2014
SERVICE MANUAL
FZ09E
FZ09EC
LIT-11616-27-39 1RC-28197-10
EAS20050
FZ09E
FZ09EC
SERVICE MANUAL
©2013 by Yamaha Motor Corporation, U.S.A.
First edition, August 2013
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-11616-27-39
EAS20071
TIP
WARNING
IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one 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.
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 vehicle will operate as designed. If there is any question about a service procedure, it is imperative that you
contact a Yamaha dealer for any service information changes that apply to this model. This policy is
intended to provide the customer with the most satisfaction from his vehicle and to conform to federal
environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
• This Service Manual contains information regarding periodic maintenance to the emission control system. Please read this material carefully.
• Designs and specifications are subject to change without notice.
EAS20081
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
result in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid
damage to the vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
EAS20091
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disassembly 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 sequentially.
EAS20101
TIP
G
M
BF
B
T
R
.
.
LS
M
S
LT
E
New
S
SYMBOLS
The following symbols are used in this manual for easier understanding.
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
Serviceable with engine mounted Gear oil
Filling fluid Molybdenum disulfide oil
Lubricant Brake fluid
Special tool Wheel bearing grease
Tightening torque Lithium-soap-based grease
Wear limit, clearance Molybdenum disulfide grease
Engine speed Silicone grease
Electrical data Apply locking agent (LOCTITE®).
Engine oil Replace the part with a new one.
Silicone fluid
EAS20110
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
CHASSIS
1
2
3
4
ENGINE
COOLING SYSTEM
FUEL SYSTEM
ELECTRICAL SYSTEM
TROUBLESHOOTING
5
6
7
8
9
GENERAL INFORMATION
IDENTIFICATION..............................................................................................1-1
VEHICLE IDENTIFICATION NUMBER ......................................................1-1
MODEL LABEL...........................................................................................1-1
FEATURES .......................................................................................................1-2
OUTLINE OF THE FI SYSTEM ..................................................................1-2
FI SYSTEM.................................................................................................1-3
INSTRUMENT FUNCTIONS ......................................................................1-4
YCC-T (Yamaha Chip Controlled Throttle) .................................................1-9
IMPORTANT INFORMATION.........................................................................1-11
PREPARATION FOR REMOVAL AND DISASSEMBLY..........................1-11
REPLACEMENT PARTS..........................................................................1-11
GASKETS, OIL SEALS AND O-RINGS ...................................................1-11
LOCK WASHERS/PLATES AND COTTER PINS ....................................1-11
BEARINGS AND OIL SEALS ...................................................................1-11
CIRCLIPS .................................................................................................1-12
RUBBER PARTS......................................................................................1-12
1
2
3
4
BASIC SERVICE INFORMATION ..................................................................1-13
QUICK FASTENERS................................................................................1-13
ELECTRICAL SYSTEM............................................................................1-13
SPECIAL TOOLS ...........................................................................................1-18
5
6
7
8
9
EAS20130
1
1
IDENTIFICATION
EAS20140
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1” is stamped
into the right side of the steering head pipe.
EAS20150
MODEL LABEL
The model label “1” is affixed to the frame. This
information will be needed to order spare parts.
IDENTIFICATION
1-1
FEATURES
1 2 3, 4, 5, 6 7 8 9
10111213
1415, 16
17
EAS20170
FEATURES
EAS1RC1101
OUTLINE OF THE FI SYSTEM
The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum
air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In
the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion
chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the
respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that meter the
fuel through the use of jets have been provided with various auxiliary devices, so that an optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the engine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases increase,
it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accommodate this need, this model has adopted an electronically controlled fuel injection (FI) system, in place
of the conventional carburetor system. This system can achieve an optimum air-fuel ratio required by
the engine at all times by using a microprocessor that regulates the fuel injection volume according to
the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine response,
better fuel economy, and reduced exhaust emissions.
1. Engine trouble warning light
2. ECU (engine control unit)
3. Throttle position sensor
4. Accelerator position sensor
5. Intake air pressure sensors
6. Throttle servo motor
7. Fuel pump
8. Lean angle sensor
9. Battery
10.Speed sensor
11.O
sensor
2
12.Crankshaft position sensor
13.Coolant temperature sensor
14.Injectors
15.Ignition coils
16.Spark plugs
17.Intake air temperature sensor
1-2
FEATURES
1
15
B
14
13
12
11
16
9
A
2
3
C
6
54
7
8
#2#1 #3
10
EAS1RC1102
FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the
fuel pressure that is applied to the fuel injector at a certain level. Accordingly, when the energizing signal
from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into
the intake manifold only during the time the passage remain open.
Therefore, the longer the length of time the fuel injector is energized (injection duration), the greater the
volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is energized
(injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from the
throttle position sensor, accelerator position sensor, coolant temperature sensor, lean angle sensor,
crankshaft position sensor, intake air pressure sensor, intake air temperature sensor, speed sensor and
O
sensor enable the ECU to determine the injection duration. The injection timing is determined
2
through the signals from the crankshaft position sensor. As a result, the volume of fuel that is required
by the engine can be supplied at all times in accordance with the driving conditions.
Illustration is for reference only.
1. Fuel pump
2. Injector
3. ECU (engine control unit)
4. Throttle position sensor
5. Accelerator position sensor
6. Speed sensor
7. Lean angle sensor
8. Intake air temperature sensor
9. O
sensor
2
10.Catalytic converter
11.Coolant temperature sensor
12.Crankshaft position sensor
13.Intake air pressure sensor
14.Throttle body
15.Air filter case
16.Throttle servo motor
A. Fuel system
B. Air system
C. Control system
1-3
FEATURES
WARNING
TIP
NOTICE
21
1
2 3 4
5
6,789
21
1
EAS1RC1103
INSTRUMENT FUNCTIONS
Multi-function meter unit
1. “SELECT” button
2. “RESET” button
• a self-diagnosis device
• a brightness control mode
• Be sure to turn the key to “ON” before using the
“SELECT” and “RESET” buttons.
• To switch the speedometer and multi-function
displays between kilometers and miles, press
the “SELECT” button for at least one second.
Tachometer
1. Tachometer
2. Tachometer red zone
1. Transmission gear display
2. Tachometer
3. Drive mode display
4. Fuel meter
5. Eco indicator “ECO”
6. Multi-function display
7. Self-diagnosis device
8. Clock
9. Speedometer
EWA12423
Be sure to stop the vehicle before making
any setting changes to the multi-function
meter unit. Changing settings while riding
can distract the operator and increase the
risk of an accident.
The multi-function meter unit is equipped with
the following:
• a speedometer
• a tachometer
• a clock
• a fuel meter
• an eco indicator
• a transmission gear display
• a drive mode display (which shows the select-
ed drive mode)
• a multi-function display
The tachometer allows the rider to monitor the
engine speed and keep it within the ideal power
range.
When the key is turned to “ON”, the tachometer
will sweep across the r/min range and then return to zero r/min in order to test the electrical circuit.
ECA10032
Do not operate the engine in the tachometer
red zone.
Red zone: 11250 r/min and above
Clock
1. Clock
The clock displays when the key is turned to
“ON”. In addition, the clock can be displayed for
10 seconds by pushing the “SELECT” button
when the main switch is in the “OFF”, “LOCK” or
“ ” position.
1-4
FEATURES
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1 2
1
1 2
1
To set the clock
1. Turn the key to “ON”.
2. Push the “SELECT” button and “RESET” button together for at least two seconds.
3. When the hour digits start flashing, push the
“RESET” button to set the hours.
4. Push the “SELECT” button, and the minute
digits will start flashing.
5. Push the “RESET” button to set the minutes.
6. Push the “SELECT” button and then release
it to start the clock.
Fuel meter
1. Fuel meter
2. Fuel level warning indicator “ ”
The fuel meter indicates the amount of fuel in the
fuel tank. The display segments of the fuel meter
disappear towards “E” (Empty) as the fuel level
decreases. When the last segment and fuel level
warning indicator “ ” start flashing, refuel as
soon as possible.
This indicator comes on when the vehicle is being operated in an environmentally friendly, fuel-efficient manner. The indicator goes off when
the vehicle is stopped.
Consider the following tips to reduce fuel consumption:
• Avoid high engine speeds during acceleration.
• Travel at a constant speed.
• Select the transmission gear that is appropri-
ate for the vehicle speed.
Transmission gear display
1. Transmission gear display
2. Neutral indicator light “ ”
This display shows the selected gear. The neutral position is indicated by “ ” and by the neutral
indicator light.
Drive mode display
This fuel meter is equipped with a self-diagnosis
system. If a problem is detected in the electrical
circuit, the following cycle is repeated until the
malfunction is corrected: fuel level segments
and fuel level warning indicator “ ” flash eight
times, then go off for approximately 3 seconds.
(Refer to “CHECKING THE FUEL METER/FUEL LEVEL WARNING LIGHT” on page 8-105.)
Eco indicator
1. Eco indicator “ECO”
1. Drive mode display
This display indicates which drive mode has
been selected: “STD”, “A” or “B”. For more details on the modes and on how to select them,
refer to “D-mode (drive mode)” on page 1-8.
1-5
FEATURES
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1
1
Multi-function display
1. Multi-function display
The multi-function display is equipped with the
following:
• an odometer
• two tripmeters (which show the distance trav-
eled since they were last set to zero)
• a fuel reserve tripmeter (which shows the dis-
tance traveled since the left segment of the fuel
meter started flashing)
• a coolant temperature display
• an air intake temperature display
• an instantaneous fuel consumption display
• an average fuel consumption display
Push the “SELECT” button to switch the display
between the instantaneous fuel consumption
mode “km/L”, “L/100 km” or “MPG”, average fuel
consumption mode “AVE_ _._ km/L”, “AVE_ _._
L/100 km” or “AVE_ _._ MPG”, coolant temperature mode “F”, air intake temperature mode
“Air_ _ F”, odometer mode “ODO”, and tripmeter modes “TRIP 1” and “TRIP 2” in the following
order:
km/L, L/100 km or MPG AVE_ _._ km/L,
AVE_ _._ L/100 km or AVE_ _._ MPG F
Air_ _ F ODO TRIP 1 TRIP 2
Push the “RESET” button to switch the display in
the reverse order.
km/L, AVE_ _._ L/100 km or AVE_ _._ MPG
F Air_ _ F ODO TRIP 1 TRIP 2
F-TRIP
To reset a tripmeter, select it by pushing the “SELECT” button, and then push the “RESET” button for at least one second.
If you do not reset the fuel reserve tripmeter
manually, it resets itself automatically and the
display returns to the prior mode after refueling
and traveling 5 km (3 mi).
Instantaneous fuel consumption display
1. Instantaneous fuel consumption display
The instantaneous fuel consumption display can
be set to either “km/L”, “L/100 km” or “MPG”.
• “km/L”: The distance that can be traveled on
1.0 L of fuel under the current riding conditions
is shown.
• “L/100 km”: The amount of fuel necessary to
travel 100 km under the current riding conditions is shown.
• “MPG”: The distance that can be traveled on
1.0 US gal of fuel under the current riding conditions is shown.
To switch between the instantaneous fuel consumption displays, push the “SELECT” button
for one second when one of the displays is
shown.
If traveling at speeds under 20 km/h (12 mi/h), “_
_._” is displayed.
If the fuel level warning indicator “ ” and left
segment of the fuel meter start flashing, the display automatically changes to the fuel reserve
tripmeter mode “F-TRIP” and starts counting the
distance traveled from that point. In that case,
push the “SELECT” button to switch the display
between the various tripmeter, odometer, instantaneous fuel consumption and average fuel
consumption modes in the following order:
F-TRIP km/L, L/100 km or MPG AVE_ _._
1-6
Average fuel consumption mode
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1
1
1
1 2
1. Average fuel consumption display
The average fuel consumption display can be
set to either “AVE_ _._ km/L”, “AVE_ _._ L/100
km” or “AVE_ _._ MPG”.
This display shows the average fuel consumption since it was last reset.
• “AVE_ _._ km/L”: The average distance that
can be traveled on 1.0 L of fuel is shown.
• “AVE_ _._ L/100 km”: The average amount of
fuel necessary to travel 100 km is shown.
• “AVE_ _._ MPG”: The average distance that
can be traveled on 1.0 US gal of fuel is shown.
To switch between the average fuel consumption displays, push the “SELECT” button for one
second when one of the displays is shown.
To reset the average fuel consumption display,
select it by pushing the “SELECT” button, and
then push the “RESET” button for at least one
second.
FEATURES
• When the coolant temperature is below 104 F,
“LO” will be displayed.
• The coolant temperature varies with changes
in the weather and engine load.
Air intake temperature display
1. Air intake temperature display
The air intake temperature display indicates the
temperature of the air drawn into the air filter
case.
This display shows the air intake temperature
from 14 F to 210 F in 1 F increments.
• 14 F will be displayed even if the air intake
temperature falls below 14 F.
• The air intake temperature may vary from the
ambient temperature.
Self-diagnosis device
After resetting an average fuel consumption display, “_ _._” is shown for that display until the vehicle has traveled 1 km (0.6 mi).
Coolant temperature display
1. Coolant temperature display
This display shows the coolant temperature from
104 F to 242 F in 1 F increments.
If the message “HI” flashes, stop the vehicle,
then stop the engine, and let the engine cool.
1. Error code display
2. Engine trouble warning light “ ”
This model is equipped with a self-diagnosis device for various electrical circuits.
If a problem is detected in any of those circuits,
the engine trouble warning light will come on and
the display will indicate an error code.
If the display indicates any error codes, note the
code number, and then check the fuel injection
system. (Refer to “FUEL INJECTION SYSTEM”
on page 8-31.)
1-7
FEATURES
NOTICE
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1
1
ECA11591
If the display indicates an error code, the vehicle should be checked as soon as possible
in order to avoid engine damage.
Brightness control mode
1. Brightness level display
This function allows you to adjust the brightness
of the multi-function meter unit panel to suit the
outside lighting conditions.
To adjust the brightness
1. Turn the key to “OFF”.
2. While pushing the “SELECT” button, turn the
key to “ON” and continue pushing the button
until the display switches to the brightness
control mode.
3. Push the “RESET” button to set the brightness level.
4. Push the “SELECT” button to return to the
original display.
D-mode (drive mode)
D-mode is an electronically controlled engine
performance system with three mode selections
(“STD”, “A”, and “B”).
Push the drive mode switch “MODE” to switch
between modes.
the drive mode switch.
Mode “STD”
Mode “STD” is suitable for various riding conditions.
This mode allows the rider to enjoy smooth and
sporty drivability from the low-speed range to the
high-speed range.
Mode “A”
Mode “A” offers a sportier engine response in
the low- to mid-speed range compared to mode
“STD”.
Mode “B”
Mode “B” offers response that is somewhat less
sharp compared to mode “STD” for riding situations that require especially sensitive throttle operation.
1. Drive mode switch “MODE”
Before using D-mode, make sure you understand its operation along with the operation of
1-8
FEATURES
1
2
3
4
EAS1RC1109
YCC-T (Yamaha Chip Controlled Throttle)
Mechanism characteristics
Yamaha developed the YCC-T system employing the most advanced electronic control technologies.
Electronic control throttle systems have been used on automobiles, but Yamaha has developed a faster, more compact system specifically for the needs of a sports motorcycle. The Yamaha-developed
system has a high-speed calculating capacity that produces computations of running conditions every
1/1000th of a second.
The YCC-T system is designed to respond to the throttle action of the rider by having the ECU instantaneously calculate the ideal throttle valve opening and generate signals to operate the motor-driven
throttle valves and thus actively control the intake air volume.
The ECU contains two CPUs with a capacity about five times that of conventional units, making it possible for the system to respond extremely quickly to the slightest adjustments made by the rider. In particular, optimized control of the throttle valve opening provides the optimum volume of intake air for
easy-to-use torque, even in a high-revving engine.
Aims and advantages of using YCC-T
• Increased engine power
By shortening the air intake path, higher engine speed is possible Increased engine power.
• Improved driveability
Air intake volume is controlled according to the operating conditions Improved throttle response to
meet engine requirement.
Driving force is controlled at the optimal level according to the transmission gear position and engine
speed Improved throttle control.
• Engine braking control
Due to the throttle control, optimal engine braking is made possible.
• Simplified idle speed control (ISC) mechanism
The bypass mechanism and ISC actuator are eliminated A simple mechanism is used to maintain
a steady idle speed.
• Reduced weight
Compared to using a sub-throttle mechanism, weight is reduced.
1. Accelerator position sensor
2. Throttle servo motor
3. Throttle position sensor
4. Throttle valves
1-9
YCC-T system outline
5
6
7
8
9
3
2
1
4
FEATURES
1. Throttle position sensor
2. Throttle servo motor
3. Accelerator position sensor
4. ECU (engine control unit)
5. Sensor input
6. Gear position sensor
7. Crankshaft position sensor
8. Speed sensor
9. Coolant temperature sensor
1-10
EAS20180
IMPORTANT INFORMATION
EAS20190
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning equipment.
Refer to “SPECIAL TOOLS” on page 1-18.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders,
pistons and other parts that have been “mated” through normal wear. Mated parts must
always be reused or replaced as an assembly.
IMPORTANT INFORMATION
EAS20210
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.
4. During disassembly, clean all of the parts and
place them in trays in the order of disassembly. This will speed up assembly and allow for
the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS20200
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replacements. 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. Oil
2. Lip
3. Spring
4. Grease
EAS20220
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
“1” and cotter pins. After the bolt or nut has been
tightened to specification, bend the lock tabs
along a flat of the bolt or nut.
EAS20231
BEARINGS AND OIL SEALS
Install bearings “1” and oil seals “2” so that the
1-11
IMPORTANT INFORMATION
NOTICE
manufacturer marks or numbers are visible.
When installing oil seals, lubricate the oil seal
lips with a light coat of lithium-soap-based
grease. Oil bearings liberally when installing, if
appropriate.
ECA13300
Do not spin the bearing with compressed air
because this will damage the bearing surfaces.
low any items other than the specified one to
contact the parts.
EAS20240
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Always 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.
EAS32080
RUBBER PARTS
Check rubber parts for deterioration during inspection. Some of the rubber parts are sensitive
to gasoline, flammable oil, grease, etc. Do not al-
1-12
EAS30380
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NOTICE
BASIC SERVICE INFORMATION
EAS30390
QUICK FASTENERS
Rivet type
1. Remove:
• Quick fastener
To remove the quick fastener, push its pin with a
screwdriver, then pull the fastener out.
BASIC SERVICE INFORMATION
2. Install:
• Quick fastener
To install the quick fastener, insert the fastener
into the part to be secured and tighten the screw
“a”.
2. Install:
• Quick fastener
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.
EAS30401
ELECTRICAL SYSTEM
Electrical parts handling
ECA16600
Never disconnect a battery lead while the engine is running; otherwise, the electrical
components could be damaged.
Screw type
1. Remove:
• Quick fastener
To remove the quick fastener, loosen the screw
with a screwdriver, then pull the fastener out.
ECA16750
When disconnecting the battery leads from
1-13
BASIC SERVICE INFORMATION
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NOTICE
NOTICE
NOTICE
NOTICE
NOTICE
the battery, be sure to disconnect the negative battery lead first, then the positive battery lead. If a tool or similar item contacts the
vehicle while only the negative battery lead
is connected, a spark could be generated,
which is extremely dangerous.
If a battery lead is difficult to disconnect due to
rust on the battery terminal, remove the rust using hot water.
while only the negative battery lead is connected, a spark could be generated, which is
extremely dangerous.
ECA16610
Turn the main switch to “OFF” before disconnecting or connecting an electrical component.
ECA16760
Be sure to connect the battery leads to the
correct battery terminals. Reversing the battery lead connections could damage the
electrical components.
ECA16770
When connecting the battery leads to the
battery, be sure to connect the positive battery lead first, then the negative battery lead.
If a tool or similar item contacts the vehicle
ECA16620
Handle electrical components with special
care, and do not subject them to strong
shocks.
ECA16630
Electrical components are very sensitive to
and can be damaged by static electricity.
Therefore, never touch the terminals and be
sure to keep the contacts clean.
1-14
TIP
When resetting the ECU by turning the main
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NOTICE
NOTICE
NOTICE
a
switch to “OFF”, be sure to wait approximately
5 seconds before turning the main switch back
to “ON”.
BASIC SERVICE INFORMATION
ECA16640
For waterproof couplers, never insert the
tester probes directly into the coupler. When
performing any checks using a waterproof
coupler, use the specified test harness or a
suitable commercially available test harness.
Checking the electrical system
Before checking the electrical system, make
sure that the battery voltage is at least 12 V.
ECA14371
Never insert the tester probes into the coupler terminal slots. Always insert the probes
from the opposite end “a” of the coupler, taking care not to loosen or damage the leads.
Checking the connections
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
• Lead
• Coupler
• Connector
ECA16780
• When disconnecting a coupler, release the
coupler lock, hold both sections of the coupler securely, and then disconnect the coupler.
• There are many types of coupler locks;
therefore, be sure to check the type of coupler lock before disconnecting the coupler.
1-15
NOTICE
ECA16790
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When disconnecting a connector, do not pull
the leads. Hold both sections of the connector securely, and then disconnect the connector.
BASIC SERVICE INFORMATION
• Make sure all connections are tight.
2. Check:
• Lead
• Coupler
• Connector
Moisture Dry with an air blower.
Rust/stains Connect and disconnect several times.
4. Check:
• Continuity
(with the pocket tester)
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (3).
• As a quick remedy, use a contact revitalizer
available at most part stores.
3. Connect:
• Lead
• Coupler
• Connector
• When connecting a coupler or connector, push
both sections of the coupler or connector together until they are connected securely.
1-16
5. Check:
TIP
• Resistance
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
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
will be shown.
BASIC SERVICE INFORMATION
Intake air temperature sensor resistance
5.40–6.60 k at 0 C (32 F)
290–390 at 80 C (176 F)
1-17
SPECIAL TOOLS
TIP
YU-01304
YU-24460-A
YU-33984
EAS20260
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
• For others, use part number starting with “90890-”.
Tool name/Tool No. Illustration
Ring nut wrench
90890-01268
Spanner wrench
YU-01268
Piston pin puller set
90890-01304
Piston pin puller
YU-01304
Radiator cap tester
90890-01325
Mityvac cooling system tester kit
YU-24460-A
Reference
pages
4-61
5-61
6-2
Radiator cap tester adapter
90890-01352
Pressure tester adapter
YU-33984
6-2
1-18
SPECIAL TOOLS
YM-A8703
Tool name/Tool No. Illustration
Flywheel puller
90890-01362
Heavy duty puller
YU-33270-B
Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472
Damper rod holder
90890-01423
Damping rod holder
YM-01423
Oil filter wrench
90890-01426
YU-38411
Reference
pages
5-32
3-18, 4-61
4-52, 4-53
3-23
Rod holder
90890-01434
Damper rod holder double ended
YM-01434
Rod puller attachment (M10)
90890-01436
Universal damping rod bleeding tool set
YM-A8703
4-51, 4-56,
4-57
4-55, 4-56,
4-57
1-19
SPECIAL TOOLS
YM-A8703
Tool name/Tool No. Illustration
Rod puller
90890-01437
Universal damping rod bleeding tool set
YM-A8703
Fork spring compressor
90890-01441
YM-01441
Fork seal driver
90890-01442
Adjustable fork seal driver (36–46 mm)
YM-01442
Reference
pages
4-55, 4-56,
4-57
4-51, 4-56,
4-57
4-54, 4-55
Pivot shaft wrench adapter
90890-01476
Pivot shaft wrench
90890-01485
Frame mount insert wrench
YM-01485
Pivot shaft wrench
90890-01518
Frame spanner socket
YM-01518
Drive chain cut & rivet tool
90890-01550
YM-01550
5-7, 5-8
5-7
5-7, 5-8
4-71, 4-73
1-20
SPECIAL TOOLS
YU-44456
Tool name/Tool No. Illustration
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
Compression gauge
90890-03081
Engine compression tester
YU-33223
Vacuum gauge
90890-03094
Vacuummate
YU-44456
Reference
pages
5-32, 5-33
5-1
3-8
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Oil pressure adapter H
90890-03139
Pressure gauge
90890-03153
YU-03153
Carburetor angle driver 2
90890-03173
1-16, 1-17,
8-91, 8-92,
8-93, 8-97,
8-98, 8-99,
8-100, 8-101,
8-103, 8-104,
8-105, 8-106,
8-107, 8-108,
8-110, 8-111
3-24
3-24, 7-11
3-9
1-21
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