securely.

2. Wire harness continuity.

• Disconnect the ECU coupler "1" and ABS ECU coupler "5".
• Remove the joint coupler cap "2", joint coupler cap "3" and joint coupler cap "4".
• Open circuit check
Between ECM coupler "1" and joint coupler "3" blue/black- blue/black
Between ECM coupler "1" and joint coupler "4" blue/white-blue/white
Between joint coupler "2" and joint coupler "3" yellow/black- yellow/black
Between joint coupler "2" and joint coupler "4" while-white
Between joint coupler "2" and ABS ECU coupler blue/black- blue/black
"5" blue/whitE7-blue/white

~ - - - - - - - - - -----<Q>--- - - - - - - ~
5

~······························-··

~ 1111I1 11:m il i'm i~

: n-, :
.~.

* MT09M/MT09MC
•• MT09SPM/MT09SPMC

9-252
 90_ABS

Is resistance O O?
YES
➔ Go to "Short circuit check".
NO
➔ Replace the wire harness.

• Short circuit check

TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ECU and ABS ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ECU" on page 9-3 and "PARTS CONNECTED TO THE ABS
ECU" on page 9-4.
Ground short circuit check "A"
blue/white-ground
Between ECU coupler "1" and ground
blue/black-ground
blue/white-ground
Between ABS ECU coupler "5" and ground
blue/black-ground

Lines short circuit check "B"

blue/white-any other coupler terminal
ECU coupler "1" blue/black-any other coupler terminal
yellow/black-any other coupler terminal
Joint coupler "2"
white-any other coupler terminal
blue/white-any other coupler terminal
ABS ECU coupler "5"
blue/black-any other coupler terminal

ffil
'*
1 -- -- - ------- - ------- - ------- - - -,
'
' =-=:-r.== '

5 ---
''
IA ~ II,\''
\' :
l@w,] LIelwJvliB a ' '
'· ~~~~~~~~·
.
A
~ -- ' ~

~--------~'
' ''
''

................''
,...........................I ~
' '
I
I I JI 11 I I:·crfi·iJttfii
• MT09M/MT09MC
•• MT09SPM/MT09SPMC

9-253
 90_ABS

Is resistance ~ O?
YES
➔ Go to step 3.
NO
➔ Replace the wire harness.

3. Defective ECU
• Replace the ECU, and check again.
4. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.

9-254
 91_ABS

..91.,.,.,,_ABS
EAS3:l301
TROUBLESHOOTING
Item
CAN communication (between IMU and hydraulic unit assembly)

Procedure
1. Defective coupler between the IMU and the hydraulic unit assembly
• Check the coupler for any pins that may be pulled out.
• Check the locking condition of the coupler.
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Turn the main switch to "OFF" before disconnecting or connecting a coupler.

Is check result OK?

YES
➔ Go to step 2.
NO
➔ If there is a malfunction, repair it and connect the coupler securely.

2. Wire harness continuity.

• Disconnect the IMU coupler "1" and ABS ECU coupler "3".
• Remove the joint coupler cap "2".
• Open circuit check
blue/white-blue/white
Between IMU coupler "1" and joint coupler "2"
blue/black-blue/black
Between joint coupler "2" and ABS ECU coupler blue/white-blue/white
"3" blue/black-blue/black

~
L - - - - --iQ I - -- - - '

11111 111 :@ ~ imi:,

9-255
 91_ABS

Is resistance 0 O?
YES
➔ Go to "Short circuit check".
NO
➔ Replace the wire harness.
• Short circuit check
TIP_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Disconnect the ABS ECU related connectors before checking.
Refer to "PARTS CONNECTED TO THE ABS ECU" on page 9-4.
Ground short circuit check "A"
blue/white-ground
Between IMU coupler "1" and ground
blue/black-ground
blue/white-ground
Between ABS ECU coupler "3" and ground
blue/black-ground

Lines short circuit check "B"

blue/white-any other coupler terminal
IMU coupler "1"
blue/black-any other coupler terminal
blue/white-any other coupler terminal
Joint coupler "2"
blue/black-any other coupler terminal
blue/white-any other coupler terminal
ABS ECU coupler "3"
blue/black-any other coupler terminal

1
Im

,, 1
' Ill'. U,
'
' ,.,. •
r,,
'""' ~

n .......!'
~◄ - - - ~
' '
I

''
'

...........
.
~
............._
~

.......................

~
3 3

i ~[t,il~ ~ i rn!"iffi!_wni,U
'' ~~~~~~~~ ·'
I I

~----
... --~

Is resistance ~ O?
YES
➔ Go to step 3.
NO
➔ Replace the wire harness.
3. Defective IMU
• Replace the IMU, and check again.

9-256
 91_ABS

4. Defective hydraulic unit assembly

• Replace the hydraulic unit assembly.

9-257
EA"""81 57. Front wheel sensor A. Wire harness
WIRING DIAGRAM 58. Rear wheel sensor B. Sub-wire harness (Oil pressure
59. IMU (Inertial Measurement swttch)
MT 09M/MT09MC 2021
Unit)
1. AC magneto
60. Purge cut valve solenoid (for
2. Rectifier/regulator
MT09MC)
3. Fuse box
61. Shift sensor
4. Mainfuse
62. YDT coupler
5. Main switch
63. Meter assembly
6. Radiator fan motor relay
64. Multi-function meter
7. Fuel injection system fuse
65. Neutral indicator light
8. Electronic throttle valve fuse
66. Oil pressure and coolant tem-
9. Backup fuse 2
perature warning light
1O. Signaling system fuse
67. Auxiliary system warning light
11. Ignition fuse 2
68. Stability control indicator light
12. Ignition fuse 1
69. Fuel level warning light
13. Headlight fuse
70. MIL (Malfunction indicator light)
14. ABS ECU fuse
71. Turn signal indicator light (left)
15. Terminal fuse 1
72. Turn signal indicator light (right)
16. ABS solenoid fuse
73. Meter light
17. ABS motor fuse
74.ABS warning light
18. Backup fuse 1
75. High beam indicator light
19. Radiator fan motor fuse
76. Oil pressure switch
20. Auxiliary DC jack
77. Rear turn signal light (left)
21. Battery
78. Rear turn signal light (right)
22. Engine ground
79. Front turn signaVposition light
23. Starter relay
(right)
24. Starter motor
80. Front turn signaVposition light
25. Handlebar switch (right)
(left)
26. Front brake light switch
81. Headlight control unit
27. Wheel switch
82. Headlight (low)
28. Stop/run/start swttch
83. Headlight (high)
29. Accelerator position sensor
84. TaiVbrake light
30. Relay unit
85. License plate light
31. Starting circuit cut-off relay
86. Auxiliary light
32. Fuel pump relay
87. Radiator fan motor
33. Neutral switch
88. Rear brake light swttch
34. Sidestand switch
89. Handlebar switch (left)
35. Fuel pump
90. Clutch switch
36.Fuelsender
91. Mode switch
37. Gear position sensor
92. Pass switch
38. Intake air pressure sensor 1
93. Dimmer switch
39. Intake air pressure sensor 2
94. Horn switch
40. 0 2 sensor
95. Hazard switch
41. Crankshaft posttion sensor
96. Turn signal switch
42. Coolant temperature sensor
97.Horn
43. Intake air temperature sensor
44. ECU (Engine Control Unit)
45. Ignition coil #1
46. Spark plug
47. Ignition coil #2
48. Ignition coil #3
~- Injector #1
50. Injector #2
51. Injector #3
52. Grip warmer (left) (OPTION)
53. Grip warmer (right) (OPTION)
54. Throttle position sensor
55. Throttle servo motor
56. ABS ECU (Electronic Control
Unit)
MT 09SPM/MT09SPMC 2021 60. ABS ECU (Electronic Control A. Wire harness
1. AC magneto Unit) B. Sub-wire harness (Oil pressure
2. Rectifier/regulator 61 . Front wheel sensor swttch)
3. Fuse box 62. Rear wheel sensor
4. Mainfuse 63. IMU (Inertial Measurement
5. Main switch Unit)
6. Radiator fan motor relay 64. Purge cut valve solenoid (for
7. Fuel injection system fuse MT09SPMC)
8. Electronic throttle valve fuse 65. Shift sensor
9. Backup fuse 2 66. YDT coupler
10. Signaling system fuse 67. Meter assembly
11. Ignition fuse 2 68. Multi-function meter
12. Ignition fuse 1 69. Neutral indicator light
13. Headlight fuse 70. Oil pressure and coolant tem-
14. ABS ECU fuse perature warning light
15. Terminal fuse 1 71. Auxiliary system warning light
16. Brake light fuse 72. Stability control indicator light
17. Cruise control fuse 73. Fuel level warning light
18. ABS solenoid fuse 74. MIL (Malfunction indicator light)
19. ABS motor fuse 75. Turn signal indicator light (left)
20. Backup fuse 1 76. Turn signal indicator light (right)
21. Radiator fan motor fuse 77. Cruise control system indicator
22, Auxiliary DC jack light
23. Battery 78. Cruise control setting indicator
24. Engine ground light
25. Starter relay 79. Meter light
26. Starter motor 80. ABS warning light
27. Clutch switch 81. High beam indicator light
28. Front brake light switch 82. Oil pressure switch
29. Rear brake light swttch 83. Rear turn signal light (left)
30. Handlebar switch (right) 84. Rear turn signal light (right)
31. Wheel switch 85. Front turn signaVposition light
32. Stop/run/start swttch (right)
33. Accelerator position sensor 86. Front turn signaVposition light
34. Relay unit (left)
35. Starting circuit cut-off relay 87. Headlight control unit
36. Fuel pump relay 88. Headlight (low)
37. Neutral switch 89. Headlight (high)
38. Sidestand switch 90. TaiVbrake light
39. Fuel pump 91. License plate light
40.Fuelsender 92. Auxiliary light
41. Gear position sensor 93. Radiator fan motor
42. Intake air pressure sensor 1 94. Brake light relay
43. Intake air pressure sensor 2 95. Handlebar switch (left)
44. 02 sensor 96. Cruise control power switch
45. Crankshaft posttion sensor 97. Cruise control setting switch
46. Coolant temperature sensor 98. Dimmer/pass switch
47. Intake air temperature sensor 99. Horn switch
48. ECU (Engine Control Unit) 100.Mode switch
49. Ignition coil #1 101.Select swttch
50. Spark plug 102.Hazard switch
51. Ignition coil #2 103.Turn signal switch
52. Ignition coil #3 104.Horn
53. Injector #1
54. Injector #2
55. Injector #3
56. Grip warmer (left) (OPTION)
57. Grip warmer (right) (OPTION)
58. Throttle position sensor
59. Throttle servo motor
EAS3Cl613
COLOR CODE
B Black
Br Brown
Dgy Dark gray
G Green
Gy Gray
L Blue
Lg Light green
0 Orange
p Pink
R Red
Sb Sky blue
V Violet
w White
y Yellow
B/L Black/Blue
B/W Black/White
B/Y Black/Yellow
Br/B Brown/Black
Br/L Brown/Blue
Br/W Brown/White
Br/Y Brown/Yellow
GIB Green/Black
GIL Green/Blue
G/0 Green/Orange
G!W Green/White
G/Y Green/Yellow
Gy/G Gray/Green
Gy/R Gray/Red
L./B Blue/Black
UiR Blue/Red
uw Blue/White
UY Blue/Yellow
Lg/B Light green/Black
Lg/L Light green/Blue
Lg/R Light green/Red
0 /G Orange/Green
ONJ Orange/White
P/ B Pink/Black
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 IG White/Green
W/L White/Blue
W/R White/Red
WN WhiteNellow
Y/B Yellow/Black
Y/L Yellow/Blue
Y/R Yellow/Red
Y/W Yellow/White
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