2016

SUPPLEMENTARY
SERVICE MANUAL

MTM660

B34-F8197-E1
EAS20236

FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
MTM660 2016. For complete service information procedures it is necessary to use this Supplementary
Service Manual together with the following manual.
MTM690/MTM690-U 2016 SERVICE MANUAL: B34-F8197-E0

EAS20002

MTM660 2016
SUPPLEMENTARY SERVICE MANUAL
©2015 by MBK Industrie
First edition, November 2015
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
MBK Industrie
is expressly prohibited.
EAS20003

IMPORTANT
This manual was produced by MBK Industrie. 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, any-
one 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 mainte-
nance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit
for use.
Yamaha Motor Company, Ltd. and MBK Industrie are 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.
TIP
Designs and specifications are subject to change without notice.

EAS30001

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential person-
al injury hazards. Obey all safety messages that follow this symbol to
avoid possible injury or death.

A WARNING indicates a hazardous situation which, if not avoided, could

WARNING result in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid

NOTICE damage to the vehicle or other property.

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

EAS20004

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc. 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.

3
4

5
2

6 7
EAS20005

SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.

SYMBOL DEFINITION SYMBOL DEFINITION

Serviceable with engine mounted Gear oil

G

Filling fluid Molybdenum disulfide oil

M

Lubricant Brake fluid

BF

Special tool B Wheel bearing grease

Tightening torque LS Lithium-soap-based grease

T.
R.

Wear limit, clearance M Molybdenum disulfide grease

Engine speed S Silicone grease

Electrical data Apply locking agent (LOCTITE®).

LT

Engine oil New Replace the part with a new one.

E

Silicone fluid
S
EAS10003

TABLE OF CONTENTS
FEATURES......................................................................................................... 1
MULTI-FUNCTION METER UNIT ................................................................ 1

GENERAL SPECIFICATIONS ........................................................................... 6

ENGINE SPECIFICATIONS ............................................................................... 7

CHASSIS SPECIFICATIONS ............................................................................. 8

CABLE ROUTING .............................................................................................. 9

PERIODIC MAINTENANCE ............................................................................. 23

CHECKING THE TIRES............................................................................. 23

ENGINE INSPECTION ..................................................................................... 25

MEASURE THE COMPRESSION PRESSURE......................................... 25

ELECTRIC STARTER ...................................................................................... 27

INSTALLING THE STARTER MOTOR ...................................................... 28

CONNECTING RODS AND PISTONS ............................................................. 29

REMOVING THE CONNECTING RODS AND PISTONS.......................... 31
CHECKING THE CYLINDER AND PISTON .............................................. 31
CHECKING THE PISTON RINGS.............................................................. 32
INSTALLING THE CONNECTING ROD AND PISTON ............................. 33

THERMOSTAT ................................................................................................. 37

FUEL TANK...................................................................................................... 38
REMOVING THE FUEL TANK ................................................................... 40
REMOVING THE FUEL PUMP .................................................................. 40
CHECKING THE FUEL PUMP BODY........................................................ 40
INSTALLING THE FUEL PUMP................................................................. 40
INSTALLING THE DAMPERS.................................................................... 41
INSTALLING THE FUEL TANK BRACKET................................................ 41
INSTALLING THE FUEL TANK.................................................................. 41

THROTTLE BODIES ........................................................................................ 43

FUEL INJECTION SYSTEM............................................................................. 45

TROUBLESHOOTING DETAILS (FAULT CODE) ..................................... 45
 FEATURES

EAS20008

FEATURES TIP
Except when switching to the brightness control
EAS30982

MULTI-FUNCTION METER UNIT mode or to display the clock, turn the key to “ON”
before using the bottom and top set buttons.

1
Speedometer
The speedometer shows the vehicle’s traveling
2 4 speed.

3 Tachometer
5

6
2
1. Transmission gear display
2. Tachometer 1
3. Eco indicator “ECO”
4. Speedometer
5. Multi-function display
6. Fuel meter

1. Tachometer
2. Tachometer red zone
The tachometer allows the rider to monitor the
engine speed and keep it within the ideal power
range.
ECA19660

1 NOTICE
Do not operate the engine in the tachometer
2 red zone.
1. Top set button
2. Bottom set button Red zone
10000 r/min and above
EWA17650

WARNING
Fuel meter
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 1
• a tachometer 1
• a fuel meter 2
• an eco indicator 1. Frame
• a transmission gear display 2. Fuel meter
• a multi-function display
The fuel meter indicates the amount of fuel in the
fuel tank. The display segments of the fuel meter
disappear from “F” (full tank) towards “E” (empty

–1–
 FEATURES

tank) as the fuel level decreases. When the last This display shows the selected gear. The neu-
segment and frame start flashing, refuel as soon tral position is indicated by “–” and by the neutral
as possible. indicator light.
TIP
This fuel meter is equipped with a self-diagnosis Multi-function display
system. If a problem is detected in the fuel tank
electrical circuit, the fuel level segments, frame,
and “ ” flash repeatedly. If this occurs, check
the electrical circuit. Refer to “SIGNALING SYS-
TEM” in chapter 8. (Manual No.: B34-F8197-E0)

1
Eco indicator

1. Multi-function display

1 The multi-function display is equipped with the

following:
• an odometer
• two tripmeters
• a fuel reserve tripmeter
• an instantaneous fuel consumption display
1. Eco indicator “ECO” • an average fuel consumption display
• a coolant temperature display
This indicator comes on when the vehicle is be- • an air temperature display
ing operated in an environmentally friendly, fuel- • a clock
efficient manner. The indicator goes off when • a brightness control mode
the vehicle is stopped.
TIP The odometer shows the total distance the vehi-
Consider the following tips to reduce fuel con- cle has traveled.
sumption: The tripmeters show the distance traveled since
• Avoid high engine speeds during acceleration. they were last reset.
• Travel at a constant speed. TIP
• Select the transmission gear that is appropri- • The odometer will lock at 999999 and cannot
ate for the vehicle speed. be reset.
• The tripmeter will reset to 0 and continue
Transmission gear display counting after 9999.9 is reached.
Push the bottom set button to switch the display
1
between odometer “ODO”, tripmeters “TRIP 1”
2 and “TRIP 2”, instantaneous fuel consumption
“km/L” or “L/100 km”, average fuel consumption
“AVE_ _._ km/L” or “AVE_ _._ L/100 km”, cool-
ant temperature “_ _ °C”, ambient temperature
“Air_ _ °C”, and clock “_ _:_ _” in the following or-
der:

ODO → TRIP 1 → TRIP 2 → km/L or L/100 km

1. Neutral indicator light “ ” → AVE_ _._ km/L or AVE_ _._ L/100 km → _ _
2. Transmission gear display °C → Air_ _ °C → Clock _ _:_ _ → ODO

–2–
 FEATURES

TIP To switch the instantaneous fuel consumption

• Push the top set button to switch the display in display settings, push the bottom set button for
the reverse order. two second.
• The fuel reserve tripmeter and error code dis- TIP
plays come on automatically, while the bright- If traveling at speeds under 20 km/h (12 mi/h), “_
ness control mode is accessed separately. _._” is displayed.

If the lower segment and frame of the fuel meter Average fuel consumption
start flashing, the display automatically changes
to fuel reserve tripmeter “TRIP F” and starts
counting the distance traveled from that point. In
this case, push the bottom set button to switch
the display between the various tripmeter,
odometer, and fuel consumption modes in the
following order: 1

TRIP F → km/L or L/100 km → AVE_ _._ km/L

or AVE_ _._ L/100 km → _ _ °C → Air_ _ °C →
Clock _ _:_ _ → ODO → TRIP 1 → TRIP 2 → 1. Average fuel consumption display
TRIP F
This display shows the average fuel consump-
tion since it was last reset.
To reset a tripmeter, select it by pushing the bot-
The average fuel consumption display can be
tom set button, and then push the top set button
set to either “AVE_ _._ km/L”, “AVE_ _._ L/100
for one second.
km”.
If you do not reset the fuel reserve tripmeter
• “AVE_ _._ km/L”: The average distance that
manually, after refueling and traveling 5km (3mi)
can be traveled on 1.0 L of fuel.
it resets automatically and disappears from the
• “AVE_ _._ L/100 km”: The average amount of
display.
fuel necessary to travel 100 km.
Instantaneous fuel consumption • “AVE_ _._ MPG”: The average distance that
can be traveled on 1.0 Imp.gal of fuel.
To switch the average fuel consumption display
settings, push the bottom set button for two sec-
onds.
To reset the average fuel consumption, push the
top set button for one second.
TIP
1
After resetting the average fuel consumption, “_
_._” will be shown until the vehicle has traveled
1 km (0.6 mi).
1. Instantaneous fuel consumption display
The instantaneous fuel consumption display can
be set to either “km/L” or “L/100 km”; or “km/L” or
“L/100 km”.
• “km/L”: The distance that can be traveled on
1.0 L of fuel under current riding conditions.
• “L/100 km”: The amount of fuel necessary to
travel 100 km under current riding.
• “MPG”: The distance that can be traveled on
1.0 Imp.gal of fuel under current riding condi-
tions.

–3–
 FEATURES

Coolant temperature Clock

1
1

1. Coolant temperature display 1. Clock

This display shows the coolant temperature from The clock displays time in 12-hour format. Even
40 °C to 116 °C in 1 °C increments. when the key is not in the “ON” position, the
If the message “HI” flashes, stop the vehicle, clock can be viewed for 10 seconds by pushing
then stop the engine and let the it cool. the bottom set button.
TIP
• When the coolant temperature is below 40 °C, To set the clock
“Lo” will be displayed. 1. Turn the main switch to “ON”.
• The coolant temperature varies with changes 2. Push the bottom set button and top set button
in the weather and engine load. together for two seconds and the hour digits
will start flashing.
3. Push the top set button to set the hours.
Air temperature 4. Push the bottom set button and the minute
digits will start flashing.
5. Push the top set button to set the minutes.
6. Push the bottom set button to confirm set-
tings and start the clock.
TIP
When setting the hours and minutes, push the
1 top set button briefly to increase the increment
value one by one, or push and hold the button to
increase the increment value continuously.
1. Air temperature display
Brightness control
This display shows the air temperature from –9
°C to 99 °C in 1 °C increments. The temperature
displayed may vary from the actual ambient tem-
perature.
TIP
• When the air temperature is below –9 °C, “Lo”
will be displayed.
• The accuracy of the temperature reading may 1
be affected when riding slowly (under 20 km/h
[12.5 mi/h]) or when stopped at traffic signals,
railroad crossings, etc. 1. Brightness level display
The brightness level of the multi-function meter
unit panel can be adjusted to suit the rider’s pref-
erence.

–4–
 FEATURES

To adjust the brightness

1. Turn the main switch to “OFF”.
2. Push and hold the bottom set button.
3. Turn the main switch to “ON” and continue
pushing the bottom set button until the dis-
play switches to the brightness control mode.
4. Push the top set button to set the brightness
level.
5. Push the bottom set button to confirm the se-
lected brightness level and exit the bright-
ness control mode.
TIP
There are 6 brightness level settings.

–5–
 GENERAL SPECIFICATIONS

EAS20013

GENERAL SPECIFICATIONS
Model
Model B343

–6–
 ENGINE SPECIFICATIONS

EAS20014

ENGINE SPECIFICATIONS
Engine
Displacement 655 cm³
Bore × stroke 78.0 × 68.6 mm (3.07 × 2.70 in)
Compression ratio 11.0 : 1
Compression pressure (#1 cylinder) 630–850 kPa/495 r/min (6.3–8.5 kgf/cm²/495
r/min, 89.6–120.9 psi/495 r/min)
Compression pressure (#2 cylinder) 610–830 kPa/495 r/min (6.1–8.3 kgf/cm²/495
r/min, 86.8–118.1 psi/495 r/min)

Fuel
Recommended fuel Regular unleaded gasoline (Gasohol (E10)
acceptable)
Minimum research octane 90

Cylinder
Bore 78.000–78.010 mm (3.0709–3.0713 in)

Piston
Diameter 77.970–77.985 mm (3.0697–3.0703 in)

Piston ring
Oil ring
End gap (installed) 0.10–0.40 mm (0.0039–0.0157 in)

Throttle body
ID mark 1WS1 30

–7–
 CHASSIS SPECIFICATIONS

EAS20015

CHASSIS SPECIFICATIONS
Front tire
Wear limit (front) 1.5 mm (0.06 in)

Rear tire
Wear limit (rear) 1.5 mm (0.06 in)

–8–
 CABLE ROUTING

EAS20021

CABLE ROUTING
Handlebar (front view)

19 I 18
18
M 13
K L
14
I
J
L K
20
1 2
14 J 5

1 2
3

5
15 4
14 3
13 A 5
F

1 7 11
E 12 6 B 3
14
7 21
D 11
8

22 C
5
6

Q 12 7 P
10
14
11 9
10 L
L K
H
O N

K
7

17
16

11

–9–
 CABLE ROUTING

1. Throttle cable (decelerator cable)

2. Throttle cable (accelerator cable)
3. Clutch cable
4. Clutch switch lead
5. Handlebar switch lead (left handlebar switch)
6. Handlebar switch coupler (left handlebar switch)
7. Wire harness
8. Cable guide
9. Brake hose (hydraulic unit to left front brake
caliper)
10. Front wheel sensor lead
11. Sub-wire harness coupler (headlight, turn signal
light, and auxiliary light)
12. Handlebar switch coupler (right handlebar switch)
13. Brake hose (front brake master cylinder to
hydraulic unit)
14. Handlebar switch lead (right handlebar switch)
15. Front brake light switch lead
16. Front turn signal light lead (right turn signal light)
17. Front turn signal light lead (left turn signal light)
18. Handlebar
19. Front brake master cylinder assembly
20. Clutch lever holder
21. Front fork
22. Coupler cover
A. Insert the projection on the holder into the hole in
the cable guide.
B. Fasten the left handlebar switch coupler to the wire
harness with tape, and then place the coupler in
the coupler cover. Make sure that the wire harness
is positioned to the rear of the coupler.
C. Route the throttle cables through the guide. Be
sure to route the throttle cable (decelerator cable)
over the throttle cable (accelerator cable).
D. Connect the sub-wire harness coupler (headlight,
turn signal light, and auxiliary light), and then insert
the projection on the coupler into the hole in the
cable guide.
E. Position the right handlebar switch coupler to the
rear of the left handlebar switch coupler.
F. Route the throttle cables to the rear of the main
switch.
G. Connect the auxiliary light coupler, and then place
the coupler in the headlight body.
H. To meter assembly
I. Upward
J. Downward
K. Forward
L. Rearward
M. Route the brake hose (front brake master cylinder
to hydraulic unit) through the guide as shown in the
illustration.
N. Outward
O. Inward
P. Bend the wire harness 180° and secure it with
tape.
Q. Connect the right handlebar switch coupler, and
then place the coupler in the coupler cover.

– 10 –
 CABLE ROUTING

ECU and clutch cable (right side view)

D 16

B
15 4
12 3
11 14
12 13
5
6
11
9 10
C 7

13
E
I 8 A

18 F

11 3
E G
19
4

12 H F

12

17

20 18 14
F E

– 11 –
 CABLE ROUTING

1. Throttle cable (accelerator cable)

2. Throttle cable (decelerator cable)
3. Brake hose (front brake master cylinder to
hydraulic unit)
4. Front wheel sensor lead
5. Handlebar switch coupler (left handlebar switch)
6. Handlebar switch coupler (right handlebar switch)
7. Sub-wire harness coupler (headlight, turn signal
light, and auxiliary light)
8. Clutch cable
9. Fuel pump coupler
10. Sub-wire harness coupler
11. Fuel tank breather hose
12. Fuel tank overflow hose
13. Wire harness
14. Intake air temperature sensor coupler
15. Brake hose (hydraulic unit to left front brake
caliper)
16. Meter assembly cover
17. Damper
18. Frame
19. Cylinder head breather hose
20. Sub-wire harness
A. Route the clutch cable through the guide as shown
in the illustration.
B. Fasten the brake hose (hydraulic unit to left front
brake caliper) and front wheel sensor lead with the
holders. Refer to “CABLE ROUTING (Hydraulic
unit assembly (top and right side view))”.
C. Blue paint mark
D. After connecting the meter assembly coupler,
install the coupler cover completely until it contacts
the meter assembly.
E. Inward
F. Outward
G. Forward
H. Rearward
I. Insert the projection on the wire harness holder
into the hole in the frame.

– 12 –
 CABLE ROUTING

Fuel tank breather hose and fuel tank overflow hose (right side view)
1

2
G
12
11

10

F 9
E
8

4 3

11 1 M A
7
D
L K B C B 6 5

M 15 7 6 3

L K

I 14

13
J

– 13 –
 CABLE ROUTING

1. Wire harness
2. Clutch cable
3. Oil pressure switch lead
4. Oil pressure switch
5. O2 sensor
6. O2 sensor lead
7. Rear brake light switch lead
8. Rear brake light switch
9. O2 sensor coupler
10. Rear brake light switch coupler
11. Rear wheel sensor coupler
12. Oil pressure switch connector
13. Fuel tank overflow hose
14. Fuel tank breather hose
15. Rear wheel sensor lead
A. Route the oil pressure switch lead through the
guide, and then secure the lead by bending the
guide around the lead.
B. Route the oil pressure switch lead to the inside of
the O2 sensor lead, and then secure the leads by
bending the guides around the leads.
C. Do not pinch the O2 sensor lead between the pivot
shaft protector and the engine.
D. Fasten the rear brake light switch lead and O2
sensor lead with the holder.
E. To rear brake caliper bracket
F. Connect the O2 sensor coupler, and then insert the
projection on the coupler into the hole in the
bracket.
G. Make sure that the wire harness is not pinched
between the pivot shaft protector (right) and the
frame.
H. Route the wire harness to the inside of the bracket
as shown in the illustration so that the harness
does not contact the air filter case bolt flange.
I. Less than 10 mm (0.39 in). Fasten the hose
protector of each hose with the holder.
J. Make sure that there is no slack in the fuel tank
breather hose and fuel tank overflow hose.
K. Forward
L. Rearward
M. Inward
N. Outward

– 14 –
 CABLE ROUTING

Engine (left side view)

10

E 13
11

12

14

4 15
A 1 B 2 3

1 F
5
H G

10

6
C
16

9 1

8 6

D
7
16 6
7
I

10 11
7
1 17
18 10 11
H
O

G J K
17
H N
P L G
M
8

– 15 –
 CABLE ROUTING

1. Starter motor lead

2. Positive battery sub-wire harness
3. Tail/brake light coupler
4. License plate light coupler
5. Rear turn signal light coupler
6. Engine ground lead
7. Sidestand switch lead
8. Sidestand switch coupler
9. Terminal cover
10. Fuel tank overflow hose
11. Fuel tank breather hose
12. Coolant temperature sensor coupler
13. Gear position switch coupler
14. Battery
15. Battery box
16. Frame
17. Drive sprocket cover
18. Gear position switch lead
A. Fasten the engine ground lead and starter motor
lead to the frame with plastic locking ties. Point the
end of each plastic locking tie rearward, and then
cut off the excess end of the tie to 2 mm (0.08 in) or
less.
B. Make sure that the starter motor lead is not
twisted.
C. Fasten the starter motor lead and engine ground
lead with the holder. Align the white tape on the
starter motor lead with the holder.
D. Make sure that there is no twist in the starter motor
lead and sidestand switch lead.
E. Insert the projection on the coupler into the hole in
the bracket.
F. Fit the starter motor lead between the bottom of
the battery box and the rib on the battery box.
G. Inward
H. Outward
I. Do not pinch the sidestand switch lead between
the engine ground lead and the frame.
J. Forward
K. Rearward
L. Blue paint mark
M. White paint mark
N. 2–3 mm (0.08–0.12 in)
O. Upward
P. Downward

– 16 –
 CABLE ROUTING

Electrical components tray (top view)

D

G F

E
25
26

5
20 4 6 7 8 9 10
N M 11
1 12
13
2 3
4
2
5 1
D
27
14
E L 15

25 K

24 16

24 17 A
23
18
22

19
25
26 I

15 I
21
J F G

C
25
H

G
20
20 D E

F
B
D
19 18
D 19 F G
18 F G
20 20 E
E
25
25

– 17 –
 CABLE ROUTING

1. Rectifier/regulator
2. Headlight relay
3. Turn signal/hazard relay
4. Throttle cable
5. Radiator fan motor relay
6. Relay unit
7. Brake hose (front brake master cylinder to
hydraulic unit)
8. Front wheel sensor lead
9. Brake hose (hydraulic unit to left front brake
caliper)
10. Intake air temperature sensor coupler
11. ABS ECU coupler
12. Hydraulic unit assembly
13. ECU (Engine Control Unit)
14. Immobilizer unit coupler
15. Immobilizer unit lead
16. ECU lead
17. Sub-wire harness coupler
18. Brake hose (hydraulic unit to rear brake caliper)
19. Brake hose (rear brake master cylinder to
hydraulic unit)
20. Wire harness
21. Fuel pump coupler
22. Intake air pressure sensor
23. Intake air pressure sensor coupler
24. Main switch coupler
25. Frame
26. Main switch lead
27. Electrical components tray 1
A. Insert the projection on the bracket into the hole in
the sub-wire harness coupler.
B. White paint mark
C. Insert the projection on the wire harness holder
into the hole in the frame.
D. Forward
E. Rearward
F. Inward
G. Outward
H. Insert the projection on the wire harness holder
into the hole in the frame from the bottom of the
frame.
I. Route the immobilizer unit lead and main switch
lead to the outside of the wire harness.
J. Face the buckle of the plastic band downward with
the end pointing inward.
K. Position the immobilizer unit coupler and main
switch couplers under the frame.
L. Route the headlight relay lead and turn
signal/hazard relay lead through the rear hole in
the electrical component tray 1.
M. Insert the projection on the main switch lead holder
into the upper hole in the frame.
N. Insert the projection on the wire harness holder
into the lower hole in the frame.

– 18 –
 CABLE ROUTING

Battery and rear fender (top view)

14 A
10 15
14 2
8
13 9
1
18
2 E 14
3

11 4

12 5 B
21

3 12 22

G F

6 C
D 11
19 20

18
14

G F
16

9 16

15
10
17
8
17 F G
10
I H 8

– 19 –
 CABLE ROUTING

1. Battery band
2. Positive battery lead
3. Negative battery lead
4. Fuse box 1
5. Yamaha diagnostic tool coupler
6. Fuse box 2
7. Lean angle sensor
8. Rear turn signal light lead (right turn signal light)
9. License plate light lead
10. Rear turn signal light lead (left turn signal light)
11. Seat lock cable
12. Starter motor lead
13. Positive battery sub-wire harness coupler
14. Wire harness
15. Tail/brake light lead
16. Rear fender
17. Lower fender cover
18. Frame
19. Rear turn signal light coupler
20. License plate light coupler
21. Battery
22. Battery box
A. Route the positive battery lead through the hole in
the battery band.
B. Position the Yamaha diagnostic tool lead and
coupler above fuse boxes 1 and 2 as shown in the
illustration.
C. Connect all of the couplers near fuse box 2, and
then install fuse box 2 to the battery box.
D. Route the seat lock cable over the each lead.
E. Insert the projection on the wire harness holder
into the hole in the battery box.
F. Inward
G. Outward
H. Right
I. Left

– 20 –
 CABLE ROUTING

Hydraulic unit assembly (top and right side view)

A
2
1

2 E
4 B C
D
G H 2

3
F

4
4 E

3 F

– 21 –
 CABLE ROUTING

1. Brake hose (rear brake master cylinder to

hydraulic unit)
2. Brake hose (front brake master cylinder to
hydraulic unit)
3. Front wheel sensor lead
4. Brake hose (hydraulic unit to left front brake
caliper)
5. Brake hose (hydraulic unit to rear brake caliper)
A. Make sure that the pipe section of the brake hose
(rear brake master cylinder to hydraulic unit) does
not contact the hydraulic unit.
B. Protective sleeve and tape
C. Tape
D. Fasten the front wheel sensor lead to the brake
hose (hydraulic unit to left front brake caliper) with
the holder. Align the edge of the holder with the
edge of the tape on the front wheel sensor lead as
shown in the illustration.
E. Upward
F. Downward
G. Inward
H. Outward

– 22 –
 PERIODIC MAINTENANCE

EAS20022

PERIODIC MAINTENANCE EWA13190

WARNING
EAS30640 It is dangerous to ride with a worn-out tire.
CHECKING THE TIRES When the tire tread reaches the wear limit, re-
The following procedure applies to both of the place the tire immediately.
tires.
1. Check:
• Tire pressure
Out of specification → Regulate.

1. Tire tread depth

2. Side wall
3. Wear indicator
EWA13181

WARNING Wear limit (front)

• The tire pressure should only be checked 1.5 mm (0.06 in)
and regulated when the tire temperature Wear limit (rear)
equals the ambient air temperature. 1.5 mm (0.06 in)
• The tire pressure and the suspension must
EWA14090
be adjusted according to the total weight
WARNING
(including cargo, rider, passenger and ac-
cessories) and the anticipated riding After extensive tests, the tires listed below
speed. have been approved by Yamaha Motor Co.,
• Operation of an overloaded vehicle could Ltd. for this model. The front and rear tires
cause tire damage, an accident or an injury. should always be by the same manufacturer
NEVER OVERLOAD THE VEHICLE. and of the same design. No guarantee con-
cerning handling characteristics can be giv-
en if a tire combination other than one
Tire air pressure (measured on
approved by Yamaha is used on this vehicle.
cold tires)
Loading condition
0–173 kg (0–381 lb) Front tire
Front Size
225 kPa (2.25 kgf/cm², 33 psi) 120/70 R17M/C (58V)
Rear Manufacturer/model
250 kPa (2.50 kgf/cm², 36 psi) PIRELLI/PHANTOM SPORTS-
High-speed riding COMP
Front
225 kPa (2.25 kgf/cm², 33 psi)
Rear Rear tire
250 kPa (2.50 kgf/cm², 36 psi) Size
Maximum load 180/55 R17M/C (73V)
172 kg (379 lb) Manufacturer/model
PIRELLI/PHANTOM SPORTS-
* Total weight of rider, passenger, cargo COMP
and accessories

2. Check:
• Tire surfaces
Damage/wear → Replace the tire.

– 23 –
 PERIODIC MAINTENANCE

EWA13210

WARNING
New tires have a relatively low grip on the
road surface until they have been slightly
worn. Therefore, approximately 100 km
should be traveled at normal speed before
any high-speed riding is done.
TIP
For tires with a direction of rotation mark “1”:
Install the tire with the mark pointing in the direc-
tion of wheel rotation.

– 24 –
 ENGINE INSPECTION

EAS20041

ENGINE INSPECTION Extension

90890-04136
EAS30249
Compression gauge
MEASURE THE COMPRESSION PRESSURE 90890-03081
The following procedure applies to all of the cyl- Engine compression tester
inders. YU-33223
TIP
Insufficient compression pressure will result in a
loss of performance. 2
1. Measure:
• Valve clearance
Out of specification → Adjust.
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” in chapter 3. (Manual No.: B34-
F8197-E0) 1
2. Start the engine, warm it up for several min-
utes, and then turn it off. 8. Measure:
3. Remove: • Compression pressure
• Seat Out of specification → Refer to steps (c) and
Refer to “GENERAL CHASSIS (1)” in chapter (d).
4. (Manual No.: B34-F8197-E0)
TIP
• Fuel tank center cover
• Air scoops Due to the engine characteristics, the compres-
Refer to “GENERAL CHASSIS (3)” in chapter sion pressure is different for cylinder #1 and cyl-
4. (Manual No.: B34-F8197-E0) inder #2.
• Fuel tank
Refer to “FUEL TANK” on page 38. Compression pressure (#1 cylin-
4. Disconnect: der)
• Ignition coil couplers “1” 630–850 kPa/495 r/min (6.3–8.5
5. Remove: kgf/cm²/495 r/min, 89.6–120.9
psi/495 r/min)
• Ignition coils “2”
Compression pressure (#2 cylin-
der)
610–830 kPa/495 r/min (6.1–8.3
kgf/cm²/495 r/min, 86.8–118.1
psi/495 r/min)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1 a. Turn the main switch to “ON”.
b. With the throttle wide open, crank the engine
2 until the reading on the compression gauge
stabilizes.
EWA12940
6. Remove:
WARNING
• Spark plugs
ECA13340 To prevent sparking, ground all spark plug
NOTICE leads before cranking the engine.
Before removing the spark plugs, use com-
TIP
pressed air to blow away any dirt accumulat-
ed in the spark plug wells to prevent it from The difference in compression pressure be-
falling into the cylinders. tween cylinders should not exceed 100 kPa (1
kg/cm², 14 psi).
7. Install:
• Extension “1”
• Compression gauge “2”

– 25 –
 ENGINE INSPECTION

c. If the compression pressure is above the

maximum specification, check the cylinder
head, valve surfaces and piston crown for
carbon deposits.
Carbon deposits → Eliminate.
d. If the compression pressure is below the min-
imum specification, pour a teaspoonful of en-
gine oil into the spark plug bore and measure
again.
Refer to the following table.
Compression pressure (with oil applied into
the cylinder)
Reading Diagnosis
Higher than without Piston ring(s) wear or
oil damage → Repair.
Pistons, valves, cylin-
der head gasket or
Same as without oil piston ring(s) possi-
bly defective → Re-
pair.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9. Install:
• Spark plugs
• Ignition coils

Spark plug
13 Nm (1.3 m·kgf, 9.4 ft·lbf)
T.
R.

10.Connect:
• Ignition coil couplers
11.Install:
• Fuel tank
Refer to “FUEL TANK” on page 38.
• Air scoops
• Fuel tank center cover
• Fuel tank cover (left)
• Fuel tank cover (right)
• Fuel tank top cover
Refer to “GENERAL CHASSIS (3)” in chapter
4. (Manual No.: B34-F8197-E0)
• Seat
Refer to “GENERAL CHASSIS (1)” in chapter
4. (Manual No.: B34-F8197-E0)

– 26 –
 ELECTRIC STARTER

EAS20052

ELECTRIC STARTER
Removing the starter motor
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
3
4

LS 10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
1
New

Order Job/Parts to remove Q’ty Remarks

Seat Refer to “GENERAL CHASSIS (1)” in chap-

ter 4. (Manual No.: B34-F8197-E0)
Fuel tank center cover/Outer side covers/Inner Refer to “GENERAL CHASSIS (3)” in chap-
side covers ter 4. (Manual No.: B34-F8197-E0)
Fuel tank Refer to “FUEL TANK” on page 38.

Pivot shaft protectors Refer to “SWINGARM” in chapter 4. (Manu-

al No.: B34-F8197-E0)

Air duct bracket Refer to “GENERAL CHASSIS (4)” in chap-

ter 4. (Manual No.: B34-F8197-E0)
Throttle bodies/Air filter case Refer to “THROTTLE BODIES” on page 43.
1 Gear position switch coupler 1
2 Coupler and hose bracket 1
3 Starter motor lead 1 Disconnect.
4 Starter motor 1

– 27 –
 ELECTRIC STARTER

EAS30327

INSTALLING THE STARTER MOTOR

1. Install:
• Coupler and hose holder bracket “1”
TIP
Make sure that the tab “a” on the coupler and
hose holder bracket contacts the projection “b”
on the cylinder block.

– 28 –
 CONNECTING RODS AND PISTONS

EAS20132

CONNECTING RODS AND PISTONS

Removing the connecting rods and pistons

1st 20 Nm (2.0 m•kgf, 14 ft•Ibf)

T.R

2nd Specified angle 180˚

.

New
New
3

M M 7

E
1
E
2
E

4 New
6

4 New
E

Order Job/Parts to remove Q’ty Remarks

The following procedure applies to all of the

connecting rods and pistons.
Refer to “CRANKCASE” in chapter 5. (Man-
ual No.: B34-F8197-E0)
1 Connecting rod cap 1
2 Big end lower bearing 1
3 Big end upper bearing 1
4 Piston pin clip 2
5 Piston pin 1
6 Piston 1
7 Connecting rod 1

– 29 –
 CONNECTING RODS AND PISTONS

Removing the connecting rods and pistons

1st 20 Nm (2.0 m•kgf, 14 ft•Ibf)

T.R

2nd Specified angle 180˚

.

New
New

M M

E E

New

New

10

9
E
8

Order Job/Parts to remove Q’ty Remarks

8 Top ring 1
9 2nd ring 1
10 Oil ring 1

– 30 –
 CONNECTING RODS AND PISTONS

EAS30745

REMOVING THE CONNECTING RODS AND

PISTONS
The following procedure applies to all of the con- 4 3
necting rods and pistons.
1. Remove:
• Connecting rod cap “1”
• Connecting rod 1 2
• Big end bearings
TIP
• Identify the position of each connecting rod cap
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
damage the mating surfaces of the connecting
rods and connecting rod caps.

1
5

3. Remove:
• Top ring
• 2nd ring
• Oil ring
TIP
2. Remove: When removing a piston ring, open the end gap
• Piston pin clips “1” with your fingers and lift the other side of the ring
• Piston pin “2” over the piston crown.
• Piston “3”
• Connecting rod “4”
ECA13810

NOTICE
Do not use a hammer to drive the piston pin
out.
TIP
• For reference during installation, put identifica-
tion marks on the piston crown.
• Before removing the piston pin, deburr the pis-
EAS30747
ton pin clip groove and the piston pin bore ar-
CHECKING THE CYLINDER AND PISTON
ea. If both areas are debarred and the piston
The following procedure applies to all of the cyl-
pin is still difficult to remove, remove it with the
inders and pistons.
piston pin puller set “5”.
1. Check:
• Piston wall
Piston pin puller set • Cylinder wall
90890-01304 Vertical scratches → Replace the cylinder,
Piston pin puller and replace the piston and piston rings as a
YU-01304
set.
2. Measure:
• Piston-to-cylinder clearance

– 31 –
 CONNECTING RODS AND PISTONS

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure cylinder bore with the cylinder bore a
gauge.
TIP
Measure cylinder bore by taking side-to-side
and front-to-back measurements of the cylinder. P

Bore
78.000–78.010 mm (3.0709–
3.0713 in)
Taper limit a. 8.0 mm (0.31 in) from the bottom edge of the
0.050 mm (0.0020 in) piston
Out of round limit d. If out of specification, replace the piston and
0.050 mm (0.0020 in) piston rings as a set.
e. Calculate the piston-to-cylinder clearance
“C” = maximum of D1, D2, D3, D4, D5, D6 with the following formula.
Taper (front-to-back) = maximum difference Piston-to-cylinder clearance =
between D1, D3, D5 Cylinder bore “C” – Piston skirt diameter “P”
Taper (side-to-side) = maximum difference
between D2, D4, D6 f. If out of specification, replace the cylinder,
and replace the piston and piston rings as a
Out of round (top) = difference between D1, set.
D2 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Out of round (middle) = difference between EAS30748
D3, D4 CHECKING THE PISTON RINGS
Out of round (bottom) = difference between 1. Measure:
D5, D6 • Piston ring side clearance
Out of specification → Replace the piston
and piston rings as a set.
TIP
Before measuring the piston ring side clearance,
eliminate any carbon deposits from the piston
ring grooves and piston rings.

Top ring
Ring side clearance
0.030–0.065 mm (0.0012–0.0026
in)
b. If out of specification, replace the cylinder, Side clearance limit
and replace the piston and piston rings as a 0.115 mm (0.0045 in)
set. Ring side clearance
c. Measure piston skirt diameter “P” with the mi- 0.020–0.055 mm (0.0008–0.0022
crometer. in)
Side clearance limit
Diameter 0.115 mm (0.0045 in)
77.970–77.985 mm (3.0697–
3.0703 in)

– 32 –
 CONNECTING RODS AND PISTONS

2. Install: a. Bottom of cylinder

• Piston ring b. Top of cylinder
(into the cylinder) EAS30751

TIP INSTALLING THE CONNECTING ROD AND

Use the piston crown to level the piston ring near PISTON
the bottom of the cylinder where the cylinder The following procedure applies to all of the con-
wear is lowest. necting rods and pistons.
1. Install:
3. Measure: • Big end bearings
• Piston ring end gap • Connecting rod cap
Out of specification → Replace the piston (onto the connecting rod)
ring. TIP
TIP
• Be sure to reinstall each big end bearing in its
The oil ring expander spacer’s end gap cannot original place.
be measured. If the oil ring rail’s gap is exces- • Align the projections “a” on the big end bear-
sive, replace all three piston rings. ings with the notches “b” in the connecting rods
and connecting rod caps.
Piston ring • Make sure that the projection “c” on the con-
Top ring necting rod cap faces the same direction as the
End gap (installed) “Y” mark “d” on the connecting rod.
0.15–0.25 mm (0.0059–0.0098
in)
End gap limit
0.50 mm (0.0197 in)
2nd ring
End gap (installed)
0.30–0.45 mm (0.0118–0.0177
in)
End gap limit
0.80 mm (0.0315 in)
Oil ring
End gap (installed)
0.10–0.40 mm (0.0039–0.0157
in)

– 33 –
 CONNECTING RODS AND PISTONS

2. Tighten: • Upper oil ring rail “3”

• Connecting rod bolts New • 2nd ring “4”
ECA18390 • Top ring “5”
NOTICE TIP
Tighten the connecting rod bolts using the Be sure to install the piston rings so that the
plastic-region tightening angle method. Al- manufacturer’s marks “a” face up.
ways install new bolts.
TIP
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 lubricate
the bolt threads and seats with molybdenum
disulfide oil.
c. After installing the big end bearing, assemble 4. Install:
the connecting rod and connecting rod cap • Piston “1”
without installing them onto the crankshaft. (onto the respective connecting rod “2”)
d. Tighten the connecting rod bolt while check- • Piston pin “3”
ing that the sections shown “a” and “b” are • Piston pin clips “4” New
flush with each other by touching the surface. TIP
Connecting rod bolt • Apply engine oil onto the piston pin.
30 Nm (3.0 m·kgf, 22 ft·lbf) • Make sure that the “Y” mark “a” on the connect-
T.
R.

ing rod faces left when the punch mark “b” on

TIP the piston is pointing up as shown.
To install the big end bearing, care should be • When installing a piston pin clip, make sure
taken not to install it at an angle and the position that the clip ends “c” are positioned away from
should not be out of alignment. the cutout “d” in the piston as shown in the illus-
tration.
• Reinstall each piston into its original cylinder.

a
b

2 1
3
New 4

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 condition.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install: c
• Oil ring expander “1” d
• Lower oil ring rail “2” New 4

– 34 –
 CONNECTING RODS AND PISTONS

5. Lubricate:
• Piston Piston ring compressor
• Piston rings 90890-05158
• Cylinder Piston ring compressor
YM-08037
(with the recommended lubricant)

Recommended lubricant
Engine oil

6. Offset:
• Piston ring end gaps
A
45˚ 45˚
a,b c

90˚

d,e
a. 2nd ring
b. Lower oil ring rail
c. Upper oil ring rail
d. Top ring
e. Oil ring expander
A. Exhaust side
9. Tighten:
7. Lubricate: • Connecting rod bolts “1”
• Crankshaft pin
• Connecting rod big end bearing inner surface 1
(with the recommended lubricant)

Recommended lubricant 1
Engine oil

8. Install:
• Connecting rod assemblies “1”
(into the cylinder and onto the crankshaft pin)
• Connecting rod caps
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
(onto the connecting rod)
TIP
TIP
Tighten the connecting rod bolts using the fol-
• While compressing the piston ring with piston lowing procedure.
ring compressor “2”, install the connecting rod
assembly into the cylinder with the other hand. a. Tighten the connecting rod bolts with a torque
• Make sure the “Y” marks “a” on the connecting wrench.
rods face towards the left side of the crank-
Connecting rod bolt (1st)
shaft.
20 Nm (2.0 m·kgf, 14 ft·lbf)
T.

• Make sure that the projection “b” on the con-

R.

necting rod cap faces the same direction as the b. Put a mark “1” on the corner of the connecting
“Y” mark “a” on the connecting rod. rod bolt “2” and the connecting rod cap “3”.
• Apply Molybdenum disulfide oil to the threads
and seats of the connecting rod bolt.

– 35 –
 CONNECTING RODS AND PISTONS

c. Tighten the connecting rod bolts further to ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

reach the specified angle 175–185°.

Connecting rod bolt (final)

Specified angle 180°
T.
R.

180˚

EWA16610

WARNING
If the bolt is tightened more than the speci-
fied angle, do not loosen the bolt and then re-
tighten it. Instead, replace the bolt with a new
one and perform the procedure again.
ECA20890

NOTICE
Do not use a torque wrench to tighten the
bolt to the specified angle.
d. After the installation, check that the section
shown “a” is flush with each other by touching
the surface.
EWA17120

WARNING
If the connecting rod and cap are not flush
with each other, remove the connecting rod
bolts and big end bearing and restart from
step (1). In this case, make sure to replace
the connecting rod bolts.

– 36 –
 THERMOSTAT

EAS20065

THERMOSTAT
Removing the thermostat

2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)

T.R
.

4
2
5 1
12 Nm (1.2 m•kgf, 8.7 ft•Ibf)
T.R
.

New

16 Nm (1.6 m•kgf, 12 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Drain.
Coolant Refer to “CHANGING THE COOLANT” in
chapter 3. (Manual No.: B34-F8197-E0)

Seat Refer to “GENERAL CHASSIS (1)” in chap-

ter 4. (Manual No.: B34-F8197-E0)

Fuel tank center cover Refer to “GENERAL CHASSIS (3)” in chap-

ter 4. (Manual No.: B34-F8197-E0)
Fuel tank Refer to “FUEL TANK” on page 38.
1 Coolant temperature sensor coupler 1 Disconnect.
2 Coolant temperature sensor 1
3 Radiator inlet hose 1 Disconnect.
4 Thermostat cover 1
5 Thermostat 1

– 37 –
 FUEL TANK

EAS20067

FUEL TANK
Removing the fuel tank and fuel pump
30 Nm (3.0 m•kgf, 22 ft•Ibf)
T.R
.

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

3.8 Nm (0.38 m•kgf, 2.8 ft•Ibf)

T.R
.

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
New

1
5
3
2
(4)
4

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.

4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Seat Refer to “GENERAL CHASSIS (1)” in chap-

ter 4. (Manual No.: B34-F8197-E0)

Fuel tank center cover/Inner side cover (left) Refer to “GENERAL CHASSIS (3)” in chap-
ter 4. (Manual No.: B34-F8197-E0)
1 Intake air temperature sensor coupler 1 Disconnect.
2 Fuel tank overflow hose 1 Disconnect.
3 Fuel tank breather hose 1 Disconnect.
4 Fuel pump coupler 1 Disconnect.
5 Fuel hose 1

– 38 –
 FUEL TANK

Removing the fuel tank and fuel pump

30 Nm (3.0 m•kgf, 22 ft•Ibf)
T.R
.

7
7 Nm (0.7 m•kgf, 5.1 ft•Ibf) 8
T.R
.

11

9
6
3.8 Nm (0.38 m•kgf, 2.8 ft•Ibf)
T.R
.

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
8
12
New

10

(4)

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.

4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

6 Fuel tank 1
7 Damper 1 1
8 Damper 2 2
9 Intake air temperature sensor 1
10 Fuel pump 1
11 Front fuel tank bracket 1
12 Rear fuel tank bracket 1

– 39 –
 FUEL TANK

EAS30450 ECA14721

REMOVING THE FUEL TANK NOTICE

1. Extract the fuel in the fuel tank through the • Do not drop the fuel pump or give it a
fuel tank cap with a pump. strong shock.
2. Remove: • Do not touch the base section of the fuel
• Fuel hose sender.
EWA17320

WARNING
EAS30454
Cover fuel hose connections with a cloth CHECKING THE FUEL PUMP BODY
when disconnecting them. Residual pres- 1. Check:
sure in the fuel lines could cause fuel to • Fuel pump body
spurt out when removing the hose. Obstruction → Clean.
ECA20020 Cracks/damage → Replace fuel pump as-
NOTICE sembly.
Although the fuel has been removed from EAS30456
the fuel tank, be careful when removing the INSTALLING THE FUEL PUMP
fuel hose, since there may be fuel remaining 1. Install:
in it.
• Fuel pump gasket “1” New
TIP • Fuel pump
• To remove the fuel hose from the fuel rail and • Fuel pump bracket
fuel pump, slide the fuel hose connector cover
Fuel pump bolt
“1” on the end of the hose in the direction of the 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
T.

arrow shown, press the two buttons “2” on the

R.

sides of the connector, and then remove the TIP

hose.
• Do not damage the installation surfaces of the
• Remove the fuel hose manually without using
fuel tank when installing the fuel pump.
any tools.
• Always use a new fuel pump gasket.
• Before removing the hose, place a few rags in
• The gasket lip “a” shall face toward the fuel
the area under where it will be removed.
tank.
• Align the projection “b” on the fuel pump with
the punch mark “c” on the fuel tank.
• Align the slot in the fuel pump bracket with the
projection “b” on the fuel pump.
• Tighten the fuel pump bolts in the proper tight-
ening sequence as shown.

1 2
3. Remove:
• Fuel tank
TIP
Do not set the fuel tank down on the installation
surface of the fuel pump. Be sure to lean the fuel
tank against a wall or the like.

EAS30451

REMOVING THE FUEL PUMP

1. Remove:
• Fuel pump

– 40 –
 FUEL TANK

EAS31081

INSTALLING THE FUEL TANK BRACKET

a 1. Install:
• Grommets
• Collars
• Front fuel tank bracket “1”

Fuel tank bolt (front side)

1 New 7 Nm (0.7 m·kgf, 5.1 ft·lbf)

T.
R.
TIP
3 Make sure that the arrow mark “a” on the front
1 fuel tank bracket points toward the hole “b” in the
fuel tank.
FWD

2
1
b 4
c a
EAS31801

INSTALLING THE DAMPERS

1. Install:
• Damper 2 “1” b
• Damper 1 “2”
2. Install:
TIP
• Grommets
• Fit the slot “a” in each damper 2 over the rib “b” • Collars
on the fuel tank. • Rear fuel tank bracket “1”
• Align the projections “c” on damper 1 with the
projection “d” on each damper 2. Fuel tank bolt (rear side)
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T.
R.

1 d 2 d 1
TIP
b a Make sure that the arrow mark “a” on the rear
fuel tank bracket points toward the punch mark
“b” on the fuel tank.

1 c
a

b
2

1 1
EAS30457

INSTALLING THE FUEL TANK

1. Tighten:
1 • Front fuel tank bracket bolt
(temporarily)

– 41 –
 FUEL TANK

TIP
Temporarily tighten the front fuel tank bracket
bolt.
2. Install:
• Fuel hose
ECA18420

NOTICE
When installing the fuel hose, make sure that
it is securely connected, and that the fuel
hose connector cover on the fuel hose is in
the correct position; otherwise, the fuel hose
will not be properly installed.
TIP
• Install the fuel hose securely onto the fuel rail
and fuel pump until a distinct “click” is heard.
• To install the fuel hose, slide the fuel hose con-
nector cover “1” on each end of the hose in the
direction of the arrow shown.

1
3. Connect:
• Fuel pump coupler
• Fuel tank breather hose
• Fuel tank overflow hose
• Intake air temperature sensor
4. Tighten:
• Rear fuel tank bracket bolts

Rear fuel tank bracket bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.

5. Tighten:
• Front fuel tank bracket bolt

Front fuel tank bracket bolt

30 Nm (3.0 m·kgf, 22 ft·lbf)
T.
R.

– 42 –
 THROTTLE BODIES

EAS20070

THROTTLE BODIES
Removing the air filter case and throttle bodies
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
1
2
3
3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf)
3

T.R
.
3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf)
T.R
.

T.R
12 Nm (1.2 m•kgf, 8.7 ft•Ibf)
.

4.5 Nm (0.45 m•kgf, 3.3 ft•Ibf) 12 Nm (1.2 m•kgf, 8.7 ft•Ibf)

T.R
T.R

.
.

Order Job/Parts to remove Q’ty Remarks

Seat Refer to “GENERAL CHASSIS (1)” in chap-

ter 4. (Manual No.: B34-F8197-E0)

Fuel tank center cover/Inner side covers Refer to “GENERAL CHASSIS (3)” in chap-
ter 4. (Manual No.: B34-F8197-E0)
Fuel tank Refer to “FUEL TANK” on page 38.

Air duct bracket Refer to “GENERAL CHASSIS (4)” in chap-

ter 4. (Manual No.: B34-F8197-E0)

Pivot shaft protector (left/right) Refer to “SWINGARM” in chapter 4. (Manu-

al No.: B34-F8197-E0)
1 Cylinder head breather hose 1
2 Throttle position sensor coupler 1 Disconnect.
3 Injector coupler 2 Disconnect.

– 43 –
 THROTTLE BODIES

Removing the air filter case and throttle bodies

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf)

T.R
.
12 10

8 10
8 11 4
12
3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf) 13
T.R
.

8
8 5

12 Nm (1.2 m•kgf, 8.7 ft•Ibf)

7

T.R
.

9 12 Nm (1.2 m•kgf, 8.7 ft•Ibf)

4.5 Nm (0.45 m•kgf, 3.3 ft•Ibf)
T.R
T.R

.
.

Order Job/Parts to remove Q’ty Remarks

4 ISC (Idle Speed Control) unit coupler 1 Disconnect.
5 Intake air pressure sensor hose 1 Disconnect.
6 Throttle cable (decelerator cable) 1 Disconnect.
7 Throttle cable (accelerator cable) 1 Disconnect.
8 Throttle body joint clamp screw 4 Loosen.
9 Air filter case bolt 2
10 Air filter case joint clamp screw 2 Loosen.
11 Throttle bodies 1
12 Throttle body joint 2
13 Air filter case 1

– 44 –
 FUEL INJECTION SYSTEM

EAS20078

FUEL INJECTION SYSTEM

EAS31791

TROUBLESHOOTING DETAILS (FAULT CODE)

Fault code No. P0107, P0108

Fault code No. P0107, P0108
[P0107] Intake air pressure sensor: ground short circuit de-
tected.
Item
[P0108] Intake air pressure sensor: open or power short cir-
cuit detected.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 03
Tool display Displays the intake air pressure.
Operate the throttle while pushing the “ ” side of the start/engine
Procedure
stop switch. (If the display value changes, the performance is OK.)
Probable cause of malfunc- Confirmation of service
Item Maintenance job
tion and check completion
1 Connection of intake air pres- Improperly connected → Turn the main switch to “ON”,
sure sensor coupler. Connect the coupler securely and then check the condition
Check the locking condition or replace the wire harness. of the fault code using the
of the coupler. malfunction mode of the
Disconnect the coupler and Yamaha diagnostic tool.
check the pins (bent or bro- Condition is “Recovered” →
ken terminals and locking Go to item 7 and finish the
condition of the pins). service.
Condition is “Detected” → Go
to item 2.
2 Connection of ECU coupler. Improperly connected → Turn the main switch to “ON”,
Check the locking condition Connect the coupler securely and then check the condition
of the coupler. or replace the wire harness. of the fault code using the
Disconnect the coupler and malfunction mode of the
check the pins (bent or bro- Yamaha diagnostic tool.
ken terminals and locking Condition is “Recovered” →
condition of the pins). Go to item 7 and finish the
service.
Condition is “Detected” → Go
to item 3.
3 Wire harness continuity. Open or short circuit → Re- Turn the main switch to “ON”,
place the wire harness. and then check the condition
of the fault code using the
malfunction mode of the
Yamaha diagnostic tool.
Condition is “Recovered”
→Go to item 7 and finish the
service.
Condition is “Detected” → Go
to item 4.

– 45 –
 FUEL INJECTION SYSTEM

3-1
2
1 5V 5V

L
3 L

P/W
4 P/W

B/L
5 B/L

1. Intake air pressure sensor

2. ECU
3. Sensor input lead
4. Sensor output lead
5. Sensor ground lead
3-2 Disconnect the ECU coupler from the ECU.
Disconnect the intake air pressure sensor coupler from the intake air pressure sensor.
3-3 [For P0107] Ground short circuit
Between intake air pressure sensor coupler and ground: pink/white–ground
If there is continuity, replace the wire harness.

B/L P/W L

3-4 [For P0108] Open circuit

Between intake air pressure sensor coupler and ECU coupler: blue–blue
If there is no continuity, replace the wire harness.

L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R Gy/R G/Y O
B/L P/W L W/G Br/L Y/G Br/W L/W G/B B/Y R/B
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B

– 46 –
 FUEL INJECTION SYSTEM

3-5 [For P0108] Open circuit

Between intake air pressure sensor coupler and ECU coupler: pink/white–pink/white
If there is no continuity, replace the wire harness.

L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R Gy/R G/Y O
B/L P/W L W/G Br/L Y/G Br/W L/W G/B B/Y R/B
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B

3-6 [For P0108] Open circuit

Between intake air pressure sensor coupler and ECU coupler: black/blue–black/blue
If there is no continuity, replace the wire harness.

L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R Gy/R G/Y O
B/L P/W L W/G Br/L Y/G Br/W L/W G/B B/Y R/B
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B

3-7 Disconnect the couplers from the parts that are connected to the ECU.
Refer to “Parts connected to the ECU” in chapter 8. (Manual No.: B34-F8197-E0)
3-8 [For P0107/P0108] Short circuit
Between intake air pressure sensor output terminal (pink/white) “a” of ECU coupler and any
other ECU coupler terminal “b”.
If there is continuity, replace the wire harness.
a

L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R Gy/R G/Y O
W/G Br/L Y/G Br/W L/W G/B B/Y R/B
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B

4 Installed condition of intake Check for looseness or Turn the main switch to “ON”,
air pressure sensor. pinching. and then check the condition
Improperly installed sensor of the fault code using the
→ Reinstall or replace the malfunction mode of the
sensor. Yamaha diagnostic tool.
Condition is “Recovered” →
Go to item 7 and finish the
service.
Condition is “Detected” → Go
to item 5.

– 47 –
 FUEL INJECTION SYSTEM

5 Defective intake air pressure Execute the diagnostic Crank the engine, and then
sensor. mode. (Code No. 03) check the condition of the
When engine is stopped: fault code using the malfunc-
Atmospheric pressure at the tion mode of the Yamaha di-
current altitude and weather agnostic tool.
conditions is indicated. Condition is “Recovered” →
At sea level: Approx. 101 kPa Go to item 7 and finish the
(757.6 mmHg, 29.8 inHg) service.
1000 m (3300 ft) above sea Condition is “Detected” → Go
level: Approx. 90 kPa (675.1 to item 6.
mmHg, 26.6 inHg)
2000 m (6700 ft) above sea
level: Approx. 80 kPa (600.0
mmHg, 23.6 inHg)
3000 m (9800 ft) above sea
level: Approx. 70 kPa (525.0
mmHg, 20.7 inHg)
When engine is cranking:
Make sure that the indication
value changes.
The value does not change
when engine is cranking. →
Check the intake air pressure
sensor.
Replace if defective.
Refer to “CHECKING THE
INTAKE AIR PRESSURE
SENSOR” in chapter 8.
(Manual No.: B34-F8197-E0)
6 Malfunction in ECU. Replace the ECU. Service is finished.
Refer to “REPLACING THE
ECU (engine control unit)” in
chapter 8. (Manual No.: B34-
F8197-E0)
7 Delete the fault code and Confirm that the fault code
check that the engine trouble has a condition of “Recov-
warning light goes off. ered” using the Yamaha diag-
nostic tool, and then delete
the fault code.

– 48 –
 FUEL INJECTION SYSTEM

Fault code No. P0112, P0113

TIP
Perform this procedure when the engine is cold.

Fault code No. P0112, P0113

[P0112] Intake air temperature sensor: ground short circuit
detected.
Item
[P0113] Intake air temperature sensor: open or power short
circuit detected.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 05
Tool display Displays the air temperature.
Compare the actually measured air temperature with the tool dis-
Procedure
play value.
Probable cause of malfunc- Confirmation of service
Item Maintenance job
tion and check completion
1 Connection of intake air tem- Improperly connected → Turn the main switch to “ON”,
perature sensor coupler. Connect the coupler securely and then check the condition
Check the locking condition or replace the wire harness. of the fault code using the
of the coupler. malfunction mode of the
Disconnect the coupler and Yamaha diagnostic tool.
check the pins (bent or bro- Condition is “Recovered” →
ken terminals and locking Go to item 7 and finish the
condition of the pins). service.
Condition is “Detected” → Go
to item 2.
2 Connection of ECU coupler. Improperly connected → Turn the main switch to “ON”,
Check the locking condition Connect the coupler securely and then check the condition
of the coupler. or replace the wire harness. of the fault code using the
Disconnect the coupler and malfunction mode of the
check the pins (bent or bro- Yamaha diagnostic tool.
ken terminals and locking Condition is “Recovered” →
condition of the pins). Go to item 7 and finish the
service.
Condition is “Detected” → Go
to item 3.
3 Wire harness continuity. Open or short circuit → Re- Turn the main switch to “ON”,
place the wire harness. and then check the condition
of the fault code using the
malfunction mode of the
Yamaha diagnostic tool.
Condition is “Recovered” →
Go to item 7 and finish the
service.
Condition is “Detected” → Go
to item 4.

– 49 –
 FUEL INJECTION SYSTEM

3-1
2
5V

1
Br/W
3 Br/W

B/L B/L
4

1. Intake air temperature sensor

2. ECU
3. Sensor output lead
4. Sensor ground lead
3-2 Disconnect the ECU coupler from the ECU.
Disconnect the intake air temperature sensor coupler from the intake air temperature sen-
sor.
3-3 [For P0112] Ground short circuit
Between intake air temperature sensor coupler and ground: brown/white–ground
If there is continuity, replace the wire harness.

Br/W B/L

3-4 [For P0113] Open circuit

Between intake air temperature sensor coupler and ECU coupler: brown/white–brown/white
If there is no continuity, replace the wire harness.

L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R Gy/R G/Y O
Br/W B/L W/G Br/L Y/G Br/W L/W G/B B/Y R/B
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B

– 50 –
 FUEL INJECTION SYSTEM

3-5 [For P0113] Open circuit

Between intake air temperature sensor coupler and ECU coupler: black/blue–black/blue
If there is no continuity, replace the wire harness.

L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R Gy/R G/Y O
Br/W B/L W/G Br/L Y/G Br/W L/W G/B B/Y R/B
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B

3-6 Disconnect the couplers from the parts that are connected to the ECU.
Refer to “Parts connected to the ECU” in chapter 8. (Manual No.: B34-F8197-E0)
3-7 [For P0112/P0113] Short circuit
Between intake air temperature sensor output terminal (brown/white) “a” of ECU coupler
and any other ECU coupler terminal “b”.
If there is continuity, replace the wire harness.
b a

L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R Gy/R G/Y O
W/G Br/L Y/G Br/W L/W G/B B/Y R/B
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B

4 Installed condition of intake Check for looseness or Turn the main switch to “ON”,
air temperature sensor. pinching. and then check the condition
Improperly installed sensor of the fault code using the
→ Reinstall or replace the malfunction mode of the
sensor. Yamaha diagnostic tool.
Condition is “Recovered” →
Go to item 7 and finish the
service.
Condition is “Detected” → Go
to item 5.
5 Defective intake air tempera- Execute the diagnostic Turn the main switch to “ON”,
ture sensor. mode. (Code No. 05) and then check the condition
When engine is cold: of the fault code using the
Displayed temperature is malfunction mode of the
close to the ambient tem- Yamaha diagnostic tool.
perature. Condition is “Recovered” →
The displayed temperature is Go to item 7 and finish the
not close to the ambient tem- service.
perature. → Check the intake Condition is “Detected” → Go
air temperature sensor. to item 6.
Replace if defective.
Refer to “CHECKING THE
INTAKE AIR PRESSURE
SENSOR” in chapter 8.
(Manual No.: B34-F8197-E0)

– 51 –
 FUEL INJECTION SYSTEM

6 Malfunction in ECU. Replace the ECU. Service is finished.

Refer to “REPLACING THE
ECU (engine control unit)” in
chapter 8. (Manual No.: B34-
F8197-E0)
7 Delete the fault code and Confirm that the fault code
check that the engine trouble has a condition of “Recov-
warning light goes off. ered” using the Yamaha diag-
nostic tool, and then delete
the fault code.

Fault code No. P0117, P0118

TIP
Perform this procedure when the engine is cold.

Fault code No. P0117, P0118

[P0117] Coolant temperature sensor: ground short circuit de-
tected.
Item
[P0118] Coolant temperature sensor: open or power short cir-
cuit detected.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 06
When engine is cold: Displays temperature closer to air tempera-
Tool display ture.
When engine is hot: Displays current coolant temperature.
Compare the actually measured coolant temperature with the tool
Procedure
display value.
Probable cause of malfunc- Confirmation of service
Item Maintenance job
tion and check completion
1 Connection of coolant tem- Improperly connected → Turn the main switch to “ON”,
perature sensor coupler. Connect the coupler securely and then check the condition
Check the locking condition or replace the wire harness. of the fault code using the
of the coupler. malfunction mode of the
Disconnect the coupler and Yamaha diagnostic tool.
check the pins (bent or bro- Condition is “Recovered” →
ken terminals and locking Go to item 7 and finish the
condition of the pins). service.
Condition is “Detected” → Go
to item 2.
2 Connection of ECU coupler. Improperly connected → Turn the main switch to “ON”,
Check the locking condition Connect the coupler securely and then check the condition
of the coupler. or replace the wire harness. of the fault code using the
Disconnect the coupler and malfunction mode of the
check the pins (bent or bro- Yamaha diagnostic tool.
ken terminals and locking Condition is “Recovered” →
condition of the pins). Go to item 7 and finish the
service.
Condition is “Detected” → Go
to item 3.

– 52 –
 FUEL INJECTION SYSTEM

3 Wire harness continuity. Open or short circuit → Re- Turn the main switch to “ON”,
place the wire harness. and then check the condition
of the fault code using the
malfunction mode of the
Yamaha diagnostic tool.
Condition is “Recovered” →
Go to item 7 and finish the
service.
Condition is “Detected” → Go
to item 4.
3-1
2
5V

1
G/W
3 G/W

B/L B/L
4

1. Coolant temperature sensor

2. ECU
3. Sensor output lead
4. Sensor ground lead
3-2 Disconnect the ECU coupler from the ECU.
Disconnect the coolant temperature sensor coupler from the coolant temperature sensor.
3-3 [For P0117] Ground short circuit
Between coolant temperature sensor coupler and ground: green/white–ground
If there is continuity, replace the wire harness.

G/W B/L

3-4 [For P0118] Open circuit

Between coolant temperature sensor coupler and ECU coupler: green/white–green/white
If there is no continuity, replace the wire harness.

L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R Gy/R G/Y O
G/W B/L W/G Br/L Y/G Br/W L/W G/B B/Y R/B
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B

– 53 –
 FUEL INJECTION SYSTEM

3-5 [For P0118] Open circuit

Between coolant temperature sensor coupler and ECU coupler: black/blue–black/blue
If there is no continuity, replace the wire harness.

L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R Gy/R G/Y O
G/W B/L W/G Br/L Y/G Br/W L/W G/B B/Y R/B
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B

3-6 Disconnect the couplers from the parts that are connected to the ECU.
Refer to “Parts connected to the ECU” in chapter 8. (Manual No.: B34-F8197-E0)
3-7 [For P0117/P0118] Short circuit
Between coolant temperature sensor output terminal (green/white) “a” of ECU coupler and
any other ECU coupler terminal “b”.
If there is continuity, replace the wire harness.
b

L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R Gy/R G/Y O
W/G Br/L Y/G Br/W L/W G/B B/Y R/B
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B

4 Installed condition of coolant Check for looseness or Turn the main switch to “ON”,
temperature sensor. pinching. and then check the condition
Improperly installed sensor of the fault code using the
→ Reinstall or replace the malfunction mode of the
sensor. Yamaha diagnostic tool.
Condition is “Recovered” →
Go to item 7 and finish the
service.
Condition is “Detected” → Go
to item 5.
5 Defective coolant tempera- Execute the diagnostic Turn the main switch to “ON”,
ture sensor. mode. (Code No. 06) and then check the condition
When engine is cold: of the fault code using the
Displayed temperature is malfunction mode of the
close to the ambient tem- Yamaha diagnostic tool.
perature. Condition is “Recovered” →
The displayed temperature is Go to item 7 and finish the
not close to the ambient tem- service.
perature → Check the cool- Condition is “Detected” → Go
ant temperature sensor. to item 6.
Replace if defective.
Refer to “CHECKING THE
COOLANT TEMPERATURE
SENSOR” in chapter 8.
(Manual No.: B34-F8197-E0)

– 54 –
 FUEL INJECTION SYSTEM

6 Malfunction in ECU. Replace the ECU. Service is finished.

Refer to “REPLACING THE
ECU (engine control unit)” in
chapter 8. (Manual No.: B34-
F8197-E0)
7 Delete the fault code and Confirm that the fault code
check that the engine trouble has a condition of “Recov-
warning light goes off. ered” using the Yamaha diag-
nostic tool, and then delete
the fault code.

Fault code No. P0122, P0123

Fault code No. P0122, P0123
[P0122] Throttle position sensor: open or ground short circuit
detected.
Item
[P0123] Throttle position sensor: power short circuit detect-
ed.
Able/Unable to start engine
Fail-safe system
Able/Unable to drive vehicle
Diagnostic code No. 01
Throttle position sensor signal
Tool display • 11–21 (fully closed position)
01 • 96–106 (fully open position)
• Check with throttle valves fully closed.
Procedure
• Check with throttle valves fully open.
Probable cause of malfunc- Confirmation of service
Item Maintenance job
tion and check completion
1 Connection of throttle posi- Improperly connected → Turn the main switch to “ON”,
tion sensor coupler. Connect the coupler securely and then check the condition
Check the locking condition or replace the wire harness. of the fault code using the
of the coupler. malfunction mode of the
Disconnect the coupler and Yamaha diagnostic tool.
check the pins (bent or bro- Condition is “Recovered” →
ken terminals and locking Go to item 8 and finish the
condition of the pins). service.
Condition is “Detected” → Go
to item 2.
2 Connection of ECU coupler. Improperly connected → Turn the main switch to “ON”,
Check the locking condition Connect the coupler securely and then check the condition
of the coupler. or replace the wire harness. of the fault code using the
Disconnect the coupler and malfunction mode of the
check the pins (bent or bro- Yamaha diagnostic tool.
ken terminals and locking Condition is “Recovered” →
condition of the pins). Go to item 8 and finish the
service.
Condition is “Detected” → Go
to item 3.

– 55 –
 FUEL INJECTION SYSTEM

3 Wire harness continuity. Open or short circuit → Re- Turn the main switch to “ON”,
place the wire harness. and then check the condition
of the fault code using the
malfunction mode of the
Yamaha diagnostic tool.
Condition is “Recovered”
→Go to item 8 and finish the
service.
Condition is “Detected” → Go
to item 4.
3-1
2
1 5V

L
3 L

W
4 W

B/L
5 B/L

1. Throttle position sensor

2. ECU
3. Sensor input lead
4. Sensor output lead
5. Sensor ground lead
3-2 Disconnect the ECU coupler from the ECU.
Disconnect the throttle position sensor coupler from the throttle position sensor.
3-3 [For P0122] Open circuit
Between throttle position sensor coupler and ECU coupler: blue–blue
If there is no continuity, replace the wire harness.

L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R Gy/R G/Y O
B/L W L W/G Br/L Y/G Br/W L/W G/B B/Y R/B
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B

3-4 [For P0122] Open circuit

Between throttle position sensor coupler and ECU coupler: white–white
If there is no continuity, replace the wire harness.

L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R Gy/R G/Y O
B/L W L W/G Br/L Y/G Br/W L/W G/B B/Y R/B
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B

– 56 –
 FUEL INJECTION SYSTEM

3-5 [For P0122] Ground short circuit

Between throttle position sensor coupler and ground: white–ground
If there is continuity, replace the wire harness.

B/L W L

3-6 [For P0123] Open circuit

Between throttle position sensor coupler and ECU coupler: black/blue–black/blue
If there is no continuity, replace the wire harness.

L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R Gy/R G/Y O
B/L W L W/G Br/L Y/G Br/W L/W G/B B/Y R/B
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B

3-7 Disconnect the couplers from the parts that are connected to the ECU.
Refer to “Parts connected to the ECU” in chapter 8. (Manual No.: B34-F8197-E0)
3-8 [For P0122/P0123] Short circuit
Between throttle position sensor output terminal (white) “a” of ECU coupler and any other
ECU coupler terminal “b”.
If there is continuity, replace the wire harness.
b a

L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R Gy/R G/Y O
W/G Br/L Y/G Br/W L/W G/B B/Y R/B
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B

4 Installed condition of throttle Check for looseness or Turn the main switch to “ON”,
position sensor. pinching. and then check the condition
Improperly installed sensor of the fault code using the
→ Reinstall or adjust the malfunction mode of the
sensor. Yamaha diagnostic tool.
Refer to “ADJUSTING THE Condition is “Recovered” →
THROTTLE POSITION SEN- Go to item 8 and finish the
SOR” in chapter 7. (Manual service.
No.: B34-F8197-E0) Condition is “Detected” → Go
to item 5.

– 57 –
 FUEL INJECTION SYSTEM

5 Throttle position sensor re- Measure the throttle position Turn the main switch to “ON”,
sistance. sensor resistance. and then check the condition
black/blue–blue of the fault code using the
Refer to “CHECKING THE malfunction mode of the
THROTTLE POSITION SEN- Yamaha diagnostic tool.
SOR” in chapter 8. (Manual Condition is “Recovered” →
No.: B34-F8197-E0) Go to item 8 and finish the
service.
Condition is “Detected” → Go
to item 6.
6 Defective throttle position Check throttle position sen- Turn the main switch to “ON”,
sensor. sor signal. and then check the condition
Execute the diagnostic of the fault code using the
mode. (Code No. 01) malfunction mode of the
When the throttle valves are Yamaha diagnostic tool.
fully closed: Condition is “Recovered” →
A value of 11–21 is indicated. Go to item 8 and finish the
When throttle valves are fully service.
open: Condition is “Detected” → Go
A value of 96–106 is indicat- to item 7.
ed.
7 Malfunction in ECU. Replace the ECU. Service is finished.
Refer to “REPLACING THE
ECU (engine control unit)” in
chapter 8. (Manual No.: B34-
F8197-E0)
8 Delete the fault code and Confirm that the fault code
check that the engine trouble has a condition of “Recov-
warning light goes off. ered” using the Yamaha diag-
nostic tool, and then delete
the fault code.

– 58 –
 FUEL INJECTION SYSTEM

Fault code No. P1604, P1605

Fault code No. P1604, P1605
[P1604] Lean angle sensor: ground short circuit detected.
Item
[P1605] Lean angle sensor: open or power short circuit.
Unable to start engine
Fail-safe system
Unable to drive vehicle
Diagnostic code No. 08
Lean angle sensor output voltage
Tool display • 0.4–1.4 (upright)
• 3.7–4.4 (overturned)
Remove the lean angle sensor and incline it more than 65 de-
Procedure
grees.
Probable cause of malfunc- Confirmation of service
Item Maintenance job
tion and check completion
1 Connection of lean angle Improperly connected → Turn the main switch to “ON”,
sensor coupler. Connect the coupler securely then to “OFF”, and then back
Check the locking condition or replace the wire harness. to “ON”.
of the coupler. Check the condition of the
Disconnect the coupler and fault code using the malfunc-
check the pins (bent or bro- tion mode of the Yamaha di-
ken terminals and locking agnostic tool.
condition of the pins). Condition is “Recovered” →
Go to item 6 and finish the
service.
Condition is “Detected” → Go
to item 2.
2 Connection of ECU coupler. Improperly connected → Turn the main switch to “ON”,
Check the locking condition Connect the coupler securely then to “OFF”, and then back
of the coupler. or replace the wire harness. to “ON”.
Disconnect the coupler and Check the condition of the
check the pins (bent or bro- fault code using the malfunc-
ken terminals and locking tion mode of the Yamaha di-
condition of the pins). agnostic tool.
Condition is “Recovered” →
Go to item 6 and finish the
service.
Condition is “Detected” → Go
to item 3.
3 Wire harness continuity. Open or short circuit → Re- Turn the main switch to “ON”,
place the wire harness. then to “OFF”, and then back
to “ON”.
Check the condition of the
fault code using the malfunc-
tion mode of the Yamaha di-
agnostic tool.
Condition is “Recovered” →
Go to item 6 and finish the
service.
Condition is “Detected” → Go
to item 4.

– 59 –
 FUEL INJECTION SYSTEM

3-1
2
1 5V 5V

L
3 L

Y/G
4 Y/G

B/L
5 B/L

1. Lean angle sensor

2. ECU
3. Sensor input lead
4. Sensor output lead
5. Sensor ground lead
3-2 Disconnect the ECU coupler from the ECU.
Disconnect the lean angle sensor coupler from the lean angle sensor.
3-3 [For P1604] Ground short circuit
Between lean angle sensor coupler and ground: yellow/green–ground
If there is continuity, replace the wire harness.

G G G
L Y/G B/L

3-4 [For P1605] Open circuit

Between lean angle sensor coupler and ECU coupler: blue–blue
If there is no continuity, replace the wire harness.

L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R Gy/R G/Y O
G G G
W/G Br/L Y/G Br/W L/W G/B B/Y R/B
L Y/G B/L
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B

– 60 –
 FUEL INJECTION SYSTEM

3-5 [For P1605] Open circuit

Between lean angle sensor coupler and ECU coupler: yellow/green–yellow/green
If there is no continuity, replace the wire harness.

L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R Gy/R G/Y O
G G G
W/G Br/L Y/G Br/W L/W G/B B/Y R/B
L Y/G B/L
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B

3-6 [For P1605] Open circuit

Between lean angle sensor coupler and ECU coupler: black/blue–black/blue
If there is no continuity, replace the wire harness.

L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R Gy/R G/Y O
G G G
W/G Br/L Y/G Br/W L/W G/B B/Y R/B
L Y/G B/L
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B

3-7 Disconnect the couplers from the parts that are connected to the ECU.
Refer to “Parts connected to the ECU” in chapter 8. (Manual No.: B34-F8197-E0)
3-8 [For P1604/P1605] Short circuit
Between lean angle sensor output terminal (yellow/green) “a” of ECU coupler and any other
ECU coupler terminal “b”.
If there is continuity, replace the wire harness.
a b

L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R Gy/R G/Y O
W/G Br/L Y/G Br/W L/W G/B B/Y R/B
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B

4 Defective lean angle sensor. Refer to “CHECKING THE Turn the main switch to “ON”,
LEAN ANGLE SENSOR” in then to “OFF”, and then back
chapter 8. (Manual No.: B34- to “ON”.
F8197-E0) Check the condition of the
fault code using the malfunc-
tion mode of the Yamaha di-
agnostic tool.
Condition is “Recovered” →
Go to item 6 and finish the
service.
Condition is “Detected” → Go
to item 5.

– 61 –
 FUEL INJECTION SYSTEM

5 Malfunction in ECU. Replace the ECU. Service is finished.

Refer to “REPLACING THE
ECU (engine control unit)” in
chapter 8. (Manual No.: B34-
F8197-E0)
6 Delete the fault code and Confirm that the fault code
check that the engine trouble has a condition of “Recov-
warning light goes off. ered” using the Yamaha diag-
nostic tool, and then delete
the fault code.

– 62 –
EAS20091
56. Coolant temperature warning EAS30613

WIRING DIAGRAM light COLOR CODE

MTM660 2016 57. High beam indicator light B Black
1. Main switch 58. Turn signal indicator light Br Brown
2. ABS solenoid fuse 59. ABS warning light Ch Chocolate
60. Horn Dg Dark green
3. ABS motor fuse
G Green
4. Parking lighting fuse 61. Gear position switch
Gy Gray
5. ABS control unit fuse 62. Handlebar switch (right) L Blue
6. Auxiliary fuse 63. Front brake light switch Lg Light green
7. Ignition fuse 64. Hazard switch O Orange
8. Signaling system fuse 65. Start/engine stop switch P Pink
9. Headlight fuse 66. Turn signal/hazard relay R Red
10. Fuel injection system fuse 67. Handlebar switch (left) Sb Sky blue
11. Backup fuse 68. Clutch switch W White
12. Radiator fan motor fuse 69. Dimmer switch Y Yellow
70. Pass switch B/G Black/Green
13. AC magneto
B/L Black/Blue
14. Rectifier/regulator 71. Turn signal switch
B/R Black/Red
15. Battery 72. Horn switch B/W Black/White
16. Engine ground 73. Rear turn signal light (right) B/Y Black/Yellow
17. Immobilizer unit 74. Rear turn signal light (left) Br/L Brown/Blue
18. Main fuse 75. Front turn signal light (right) Br/R Brown/Red
19. Starter relay 76. Headlight assembly Br/W Brown/White
20. Starter motor 77. Auxiliary light G/B Green/Black
21. Rear brake light switch 78. Headlight G/L Green/Blue
22. Relay unit 79. Front turn signal light (left) G/R Green/Red
23. Starting circuit cut-off relay 80. License plate light G/W Green/White
81. Tail/brake light G/Y Green/Yellow
24. Fuel pump relay
Gy/G Gray/Green
25. Joint coupler 82. Radiator fan motor
Gy/R Gray/Red
26. Sidestand switch 83. Radiator fan motor relay L/B Blue/Black
27. Crankshaft position sensor 84. Headlight relay L/G Blue/Green
28. O2 sensor 85. Auxiliary DC outlet L/R Blue/Red
29. Throttle position sensor A. Wire harness L/W Blue/White
30. Ignition coil #1 B. Positive battery sub-wire har- L/Y Blue/Yellow
31. Ignition coil #2 ness P/B Pink/Black
32. Spark plug C. Sub-wire harness (gear posi- P/L Pink/Blue
tion switch, coolant tempera- P/W Pink/White
33. Fuel injector #1
ture sensor, fuel injector) R/B Red/Black
34. Fuel injector #2 R/G Red/Green
35. ISC (Idle Speed Control) unit D. Sub-wire harness (throttle posi-
R/L Red/Blue
36. ECU (Engine Control Unit) tion sensor, ISC) R/W Red/White
37. Intake air temperature sensor E. Sub-wire harness (headlight, R/Y Red/Yellow
38. Coolant temperature sensor turn signal light, auxiliary light) Sb/W Sky blue/White
39. Intake air pressure sensor W/G White/Green
40. Lean angle sensor W/L White/Blue
41. Front wheel sensor W/R White/Red
42. Rear wheel sensor W/Y White/Yellow
Y/B Yellow/Black
43. ABS ECU (electronic control
Y/G Yellow/Green
unit) Y/L Yellow/Blue
44. Yamaha diagnostic tool coupler Y/W Yellow/White
45. Fuel sender
46. Fuel pump
47. Oil pressure switch
48. Meter assembly
49. Immobilizer system indicator
light
50. Neutral indicator light
51. Meter light
52. Tachometer
53. Multi-function meter
54. Oil pressure warning light
55. Engine trouble warning light
MTM660 2016
WIRING DIAGRAM
A B C

G/W B/L W P Y/W W/R W/R Y/W P W B/L G/W R/G W/G Br/L P/L
17 B B/W
Y/L
P/L Br/L W/G R/G
O Gy Sb G/B R/L R/L R/B R/B R/L R/L G/B Sb Gy O L W B/L R/W
R R B/L W L
R/G B B Lg G/B
(B) (B) (B) (B) R/G
R/W Lg Y/L
R/W R/W
A B A C A D L/W R/W Y L/R B/L B/L B/L
D P/B B/L
B/W R/G
Y/L G/B R/W
L/W L/WL/WL/W R/W R/W R/W R/W R/W R/W R/W 25 25 B/L
W
O R/B
G L/R Ch Ch L/R G
Y Y Y Y L/R L/R L/R L/R B/L B/L B/L
B/L 28 B
L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R Gy/R G/Y O
(B)
Dg B Y Y B Dg (B)
W/G Br/L Y/G Br/W L/W G/B B/Y R/B
R A R L/W
L/W
L/W
R/W R/W
R/W R/W
Y Y Y L/R
L/R L/R
B/L B/L B/L B/L B/L B/L B/L B/L B/L B/L
W
B B
L P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B
R/B
30
A E B/L B/L B/L B/L
(B)
B L O
(O)
R
R
R/B B/L
R/W Gy/G
(B)
32
R R R R R/B
R R C R/W P/B R/W R/B
R R R/B Gy/G B/L Y/L
B/L
W W W
18 Br Y L/R Y (B) P/B Gy/R R/B
1 R/W
R/W R R R
21 (B)
R/B Gy/G (B)
Br/L Br/L 13 15 L/W R/W R/W
(B)
L/W
ON
OFF (B) 19 L/W
Y Br Y L/R
R/B
31
P W W W O
Br/R Br/R B B/L Gy/R Gy/R
16 B
29 W W C W W
B
B/L 32
Br/L Br/R 14 R
B B/G L
B R B/G 27 Gy

B
B
L/W L/W
R/B
Sb/W R/W
33
(B) B B/L W L
B R/B R/B B R/B R/B R/L
L
22 Gy B
(B)
R R/W
20 23 24 R/W L/W R/B W/L R/L C
R/L R/B
L/W L/Y R/W L/G B/R Sb B/Y Sb/W Gy L
2 Gy B/L (Gy)
R/L
R/W B/Y Sb B/R L/G L/Y
34
3 W/L R/L L/Y
G/B G/B B G/B G/B R/L

Br/R L/R 25 25 B/R B/R

B/Y R/L G/B
4 B/Y
Br/W
B/Y B/R 26 B B L/G B
L
B/Y (Gy) Br/L P/L W/G R/G
(B)
Br/L 5 B/Y B/Y B/Y B/R B/R B/R
L/G B
(B)
B (B) L
Gy

Br/L Br/L R/Y L L

L
36 R/G R/G C R/G R/G 35
Br/L
6 B/L
W/G W/G C W/G W/G
R/W Br/L Br/L C Br/L Br/L
R/W Br/W B/L
Br/L R/W R/W
R/W
R/W 37 (B)
P/L P/L C P/L P/L
7 48 B/L Br/W Br/W
L/R
L/R L/R L/R 49
G/B
8 L/R
L/R
B Dg W/L R/W
G/W B/L
R/Y
R/Y
62 L/R Y R/W R/B W/L
Y Ch Br/W L/R R/B
50 B/L P/W L
38 (B)
(B)
9 B/L B/L
Sb/W (L) B/L B B/L B/L G/W G/W B G/W G/W
L/W
R R/B
64 65 R/W L/W
R/B B/L Br/W Ch B/L
Dg B
51 39 L/B
R/W L
10 R/G 63 (B)
51 B/L
L/R

R/G P/W P/W

11 Sb
Y/B
R Br/W
Ch Br/W Dg B
B
52 G G G
40 G/Y
12 L/R Sb L Y/G B/L L
Y/G Y/G B
61 R/W B/L
66 Br/W Sb
R/G R/L B/W
L/R Br/W Br/W Br/W P W W B W W G G G
L/R
W P P B P P
B/R Y G/L Br/W Dg Gy Y/W Y/W B Y/W Y/W L/B
67 B/R B/Y G/L Ch L/R G B/Y P Br/W L/R O W/R W/R B W/R W/R 53 W/Y

R/Y R/Y R R/W W/R O O B O O

R/L
B/Y B/R L/B Br Y/W Gy Gy B Gy Gy
Dg Br/W L/B Y B/Y R/L
84 83 B/W B/R G Br Ch
G/W
R/L R/L R/L B R/L

68 69 70 72 O Y/W W Sb
G/R
R/L
R/L B R/L

B/R 71 Gy W/R P
Sb P Gy W/R
W O Y/W
54
G/R
B/Y (B) (B)
(B) B/W
G/L Y/B R/Y L G/Y R L/R
G/L L
Y G Ch Dg P
55 G/R
L/R L/R Br/W
R/Y Y/B R/W G/Y L/R R/L
Ch Ch
P
56 R/L G/W
R/W G

Y L/R Ch Ch
Dg 60 47 L/B
W/Y
Ch
Dg Dg
B
46 45 L/B
L/B
L/B L/B
L/R
81 L
Y Dg Dg 57
L Y Y
G
43
82 Ch L/R G Y B Dg 74 Ch Dg 73 G W B
D D D D D D Ch 58 B B G/R
W W Gy
Ch L/R G Y B
B
Dg
Ch Dg R/L B G/W B Y B B W 41 W Gy
B B Dg B/W
B B (B) B/G B B Gy
L B L Y B B (Gy) (B)
59 B W W 42 W Gy

(B) B B Ch L/R G Y 76 Dg
Ch
B B
Dg
G/R
B/L B/L
B W
B
B L Y L/R
B/W L/R
79 L 77 75 B B
G/R G/W L/R L/B Sb/W Y Dg Ch G/R 25
B/W 80 L
Ch 78 Dg
(Gy)
B
B
B
(B)
B/G
Gy O W/R Y/W P W R/W R/G G/B B/W

B B (Gy)
(B) R/W W B B W G G/R W/Y B
L B L B B B/G
B B/G L/R L/B R/W
B (Gy) (B) B B B B B/GB/WB/W R/L Y G G Br/W L/R L/B B/L B/G
B
(Gy)
B
B B G
B
B
R/W B
44 L/B (B)

L/R
B
B
Ch
B L/R
Y
(B)
B
B
Dg
B
B B/G 25 B/G B B B/W B/W B/G
B/W B/W B/W
L/R
B B B B
B (B)
(Gy) (B) B B B/W B/W (O)
(Gy)
B/W
B/W R/Y

R/Y
85 B/W
MTM660 2016
WIRING DIAGRAM
A B C

17

(B) (B) (B) (B)

A B A C A D
D

25 25
28 (B)
(B)

A
30
A E (B)
(O)
(B)
32
C

18 (B)
1 21 (B) (B)

13 15 (B)
ON
OFF (B) 19 31
P

16 29 C
32
14
27
33
(B)
B

22 (B)
20 23 24 C

2 (Gy)
34
3 B

25 25
4
26 (Gy)
(B)
5 (B)
(B)

36 C 35
6 C
C

37 (B)
C

7 48 49
8
62 50 38 (B)
(B)
9 (L) B B

64 65 51 39
10 63 (B)
51
11
B
52 40
12
61
66
B
B
B

67 B 53
B
B

84 83 B

68 69 70 72 B

71 54
(B) (B)
(B)
55
56
60 47
46 45
81 57
43
82 74 73
D D D D D D 58
41
(B)
(Gy) (B)
59 42
(B) 76
79 77 75 25
80 78
(Gy) (B)
(Gy)
(B)

(Gy) (B)
(Gy) 44 (B)

(B)
25
(B)
(Gy) (B) (O)
(Gy)

85