2024

SERVICE MANUAL

MT-09
MT-09SP

MT09R
MT09RC
MT09SPR
MT09SPRC
LIT-11616-37-68 BME-28197-10
EAS20003

IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Please refer to “BASIC INFORMATION” (separate volume, Y0A-28197-10*) for basic instructions that
must be observed during servicing. Repair and maintenance work attempted by anyone without this
knowledge is likely to render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the vehi-
cle will operate as designed. If there is any question about a service procedure, it is imperative that you
contact a Yamaha dealer for any service information changes that apply to this model. This policy is in-
tended to provide the customer with the most satisfaction from their vehicle and to conform to federal
environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
TIP
• * If the contents of the manual are revised, the last digit of the manual number will be increased by one.
• This Service Manual contains information regarding periodic maintenance to the emission control sys-
tem. Please read this material carefully.
• Designs and specifications are subject to change without notice.

EAS30001

IMPORTANT MANUAL INFORMATION

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

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

WARNING result in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid

NOTICE damage to the vehicle or other property.

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

EAS20002

MT09R/MT09RC
MT09SPR/MT09SPRC
SERVICE MANUAL
©2024 by Yamaha Motor Corporation, U.S.A.
First edition, February 2024
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-11616-37-68
EAS20004

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive ex-
planations of all installation, removal, disassembly, assembly, repair and check procedures are laid out
with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc. This step explains removal and disassembly procedure only. For installation
and assembly procedure, reverse the steps.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
1

2
4

5
6 7

G088877
EAS20005

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

SYMBOL DEFINITION SYMBOL DEFINITION

Serviceable with engine mounted Gear oil

G

Filling fluid Molybdenum disulfide oil

M

Lubricant Brake fluid

BF

Special tool B Wheel bearing grease

Tightening torque LS Lithium-soap-based grease

T.
R.

Wear limit, clearance M Molybdenum disulfide grease

Engine speed S Silicone grease

Electrical data Apply locking agent (LOCTITE®).

LT

Engine oil New Replace the part with a new one.

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

IDENTIFICATION ............................................................................................ 1-1

VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL.......................................................................................... 1-1

FEATURES...................................................................................................... 1-2
1
GLOSSARY............................................................................................... 1-2
DISPLAY ...................................................................................................1-2
MENU SYSTEM ........................................................................................1-9

BASIC SERVICE INFORMATION.................................................................1-24

ELECTRICAL SYSTEM...........................................................................1-24

SPECIAL TOOLS .......................................................................................... 1-25

 IDENTIFICATION

EAS20007

IDENTIFICATION
EAS30002

VEHICLE IDENTIFICATION NUMBER

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

EAS30003

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

1-1
 FEATURES

EAS20008

FEATURES Theme3
2
EAS31706

4 6
GLOSSARY
ABS - Anti-lock Brake System 3 2
ABS ECU - Anti-lock Brake System Electronic 5
Control Unit
BC - Brake Control 7
BCM - Body Control Module
BSR - Back Slip Regulator 1
EBM - Engine brake management
ECU - Engine Control Unit Theme4
GCU - Generator Control Unit 2
IMU - Inertial Measurement Unit
3
LIF - Lift Control System 7
PWR - Power delivery mode 2
QS - Quick Shifter 2
SCS - Slide Control System 4
TCS - Traction Control System 5
1
YRC - Yamaha Ride Control
6
EAS31707

DISPLAY 1. Vehicle information display

The following items can be found on the display: 2. Indicator icons
Theme1 3. Clock
5 4. Transmission gear display
6 5. Speedometer
4 6. YRC mode display
3 7. Tachometer
2
TRACK (for MT09SPR/MT09SPRC)
2 6 7 8 6
7
5
1
9
4 6
Theme2 mile

2 3 10
6 2 60 26 °F 11
4 MPH
12
3
1
7
2 1. YRC mode display
2 2. Speedometer
3. Vehicle information display
5
4. Lap counter
1
5. Transmission gear display
6. Indicator icons
7. Shift indicator
8. Revolution peak hold indicator
9. Tachometer
10. Clock
11. Coolant temperature display
12. Lap time display

1-2
 FEATURES

Minimized display view (while menu system/ • The display units can be switched between ki-
navigation are open) lometers-miles and Celsius-Fahrenheit.
When the menu system or the navigation func- • The navigation system display units can be
tion are open, the information on the main dis- changed separately using the Garmin Street-
play is relocated as shown. Cross app.
Theme1, 2, 3 Display system controls
4 1 5 1 The display user interface is controlled with the
6 joystick / “ ” and the home button “ ”. Each
3 control has various functions for different situa-
2 2 tions, see the following list for details.
Operate the joystick left-right-updown:
Main display active: highlights and adjusts items
1 1
in the vehicle information display, and also the
YRC mode display (Theme4, TRACK).
Navigation active: up-down zoom the map view
in-out.
Theme4, TRACK (for MT09SPR/MT09SPRC)
Turn-by-turn pop-up active: left-right adjust the
1 7 5 1
displayed information.
6 3 Menu system active: highlight and adjusts vari-
ous menu items.
2 2 Short press “ ”:
Main display active: highlight and select items in
1 1 the vehicle information display, and also the
YRC mode display (Theme4, TRACK).
Navigation active: directly open the “Navigation”
4
menu display.
1. Indicator icons Menu system active: select highlighted menu
2. Vehicle information display items.
3. Transmission gear display
Long press “ ”:
4. Clock
Highlighted vehicle information display item
5. Speedometer
flashing: reset the item.
6. YRC mode display
Smartphone connected with music app: play/
7. Tachometer
pause music (except TRACK).
TIP Short press the home button “ ”:
• The brightness level of the display screen can Main display/navigation active: open the first
be adjusted in the menu system. pop-up layer of the menu system.
• If the display becomes too hot, the display Menu system active: cancel/return to previous.
screen brightness levels will automatically re- Long press the home button “ ”:
duce to avoid damage. Main display active: switch to navigation display
• This model uses a thin-film-transistor liquid- (except TRACK).
crystal display (TFT LCD) for good contrast Navigation active: switch to main display.
and readability in various lighting conditions. Menu system active: exit to the previously open
However, due to the nature of this technology, main display/navigation display.
it is normal for a small number of pixels to be in-
active. Clock
• In TRACK theme, the audio player, telephone The clock uses a 12-hour time system. The
and headset related functions are not control- clock is updated automatically from connected
lable from the vehicle. smartphones or can also be manually set in “
Settings” > “Clock”.

1-3
 FEATURES

Speedometer In Theme1-3:
The speedometer shows the vehicle’s traveling
speed.

Tachometer
The tachometer shows the engine speed, as
measured by the rotational velocity of the crank-
shaft, in revolutions per minute (r/min).
ECA19660

NOTICE
Do not operate the engine in the tachometer
red zone.
Long press the YRC mode button “MODE” to
open/close an expanded YRC mode pop-up at
Transmission gear display
the bottom of the screen. While the pop-up is
This display shows which gear the transmission
open, short press the YRC mode button
is in. This vehicle has 6 gears and a neutral po-
“MODE” to cycle through the presets and use
sition. The neutral position is indicated by the
the joystick to adjust individual items.
neutral indicator light “ ” and by the transmis-
TIP
sion gear display reading: “ ”.
• If the selected YRC mode is customizable,
YRC mode display “PWR”, “TCS”, “SCS”, and “LIF” can be high-
This display indicates which YRC mode is cur- lighted and adjusted using the joystick.
rently selected: “SPORT”, “STREET”, “RAIN”, • “EBM” can be adjusted for any of the YRC
“CUSTOM 1” and “CUSTOM 2” (In TRACK modes.
theme, “TRACK 1” or “TRACK 2”).
Cycle through the YRC modes by using the YRC Vehicle information display
mode button “MODE” and also view/customize The vehicle information display contains 3 cells
them in the menu system. which can be set to display the following:
TIP • Odometer (ODO)
The names of “CUSTOM 1” and “CUSTOM 2” • Two tripmeters (TRIP 1 / TRIP 2)
can also be customized via the My Ride app. • Fuel reserve tripmeter (TRIP F)
• Instantaneous fuel consumption (INST FUEL)
In Theme4, TRACK (for MT09SPR/ • Average fuel consumption (AVG FUEL)
MT09SPRC): • Estimated fuel range (RANGE)
In these themes, the YRC mode display is ex- • Coolant temperature (COOLANT)
panded to show the current “PWR”, “TCS”, • Air temperature (AIR)
“SCS”, “LIF” and “EBM” settings for each YRC • Trip timer (TRIP TIME)
mode. In addition to using the YRC mode button • Fuel Meter
“MODE”, you can move the joystick up-down to In Theme1-3:
cycle between the vehicle information display • Move the joystick left-right to cycle between the
and the YRC mode display. When highlighted, cells. Move the joystick up-down to cycle the
short press “ ” to select the YRC mode display. display item for the highlighted cell. If a display
Move the joystick left-right to cycle between the item is flashing, long press “ ” to reset it.
available items. Move the joystick up-down to
• It can also be set in “Vehicle Info ” in the
cycle the highlighted YRC mode or change the
menu system.
setting for the highlighted item.
TIP
In TRACK theme, simply operating the joystick
will adjust the YRC mode display. You do not
need to first highlight and select the YRC mode
display.

1-4
 FEATURES

In Theme4: Instantaneous fuel consumption (INST FUEL)

Move the joystick up-down to cycle between the When using kilometers, the instantaneous fuel
vehicle information display and the YRC mode consumption display can be set to “km/L” or “L/
display. When highlighted, short press “ ” to se- 100km”.
lect the vehicle information display. Move the When using miles, the instantaneous fuel con-
joystick left-right to cycle between the cells. sumption is displayed in “MPG”.
Move the joystick updown to cycle the display Average fuel consumption (AVG FUEL)
item for the highlighted cell. If a display item is When using kilometers, the average fuel con-
flashing, long press “ ” to reset it. sumption display can be set to “km/L” or “L/
In TRACK (for MT09SPR/MT09SPRC): 100km”. When using miles, the average fuel
The vehicle information display contains 1 cell consumption is displayed in “MPG”.
which can be set to display the following: Estimated fuel range (RANGE)
• Fastest lap time (FASTEST) The estimated distance that can be traveled un-
• Latest lap time (LATEST) der the current riding conditions with the remain-
• Odometer (ODO) ing fuel.
• Average fuel consumption (AVG FUEL) Coolant temperature (COOLANT)
• Air temperature (AIR) The coolant temperature is displayed from –30
Navigate to “ Vehicle Info” in the menu system °C (–22 °F) to 130 °C (266 °F) in 1 °C (1 °F) in-
to highlight the vehicle information display. Once crements.
highlighted, operate the joystick up-down to cy- TIP
cle the visible item. • When using Celsius, the coolant temperature
If a display item is flashing, long press “ ” to re- display will read “–30” when the vehicle coolant
set it. temperature is below –30 °C.
TIP • When using Fahrenheit, the coolant tempera-
• Resettable items can also be individually ture display will read “–22” when the vehicle
viewed and reset by navigating to “ Settings” coolant temperature is below –22 °F.
> “Information / Reset” in the menu system. • If the vehicle coolant temperature is too high
the coolant temperature display will read “Hi”.
• While on the navigation display, navigate to “
Vehicle Info” in the menu system to highlight Air temperature (AIR)
the two cells. The air temperature is displayed from –9 °C (15
°F) to 50 °C (122 °F) in 1 °C (1 °F) increments.
Odometer (ODO)
The temperature displayed may vary from the
The odometer shows the total distance traveled
actual ambient temperature.
by the vehicle.
TIP
TIP
• “---” will be displayed if the detected tempera-
The odometer will lock at 999999 and cannot be
ture is lower than –9 °C (15 °F).
reset.
• “---” will be displayed if the detected tempera-
Tripmeters (TRIP 1 / TRIP 2) ture is higher than 50 °C (122 °F).
“TRIP 1” and “TRIP 2” show the distance trav-
Trip timer (TRIP TIME)
eled since they were last set to zero.
Displays the engine running time.
“TRIP 1” and “TRIP 2” will reset to 0 and begin
Fuel Meter
counting again after 9999.9 has been reached.
The fuel meter indicates the amount of fuel in the
Fuel reserve tripmeter (TRIP F)
fuel tank. The display segments of the fuel meter
When the fuel tank reserve level has been
disappear from “F” (full) towards “E” (empty) as
reached, “TRIP F” activates and begins record-
the fuel level decreases. When the last segment
ing distance traveled from that point. After refu-
starts flashing, refuel as soon as possible.
eling and traveling some distance, “TRIP F” will ECAE0121
automatically deactivate and reset. NOTICE
TIP Do not let the vehicle run completely out of
When “TRIP F” is inactive it will show as “--.-”. fuel. This may cause damage to the catalytic
converter.

1-5
 FEATURES

Fastest lap time (FASTEST) (for MT09SPR/ Quick shift indicator “QS”
MT09SPRC) This icon and accompanying arrow icons indi-
Indicates the fastest lap time recorded since the cate the status of the quick shifter.
lap timer was started. If no laps have been re- Respective arrow icon off: the quick shifter is dis-
corded, it will read 00:00.00. abled.
Latest lap time (LATEST) (for MT09SPR/ “ ”: the system is active for upshifts but cannot
MT09SPRC) currently quickshift.
Indicates the latest lap time recorded. If no laps “ ”: the system is active for downshifts but can-
have been recorded, it will read 00:00.00. not currently quickshift.
“ ”: quick upshift available.
Warning and indicator icons
“ ”: quick downshift available.
TIP
The upshift and downshift functions are inde-
pendent and can be activated separately in the
MPH menu system.
Network connectivity indicator “ ” (except
TRACK)
This icon indicates the connected smartphone’s
network connection status.
Low fuel indicator “ ” Icon off: No smartphone connected.
This icon comes on when approximately 2.5 L : A smartphone is connected but has no net-
(0.66 US gal, 0.55 Imp.gal) of fuel remains in the work connectivity.
tank. : A smartphone is connected and has network
Coolant temperature warning “ ” connectivity. The icon segments indicate the sig-
This icon appears when the coolant temperature nal strength.
is high. Stop the vehicle and turn off the engine. TIP
Allow the engine to cool. This icon may not operate with some smart-
ECA10022
phone models, even if the connected smart-
NOTICE phone has network connectivity.
Do not continue to operate the engine if it is
overheating. Smartphone battery level indicator “ ” (except
TRACK)
Oil pressure warning “ ” This icon indicates the connected smartphone’s
This icon appears when the engine oil pressure battery level.
is low. When the vehicle is first turned on, engine Icon off: No smartphone connected.
oil pressure has yet to build, so this indicator will : The center bar moves up and down to indi-
come on and stay on until the engine has been cate the battery level.
started. : Smartphone is charging.
TIP TIP
If a malfunction is detected, this icon will flash re- The battery level indicated by the icon may not
peatedly. always be consistent with the battery level dis-
ECA26410 played on the smartphone.
NOTICE
Headset indicator “ ” (except TRACK)
Do not continue to operate the engine if the
This icon comes on if a Bluetooth headset is
oil pressure is low.
connected to the smartphone.
Auxiliary system warning “ ” TIP
This icon appears if a problem is detected in a For some smartphones, this icon may go off
system not related to the engine. during phone calls.

1-6
 FEATURES

ECA17932
My Ride app indicator “ ” (except TRACK)
NOTICE
This icon comes on when the My Ride app is
successfully connected to the vehicle. • Be sure to wear gloves when using the grip
: The icon turns yellow when the connected warmers.
smartphone becomes overheated. • Do not use the grip warmers in warm
weather.
TIP
• If the handlebar grip or throttle grip be-
Depending on the smartphone, the icon may re- comes worn or damaged, stop using the
main yellow even after the smartphone is no lon- grip warmers and replace the grips.
ger overheating.
BC indicator “ ”
Navigation connection indicator “ ” (except This icon comes on if “BC” (brake control sys-
TRACK) tem) is deactivated.
This icon comes on when the Garmin Street- ECA28560

Cross app is connected. NOTICE

Telephone indicator “ ”/“ ” (except TRACK) When turning the main switch on, avoid any
This icon comes on green when there is an ac- movement or vibration of the vehicle as it
tive call and red when there is a recent missed may interfere with the initialization of the
call. The missed call icon will disappear when IMU. If this occurs, the brake control system
the recent contact list is opened at “ Applica- will not operate and the BC indicator will
tions” > “Phone” in the menu system. come on until the IMU can initialize.
Notification indicator “ ” (except TRACK)
SCS indicator “ ”
This icon comes on when the connected smart-
This icon comes on if “SCS” (slide control sys-
phone receives an SNS, Email or other notifica-
tem) is deactivated.
tion. After that, the icon stays on until you turn
the vehicle off. Check the notifications by navi- LIF indicator “ ”
gating to “ Applications” > “Notification” in the This icon comes on if the “LIF” (lift control sys-
menu system. tem) is deactivated.
TIP BSR indicator “ ”
• This function works only when a smartphone is This icon comes on if the “BSR” (back slip regu-
connected to the CCU via the My Ride app. lator) is deactivated.
• Permission to access notifications must be REAR ABS OFF indicator “ ” (for MT09SPR/
granted to the My Ride app on your smart- MT09SPRC)
phone. This icon comes on to indicate that “REAR ABS
OFF” has been selected in the menu system and
Grip warmer indicator “ ” (except TRACK) (if the rear wheel anti-lock braking system is dis-
equipped) abled.
The grip warmers can be used when the engine Cruise control indicator “ / / ” (except
is running. There are 3 customizable tempera- TRACK)
ture presets that can be customized between 10 This icon comes on if the cruise control system is
different temperature levels. on standby, turns green when the system is ac-
The icon displays the current temperature set- tive, or amber if there is an error.
ting: Set speed indicator “ / ” (except TRACK)
: Grip warmer off This indicator displays the current set speed of
: Low preset the cruise control system. This icon comes on if
: Medium preset the cruise control system is on standby and
: High preset turns green when the system is active.
Coolant temperature display (TRACK) (for
MT09SPR/MT09SPRC)
The coolant temperature is displayed from –30
°C (–22 °F) to 130 °C (266 °F) in 1 °C (1 °F) in-
crements.

1-7
 FEATURES

TIP Shift indicator (TRACK) (for MT09SPR/

• When using Celsius, the coolant temperature MT09SPRC)
display will read “– 30” when the vehicle cool- A series of cells that sequentially come on and
ant temperature is below –30 °C. change color as engine speed increases. This
• When using Fahrenheit, the coolant tempera- indicator uses the same settings as the shift in-
ture display will read “–22” when the vehicle dicator light, which can be adjusted by navigat-
coolant temperature is below –22 °F. ing to “ Settings” > “Shift Indicator” in the menu
• If the vehicle coolant temperature is too high system.
the coolant temperature display will read “Hi”.
Navigation Display
Lap timer (TRACK) (for MT09SPR/MT09SPRC) There are 3 display modes for route guidance:
This stopwatch function is controlled using the “Default View”, “Turn-by-Turn”, and “Turn List”.
menu system and the dimmer/pass switch. Default View
In TRACK theme, open the menu system and
select “ Timer Ready”. The menu will exit to the
main display and the “:” and “.” in the lap timer
will blink to indicate the lap timer is on standby.
Press the dimmer/pass switch down towards
“PASS” to start the timer.
Each press of the dimmer/pass switch will in-
crease the lap count by 1 and reset the current
lap timer.
To stop the lap timer, open the menu system
and select “ Timer Stop” and the timer will re- In “Default View” mode: Operate the joystick up-
turn to standby. down to zoom in/out.
The lap timer can be resumed by selecting “ Turn List
Timer Ready” in the menu system and once
again pressing the dimmer/pass switch down to-
wards “PASS”.
To reset the lap timer and delete all recorded lap
times and other lap data, navigate to “ TRACK
Settings” > “Lap Reset” in the menu system.
TIP
The headlight does not flash when the dimmer/
pass switch is pressed in TRACK.
Lap counter (TRACK) (for MT09SPR/ In “Turn List” mode: Operate the joystick up-
MT09SPRC) down to scroll through the list of turns on the
Counts the number of times the dimmer/pass route.
switch is pressed down towards “PASS” to a Turn-by-Turn
maximum of 40 before resetting.
Revolution peak hold indicator (TRACK) (for
MT09SPR/MT09SPRC)
This small bar momentarily appears within the
tachometer to mark the most recent peak engine
speed.

1-8
 FEATURES

In “Turn-by-Turn” mode: Operate the joystick left- • Short press the home button “ ” to cancel/re-
right to cycle the information at the bottom of the turn to previous.
display between distance remaining to destina- • Long press the home button “ ” to close the
tion/estimated time to arrival and current location. menu system.
Short press “ ” to open the menu system and TIP
navigate to “ Applications” > “Navigation” >
When arrows appear “ ”/ “ ” a menu item, op-
“Change View” to switch between the display
erating the joystick in the direction of the arrows
modes.
will adjust the selected function.
TIP
• If the Bluetooth connection becomes unstable, The pop-up menu is divided into the following
the navigation display may automatically main functions:
change to the “Turn-by-Turn” mode or freeze Select the visual theme of
with a loading animation. When the connection “Theme” the display.
improves, the navigation display will return to
Access the smartphone re-
the former setting.
“Applications” lated functions.
• For some smartphones, using the phone func-
tion while navigation is in progress may display
a connection error after returning to the naviga- “Grip Warmer” Control the grip warmers.
tion display. If this happens, follow the instruc- (if equipped)
tions on the display. Reset/cycle the vehicle in-
• If the connected smartphone’s AI assistant “Vehicle Info” formation display items.
function is deactivated in the smartphone’s set- Adjust settings related to
tings, and a headset is also connected, a con- “Settings” the vehicle’s operation.
nection error may be displayed when using the
navigation home display (iOS only). Open the telephone func-
“Phone” (if call
tion for an active call.
active)
EAS33988

MENU SYSTEM Access simple pop-up au-

“Music” dio player.
Open the navigation dis-
“Navigation” play.

Open the main display.

“Meter Display”
Activate Turn-by-Turn
“Turn-by-Turn” route guidance.
1
De-activate Turn-by-Turn
“Turn-by-Turn
1. Pop-up menu route guidance.
OFF”
The menu system for this vehicle is controlled
with the joystick/home button on the left handle- “Timer Stop”
Stops lap timer.
bar. (for MT09SPR/
The first layer of the menu is a pop-up at the bot- MT09SPRC)
tom of the main display. Deeper layers of the
menu system are viewed using the minimized “Timer Ready” Resets lap timer to stand-
display view. (for MT09SPR/ by.
To open the pop-up menu from the main display: MT09SPRC)
Short press the home button “ ”.
Menu system operation: “TRACK Set-
• Operate the joystick left-right-updown to high- Shift indicator and lap timer
tings” (for
settings.
light and adjust menu items. MT09SPR/
• Short press “ ” to select an item. MT09SPRC)

1-9
 FEATURES

TIP When a command is used to select a destina-

• The items contained in the menu vary depend- tion, the navigation display will open and show
ing on the currently selected theme and also the new/updated route.
whether the main display or navigation display
is active.
• If the vehicle is in motion, “ Theme” and “
Settings” will be grayed out.
• If a smartphone is not connected to the vehicle,
“ Music” and “ Turn-by Turn/Turn-by-Turn
OFF” will be grayed out.

Theme
The visual theme of the main display can be If route guidance is already active when a com-
changed between four options. mand is used to select a destination, the follow-
ing options will be available:
Applications > Navigation “Start a New Route”: Cancels previous route and
sets route to new destination.
“Add as Next Stop”: Adds new destination as the
next stop in the current route.
“Add as Last Stop”: Adds new destination as the
last stop in the current route.

This menu contains the following commands for

the navigation system:
• “Change View”
• “Stop Navigation”
• “Skip Next Stop”
• “Go Home” If a route requires a toll, you will be prompted to
• “Go to Work” search for another route without tolls. Select
• “Favorites” “Yes” to find a route without tolls. Select “No” to
• “Nearby Gas Stations” accept the current route.
TIP TIP
• Except for the commands listed above, oper- After 10 seconds, the route (with tolls) will be se-
ate the navigation system using the Garmin lected automatically.
StreetCross app on your smartphone. “Change View”
• “Change View”, “Stop Navigation” and “Skip
Next Stop” are not available unless route guid-
ance is active.

1-10
 FEATURES

This menu changes the navigation system dis- TIP

play mode (Default View/Turn List/Turn-by- If route guidance is in progress, arrows appear
Turn). After selection, the navigation display will showing direction to the gas stations. The cur-
open in the selected display mode. rent direction of travel is indicated by the up-
“Stop Navigation” wards arrow.
Cancels the current route guidance and opens
the navigation home display.
“Skip Next Stop” Applications > Music
Skips the next stop in your planned route and
opens the navigation home display.
“Go Home”
Sets route guidance for home location (home lo-
cation must already be set in the Garmin Street-
Cross app).
“Go to Work”
Sets route guidance for work location (work lo-
cation must already be set in the Garmin Street-
Cross app).
“Favorites” This opens an audio player which interfaces with
your smartphone’s audio player app.
Operate the joystick up-down to adjust the vol-
ume.
Operate the joystick left-right to skip to the next/
previous track.
Short press “ ” to play/pause the track.
TIP
• All audio track information is imported from the
music player application on your smartphone.
• Depending on the smartphone and music play-
Shows a list of saved locations and their dis- er application, the audio player may start play-
tance from current location (must have saved lo- ing automatically, the track information may
cations in the Garmin StreetCross). not display, or the next/previous track and vol-
TIP ume adjustment may not function.
If route guidance is in progress, arrows appear
showing the direction to the saved locations.
Applications > Phone
The current direction of travel is indicated by the
upwards arrow.
“Nearby Gas Stations”

This is a list of recent telephone calls (since con-

nection to CCU) from the connected smart-
phone. When this list has been viewed, the
Shows a list of nearby gas stations and their dis- missed call indicator “ ” will disappear.
tance from current location. : Inbound missed call (red arrow)
: Inbound call (green arrow)

1-11
 FEATURES

TIP
• Repeated calls for the same contact are indi-
cated by the number next to the contact in
brackets.
• The maximum number of stored items is 30;
when the limit is reached, older items will be
deleted.

Applications > Weather

TIP
• For some smartphones and/or applications,
notifications may not function.
• The maximum number of stored items is 30.
When the limit is reached, older items will be
deleted.
• If a message is too long then not all of it will be
displayed.
• Messages cannot be opened and read while
the vehicle is in motion.
This menu displays weather information at your
• Notification timestamps may be slightly differ-
current location. Operate the joystick up-down to
ent than when displayed on your smartphone.
change the timeframe of the weather information
(hourly/daily).
TIP Applications > Information Transfer
The weather information in this menu may be This menu allows you to transfer and display im-
different than on the navigation home display. ages on the display using the My Ride app.

Applications > Connectivity Settings > Con-

Applications > Notification nection > Bluetooth

This is a list of notifications (since connection to “Bluetooth”

CCU) from the connected smartphone. Select Turns the CCU’s Bluetooth ON/OFF. The check-
an item to read the notification message. The mark indicates ON.
notification indicator “ ” will not turn off until the “Discovery Mode”
vehicle power is turned off. Puts the CCU in Bluetooth discovery mode
when pairing a smartphone.

1-12
 FEATURES

“Paired Devices” Applications > Connectivity Settings > Sys-

tem Information

Paired smartphones are listed here. The My

Ride app symbol “ ” next to a device name indi- This menu displays the current system software
cates that the app is currently connected to the version.
CCU. The Bluetooth symbol “ ” next to a device “Unit ID”
name indicates that Garmin Street- Cross is cur-
rently connected to the CCU.
TIP
There is a maximum of 8 paired devices.
Select a device name for more options:

This menu contains a QR code with the CCU’s

unit identification number. Short press “ ” to re-
turn to the previous menu.
TIP
The CCU’s unit ID is only required for dealer ser-
vice operations.
“Delete Pairing”: Deletes the selected paired de-
vice from the CCU memory.
“Connect”: Connect to the selected paired de- Applications > Connectivity Settings > Legal
vice. Information
“Disconnect”: Disconnect from the selected
paired device.
TIP
If “Bluetooth Auto Connect” is on, the CCU may
immediately reconnect to the smartphone after
being disconnected.
“Bluetooth Auto Connect”
Turns the Bluetooth automatic connection ON/
OFF. The checkmark indicates ON. When the
auto connect is ON, the CCU will automatically Third-party license agreements can be viewed
connect to the last connected device. If it is not here.
available, the CCU will attempt to connect to an-
other device in the paired device list.
TIP
If “Bluetooth Auto Connect” is OFF, previously
paired devices can be connected manually via
the “Paired Devices” list.

1-13
 FEATURES

Grip Warmer (if equipped) Module Description

Reset vehicle infor-
“Information /Reset”
mation.
Adjust vehicle elec-
“Vehicle Function”
tronic rider aids.
Adjust time/set auto-
“Clock”
matic update.
Change display
“Display” brightness and back-
ground settings.
With this item highlighted, operate the joystick
up-down to cycle between grip warmer OFF and Change the display
“Unit”
3 presets which can be customized in “ Set- units.
tings” > “Grip Warmer Settings”. “Grip Warmer Set- Customize the grip
With this item highlighted, long press “ ” to tings” (if equipped) warmer presets.
shortcut to “ Settings” > “Grip Warmer Set- Change the shift indi-
“Shift Indicator”
tings” where the grip warmer presets can be fur- cator settings.
ther customized. “Connectivity Set- Smartphone connec-
TIP tings” tivity settings.
Theme4: This function is not accessible via the
menu system and is instead located within the
vehicle information display. The function is the Settings > Information / Reset
same.

Vehicle Info
This allows you to adjust the vehicle information
display items.
TIP
This function is not available in Theme4.

Settings This menu allows the viewing and reset of trip-

meters, maintenance tripmeters, vehicle infor-
mation items, and the mass reset of other
settings to factory defaults.
“Trip Mileage Reset”

The “Settings” menu contains the following:

This menu allows reset of the tripmeters on the

vehicle information display. Operate the joystick
to highlight an item. Short press “ ” to reset the
item. Confirm by selecting “OK”.

1-14
 FEATURES

TIP TIP
“TRIP F” can only be selected when the fuel is • After a reset, the display will restart and may
low. Otherwise the item is grayed out. take several minutes to reboot.
• If “All Reset” is executed, the corresponding
“Maintenance Reset”
pairing record must be deleted from the smart-
phone in order to pair again.
• Before selling or changing ownership of the ve-
hicle, reset the multi-function meter to ensure
all personal data from your smartphone (i.e.,
call history and contact information) is deleted.
• After the multi-function meter is reset, Blue-
tooth pairing records and the My Ride app pair-
ing records must be deleted from your
smartphone. If this is not completed, the CCU
This menu allows you to record distance trav- will not be able to pair with the smartphone
eled between engine oil changes “OIL” and two again.
other maintenance items of your choice “FREE- • The multi-function meter cannot be reset while
1” and “FREE-2”. After maintenance to one of the vehicle is in motion.
the items has been completed, operate the joy-
stick to highlight the item. Short press “ ” to re- Settings > Vehicle Function > YRC Settings >
set the item. Confirm by selecting “OK”. YRC Modes
“Vehicle Info”

This menu allows reset of the vehicle informa-

tion display items. Operate the joystick to high-
light an item. Short press “ ” to reset the item.
Confirm by selecting “OK”. ALL MODES
“All Reset”

This menu allows you to:

• View the five YRC mode presets and the two
presets: “SPORT”, “STREET”, “RAIN”, “CUS-
TOM 1” and “CUSTOM 2”.
• Customize the “PWR”, “TCS”, “SCS” and “LIF”
setting levels for the “CUSTOM 1” and “CUS-
Use this menu to mass reset the multi-function TOM 2” YRC mode presets.
meter to its default settings. This includes YRC • Customize the “QS ”, “QS ” and “BC” set-
settings, display settings, grip warmer presets, ting levels for all YRC mode presets.
traction control, units, Bluetooth connection set-
tings, and vehicle information display items.
Confirm by selecting “OK”.

1-15
 FEATURES

Operate the joystick up-down to select the YRC This model uses a variable traction control sys-
mode preset that you want to adjust. tem. For each setting level, the farther the vehi-
Operate the joystick left-right to select the YRC cle is leaned over, the more traction control
item that you want to adjust. Adjust the selected (system intervention) is applied. There are 3 set-
YRC item by operating the joystick up-down. ting levels available. Level 1 applies the least
Short press “ ” to switch to a visual representa- system intervention, while level 3 applies the
tion of the highlighted YRC item. Short press the most overall traction control to reduce rear
home button “ ” to exit the visual representa- wheel slippage.
tion. Level 1 - Suitable for more sporty riding.
Short press the home button “ ” to save and go Level 2 - Suitable for street riding.
back to the previous menu. Level 3 - Suitable for riding on wet or slippery
TIP surfaces.
• The names and setting levels for “CUSTOM 1”, TIP
“CUSTOM 2”, “TRACK 1” and “TRACK 2” can The traction control system can only be turned
also be changed via the My Ride app. off completely via “ Settings” > “Vehicle Func-
• Adjustments to “QS” or “BC” settings affect all tion” > “Stability Control ON/OFF”.
YRC mode presets.
“SCS” (Slide control system)
“PWR” (Power delivery mode)

“SCS” can be set to 1, 2, and 3. Setting level 1

“PWR” can be set to 1, 2, 3 and 4. provides the least amount of system interven-
Level 1 - Sporty engine response. tion, and setting level 3 provides the greatest
Level 2 - Moderate engine response. amount of system intervention to reduce lateral
Level 3 - Mild engine response. wheel slippage.
Level 4 - Rainy days or whenever less engine Level 1 - Suitable for racing more sporty riding.
power is desirable. Level 2 - Suitable for street riding.
TIP Level 3 - Suitable for riding on wet or slippery
35kw restricted vehicles are limited to two PWR surfaces.
levels: TIP
Level 1: Moderate engine response. The slide control system can only be turned off
Level 2: Rainy days or whenever less engine completely via “ Settings” > “Vehicle Function”
power is desirable. > “Stability Control ON/OFF”.
“TCS” (Traction control system) “LIF” (Lift control system)

1-16
 FEATURES

“LIF” can be set to 1, 2, and 3. Setting level 1

provides the least amount of system intervention Quick Shift

and setting 3 most strongly reduces the amount

of wheel lift.
Level 1 - Least lift control. Suitable for more
sporty riding.
Level 2 - More lift control. Suitable for sporty rid-
ing.
Level 3 - Most lift control. Suitable for street rid- ALL MODES
ing.
TIP The quick shifter is divided into “QS ” (upshift)
The lift control system can only be turned off and “QS ” (downshift) sections. “QS ” and
completely via “ Settings” > “Vehicle Function” “QS ” are not linked and can be set inde-
> “Stability Control ON/OFF”. pendently.
Setting 1: Can quick upshift only while accelerat-
“EBM” (Engine brake management) (for ing. Can quick downshift only while decelerating.
MT09SPR/MT09SPRC) Setting 2: Can quick upshift while accelerating or
decelerating. Can quick downshift while deceler-
ating or accelerating.
“OFF” turns the respective upshift or downshift
function off, and the clutch lever must then be
used when shifting in that direction.
TIP
• Setting 1 has more limited conditions for quick-
shifts and may be preferable for preventing un-
ALL MODES
intentional gearshifts if the shift pedal is
“EBM” can be set to 1 or 2. Setting level 1 pro- touched accidentally when track riding.
vides the least amount of system intervention • Setting 2 allows quickshifts under a wider array
and setting 2 most strongly reduces engine of conditions to better suit normal riding.
braking. • “QS ”/“QS ” ON/OFF status is reflected by
Level 1 - Least engine brake management suit- the quick shifter indicator.
able for more sporty riding.
“BC” (Brake control system)
Level 2 - More engine brake management. Suit-
able for street riding.
“QS ”/ “QS ” (Quick shifter)

Quick Shift

ALL MODES

OFF: Only the standard ABS (anti-lock brake

ALL MODES system), which adjusts brake pressure based on
vehicle speed and wheel speed data. The stan-
dard ABS is designed to engage and maximize
braking when the vehicle is upright.

1-17
 FEATURES

ON: ABS (Anti-lock brake system) and cornering Settings > Vehicle Function > Stability Con-
assist braking are both active. In addition to the trol ON/OFF
standard ABS, it suppresses the increase in
brake pressure when unavoidable abrupt brak- ON
ing occurs during cornering, making the vehi-
cle’s recovery to upright position more gradual.
ON
Also, additional data from the IMU regulates ap-
plied brake power depending on lean angle in
ON
order to increase the feeling of stability and to
suppress wheel lock.
ON
TIP
For skilled riders or when track riding, a variety
This menu allows you to activate/deactivate the
of conditions may cause BC to brake faster than
stability control systems: “Traction Control”
expected for a desired cornering speed or in-
(TCS), “Slide Control” (SCS), “Lift Control” (LIF),
tended cornering line.
and “Back Slip Regulator” (BSR).
If a system is turned off, the corresponding indi-
Settings > Vehicle Function > YRC Settings > cator will come on.
TRACK YRC Modes Turning on/off “TCS” will turn “SCS”, “LIF” and
“BSR” on/off together. The stability control sys-
tem indicator light “ ” will come on to indicate
“TCS” OFF status.
TIP
• “BSR” turns off automatically and “Back Slip
Regulator” is grayed out when in TRACK
theme.
• “TCS” turns on automatically when the vehicle
power is turned on.
This menu contains 4 additional custom YRC
mode presets which are used for TRACK theme. Settings > Vehicle Function > ABS

Settings > Vehicle Function > YRC Settings >

Import / Export to App

This module allows you to turn the rear wheel

ABS (anti-lock braking system) on/off. The cur-
rently selected ABS mode is indicated by the
This menu allows you to import/export custom REAR ABS OFF indicator “ ”.
YRC mode settings using the My Ride app.
TIP
• The rear wheel ABS will remain disabled until:
• The main switch is turned off.
• The Stop/Run/Start switch “ / / ” is turned
to off “ ” while the engine is running.
• The ABS is reactivated via the menu system
while the vehicle is not moving.

1-18
 FEATURES

EWA22690
The multi-function meter is equipped with a sen-
WARNING sor to detect ambient lighting conditions and au-
Turn the ABS off only when riding on a tomatically switch the display between day/night
closed circuit course. presets. The preset brightness levels can be
customized here.
Settings > Clock Select a preset by operating the joystick left-right
and adjust its brightness level from 1–6 by oper-
ating the joystick up-down. Short press “ ” to
confirm the setting and return to the previous
menu.
TIP
Only adjust brightness presets in ambient light
conditions which are appropriate for that preset.

Settings > Display > Background

The clock can be set to auto-adjust in sync with
a smartphone. “Auto Adjustment” ON is indicat-
ed by the checkmark and requires a connection
with the My Ride app.
“Manual Adjustment” allows the clock to be cali-
brated manually.

The multi-function meter is equipped with a sen-

sor to detect ambient lighting conditions and ad-
just the display between day/night presets.
Select “White” (day) or “Black” (night) to keep
the display in that preset.
Select “Auto” to enable automatic switching de-
To manually adjust the clock, operate the joy- pending on the ambient light levels.
stick left-right to highlight an item and up-down TIP
to adjust the highlighted item. Short press “ ” to Only “White” (day) is available for TRACK
finalize the clock setting and then select “OK” to theme.
confirm.
Settings > Display > Brightness
Settings > Unit

1 2
1. Day preset
The display units can be customized as follows:
2. Night preset
• “Distance”: “km” or “mile”
• “Fuel”: “km/L”, “L/100km” or “MPG”
• “Temperature”: “°C” or “°F”

1-19
 FEATURES

When “mile” is selected for the distance unit, the Select “ON” to have the indicator come on at the
fuel consumption unit is automatically changed final r/min. Select “FLASH” to have the indicator
to “MPG”. At this time, the “Fuel” is grayed out start flashing at the initial r/min. When the final r/
and cannot be selected. min is reached, the indicator light will start flash-
ing at a higher frequency. Select “OFF” to turn
Settings > Grip Warmer Settings (if the indicator off. Short press “ ” to select the
equipped) highlighted option and return to the previous
menu.
TIP
The shift indicator light will come on or flash as a
demonstration of each setting in this menu as it
is selected.
“r/min Range”
Low

The three grip warmer presets can be custom-

ized here. Short press “ ” to select a preset and
then adjust its heat level from 1–10 by operating
the joystick up-down. Short press “ ” to confirm
the setting and return to the previous menu.

Settings > Shift Indicator

Select the r/min at which the shift indicator light
will come on. The operational range is 3000–
10500 r/min. It can be adjusted by 250 r/min in-
crements. Short press “ ” to confirm the setting
and return to the previous menu.
TIP
• The “Initial” r/min cannot be higher than the “Fi-
nal” r/min.
• The shift indicator light does not come one
when in neutral or 6th gear.
This menu contains settings for the shift indica-
tor light. “Brightness”
“Indicator Type”

1 2
1. Day preset
2. Night preset
Select the day/night brightness levels of the shift
indicator light from 1–6 by operating the joystick
up-down. Short press “ ” to confirm the setting
and return to the previous menu.

1-20
 FEATURES

TIP
Only adjust brightness presets in ambient light
conditions which are appropriate for that preset.

Phone (if call active)

This opens an audio player which interfaces with

your smartphone’s audio player app.
Operate the joystick up-down to adjust the vol-
ume.
Operate the joystick left-right to skip to the next/
previous track.
Selecting this menu opens an active call display. Short press “ ” to play/pause the track.
The contact name and call time are displayed.
TIP
Operate the joystick up-down to adjust the call
• All audio track information is imported from the
volume.
music player application on your smartphone.
Short press “ ” to end the call.
• Depending on the smartphone and music play-
TIP er application, the audio player may start play-
Call volume control and/or ending call via the ve- ing automatically, or the next/previous track
hicle is not available for all types of smart- and volume adjustment may not function.
phones. If this function is unavailable, the • Theme4: This function is not accessible via the
volume adjustment and end call graphics will be menu system and is instead located within the
grayed out. If this occurs, the call can be con- vehicle information display. The function is the
trolled directly on your smartphone. same.

Music Navigation

While this item is shown in the menu, operate This opens the navigation display. This menu
the joystick up-down to adjust the volume. option is only available from the main display.
Short press “ ” to open additional audio con-
trols.

1-21
 FEATURES

Meter Display Sets the lap timer to standby. The menu will exit
to the main display and the “:” and “.” in the lap
timer will blink to indicate the lap timer is on
standby. This menu option is only available in
TRACK.

Timer Stop (for MT09SPR/MT09SPRC)

This opens the main display. This menu option is

only available from the navigation display.

Turn-by-Turn / Turn-by-Turn OFF

Pauses the lap timer and returns to the main dis-

play. The lap timer can be resumed by once
again selecting “ Timer Ready”.
This menu option is only available in TRACK.

TRACK Settings > Shift Indicator Mode (for

MT09SPR/MT09SPRC)

This activates/deactivates a turn-by-turn route

guidance at the bottom of the main display.

This module enables you to choose between the

LED shift indicator light and the shift indicator lo-
cated on the TFT display in the TRACK theme.
This menu option is only available from the main “LED+Sequential”: Both shift indicators are ac-
display. tive.
“Sequential”: Only TFT indicator is active.
Timer Ready (for MT09SPR/MT09SPRC) “LED”: Only LED shift indicator light is active.

TRACK Settings > Peak Rev Indicator (for

MT09SPR/MT09SPRC)
This item activates / deactivates the peak rev
hold indicator.

TRACK Settings > Lap Time (for MT09SPR/

MT09SPRC)
This module contains recorded lap times the
date of the first recorded lap and additional lap
data.

1-22
 FEATURES

Operate the joystick in the direction of the arrows

to access additional lap data and delete lap data
individually.

MPH
MPH

TRACK Settings > Lap Reset (for MT09SPR/

MT09SPRC)
This item deletes all recorded lap times and ad-
ditional recorded lap data and resets the lap tim-
er.

1-23
 BASIC SERVICE INFORMATION

EAS20010

BASIC SERVICE INFORMATION

EAS30014

ELECTRICAL SYSTEM

Electrical parts handling

ECA22611

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

1-24
 SPECIAL TOOLS

EAS20012

SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
TIP
• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
• For others, use part number starting with “90890-”.

Reference
Tool name/Tool No. Illustration
pages
Yamaha diagnostic tool USB (US) 3-4, 4-67, 4-68,
90890-03275 7-12, 9-3, 9-39,
9-40

Yamaha diagnostic tool (A/I) 3-4, 4-67, 4-68,

90890-03273 7-12, 9-3, 9-39,
9-40

Thickness gauge 3-6, 4-22, 4-30,

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

Valve lapper (ø14) 90890-04101 3-7

90890-04101
Valve lapper (ø14)
YM-A8998

YM-A8998

Vacuum gauge 3-9

90890-03094
Vacuummate
YU-44456

YU-44456

1-25
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Carburetor angle driver 2 3-10
90890-03173

Steering nut wrench 3-20, 4-90

90890-01403
Exhaust flange nut wrench
YU-A9472

Oil filter wrench 3-29

90890-01426
Oil filter wrench
YU-38411

Oil pressure gauge joint 18 mm 3-30

90890-04176
YU-04176
ø18

Oil pressure gauge set 3-30

90890-03120

Cylinder cup installer 4-47

90890-01996

HU holder 4-64, 4-65

90890-01912

Fork spring compressor 4-80, 4-85

90890-01441
Fork spring compressor
YM-01441

Rod holder 4-80, 4-85

90890-01434
Damper rod holder double ended
YM-01434

1-26
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Damper rod holder (ø27) 4-81, 4-82
90890-01582
Damper rod holder
YM-01582

Fork seal driver 4-83, 4-83, 4-84

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

Rod puller 4-84, 4-85

90890-01437
Universal damping rod bleeding tool set
YM-A8703

YM-A8703

Rod puller attachment (M10 long) 4-84, 4-85

90890-01578
90890-01578
Universal damping rod bleeding tool set
YM-A8703

YM-A8703

Ring nut wrench 4-90

90890-01268
Spanner wrench
YU-01268

Drive chain cut & rivet tool 4-103, 4-105

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

1-27
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Compression gauge 90890-03081 5-7
90890-03081
Engine compression tester
YU-33223

YU-33223

Compression gauge extension 122mm 5-7

90890-04136
Compression gauge extension 122mm
YM-04136

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

90890-01518
Frame spanner socket
YM-01518

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

90890-01476

Camshaft wrench 5-19, 5-22

90890-04162
Camshaft wrench
YM-04162

Valve spring compressor 5-31, 5-35

90890-04200
Valve spring compressor
YM-04019

Valve spring compressor attachment 5-31, 5-35

(ø23)
90890-04179
Valve spring compressor adapter (ø23) 23
YM-04179

Valve guide remover (ø4.5) 5-32

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

1-28
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Valve guide installer (ø4.5) 5-32
90890-04117
Valve guide installer (4.5 mm)
YM-04117

Valve guide reamer (ø4.5) 5-32

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

Sheave holder 5-38, 5-38,

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

Flywheel puller 5-38

90890-01362
Heavy duty puller
YU-33270-B

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

90890-85505
Three bond No. 1215®

Digital circuit tester (CD732) 5-43, 8-70,

90890-03243 8-73, 8-73,
Model 88 Multimeter with tachometer 8-75, 8-77,
YU-A1927 8-78, 8-78,
8-79, 8-80,
8-80, 8-80,
8-82, 8-83,
8-83, 8-83,
8-84, 8-84,
8-85, 8-85
Clutch holder 5-49, 5-52
90890-04199
Universal clutch holder
YM-91042

1-29
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Piston pin puller set 5-70
90890-01304
Piston pin puller
YU-01304

YU-01304

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

ø8.1 ø9.1
90890-04193 ø7
Connecting rod big end bearing installer
YM-04193

Piston installing tool 5-77

90890-04161
Piston installing tool
YM-04161

Radiator cap tester 6-5, 6-5

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

YU-24460-A

Radiator cap tester adapter 6-5, 6-5

90890-01352
Pressure tester adapter
YU-33984

YU-33984

Mechanical seal installer 6-14

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

1-30
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Middle driven shaft bearing driver 6-14
90890-04058
Middle drive bearing installer 40 & 50 mm
YM-04058

Pressure gauge 7-11, 7-12

90890-03153
Pressure gauge
YU-03153

Fuel injector pressure adapter 7-11

90890-03210
Fuel injector pressure adapter
YU-03210

Fuel pressure adapter 7-12

90890-03176
Fuel pressure adapter
YM-03176

Ignition checker 8-78

90890-06754
Oppama pet–4000 spark checker
YM-34487

TIP
Yamaha diagnostic tool (A/I) 90890-03273
This special tool includes the YDT sub harness (6P) (90890-03266).

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

1-31
 SPECIAL TOOLS

1-32
 SPECIAL TOOLS

1-33
 SPECIFICATIONS

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

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

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

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

2
TIGHTENING TORQUES .............................................................................. 2-12
ENGINE TIGHTENING TORQUES......................................................... 2-12
CHASSIS TIGHTENING TORQUES.......................................................2-12

CABLE ROUTING ......................................................................................... 2-15

OPTION COUPLER LOCATION CHART................................................ 2-71
 GENERAL SPECIFICATIONS

EAS20013

GENERAL SPECIFICATIONS
Model
Model BME3 (MT09R)
BME4 (MT09RC)
BMM4 (MT09SPR)
BMM5 (MT09SPRC)

Dimensions
Overall length 2090 mm (82.3 in)
Overall width 820 mm (32.3 in)
Overall height 1145 mm (45.1 in)
Wheelbase 1430 mm (56.3 in)
Ground clearance 140 mm (5.51 in)
Minimum turning radius 3.0 m (9.84 ft)

Weight
Curb weight 193 kg (425 lb) (MT09R, MT09RC)
194 kg (428 lb) (MT09SPR, MT09SPRC)

Loading
Maximum load 167 kg (368 lb) (MT09SPR, MT09SPRC)
168 kg (372 lb) (MT09R, MT09RC)
Riding capacity 2 person

2-1
 ENGINE SPECIFICATIONS

EAS20014

ENGINE SPECIFICATIONS
Engine
Combustion cycle 4-stroke
Cooling system Liquid cooled
Valve train DOHC
Displacement 890 cm³
Cylinder arrangement Inline
Number of cylinders 3-cylinder
Bore × stroke 78.0 × 62.1 mm (3.07 × 2.44 in)
Compression ratio 11.5 : 1
Compression pressure 1392–1792 kPa/425 r/min (13.9–17.9 kgf/cm²/
425 r/min, 198.0–254.9 psi/425 r/min)
Compression pressure (#2 cylinder) 1383–1780 kPa/425 r/min (13.8–17.8 kgf/cm²/
425 r/min, 196.7–253.3 psi/425 r/min)

Fuel
Recommended fuel Unleaded gasoline (E10 acceptable)
Octane number (RON) 95
Fuel tank capacity 14 L (3.7 US gal, 3.1 Imp.gal)
Fuel reserve amount 2.5 L (0.66 US gal, 0.55 Imp.gal)

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

Oil filter
Oil filter type Cartridge

Oil pump
Oil pressure 200.0 kPa/5000 r/min (2.00 kgf/cm²/5000 r/min,
29.0 psi/5000 r/min)

Cooling system
Coolant quantity
Radiator (including all routes) 1.72 L (1.82 US qt, 1.51 Imp.qt)
Coolant reservoir (up to the maximum level
mark) 0.28 L (0.30 US qt, 0.25 Imp.qt)
Radiator cap valve opening pressure 107.9–137.3 kPa (1.08–1.37 kgf/cm², 15.6–19.9
psi)
Cooling system leak test pressure 137.3 kPa (1.37 kgf/cm², 19.9 psi)

2-2
 ENGINE SPECIFICATIONS

Thermostat
Valve opening temperature 80.0–84.0 °C (176.00–183.20 °F)
Valve full open temperature 95.0 °C (203.00 °F)

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

Cylinder head
Warpage limit 0.10 mm (0.0039 in)

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

Valve, valve seat, valve guide

Valve clearance (cold)
Intake 0.11–0.20 mm (0.0043–0.0079 in)
Exhaust 0.28–0.32 mm (0.0110–0.0126 in)
Valve dimensions
Valve seat contact width limit (intake) 1.6 mm (0.06 in)
Valve seat contact width limit (exhaust) 1.8 mm (0.07 in)
Valve stem diameter limit (intake) 4.445 mm (0.1750 in)
Valve stem diameter limit (exhaust) 4.430 mm (0.1744 in)
Valve guide inside diameter (intake) 4.500–4.512 mm (0.1772–0.1776 in)
Valve guide inside diameter (exhaust) 4.500–4.512 mm (0.1772–0.1776 in)
Valve-stem-to-valve-guide clearance limit
(intake) 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance limit
(exhaust) 0.100 mm (0.0039 in)
Valve stem runout 0.020 mm (0.0008 in)

Valve spring
Free length limit (intake) 39.18 mm (1.54 in)
Free length limit (exhaust) 38.58 mm (1.52 in)

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

Piston
Diameter 77.975–77.990 mm (3.0699–3.0705 in)
Measuring point (from piston skirt bottom) 9.0 mm (0.35 in)
Piston-to-cylinder clearance 0.010–0.035 mm (0.0004–0.0014 in)

2-3
 ENGINE SPECIFICATIONS

Piston pin bore inside diameter limit 17.043 mm (0.6710 in)

Piston pin outside diameter limit 16.970 mm (0.6681 in)

Piston ring
Top ring
End gap limit 0.50 mm (0.0197 in)
Side clearance limit 0.115 mm (0.0045 in)
2nd ring
End gap limit 1.15 mm (0.0453 in)
Side clearance limit 0.115 mm (0.0045 in)

Connecting rod
Oil clearance 0.027–0.051 mm (0.0011–0.0020 in)
Bearing color code
Code 1 Blue
Code 2 Black
Code 3 Brown
Code 4 Yellow green

Crankshaft
Runout limit 0.030 mm (0.0012 in)
Journal oil clearance 0.013–0.037 mm (0.0005–0.0015 in)
Bearing color code
Code 0 White
Code 1 Blue
Code 2 Black
Code 3 Brown
Code 4 Yellow green

Balancer
Balancer shaft runout limit 0.030 mm (0.0012 in)
Bearing color code
Code 1 Blue
Code 2 Black
Code 3 Brown
Code 4 Green
Code 5 Yellow
Balancer shaft journal to balancer shaft
bearing clearance 0.023–0.047 mm (0.0009–0.0019 in)

Clutch
Clutch type Wet, multiple-disc
Clutch lever free play 5.0–10.0 mm (0.20–0.39 in)
Assembly width 42.7–43.5 mm (1.68–1.71 in)
Friction plate 1 thickness 2.92–3.08 mm (0.115–0.121 in)
Plate quantity 6 pcs
Wear limit 2.82 mm (0.111 in)
Friction plate 2 thickness 2.92–3.08 mm (0.115–0.121 in)
Plate quantity 3 pcs
Wear limit 2.82 mm (0.111 in)

2-4
 ENGINE SPECIFICATIONS

Clutch plate 1 thickness 2.18–2.42 mm (0.086–0.095 in)

Plate quantity 1 pcs
Warpage limit 0.10 mm (0.004 in)
Clutch plate 2 thickness 1.90–2.10 mm (0.075–0.083 in)
Plate quantity 7 pcs
Warpage limit 0.10 mm (0.004 in)
Clutch spring free length limit 42.53 mm (1.67 in)

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

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

Air filter
Air filter element Oil-coated paper element

Fuel injector
Resistance 12.0 Ω

Idling condition
Engine idling speed 1200–1400 r/min
O2 feedback control Active
Coolant temperature 90–100 °C (194–212 °F)
Difference in vacuum pressure between the
cylinders 0 kPa–1.3 kPa (0 mmHg–10 mmHg, 0 inHg–0.4
inHg)
CO% 0.0–2.0 %
Fuel line pressure (at idle) 300–390 kPa (3.0–3.9 kgf/cm², 43.5–56.6 psi)

2-5
 CHASSIS SPECIFICATIONS

EAS20015

CHASSIS SPECIFICATIONS
Chassis
Caster angle 24.7 °
Trail 108 mm (4.3 in)

Front wheel
Wheel type Cast wheel
Rim size 17M/C x MT3.50
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Wheel axle bending limit 0.40 mm (0.02 in)

Rear wheel
Wheel type Cast wheel
Rim size 17M/C x MT5.50
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Wheel axle bending limit 0.40 mm (0.02 in)

Front tire
Type Tubeless
Size 120/70ZR17M/C (58W)
Manufacturer/model BRIDGESTONE/BATTLAX HYPERSPORT
S23F

Rear tire
Type Tubeless
Size 180/55ZR17M/C (73W)
Manufacturer/model BRIDGESTONE/BATTLAX HYPERSPORT
S23R

Tire air pressure (measured on cold tires)

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

Front brake
Brake disc thickness limit 4.0 mm (0.16 in)
Brake disc runout limit (as measured on
wheel) 0.10 mm (0.0039 in)
Brake pad lining thickness limit 0.5 mm (0.02 in) (MT09R, MT09RC)
1.0 mm (0.04 in) (MT09SPR, MT09SPRC)
Master cylinder inside diameter 16.00 mm (0.63 in)

2-6
 CHASSIS SPECIFICATIONS

Caliper cylinder inside diameter (Left) 30.00 mm, 30.00 mm (1.18 in, 1.18 in)
(MT09SPR, MT09SPRC)
30.23 mm, 27.00 mm (1.19 in, 1.06 in) (MT09R,
MT09RC)
Caliper cylinder inside diameter (Right) 30.00 mm, 30.00 mm (1.18 in, 1.18 in)
(MT09SPR, MT09SPRC)
30.23 mm, 27.00 mm (1.19 in, 1.06 in) (MT09R,
MT09RC)
Specified brake fluid DOT 4

Rear brake
Brake disc thickness limit 4.5 mm (0.18 in)
Brake disc runout limit (as measured on
wheel) 0.15 mm (0.0059 in)
Brake pad lining thickness limit 1.0 mm (0.04 in)
Master cylinder inside diameter 12.7 mm (0.50 in)
Caliper cylinder inside diameter 38.18 mm (1.50 in)
Specified brake fluid DOT 4

Front suspension
Shock absorber Hydraulic damper
Fork spring free length limit 251.4 mm (9.90 in) (MT09R, MT09RC)
261.7 mm (10.31 in) (MT09SPR, MT09SPRC)
Inner tube bending limit 0.2 mm (0.01 in)
Recommended oil Yamaha Suspension Oil 01
Quantity (left) 456.0 cm³ (15.42 US oz, 16.08 Imp.oz) (MT09R,
MT09RC)
466.0 cm³ (15.76 US oz, 16.44 Imp.oz)
(MT09SPR, MT09SPRC)
Quantity (right) 460.0 cm³ (15.55 US oz, 16.22 Imp.oz) (MT09R,
MT09RC)
466.0 cm³ (15.76 US oz, 16.44 Imp.oz)
(MT09SPR, MT09SPRC)
Level (left) 105 mm (4.1 in) (MT09SPR, MT09SPRC)
109 mm (4.3 in) (MT09R, MT09RC)
Level (right) 105 mm (4.1 in) (MT09SPR, MT09SPRC)
109 mm (4.3 in) (MT09R, MT09RC)
Spring preload
Adjustment value (Soft) 19.0 mm (0.75 in)
Adjustment value (STD) 14.0 mm (0.55 in) (MT09SPR, MT09SPRC)
16.0 mm (0.63 in) (MT09R, MT09RC)
Adjustment value (Hard) 4.0 mm (0.16 in)
Rebound damping
Unit for adjustment Click
Adjustment value from the start position
(Soft) 11 (MT09R, MT09RC)
26 (MT09SPR, MT09SPRC)
Adjustment value from the start position
(STD) 11 (MT09SPR, MT09SPRC)
6 (MT09R, MT09RC)

2-7
 CHASSIS SPECIFICATIONS

Adjustment value from the start position

(Hard) 1
Compression damping
Unit for compression damping adjustment Click (MT09R, MT09RC)
Adjustment value from the start position
(Soft) 11 (MT09R, MT09RC)
Adjustment value from the start position
(STD) 6 (MT09R, MT09RC)
Adjustment value from the start position
(Hard) 1 (MT09R, MT09RC)
Fast compression damping
Unit for adjustment Turn (MT09SPR, MT09SPRC)
Adjustment value from the start position
(Soft) 5+1/2 (MT09SPR, MT09SPRC)
Adjustment value from the start position
(STD) 2+3/4 (MT09SPR, MT09SPRC)
Adjustment value from the start position
(Hard) 0 (MT09SPR, MT09SPRC)
Slow compression damping
Unit for adjustment Click (MT09SPR, MT09SPRC)
Adjustment value from the start position
(Soft) 18 (MT09SPR, MT09SPRC)
Adjustment value from the start position
(STD) 9 (MT09SPR, MT09SPRC)
Adjustment value from the start position
(Hard) 1 (MT09SPR, MT09SPRC)

Rear suspension
Shock absorber Gas-hydraulic damper
Spring preload
Unit for adjustment Cam position (MT09R, MT09RC)
Adjustment value (Soft) 1 (MT09R, MT09RC)
Adjustment value (STD) 4 (MT09R, MT09RC)
Adjustment value (Hard) 7 (MT09R, MT09RC)
Adjustment value (Soft) 154.5 mm (6.08 in) (MT09SPR, MT09SPRC)
Adjustment value (STD) 150.0 mm (5.91 in) (MT09SPR, MT09SPRC)
Adjustment value (Hard) 146.5 mm (5.77 in) (MT09SPR, MT09SPRC)
Rebound damping
Unit for adjustment Click (MT09SPR, MT09SPRC)
Turn (MT09R, MT09RC)
Adjustment value from the start position
(Soft) 2 1/2 (MT09R, MT09RC)
30 (MT09SPR, MT09SPRC)
Adjustment value from the start position
(STD) 1 (MT09R, MT09RC)
18 (MT09SPR, MT09SPRC)
Adjustment value from the start position
(Hard) 0
Compression damping
Unit for adjustment Click (MT09SPR, MT09SPRC)

2-8
 CHASSIS SPECIFICATIONS

Adjustment value from the start position

(Soft) 20 (MT09SPR, MT09SPRC)
Adjustment value from the start position
(STD) 14 (MT09SPR, MT09SPRC)
Adjustment value from the start position
(Hard) 0 (MT09SPR, MT09SPRC)

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

2-9
 ELECTRICAL SPECIFICATIONS

EAS20016

ELECTRICAL SPECIFICATIONS
Voltage
System voltage 12 V

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

Engine control unit

Model TBDFBT (MT09R)
TBDFBY (MT09RC)
TBDFCA (MT09SPR)
TBDFCE (MT09SPRC)

Ignition coil
Primary coil resistance 1.19–1.61 Ω
Secondary coil resistance 9.35–12.65 kΩ

Charging system
Charging system AC magneto
Standard output 14.0 V, 42.5 A at 5000 r/min

Generator control unit

Regulated voltage (DC) 14.1–14.9 V

Battery
Model YTZ10S
Voltage, capacity 12 V, 8.6 Ah (10 HR)

Bulb wattage
Headlight LED
Brake/tail light LED
Front turn signal/position light LED
Rear turn signal light LED
Auxiliary light LED
License plate light 5.0 W
Meter lighting LED

Indicator light
Neutral indicator light LED
Stability control indicator light LED
High beam indicator light LED
Turn signal indicator light LED
Engine trouble warning light LED
ABS warning light LED
Shift timing indicator light LED
Smart key system indicator light LED (MT09SPR/MT09SPRC)

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

2-10
 ELECTRICAL SPECIFICATIONS

Fuel sender unit

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

Fuel injection sensor

Crankshaft position sensor resistance 228–342 Ω
Intake air temperature sensor resistance 5400–6600 Ω at 0 °C (5400–6600 Ω at 32 °F)
Intake air temperature sensor resistance 290–390 Ω at 80 °C (290–390 Ω at 176 °F)
Intake air pressure sensor output voltage 3.59–3.67 V at 101.3 kPa (3.59–3.67 V at 1.01
kgf/cm², 3.59–3.67 V at 14.7 psi)
Coolant temperature sensor resistance 2513–2777 Ω at 20 °C (2513–2777 Ω at 68 °F)
Coolant temperature sensor resistance 210–221 Ω at 100 °C (210–221 Ω at 212 °F)

Fuse(s)
Main fuse 50.0 A
Headlight fuse 7.5 A
Brake light fuse 2.0 A
Signaling system fuse 7.5 A
Ignition fuse 10.0 A
Radiator fan motor fuse 15.0 A
Fuel injection system fuse 7.5 A
ABS control unit fuse 7.5 A
ABS motor fuse 30.0 A
ABS solenoid fuse 15.0 A
Accessory fuse 2.0 A
Terminal fuse 1 5.0 A
Cruise control fuse 2.0 A
Backup fuse 7.5 A
Electronic throttle valve fuse 7.5 A
Ignition fuse 2 7.5 A
Backup fuse 2 15.0 A

2-11
 TIGHTENING TORQUES

EAS20017

TIGHTENING TORQUES
EAS30016

ENGINE TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Exhaust pipe nut M8 6 20 N·m (2.0 kgf·m, 15 lb·ft)
Spark plug M10 3 13 N·m (1.3 kgf·m, 9.6 lb·ft)
Cylinder head cover bolt M6 4 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Generator rotor bolt M12 1 75 N·m (7.5 kgf·m, 55 lb·ft) E

Generator cover bolt M6 2 12 N·m (1.2 kgf·m, 8.9 lb·ft) LT

Generator cover bolt M6 8 12 N·m (1.2 kgf·m, 8.9 lb·ft)

Stake.
Clutch boss nut M20 1 125 N·m (12.5 kgf·m, 92 lb·ft)
LT

Clutch spring bolt M6 3 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Clutch cover bolt M6 11 12 N·m (1.2 kgf·m, 8.9 lb·ft)
Oil filter cartridge M20 1 17 N·m (1.7 kgf·m, 13 lb·ft)
Oil filter cartridge union bolt M20 1 70 N·m (7.0 kgf·m, 52 lb·ft) E

Water pump drain bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Engine oil drain bolt M14 1 43 N·m (4.3 kgf·m, 32 lb·ft)

EAS30017

CHASSIS TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Front wheel axle M18 1 72 N·m (7.2 kgf·m, 53 lb·ft)
Front wheel axle pinch bolt M8 1 23 N·m (2.3 kgf·m, 17 lb·ft)
Rear wheel sprocket nut M10 5 80 N·m (8.0 kgf·m, 59 lb·ft)
Rear wheel axle nut M24 1 105 N·m (10.5 kgf·m, 77 lb·ft) LS

Rear brake caliper bolt (front) M12 1 27 N·m (2.7 kgf·m, 20 lb·ft) S

S
Rear brake caliper bolt (rear) M8 1 22 N·m (2.2 kgf·m, 16 lb·ft) and
LT

Front brake master cylinder bleed M8 1 6 N·m (0.6 kgf·m, 4.4 lb·ft)
screw
Front brake caliper bleed screw M8 2 5 N·m (0.5 kgf·m, 3.7 lb·ft)
(MT09R/MT09RC)
Front brake caliper bleed screw M8 2 8 N·m (0.8 kgf·m, 5.9 lb·ft)
(MT09SPR/MT09SPRC)
Rear brake caliper bleed screw M8 1 5 N·m (0.5 kgf·m, 3.7 lb·ft)
Front brake caliper bolt M10 4 35 N·m (3.5 kgf·m, 26 lb·ft)
Upper handlebar holder bolt M8 4 22 N·m (2.2 kgf·m, 16 lb·ft)
Lower handlebar holder nut M10 2 40 N·m (4.0 kgf·m, 30 lb·ft)
Clutch cable locknut M8 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)

2-12
 TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Lower bracket pinch bolt M8 4 23 N·m (2.3 kgf·m, 17 lb·ft)
Upper bracket pinch bolt M8 2 26 N·m (2.6 kgf·m, 19 lb·ft)
Lower ring nut M30 1 See TIP.
Stake.
Drive sprocket nut M22 1 160 N·m (16 kgf·m, 118 lb·ft)
LT

Sidestand nut M10 1 65 N·m (6.5 kgf·m, 48 lb·ft)

Sidestand switch screw M5 2 4.3 N·m (0.43 kgf·m, 3.2 lb·ft) LT

TIP
Lower ring nut
1. Tighten the ring nut to approximately 52 N·m (5.2 kgf·m, 38 lb·ft) with a torque wrench, then loosen
the lower ring nut completely.
2. Tighten the lower ring nut to 14 N·m (1.4 kgf·m, 10 lb·ft).

2-13
 TIGHTENING TORQUES

2-14
 CABLE ROUTING

EAS20021

CABLE ROUTING
Headlight (front side view)

5, A
1

3
4

7 7
9, C 9,D
E
10,F
8 2
G

4,B

2-15
 CABLE ROUTING

1. Meter assembly
2. Headlight assembly
3. Auxiliary light
4. Auxiliary light coupler
5. Coupler cover
6. Clutch cable
7. Brake hose
8. Upper bracket
9. Clamp
10. Wire harness (to handlebar switch (right))

A. Connect the meter assembly coupler to the

meter assembly, and then insert the coupler
cover until it contacts the meter assembly.
B. Insert the auxiliary light coupler into the
bracket of the headlight assembly from the
rear side of the vehicle.
C. Mount the clamp more to the lower side of the
vehicle than the upper bracket.
D. Face the opening of the clamp to the right
side of the vehicle.
E. Front side of the vehicle
F. Pass the wire harness (to handlebar switch
(right)) more to the left side of the vehicle
than the brake hose.
G. Left side of the vehicle

2-16
 CABLE ROUTING

Handlebar 1 (front side view)

K
1 2 3, A
14, J 10, L

13, I
5, B
5, B
C
6, 7, 8
D
12, H
9
G
F 5, B

5, B 10

5, E

11

2-17
 CABLE ROUTING

1. Wire harness (to handlebar switch (right))

2. Wire harness (to handlebar switch (left))
3. Clutch cable
4. Meter assembly bracket
5. Clamp
6. Joint connector
7. Grip warmer coupler (right) (option)
8. Grip warmer coupler (left) (option)
9. Headlight control unit coupler
10. Wire harness
11. Headlight bracket
12. Auxiliary DC jack coupler (option)
13. Wire harness (to meter assembly coupler)
14. Brake hose

A. Pass the clutch cable more to the front side of

the vehicle than the wire harness (to handle-
bar switch (left)).
B. Insert the clamp into the hole of the meter
assembly bracket.
C. Pass the wire harness (to handlebar switch
(left)) through the hole of the meter assembly
bracket.
D. Clamp the bonder, grip warmer coupler
(right), and grip warmer coupler (left) with the
wire harness clamp, and insert the wire har-
ness clamp into the hole of the meter assem-
bly bracket.
E. Insert the clamp into the hole of the headlight
bracket.
F. Pass the wire harness (to USB jack) to the
wire harness (to handlebar switch (right)) and
brake hose at the rear side of the vehicle.
G. Pass the wire harness (to handlebar switch
(right) through the hole of the meter assem-
bly bracket.
H. Insert the USB jack coupler into the hook part
of the meter assembly bracket.
I. Pass the wire harness (to meter assembly
coupler) through the hole of the meter
assembly bracket.
J. Pass the brake hose through the hole of the
meter assembly bracket.
K. Hook part of the meter assembly bracket
L. Hook the white tape part of the wire harness
with the hook part of the meter assembly
bracket.

2-18
 CABLE ROUTING

Handlebar 2 (top view)

C C
4
3 3
E F

D 1, A 1,A 5 D
4
1,A 2

3 1,B

7
6

9 8, G 7 D 10, H C
6

12
M

16
11
17, O
15
18, O

12 13
10, I 11 11
J 14 15
12 19
D 14
D C 10, K D C
C 10, L

2-19
 CABLE ROUTING

1. Rubber band K. Fasten the plastic locking tie over the protec-
2. Clutch cable tive tube of the wire harness (to handlebar
switch coupler (right) 1). Face the tip down-
3. Handlebar ward to the front of the vehicle and cut it. Do
4. Wire harness not forcefully pull on the leads when fastening
5. Brake hose them.
6. Handlebar switch (left) L. Fasten the plastic locking tie over the protec-
tive tube of the wire harness (to handlebar
7. Wire harness (to handlebar switch coupler switch coupler (right) 2). Face the tip down-
(left)) ward to the front of the vehicle and cut it. Do
8. Handlebar switch coupler (left) not forcefully pull on the leads when fastening
9. Handlebar switch cover (left) them.
10. Plastic locking tie M. Assemble the L-type terminals to the front
11. Handlebar switch (right) brake light switch so the bases of the lead
wires face the upper side of the vehicle.
12. Wire harness (to front brake light switch)
N. Pass the front brake light switch lead
13. Front brake light switch between the front brake light switch and han-
14. Wire harness (to handlebar switch coupler 1 dlebar switch (right).
(right)) O. Insert the handlebar switch coupler 1 and 2
15. Wire harness (to handlebar switch coupler 2 (right) precisely. Insert the coupler 1 (6-pin
(right)) terminal) to the front side of the vehicle and
16. Front brake light switch cover the coupler 2 (8-pin terminal) to the rear side
of the vehicle.
17. Handlebar switch coupler 2 (right)
18. Handlebar switch coupler 1 (right)
19. Handlebar switch cover (right)

A. Fasten the wire harness near the center of

the curved part of the handlebar with a rub-
ber band. Face the fastener of the rubber
band toward the front of the vehicle, and face
the end downwards.
B. Fasten the wire harness near the center of
the curved part of the handlebar with a rub-
ber band. Face the fastener of the rubber
band downwards, and face the end towards
the rear of the vehicle.
C. Front side of the vehicle
D. Lower side of the vehicle
E. Pass the wire harness through the range as
shown in the illustration.
F. Pass the wire harness more to the front side
of the vehicle than the brake hose and within
the range as shown in the illustration.
G. Insert the handlebar switch coupler (left) pre-
cisely.
H. Fasten the plastic locking tie over the protec-
tive tube of the wire harness (to handlebar
switch coupler (left)). Face the tip downward
to the rear of the vehicle and cut it. Do not
forcefully pull on the leads when fastening
them.
I. Fasten the plastic locking tie over the protec-
tive tube of the wire harness (to front brake
light switch). Face the tip downward to the
rear of the vehicle and cut it. Do not forcefully
pull on the leads when fastening them.
J. Install the front brake light switch cover and
then fasten the plastic locking tie.

2-20
 CABLE ROUTING

Frame and engine 1 (right side view)

9 B
12

6 10
E
11 1

1 F
1

10, A 10, D C

1 2 3 4

5
8 13, G
6

6, H 5

6, J 8 14, I

6
8
5

2-21
 CABLE ROUTING

1. Radiator hose (cylinder head to radiator)

2. Coolant reservoir hose
3. Front turn signal/position light (right)
4. Wire harness
5. Wire harness (to front turn signal/position
light (right))
6. Wire harness (to oil pressure switch)
7. Front turn signal/position light coupler (right)
8. Front turn signal/position light lead (right)
9. Grommet
10. Clamp
11. Radiator cover (right)
12. Frame
13. Front side panel (right)
14. Plastic locking tie

A. Fasten the clamp on the gray tape section of

the wire harness (to oil pressure switch) and
more to the right side of the vehicle than the
grommet.
B. Pass the front turn signal/position light cou-
pler (right) and wire harness (to oil pressure
switch) to the rear side of the vehicle around
the radiator mounting boss on the frame.
C. Do not allow the wire harness (to oil pressure
switch) to be pinched horizontally between
the radiator and frame.
D. Fasten the clamp at the gray tape on the wire
harness (to oil pressure switch). Face the
clamp opening towards the front of the vehi-
cle.
E. Pass the front turn signal/position light cou-
pler (right) and wire harness (to oil pressure
switch) to the upper side of the vehicle over
the radiator hose (cylinder head to radiator).
F. Front side of the vehicle
G. Pass the wire harness and lead wire within
the range shown in the illustration through the
cut-out in the front side panel (right) and
route them in the order in the illustration.
H. Do not allow the wire harness (to oil pressure
switch) to be pinched while assembling the
radiator cover (right).
I. Pass a plastic locking tie through the hole in
the front side panel (right) to fasten the front
turn signal/position light lead (right), wire har-
ness (to front turn signal/position light (right)),
and wire harness (to oil pressure switch).
Face the fastener toward the front side of the
vehicle, and face the tip of the plastic locking
tie, which does not need to be cut, towards
the front of the vehicle. But, do not allow the
tip of the plastic locking tie to extend beyond
the side cover.
J. Fit the wire harness (to oil pressure switch)
into the groove when assembling the exterior
cover. But, after the outer cover is assem-
bled, it is OK for it to come out of the groove.

2-22
 CABLE ROUTING

Frame and engine 2 (right side view)

11

10

11

10

3
4
5 B
2

1, A H 8, J
6, C
4
E 7

K K
7 8, L
8, O 6, M
9 G 8 F 6, D
I
N 6, P 7

2-23
 CABLE ROUTING

1. Clutch cable
2. Stator coil lead
3. Front turn signal/position light lead (right)
4. Front side panel (right)
5. Hose clamp
6. Plastic locking tie
7. Radiator inlet hose
8. Wire harness (to oil pressure switch)
9. Oil pressure switch
10. Throttle servo motor coupler
11. Throttle body

A. Pass the clutch cable more to the front side of

the vehicle than the stator coil lead.
B. Fit the front turn signal/position light lead
(right) to the hook of the front side panel
(right).
C. Fix the plastic locking tie to the radiator inlet
hose more to the lower side of the vehicle
than the hose clamp.
D. Fix the plastic locking tie at the lower end of
the radiator inlet hose.
E. Route the wire harness (to oil pressure
switch) as shown between the arrows in the
illustration.
F. Pass the wire harness (to oil pressure switch)
more to the inside of the vehicle than the radi-
ator inlet hose.
G. Pass the wire harness (to oil pressure switch)
into the clamp.
H. Left side of the vehicle
I. Front side of the vehicle
J. Fit the wire harness (to oil pressure switch) to
the hook of the front side panel (right).
K. Inside of the vehicle
L. Fix the wire harness (to oil pressure switch)
with the plastic locking tie more the rear of
the vehicle than the radiator inlet hose.
M. Face the locking part of the plastic locking tie
toward of the vehicle. Face the end of the
plastic locking tie to the inside of the vehicle.
N. Lower side of the vehicle
O. Fix the wire harness (to oil pressure switch)
with the plastic locking tie more to the inside
of the vehicle than the radiator inlet hose.
P. Face the locking part of the plastic locking tie
lower side of the vehicle. Face the end of the
plastic locking tie to the inside of the vehicle.

2-24
 CABLE ROUTING

Frame and engine 3 (right side view)

10 G 14
C
7
6
I
E 2, J
8 11, D 15
11
E 6
12, F H 14
8 17 K 16
13

7 6, B

A
8

7
M 8

6
5
20 21
H
18
22
19
4 3 2 1
5 3 4 2 23 H

2
18, L

2-25
 CABLE ROUTING

1. Starter motor
2. Starter motor lead
3. Canister (for California only)
4. Canister breather hose (for California only)
5. Fuel tank drain hose
6. Rear brake light switch lead
7. Rear wheel sensor lead
8. Battery box
9. Brake hose joint holder
10. Hydraulic unit
11. Clamp
12. Neutral switch lead
13. Rear shock absorber sub tank hose (for
MT09SPR/MT09SPRC)
14. Wire harness (to neutral switch)
15. Neutral switch coupler
16. Canister holder (for California only)
17. Spring preload adjuster hose (for MT09SPR/
MT09SPRC)
18. Clutch cable
19. Clutch cable holder
20. Fuel tank breather hose
21. Canister purge hose (purge cut valve sole-
noid to canister) (for California only)
22. Radiator hose (cylinder head to radiator)
23. Coolant temperature sensor coupler

A. To fuel pump
B. Pass the rear brake light switch lead more to
the front side of the vehicle than the rear
wheel sensor lead.
C. Pass the rear brake light switch lead more to
the upper side of the vehicle than the rear
wheel sensor lead.
D. Insert it into the hole in the battery box so the
notch in the clamp faces to the outside of the
vehicle.
E. For MT09SPR/MT09SPRC
F. Pass the neutral switch lead more to the
inside of the vehicle than the spring preload
adjuster hose.
G. Left side of the vehicle
H. Right side of the vehicle
I. The direction of installation of the neutral
switch coupler must be within the range as
shown in the illustration. Route the wire har-
ness (to neutral switch) more to the outside of
the vehicle.
J. Pass the starter motor lead more to the front
side of the vehicle than the spring preload
adjuster hose and the rib of the canister
holder (for MT09SPR/MT09SPRC).
K. The rib of canister holder (for California only)
L. Pass the clutch cable more to the front side of
the vehicle than the starter motor lead.
M. Pass the wire harness (to neutral switch)
through the hole in the battery box.

2-26
 CABLE ROUTING

Frame and engine 4 (left side view)

2, D
12
17 4, J
6 14, K
13, E F 14

11 14, G 16 I
15 H

14, L 4
U
10 9 8
I J H
1 2
14, L 4

17
I J H
10

10 8
16 4, T 9 8, S C 7
10, Q
8, R 9
17
6
16

18 1, O 8, M 4, B
19 5
23, P

9, 10
20 20 4, A
16 3
8, M
N
7

21

22

2-27
 CABLE ROUTING

1. Clutch cable N. Edge of the horn

2. Intake air temperature sensor O. Pass the clutch cable through recess of the
3. O2 sensor cable guide.
4. Plastic locking tie P. Insert the clamp into the hole in the cable
guide.
5. Radiator hose
Q. Fit the radiator cover (left) in the groove of the
6. O2 sensor coupler front side panel (left) during assembly. But,
7. Front turn signal/position light coupler (left) after the radiator cover (left) is assembled, it
8. Front turn signal/position light lead (left) is OK for it to come out of the groove of the
front side panel (left).
9. Wire harness (to front turn signal/position
light (left)) R. Fit the front turn signal/position light lead
(left) to the clamp.
10. Wire harness (to O2 sensor)
S. Pass the plastic locking tie through the hole in
11. Main switch bracket
the front side panel (left) to fasten the front
12. Air filter case assembly turn signal/position light coupler (left) and
13. Intake air temperature sensor coupler front turn signal/position light lead (left).
14. O2 sensor lead T. Face the fastener toward the front side of the
15. Hose clamp vehicle, and face the plastic locking tie, which
does not need to be cut, towards the front of
16. Radiator cover (left) the vehicle. However, do not let the tip of the
17. Front side panel (left) plastic locking tie extend out more than the
18. Cable guide radiator cover (left).
19. Front turn signal/position light (left) U. Pass the front turn signal/position light lead
(left), wire harness (to front turn signal/posi-
20. Horn tion light (left)), and O2 sensor lead through
21. Radiator the cut-out in the front side panel (left) and
22. Horn coupler route them in the order shown in the illustra-
23. Clamp tion.

A. Clamp the plastic locking tie at the base of

the curve of the radiator hose.
B. Clamp the plastic locking tie at the radiator
hose more to the under of the vehicle than
the hose clamp.
C. Align the wire harness along the guide to the
rear of the vehicle.
D. Insert the intake air temperature sensor into
the pin of the air filter case assembly.
E. Install the intake air temperature sensor more
to the under of the vehicle than the rib part of
the air filter case.
F. Connect the intake air temperature sensor to
its coupler and install the intake air tempera-
ture sensor to the hook of the air filter assem-
bly. Do not ride the intake air temperature
sensor lead over the main switch bracket.
G. Route the white tape part of the O2 sensor
lead more to lower side of the hook part of
the front side panel (left).
H. Left and outside of the vehicle
I. Front and lower side of the vehicle
J. Face the lock part of the plastic locking tie to
the front side of the vehicle. Face the end of
the plastic locking tie to the inside of the vehi-
cle.
K. Fix the O2 sensor lead more to the rear side
of the vehicle than the radiator hose.
L. Fix the O2 sensor lead more to the inside of
the vehicle than the radiator hose.
M. Route the slacking of the front turn signal/
position light lead (left) more to outside of the
vehicle than edge of the horn.

2-28
 CABLE ROUTING

Frame and engine 5 (left side view)

27 H
28
K
23
2, J 6
24, F I
18 1
19 25
23 G
D 26
17
16 20
12 7
21
15
2
12
D
24, F 22, E 9

11
10
5
1 7
A
2

3
4

5
6

7
C 12 5 11, B 10 9 8

9, L 5 10
6
9, L
11
14 13 10, M 29
11, N

2-29
 CABLE ROUTING

1. Air filter case assembly K. Front side of the vehicle

2. Wire harness L. Route the sidestand switch lead more to the
3. Gear position sensor coupler inside of the vehicle than the fuel tank drain
hose and fuel tank breather hose (except for
4. Gear position sensor California) or canister breather hose (for Cali-
5. Clamp fornia only).
6. Drive sprocket cover M. Pass the fuel tank breather hose (except for
7. Shift sensor California) or canister breather hose (for Cali-
fornia only) to the inside of the vehicle of the
8. Sidestand switch drive sprocket cover.
9. Sidestand switch lead N. Pass the fuel tank drain hose to the inside of
10. Fuel tank breather hose (except for Califor- the vehicle of the drive sprocket cover.
nia) or canister breather hose (for California
only)
11. Fuel tank drain hose
12. Shift sensor lead
13. Starter motor holder (except for California) or
canister holder (for California only)
14. Stator coil lead
15. ECU coupler 3
16. ECU (Engine Control Unit)
17. ECU coupler 2
18. ECU coupler 1
19. Wire harness (to ECU coupler 1)
20. Wire harness (to ECU coupler 2)
21. Wire harness (to ECU coupler 3)
22. Wire harness (to gear position sensor)
23. Battery box
24. Starter motor lead
25. Shift arm
26. Dust cover
27. Locknut
28. Shift rod joint
29. Muffler bracket (left)

A. To fuel pump
B. Pass the fuel tank drain hose more to the
front side of the vehicle than fuel tank
breather hose (except for California) or canis-
ter breather hose (for California only) and
more to the outside of the vehicle than side-
stand switch lead.
C. Hook the stator coil lead on the hook of the
starter motor holder (except for California) or
canister holder (for California only).
D. Fit the wire harness between the hook ribs
and recesses of the air filter case assembly.
E. Pass the wire harness (to gear position sen-
sor) more to the left side of the vehicle than
the stator coil lead and starter motor lead.
F. Pass the starter motor lead from the front
side of the vehicle through the battery box.
G. Pass the shift sensor lead more to the front of
the vehicle than the dust cover and shift arm.
H. Face the clamp opening towards the right
side of the vehicle.
I. Left side of the vehicle
J. Route the shift sensor lead to the front side of
the vehicle.

2-30
 CABLE ROUTING

Frame and engine 6 (left side view)

L
I
5 1 A 2
11, N
5
10
13, K M 1
J

3, B

12 C
5
H
6
11, G 7
D
F
8
E
9

10

2-31
 CABLE ROUTING

1. Clutch cable
2. Engine bracket (left)
3. Stator coil lead
4. Frame
5. Shift sensor lead
6. Sidestand switch lead
7. Canister holder (for California only)
8. Canister breather hose (for California only)
9. Fuel tank drain hose
10. Shift sensor lead bracket
11. Plastic locking tie
12. Cylinder head
13. Clamp

A. Pass the clutch cable between the cylinder

head and the engine bracket (left).
B. Pass the stator coil lead more to the front and
the upper side of the frame.
C. Connect the shift sensor coupler to the con-
nectors of the wire harness inside the coupler
cover.
D. Pass the shift sensor lead more to the out-
side of the vehicle than the fuel tank drain
hose.
E. Pass the stator coil lead more to the lower
side than the canister holder (for California
only).
F. Fit the shift sensor lead into the recess of the
canister holder (for California only).
G. Align the installation position of the clamp
with the taping on the shift sensor lead.
H. Pass the shift sensor lead and stator coil lead
more to the left side of the vehicle than the
clutch cable.
I. Insert the clamp into the hole of the bracket.
J. Left side of the vehicle
K. Face the tip of the clamp to left side of the
vehicle and cut it.
L. Right side of the vehicle
M. Front side of the vehicle
N. Fasten the plastic locking tie at the gray tape
on the stator coil lead to fasten the stator coil
lead and shift sensor lead, and face the tip to
the right side of the vehicle.

2-32
 CABLE ROUTING

Main switch (rear view) (for MT09R/MT09RC)

13
12
2
11
3, A
4, B
10
5
9 6
8

7, C

19 20, I

16
18, H
7, E
14, F
15, G
17

16

2-33
 CABLE ROUTING

1. Main switch bracket

2. Brake hose joint bracket
3. Wire harness
4. Radiator fan motor lead
5. Brake hose (front brake master cylinder to
hydraulic unit)
6. Brake hose (hydraulic unit to front brake cali-
pers)
7. Clamp
8. Front wheel sensor coupler
9. BCM (Body Control Module)
10. BCM coupler
11. Wire harness (to intake air temperature sen-
sor)
12. Intake air temperature sensor coupler
13. Intake air temperature sensor
14. Radiator fan motor coupler
15. Radiator fan motor lead
16. Wire harness (to main switch)
17. Main switch coupler
18. Main switch lead
19. Coupler cover
20. Joint connector

A. Pass the wire harness between the brake

hoses and the frame.
B. Pass the radiator fan motor lead between the
brake hoses and the frame.
C. Insert the clamp into the hole of the brake
hose joint bracket.
D. After removing the BCM
E. Insert the clamp from the inside of the vehicle
through the hole in the coupler cover.
F. Insert the radiator fan motor coupler from out-
side the vehicle through the hole in the cou-
pler cover.
G. Pass the radiator fan motor lead to the rear of
the vehicle of the wire harness (to front turn
signal/position light (right).
H. When assembling the vehicle, face the lock of
the main switch coupler to the right side of
the vehicle. The direction after that does not
matter.
I. Insert the joint connector through the hole in
the coupler cover.

2-34
 CABLE ROUTING

Main switch (rear view) (for MT09SPR/MT09SPRC)

13
12
2
11
3, A
4, B
10
5
9 6
8

7, C

20 20 21, K

J
19
16

7, E
14, F
19
15, G

17 16, I 18, H

2-35
 CABLE ROUTING

1. Main switch bracket

2. Brake hose joint bracket
3. Wire harness
4. Radiator fan motor lead
5. Brake hose (front brake master cylinder to
hydraulic unit)
6. Brake hose (hydraulic unit to front brake cali-
pers)
7. Clamp
8. Front wheel sensor coupler
9. BCM (Body Control Module)
10. BCM coupler
11. Wire harness (to intake air temperature sen-
sor)
12. Intake air temperature sensor coupler
13. Intake air temperature sensor
14. Radiator fan motor coupler
15. Radiator fan motor lead
16. Wire harness (to main switch coupler 1)
17. Wire harness (to main switch coupler 2)
18. Main switch coupler 1
19. Main switch coupler 2
20. Coupler cover
21. Joint connector

A. Pass the wire harness between the brake

hoses and the frame.
B. Pass the radiator fan motor lead between the
brake hoses and the frame.
C. Insert the clamp into the hole of the brake
hose joint bracket.
D. After removing the BCM
E. Insert the clamp from the inside of the vehicle
through the hole in the coupler cover.
F. Insert the radiator fan motor coupler from out-
side the vehicle through the hole in the cou-
pler cover.
G. Pass the radiator fan motor lead to the rear of
the vehicle of the wire harness (to front turn
signal/position light (right).
H. When assembling the vehicle, face the lock of
the main switch coupler 1 to the right side of
the vehicle. The direction after that does not
matter.
I. Pass the wire harness (to main switch cou-
pler 1) more to the rear of the vehicle than the
wire harness (to main switch coupler 2).
J. Insert the main switch coupler 2 into the ribs
of the coupler cover.
K. Insert the joint connector through the hole in
the coupler cover.

2-36
 CABLE ROUTING

Remote Control Unit (top and left side view) (for MT09SPR/MT09SPRC)

4
3
C
B
2

4
5

A
1

D 6
E
7
3
6, F
8

2-37
 CABLE ROUTING

1. Rubber band
2. Remote control unit
3. Wire harness (to remote control unit)
4. Remote control unit bracket
5. Buzzer
6. Clamp
7. Buzzer lead
8. Buzzer coupler

A. Insert the rubber band into the rib of the

remote control unit bracket.
B. Insert the remote control unit coupler into the
remote control unit until it makes a sound.
C. Insert it until the buzzer goes over the clinch
part of the rib on the remote control unit
bracket.
D. Protrusion
E. Insert the clamp into the hole of the remote
control unit bracket with the clamp opening
facing toward the protrusion on the remote
control unit bracket.
F. Face the lock of the buzzer coupler to the
front side of the vehicle, align the different
levels of the connectors and clamp them
together with the wire harness, and face the
openings toward the front of the vehicle.
Buzzer coupler is more to the front side of the
vehicle than the wire harness.

2-38
 CABLE ROUTING

Frame 1 (top view)

1 2 3 4 5 6 7, A 8 E 23, F

22, D 21

12

9
10
11
12
21
13
20 14
19, C
18 H 25, I
17 24, G
16 26

15 J
L 11
K

15, B

2-39
 CABLE ROUTING

1. Injector #1 coupler
2. Ignition coil #1 coupler
3. Intake air pressure sensor 2
4. Injector #2 coupler
5. Ignition coil #2 coupler
6. Intake air pressure sensor 1
7. Wire harness (to ignition coil #3 coupler)
8. Ignition coil #3 coupler
9. Injector #3 coupler
10. Throttle position sensor coupler
11. Fuel tank breather hose
12. Throttle body
13. Throttle servo motor coupler
14. Wire harness
15. Stator coil lead
16. Fuel tank drain hose
17. Wire harness (to ECU (engine control unit))
18. Shift sensor coupler
19. Coupler cover
20. Shift sensor lead
21. Wire harness
22. Clamp
23. Fuel tank cap coupler (for MT09SPR/
MT09SPRC)
24. Plastic locking tie
25. Crankshaft position sensor lead (to crank-
shaft position sensor coupler)
26. Crankshaft position sensor lead (to stator coil
lead)

A. Pass the wire harness (to ignition coil #3 cou-

pler) to the left side of the vehicle of the
mount of the cylinder head breather hose.
B. Fix the stator coil lead between the branches
and the clamp, with plastic locking ties.
C. Slide the coupler cover until the coupler is
completely hidden, then face the opening to
the lower side of the vehicle.
D. Insert the clamp into the hole on the throttle
body.
E. For MT09SPR/MT09SPRC
F. Insert the fuel tank cap coupler into the hole
in the frame.
G. Face the lock part of the plastic locking tie to
the left side of the vehicle and insert the tip of
the plastic locking tie between the frame and
wire harness.
H. Upper side of the vehicle
I. Bend the crankshaft position sensor lead into
a U shape and secure the extra wire, facing
the front side of the vehicle, with a plastic
locking tie.
J. The crankshaft position sensor lead must be
within the range shown in the illustration.
K. Inside of the vehicle
L. Pass the wire harness (to purge cut valve
solenoid) to the front side of the vehicle of the
fuel tank breather hose (for California only).

2-40
 CABLE ROUTING

Frame 2 (top view)

13, E 18
14, F 14, F
13 14
15 16
12

11

17, D 17, D

10
1
9, C 2, A
3
4
8 5

6, B

17, G 19, H

15 15, I
22, O 20, J
L 4 K
21, N

17, M

2-41
 CABLE ROUTING

1. Rear brake light switch coupler N. Pass the stator coil lead more to the left side
2. Rear wheel sensor coupler of the vehicle than the wire harness and more
to the under side of the vehicle than the
3. Fuel pump coupler starter motor lead.
4. Battery box O. Pass the starter motor lead more to the left
5. ABS ECU coupler side of the vehicle than the wire harness and
6. Radiator fan motor relay lower than the centerline of the clamp.
7. Crankshaft position sensor coupler
8. Sidestand switch coupler
9. Horn relay
10. Wire harness (to frame ground 3)
11. Sidestand switch lead
12. Crankshaft position sensor lead
13. Frame ground 3
14. Frame ground 1, 2, 4, 5
15. Wire harness
16. Wire harness (to throttle servo motor coupler)
17. Clamp
18. Washer
19. Rear brake light switch lead
20. Wire harness (to neutral switch coupler)
21. Stator coil lead
22. Starter motor lead

A. Insert the rear wheel sensor coupler into the

hole in the battery box.
B. Insert the radiator fan motor relay into the ribs
on the battery box.
C. Insert the horn relay into the ribs on the bat-
tery box.
D. Insert the clamp into the hole of the frame.
E. Route the frame ground 3 more to the upper
side of the vehicle than the frame ground
1,2,4 and 5 with a washer interposed
between them, and assemble them so the
crimped terminals do not overlap.
F. Route the frame ground 1,2,4 and 5, with a
washer interposed between them, more to
the lower side of the vehicle than frame
ground 3, and assemble the crimped termi-
nals of each lead wire to face the upper side
of the vehicle.
G. Insert the clamp into the hole in the battery
box.
H. Fasten the rear brake light switch lead at the
gray tape part.
I. Fasten the clamp at the white tape on the
wire harness.
J. Pass the wire harness (to neutral switch) to
the rear side of the vehicle of the clamp.
K. Insert the tip of the clamp into the hole in the
battery box.
L. Centerline of the clamp
M. Insert the clamp into the hole of the battery
box.

2-42
 CABLE ROUTING

Rear fender 1 (top view)

17 2
16
15, F
14
1
2
7, G
13 3
4 22, O
21 E 4
5
19 12
23 11 18
5, A
24
6
10, D
7
9, C 8, B

19

4 20, H

J 25 26
13
12 27
20, P 9 9
I 20
2 31
32, Q 28 36
33, R 32, T
35
15, S 29 19
34 15
29
14 31, U
15, V
27
21
30
N M L K

2-43
 CABLE ROUTING

1. Positive battery terminal I. Do not allow the wire harness (to GCU cou-
2. Battery pler 1) to extend above the upper side of the
vehicle more than the hook of the battery
3. Negative battery terminal box. The wire harness may extend from the
4. Relay unit cover hook.
5. Starter relay J. Details near GCU (Generator Control Unit)
6. Starter relay coupler K. Hook of the battery box
7. Starter relay cover L. Fit the wire harness (to GCU coupler 3) to the
8. Starting circuit cut-off relay 2 hook of the battery box.
9. Fuse box M. Pass the wire harness (to negative battery
terminal) to the upper side of the vehicle of
10. Engine stop relay the wire harness (to relay unit).
11. USB jack coupler N. Pass the wire harness (to GCU coupler 1) to
12. Rubber band the upper side of the vehicle of the wire har-
13. USB jack ness (to GCU coupler 3) and stator coil lead.
14. Stator coil lead O. After putting the relay unit in the relay unit
15. Starter motor lead cover, fit it to the rib of the IMU cover.
16. Wire harness P. Pass the wire harness (to YDT coupler) more
to the front side of the vehicle than the wire
17. Battery box harness (to positive battery terminal).
18. Starter relay inner cover Q. Pass the wire harness (to negative battery
19. IMU cover terminal) to the upper side of the vehicle of
20. Wire harness (to YDT coupler) the wire harness (to positive battery termi-
nal).
21. Relay unit coupler
R. Insert the clamp into the hole of the battery
22. Relay unit box.
23. IMU (Inertial Measurement Unit) S. Pass the starter motor lead to the front side
24. IMU coupler of the vehicle of the clamp.
25. GCU coupler 1 T. Pass the wire harness (to negative battery
26. Stator coil coupler terminal) to the upper side of the vehicle of
the wire harness (to starter relay coupler) and
27. GCU (Generator Control Unit) the wire harness (to IMU coupler).
28. GCU coupler 3 U. Pass the wire harness (to positive battery ter-
29. Wire harness (to GCU coupler 3) minal) to the lower side of the vehicle of the
30. Starter relay coupler starter motor lead.
31. Wire harness (to positive battery terminal) V. Pass the starter motor lead to the lower side
32. Wire harness (to negative battery terminal) of the vehicle of the IMU cover.
33. Clamp
34. Wire harness (to GCU coupler 1)
35. Wire harness (to relay unit coupler)
36. Wire harness (to IMU coupler)

A. Insert the starter relay until it contacts the

stopper rib in the battery box.
B. Insert the starting circuit cut-off relay 2 into
the rib of the battery box.
C. Insert the fuse box into the ribs of the battery
box.
D. Insert the engine stop relay into the ribs of
the battery box.
E. After putting the USB jack in the rubber band,
insert the rubber band into the ribs of the bat-
tery box.
F. Pass the starter motor lead to the upper side
of the vehicle of the stator coil lead.
G. When installing the starter relay cover, put it
directly against the inside relay cover.
H. Pass the wire harness (to YDT coupler)
below the IMU cover, but between the IMU
cover and relay unit cover.

2-44
 CABLE ROUTING

Rear fender 2 (top view)

11 12 13
1
12
14
16
15, K

10, J

17 A

1
18
15, K 2, B
3, B
9, I
4
H
8 C

7, G

F D, E
5
18 7 5 8 4
L

2-45
 CABLE ROUTING

1. License plate light coupler

2. Rear turn signal light coupler (right) (white)
3. Rear turn signal light coupler (left) (black)
4. Rear turn signal light lead (right)
5. Tail/brake light lead
6. Tail/brake light coupler
7. License plate light lead
8. Rear turn signal light lead (left)
9. Accessory coupler (option)
10. YDT coupler
11. Wire harness (to starter relay coupler)
12. Joint connector
13. Wire harness (to rear turn signal light cou-
pler)
14. Wire harness (to accessory coupler)
15. Clamp
16. Wire harness (to starting circuit cut-off relay
2)
17. Wire harness
18. Battery box

A. Pass the wire harness (to starter relay cou-

pler) to the upper side of the vehicle of the
wire harness (to starting circuit cut-off relay
2).
B. Fit the rear turn signal light (right) (white) and
rear turn signal light (left) (black) to the hook
of the battery box.
C. Fit the rear turn signal light lead (left) and
rear turn signal light lead (right) to the hook of
the battery box.
D. Do not allow the turn signal light lead(s) to
rise up above the hook of the battery box.
E. Let the turn signal light lead(s) hang from the
hook to the rear side of the vehicle.
F. Fit the rear turn signal light lead (left), the
rear turn signal light lead (right), tail/brake
light lead and license plate light lead to the
hook of the battery box.
G. Pass the license plate light lead to the lower
side of the vehicle of the wire harness (to tail/
brake light coupler).
H. Pass the wire harness (to tail/brake light cou-
pler) in front of the hook and over the license
plate light lead.
I. Insert the accessory coupler into the hole in
the battery box.
J. Insert the YDT coupler into the ribs of the
battery box.
K. Insert the clamp into the hole of the battery
box.
L. Route the rear turn signal light lead (right),
rear turn signal light lead (left), tail/brake light
lead, and license plate light lead in the posi-
tional relationship shown in the illustration.

2-46
 CABLE ROUTING

Main switch (left side view)

6
1
7, A

5 7, C

1 B

3 2

7, D

2-47
 CABLE ROUTING

1. Wire harness
2. Front wheel sensor coupler
3. Front wheel sensor lead
4. Wire harness (to O2 sensor)
5. Brake hose joint bracket
6. Frame
7. Clamp

A. Insert the clamp into the hole of the brake

hose joint bracket.
B. Insert the clamp with touched the protrusion
on the frame.
C. Insert the clamp into the rib of the frame.
D. Insert the clamp between the protrusions on
the frame.

2-48
 CABLE ROUTING

Front brake hose (right side view)

3 5 D
2 6
1
5
5
E
2
C 6

8
1 2
1 2 B 1 5
G

F 4

6 A 5
7

4 5
9
10

H 9
5
9
I
5

11
4
4

2-49
 CABLE ROUTING

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

per (left))
2. Brake hose (front brake master cylinder to
hydraulic unit)
3. Meter assembly bracket
4. Front fender
5. Clamp
6. Brake hose bracket
7. Frame
8. Front wheel sensor lead
9. Brake hose (front brake caliper (left) to front
brake caliper (right))
10. Front brake caliper (right) (for MT09R/
MT09RC)
11. Front brake caliper (right) (for MT09SPR/
MT09SPRC)

A. It is OK for the stopper of the bracket to not

contact the frame.
B. Put the brake hose (front brake master cylin-
der to hydraulic unit) and brake hose (hydrau-
lic unit to front brake caliper (left)) against the
stopper of the bracket.
C. Insert the clamp all the way into the brake
hose bracket precisely.
D. Tighten the claws of the clamps at least 2
notches. Also, assemble it with the opening
facing the left side of the vehicle.
E. Insert the clamp all the way into the meter
assembly bracket precisely.
F. Insert the clamp all the way into the front
fender precisely.
G. Tighten the claws of the clamps at least 2
notches. Also, assemble it with the opening
facing the rear of the vehicle.
H. For MT09SPR/MT09SPRC
I. 12°

2-50
 CABLE ROUTING

Front brake hose (left side view)

3
2

G
1
I

H
J
1
3 6

K 1, A
L 1, B
2, C
2 3
1, D
G
4, O
M 4
1 2 3, P

L 4
3 5
3 E
2
2 Q
N

2 5 9
7 F 8

R 3 4

3 S 7
2

T N
4 2
10

2-51
 CABLE ROUTING

1. Clamp S. 16°
2. Front wheel sensor lead T. Put the pin of the brake hose (front brake cal-
3. Brake hose (hydraulic unit to front brake cali- iper (left) to front brake caliper (right)) against
per (left)) the metal fitting of the brake hose (hydraulic
unit to front brake caliper (left)).
4. Brake hose (front brake caliper (left) to front
brake caliper (right))
5. Front brake caliper (left) (for MT09R/
MT09RC)
6. Brake hose (front brake master cylinder to
hydraulic unit)
7. Reflector bracket
8. Front fork
9. Holder
10. Front brake caliper (left) (for MT09SPR/
MT09SPRC)

A. Fasten the white tape portion of the front

wheel sensor lead with the clamp.
B. Fasten the white tape portion of the brake
hose (hydraulic unit to front brake caliper
(left)) with the clamp.
C. Make the front wheel sensor lead to follow
the brake hose (hydraulic unit to front brake
caliper (left)). After routing, it is OK to have a
gap between the front wheel sensor lead and
brake hose (hydraulic unit to front brake cali-
per (left)).
D. Fix the clamp at the end of the protector of
the brake hose (hydraulic unit to front brake
caliper (left)).
E. Install the brake hose (front brake caliper
(left) to front brake caliper (right)) with its
white paint mark facing outward.
F. Install the holder with contacted the front fork
leg.
G. Left side of the vehicle
H. Lower side of the vehicle
I. Face the opening of the clamp and the front
wheel sensor lead to the lower side of the
vehicle. Tighten the claws to the end (4
notches).
J. Upper side of the vehicle
K. Face the opening of the clamp and the front
wheel sensor lead to the rear of the vehicle.
Tighten the claws to the end (4 notches).
L. Rear of the vehicle
M. Face the opening of the clamp and the wheel
sensor lead to the left side of the vehicle.
Tighten the claws to the end (4 notches).
N. Insert the grommet of the front wheel sensor
lead into the reflector bracket.
O. Put the brake hose (hydraulic unit to front
brake caliper (left)) against the positioning
stopper of the caliper.
P. Face the brake hose (front brake caliper (left)
to front brake caliper (right)) with the orienta-
tion of the metal fitting of the brake hose
(hydraulic unit to front brake caliper (left)).
Q. Fasten the white tape portion of the front
wheel sensor lead with the holder.
R. For MT09SPR/MT09SPRC

2-52
 CABLE ROUTING

Rear brake hose (right side view)

1 Q 3
1
3 F
E K F
2
2
2 3

1,D

1,C

4 1 N
F

1 1,A 2 3 4 P
6

2 7, M 3 1 H
3 I 3, G 2
1 J
F F
E E F
2

G 5 2 3,L

2-53
 CABLE ROUTING

1. Clamp
2. Rear brake hose (hydraulic unit to rear brake
caliper)
3. Rear wheel sensor lead
4. Rear brake hose (rear brake master cylinder
to hydraulic unit)
5. Rear fender
6. Rear brake light switch lead
7. Wire harness guide

A. Fasten the white tape portion of the rear

wheel sensor lead with the clamp.
B. Fasten the grommet of the rear wheel sensor
lead with the clamp.
C. Fasten the gray tape portion of the rear brake
light switch lead with the clamp.
D. Fasten the white tape portion of the rear
brake hose (hydraulic unit to rear brake cali-
per) with the clamp.
E. 45°
F. Right side of the vehicle
G. Put the rear wheel sensor lead more to the
right side of the vehicle than the rear brake
hose (hydraulic unit to rear brake caliper).
H. Face the opening of the clamp and the rear
wheel sensor lead to the right side of the
vehicle. Tighten the claws to 4 notches.
I. Upper side of the vehicle
J. Face the clamp opening towards the upper
side of the vehicle. Tighten the claws to at
least 3 notches.
K. Route the rear wheel speed sensor lead to
the distance between the clamp(s) in the
illustration along the rear brake hose (hydrau-
lic unit to rear brake caliper).
L. Pass the rear wheel sensor lead more to the
right side of the vehicle than the rear brake
hose (hydraulic unit to rear brake caliper).
M. Pass the rear brake hose (hydraulic unit to
rear brake caliper) and rear wheel sensor
lead through the inside of the wire harness
guide.
N. Face the opening of the clamp and the rear
brake light switch lead to the right side of the
vehicle and to the front of the vehicle. Tighten
the claws to at least 3 notches.
O. Front side of the vehicle
P. 90°
Q. Fasten the protector of the rear brake hose
(hydraulic unit to rear brake caliper) with the
clamp.

2-54
 CABLE ROUTING

ABS ECU (top and left side view)

1
2

3 A
4
B

5
C
B

1 2

3
G

2-55
 CABLE ROUTING

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

per (left))
2. Brake hose (hydraulic unit to front brake mas-
ter cylinder)
3. Brake hose (hydraulic unit to rear brake mas-
ter cylinder)
4. Brake hose (hydraulic unit to rear brake cali-
per)
5. Battery box
6. Hydraulic unit assembly

A. 120°
B. 85°
C. 89°
D. Tighten while keeping the pin of the brake
hose (hydraulic unit to rear brake caliper)
against the brake hose (rear brake master
cylinder to hydraulic unit). After tightening, it
is OK to have a gap between the brake hose
(hydraulic unit to rear brake caliper) and the
brake hose (rear brake master cylinder to
hydraulic unit).
E. Tighten while keeping the pin of the brake
hose (rear brake master cylinder to hydraulic
unit) against the brake hose (hydraulic unit to
rear brake caliper). After tightening, it is OK
to have a gap between the brake hose
(hydraulic unit to rear brake caliper) and the
brake hose (rear brake master cylinder to
hydraulic unit).
F. Front side of the vehicle
G. Tighten the bolt after assembling brake hose
(rear brake master cylinder to hydraulic unit)
and the brake hose (hydraulic unit to rear
brake caliper) at the hydraulic unit assembly.

2-56
 CABLE ROUTING

Fuel tank (left side view)

F G

6
6

5 4, A 3 2

3 C

D, E

2-57
 CABLE ROUTING

1. Fuel tank
2. Frame
3. Fuel pump
4. Fuel tank drain hose
5. Fuel hose
6. Fuel tank breather hose
7. Fuel tank cap lead (for MT09SPR/
MT09SPRC)

A. Pass the fuel tank drain hose over the fuel

hose.
B. To fuel rail
C. Recess mark
D. Boss
E. Face the positioning boss of the fuel pump
toward the recess mark on the fuel tank.
F. For MT09R/MT09RC
G. For MT09SPR/MT09SPRC

2-58
 CABLE ROUTING

Starter motor (except for California)

1 2
4
C
B D
E H
2
3, F
A J
3, G K
2
6

1
2
5 1

I
5
6
1
2

7 1 2 6

2 N M L

7 2
1

2-59
 CABLE ROUTING

1. Fuel tank drain hose

2. Fuel tank breather hose
3. Clip
4. Clamp
5. Starter motor holder
6. Starter motor
7. Sidestand switch lead

A. Assemble the fuel tank breather hose so the

white paint mark faces the rear of the vehicle.
B. To fuel tank cap
C. To fuel tank
D. Insert the end of the fuel tank drain hose until
it contacts the fuel tank.
E. Assemble the fuel tank drain hose so the blue
paint faces the rear of the vehicle.
F. Assemble the knob of the clip to align with the
blue paint mark on the fuel tank drain hose.
G. Assemble the knobs of the clips to align with
the white paint mark on the fuel tank breather
hose.
H. Fasten the white paint portion of the fuel tank
drain hose and the white paint portion of the
fuel tank breather hose with the clamp.
I. Front side of the vehicle
J. Right side of the vehicle
K. Locate the protrusion on the starter motor
holder between the starter motor mounting
bosses on the crankcase.
L. Assemble the fuel tank breather hose so it is
lower than the fuel tank drain hose.
M. Fit the gray tape portion of the sidestand
switch lead to the starter motor holder.
N. While installing the fuel tank drain hose and
fuel tank breather hose to the holder, do not
allow the bases of the curves of the hoses to
rise up on the starter motor holder.

2-60
 CABLE ROUTING

Canister (for California only)

J Q J
K P
I
6 8
4
L 5, O R
6 2 7
5, N
D E 1
3 3
C F M
5, G
B 5, H I
2
4 S
7
A 3
2 8
1
9

11
1 10

10 T
Y
5, U
11
V
Y 8
X W 1 9

9
10
9
1

2-61
 CABLE ROUTING

1. Fuel tank drain hose T. Insert the end of the canister breather hose
2. Canister purge hose (purge cut valve sole- until it contacts the canister.
noid to hose joint) U. Assemble the knob of the clip to align with the
3. Fuel tank breather hose (fuel tank cap to can- white paint mark on the canister breather
ister) hose.
4. Purge cut valve solenoid V. Assemble the canister breather hose so the
white paint mark faces the upper side of the
5. Clip vehicle.
6. Canister purge hose (purge cut valve sole- W. Assemble the canister breather hose so it is
noid to canister) lower than the fuel tank drain hose.
7. Canister X. Fit the gray tape portion of the sidestand
8. Canister holder switch lead to the canister holder.
9. Canister breather hose Y. While installing the fuel tank drain hose and
10. Sidestand switch lead canister breather hose to the canister holder,
do not allow the bases of the curves of the
11. Starter motor hoses to rise up on the canister holder.
A. To throttle body
B. Assemble the fuel tank breather hose (fuel
tank cap to canister) so the white paint mark
faces the rear of the vehicle.
C. To fuel tank cap
D. To fuel tank
E. Insert the end of the fuel tank drain hose until
it contacts the fuel tank.
F. Assemble the fuel tank drain hose so the blue
paint faces the rear of the vehicle.
G. Assemble the knob of the clip to align with the
blue paint mark on the fuel tank drain hose.
H. Assemble the knobs of the clips to align with
the white paint mark on the fuel tank breather
hose (fuel tank cap to canister).
I. Front side of the vehicle
J. Right side of the vehicle
K. Insert the end of the canister purge hose
(purge cut valve solenoid to canister) until it
contacts the purge cut valve solenoid.
L. Assemble the canister purge hose (purge cut
valve solenoid to canister) so the yellow paint
mark faces the upper side of the vehicle.
M. Assemble the fuel tank breather hose (fuel
tank cap to canister) so the yellow paint mark
faces the upper side of the vehicle.
N. Assemble the knob of the clip to align with the
yellow paint mark on the fuel tank breather
hose (fuel tank cap to canister).
O. Assemble the knob of the clip to align with the
blue paint mark on the canister purge hose
(purge cut valve solenoid to canister).
P. Assemble the canister purge hose (purge cut
valve solenoid to canister) so the blue paint
mark faces the upper side of the vehicle.
Q. Locate the protrusion on the canister holder
between the starter motor mounting bosses
on the crankcase.
R. Insert the end of the hose until it contacts the
canister.
S. While installing the fuel tank drain hose to the
canister holder, do not allow the base of the
curves of the fuel tank drain hose to rise up
on the clamp of the canister holder.

2-62
 CABLE ROUTING

Fuel tank (top and right side view)

7
6
4 F 2
2 A
E 4 2 6
I
J
L
1, H
B 7

6
5 2
E 4 2 6 G

3 1
A
C 2
2
3
3

2
2
D
A
3 A
C B
C
2
2
1

2-63
 CABLE ROUTING

1. Clamp
2. Fuel tank breather hose
3. Air filter case assembly
4. Clip
5. Fuel tank cap lead (for MT09SPR/
MT09SPRC)
6. Fuel tank
7. Fuel tank cap

A. Upper side of the vehicle

B. Right side of the vehicle
C. Assemble the fuel tank breather hose so the
white paint faces the upper side of the vehi-
cle.
D. Assemble the fuel tank breather hose to the
claw on the air filter case assembly.
E. Insert the end of the fuel tank breather hose
until it contacts the fuel tank cap.
F. Install the knob of the clip to align with the
yellow paint on the fuel tank breather hose.
G. Route the fuel tank breather hose on the rib
side of the fuel tank.
H. Fix the fuel tank cap lead with a clamp.
I. Assemble so the yellow paint on the fuel tank
breather hose is located within the range
shown in the illustration.
J. 90°
K. For MT09R/MT09RC
L. For MT09SPR/MT09SPRC

2-64
 CABLE ROUTING

Air filter case and throttle bodies (left side view)

E A

2, D 9 10 9 2, F 9 2, F

E 3 2, D C B A

2, F
2, L K 6 5 J
B
G
H

7
P
P
5 P
I
I
G
M N
8
O 2, Q G R

2-65
 CABLE ROUTING

1. Air filter case

2. Clip
3. Cylinder head breather hose
4. Cylinder head cover
5. Hose clamp
6. Hose joint
7. Canister purge hose (purge cut valve sole-
noid to hose joint) (for California only)
8. Purge cut valve solenoid (for California only)
9. Canister purge hose (for California only)
10. Throttle body

A. Left side of the vehicle

B. Yellow paint mark
C. Assemble the cylinder head breather hose so
the yellow paint mark faces the left side of the
vehicle. Insert the end of the cylinder head
breather hose until it contacts the air filter
case.
D. Face the claw of the clip to left side of the
vehicle.
E. Right side of the vehicle
F. Face the claw of the clip to right side of the
vehicle.
G. White paint mark
H. Assemble the cylinder head breather hose so
the white paint mark faces the right side of
the vehicle. Insert the end of the cylinder
head breather hose until it contacts the cylin-
der head cover.
I. 1–3 mm (0.04–0.12 in)
J. Front side of the vehicle
K. Insert the end of the canister purge hose
(purge cut valve solenoid to hose joint) until it
contacts the hose joint. (for California only)
L. Face the claw of the clip to front side of the
vehicle.
M. 10°
N. 105°
O. 123°
P. Face the bolt head to the position as shown
in the illustration.
Q. Face the claw of the clip to upper side of the
vehicle.
R. Insert the end of the canister purge hose
(purge cut valve solenoid to hose joint) until it
contacts the purge cut valve solenoid. (for
California only)
S. Insert the end of the canister purge hose until
it contacts the throttle body. (for California
only)
T. 5–7 mm (0.20–0.28 in)

2-66
 CABLE ROUTING

Radiator 1 (right side view)

C
D
4 5

3
6

7
B

1, A

2-67
 CABLE ROUTING

1. Coolant reservoir breather hose

2. Coolant reservoir hose
3. Front side panel (right)
4. Radiator fan cover
5. Radiator
6. Radiator hose (cylinder head to radiator)
7. Radiator fan motor lead

A. Direction of the coolant reservoir breather

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

2-68
 CABLE ROUTING

Radiator 2 (front side view)

9 G Q U R V
R R
4, H

S
10

2 W T
T

8 1

F
2

4, D

C 3
B 4, A
J
11 O
2
N P

12, L
6 I 3
12, L 12, K

2-69
 CABLE ROUTING

1. Front turn signal/position light lead (left) U. Make sure not to install the hose clamp on
2. Radiator the raised portion of the hose fitting.
3. Radiator outlet hose V. Clip fixed position details.
4. Clip W. Make sure not to install the clip on the raised
portion of the hose fitting.
5. Thermostat assembly
6. Radiator inlet hose
7. Radiator hose (cylinder head to radiator)
8. Front turn signal/position light lead (right)
9. Radiator cap
10. Coolant reservoir hose
11. Water jacket joint
12. Hose clamp

A. Face the knob of the clip toward the yellow

paint mark on the radiator outlet hose.
B. Align the yellow paint mark on the radiator
outlet hose with the rib on the thermostat
assembly.
C. Insert the radiator outlet hose until it touches
the rib of the thermostat assembly.
D. Install the clip with its knob facing the down of
the vehicle.
E. Assemble the radiator hose (cylinder head to
radiator) so the white paint mark faces the
front of the vehicle.
F. Install the radiator hose (cylinder head to
radiator) up to the base of the bend in the
radiator pipe.
G. Insert the coolant reservoir hose up to the
section where the radiator pipe increases in
diameter.
H. Face the knob of the clip to the inside of the
vehicle. Fit the clip in the center between the
raised portion of the hose fittings, never ride
on the raised portion of the hose fitting.
I. Insert the radiator inlet hose until it touches
the rib of the water jacket joint.
J. Align the yellow paint mark on the radiator
inlet hose with the rib on the water jacket
joint.
K. Install the hose clamp screw to face it top
side of the vehicle.
L. Install the hose clamp with the screw head
facing the inside of the vehicle.
M. Install the radiator inlet hose with its white
paint mark facing outside of the vehicle.
N. Insert the radiator inlet hose up to the section
where the fuel tank pipe increases in diame-
ter.
O. Insert the radiator outlet hose up to the sec-
tion where the fuel tank pipe increases in
diameter.
P. Install the radiator outlet hose with its white
paint mark facing outside of the vehicle.
Q. Hose clamp fixed position details.
R. 3 mm (0.12 in) or more
S. 0–1 mm (0–0.04 in)
T. Hose plug-in section

2-70
 CABLE ROUTING

EAS34037

OPTION COUPLER LOCATION CHART

Option coupler (auxiliary DC jack and grip warmer)

5
6

4 1

Order Job/Parts to remove Q’ty Remarks

1 Meter cover 1
2 Headlight front cover 1
3 Auxiliary light cover/Auxiliary light 1
4 Auxiliary DC jack coupler 1
5 Grip warmer coupler (right) 1
6 Grip warmer coupler (left) 1

2-71
 CABLE ROUTING

Option coupler (accessory)

Order Job/Parts to remove Q’ty Remarks

1 Passenger seat 1
2 Accessory coupler 1

2-72
 CABLE ROUTING

2-73
 PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE ............................................................................3-1

INTRODUCTION .......................................................................................3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM ...................................................................................................3-1
GENERAL MAINTENANCE AND LUBRICATION CHART .......................3-1
CHECKING THE VEHICLE USING THE YAMAHA DIAGNOSTIC
TOOL ........................................................................................................ 3-4
CHECKING THE FUEL LINE .................................................................... 3-4
CHECKING THE SPARK PLUGS ............................................................. 3-5
ADJUSTING THE VALVE CLEARANCE .................................................. 3-5
CHECKING THE ENGINE IDLING SPEED ..............................................3-8
SYNCHRONIZING THE THROTTLE BODIES.......................................... 3-8
CHECKING THE THROTTLE BODY JOINTS ........................................ 3-10
CHECKING THE CYLINDER HEAD BREATHER HOSE .......................3-10
CHECKING THE EXHAUST SYSTEM....................................................3-10
CHECKING THE CANISTER (for California only)................................... 3-11
3
CHECKING THE PURGE CUT VALVE SOLENOID
(for California only) ................................................................................. 3-11
REPLACING THE AIR FILTER ELEMENT ............................................. 3-11
ADJUSTING THE CLUTCH LEVER POSITION ..................................... 3-12
ADJUSTING THE CLUTCH LEVER FREE PLAY................................... 3-12
CHECKING THE BRAKE OPERATION .................................................. 3-13
CHECKING THE BRAKE FLUID LEVEL................................................. 3-13
ADJUSTING THE FRONT DISC BRAKE................................................ 3-13
CHECKING THE FRONT BRAKE PADS ................................................ 3-14
ADJUSTING THE REAR DISC BRAKE .................................................. 3-14
CHECKING THE REAR BRAKE PADS .................................................. 3-15
CHECKING THE FRONT BRAKE HOSE................................................ 3-15
CHECKING THE REAR BRAKE HOSE .................................................. 3-15
BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)......................... 3-15
CHECKING THE WHEELS ..................................................................... 3-17
CHECKING THE TIRES..........................................................................3-17
CHECKING THE WHEEL BEARINGS ....................................................3-18
CHECKING THE SWINGARM OPERATION ..........................................3-18
LUBRICATING THE SWINGARM PIVOT ............................................... 3-18
DRIVE CHAIN SLACK............................................................................. 3-18
LUBRICATING THE DRIVE CHAIN ........................................................ 3-19
CHECKING AND ADJUSTING THE STEERING HEAD ......................... 3-20
LUBRICATING THE STEERING HEAD.................................................. 3-21
CHECKING THE CHASSIS FASTENERS .............................................. 3-21
LUBRICATING THE BRAKE LEVER ......................................................3-21
LUBRICATING THE CLUTCH LEVER....................................................3-21
LUBRICATING THE PEDAL ................................................................... 3-21
ADJUSTING THE SHIFT PEDAL............................................................ 3-21
CHECKING THE SIDESTAND................................................................3-21
LUBRICATING THE SIDESTAND........................................................... 3-21
CHECKING THE SIDESTAND SWITCH................................................. 3-21
CHECKING THE FRONT FORK ............................................................. 3-21
ADJUSTING THE FRONT FORK LEGS (for MT09R/MT09RC) ............. 3-21
ADJUSTING THE FRONT FORK LEGS (for MT09SPR/MT09SPRC).... 3-23
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 3-25
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
(for MT09R/MT09RC) ............................................................................. 3-25
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
(for MT09SPR/MT09SPRC) ................................................................... 3-26
CHECKING THE CONNECTING ARM AND RELAY ARM.....................3-28
CHECKING THE ENGINE OIL LEVEL....................................................3-28
CHANGING THE ENGINE OIL ...............................................................3-29
MEASURING THE ENGINE OIL PRESSURE ........................................ 3-30
CHECKING THE COOLANT LEVEL.......................................................3-31
CHECKING THE COOLING SYSTEM ....................................................3-31
CHANGING THE COOLANT................................................................... 3-32
CHECKING THE FRONT BRAKE LIGHT SWITCH ................................3-33
ADJUSTING THE REAR BRAKE LIGHT SWITCH .................................3-34
CHECKING AND LUBRICATING THE CABLES .................................... 3-34
CHECKING THE THROTTLE GRIP........................................................ 3-34
LUBRICATING THE THROTTLE GRIP .................................................. 3-34
CHECKING AND CHARGING THE BATTERY....................................... 3-34
CHECKING THE FUSES ........................................................................3-34
ADJUSTING THE HEADLIGHT BEAMS................................................. 3-35
 PERIODIC MAINTENANCE

EAS20022

PERIODIC MAINTENANCE
EAS30022

INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a lon-
ger service life and reduce the need for costly overhaul work. This information applies to vehicles al-
ready in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
TIP
• From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi
(13000 km) or 12 months.
• Items marked with an asterisk require special tools, data and technical skills, have a Yamaha dealer
perform the service.

EAS30614

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

INITIAL ODOMETER READINGS

8000 mi 12000 mi 16000 mi 20000 mi

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

• Check fuel hoses for cracks or

1 * Fuel line damage. √ √ √ √ √
• Replace if necessary.
• Check condition. √ √ √ √ √
2 * Spark plugs • Adjust gap and clean.
• Replace. Every 12000 mi (19000 km) or 18 months

3 * Valve clearance • Check and adjust valve clear- Every 26600 mi (42000 km)
ance when engine is cold.
• Check breather hose for
Crankcase breath-
4 * er system cracks or damage. √ √ √ √ √
• Replace if necessary.
5 * Fuel injection • Adjust synchronization. √ √ √ √ √ √
• Check for leakage.
• Tighten if necessary.
6 * Exhaust system • Replace gasket(s) if neces- √ √ √ √ √ √
sary.
Evaporative emis-
sion control sys- • Check control system for
7 * damage. √ √
tem (for California • Replace if necessary.
only)

EAS30615

GENERAL MAINTENANCE AND LUBRICATION CHART

INITIAL ODOMETER READINGS

8000 mi 12000 mi 16000 mi 20000 mi

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

Diagnostic sys- • Perform dynamic inspection

1 * using Yamaha diagnostic tool. √ √ √ √ √ √
tem check • Check the error codes.
2 * Air filter element • Replace. Every 24000 mi (37000 km)
• Check operation.
3 * Clutch • Adjust or replace cable. √ √ √ √ √ √

3-1
 PERIODIC MAINTENANCE

INITIAL ODOMETER READINGS

8000 mi 12000 mi 16000 mi 20000 mi
600 mi 4000 mi
No. ITEM ROUTINE (1000 km) (7000 km) (13000 (19000 (25000 (31000
km) km) km) km)
or or or or or or
1 month 6 months
12 months 18 months 24 months 30 months
• Check operation, fluid level,
and for fluid leakage.
4 * Front brake √ √ √ √ √ √
• Replace brake pads if neces-
sary.
• Check operation, fluid level,
5 * Rear brake and for fluid leakage. √ √ √ √ √ √
• Replace brake pads if neces-
sary.
• Check for cracks or damage.
• Check for correct routing and √ √ √ √ √
6 * Brake hoses clamping.
• Replace. Every 4 years
7 * Brake fluid • Change. Every 2 years
• Check runout and for damage.
8 * Wheels √ √ √ √ √
• Replace if necessary.
• Check tread depth and for
damage.
9 * Tires • Replace if necessary. √ √ √ √ √
• Check air pressure.
• Correct if necessary.
• Check bearings for smooth
10 * Wheel bearings operation. √ √ √ √ √
• Replace if necessary.
• Check operation and for ex- √ √ √ √ √
Swingarm pivot cessive play.
11 * bearings
• Moderately repack with lithi-
Every 32000 mi (50000 km)
um-soap-based grease.
• Check chain slack, alignment
and condition.
Every 600 mi (1000 km) and after washing the motorcycle, riding in the
12 Drive chain • Adjust and lubricate chain with rain or riding in wet areas
a special O-ring chain lubri-
cant thoroughly.
• Check bearing assemblies for √ √ √ √ √ √
looseness.
13 * Steering bearings
• Moderately repack with lithi-
Every 12000 mi (19000 km)
um-soap-based grease.
• Check all chassis fitting and
14 * Chassis fasteners fasteners. √ √ √ √ √
• Correct if necessary.
Brake lever pivot
15 • Apply silicone grease lightly. √ √ √ √ √
shaft
Brake pedal pivot • Apply lithium-soap-based
16 shaft grease lightly. √ √ √ √ √

17 Clutch lever pivot • Apply lithium-soap-based √ √ √ √ √

shaft grease lightly.
Shift pedal pivot • Apply lithium-soap-based
18 √ √ √ √ √
shaft grease lightly.
• Check operation.
19 Sidestand pivot • Apply lithium-soap-based √ √ √ √ √
grease lightly.
• Check operation and replace
20 * Sidestand switch if necessary. √ √ √ √ √ √

• Check operation and for oil

21 * Front fork leakage. √ √ √ √ √
• Replace if necessary.

Shock absorber • Check operation and for oil

22 * leakage. √ √ √ √ √
assembly • Replace if necessary.

23 * Rear suspension • Apply lithium-soap-based √ √

link pivots grease lightly.

3-2
 PERIODIC MAINTENANCE

INITIAL ODOMETER READINGS

8000 mi 12000 mi 16000 mi 20000 mi

600 mi 4000 mi
No. ITEM ROUTINE (1000 km) (7000 km) (13000 (19000 (25000 (31000
km) km) km) km)
or or or or or or
1 month 6 months
12 months 18 months 24 months 30 months
• Change (warm engine before
24 Engine oil draining). √ √ √ √ √ √

25 Engine oil filter • Replace. √ √ √

cartridge
• Check coolant level and vehi-
√ √ √ √ √
26 * Cooling system cle for coolant leakage.
• Change coolant. Every 3 years
Front and rear
27 * • Check operation. √ √ √ √ √ √
brake switches
• Apply Yamaha cable lubricant
28 * Control cables or other suitable cable lubri- √ √ √ √ √ √
cant thoroughly.
• Check operation.
29 * Throttle grip • Lubricate throttle grip housing √ √ √ √ √
tube guides.
Lights, signals • Check operation.
30 * and switches • Adjust headlight beam. √ √ √ √ √ √

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

3-3
 PERIODIC MAINTENANCE

EAS32024 EAS30619

CHECKING THE VEHICLE USING THE CHECKING THE FUEL LINE

YAMAHA DIAGNOSTIC TOOL The following procedure applies to all of the fuel,
Use the YDT and check the vehicle according to drain and breather hoses.
the following procedure. 1. Remove:
1. Remove: • Passenger seat
• Rider seat • Rider seat
Refer to “GENERAL CHASSIS (1)” on Refer to “GENERAL CHASSIS (1)” on
page 4-1. page 4-1.
2. Remove the protective cap, and then connect • Fuel tank center cover
the YDT to the coupler. • Air scoop
Refer to “YDT” on page 9-3. Refer to “GENERAL CHASSIS (1)” on
page 4-1.
Yamaha diagnostic tool USB • Fuel tank
(US) Refer to “FUEL TANK” on page 7-1.
90890-03275 2. Check:
Yamaha diagnostic tool (A/I) • Fuel hose “1”
90890-03273 • Fuel tank breather hose “2”
• Fuel tank drain hose “3”
TIP Cracks/damage → Replace.
• Yamaha diagnostic tool (A/I) (90890-03273) in- Loose connection → Connect properly.
cludes YDT sub harness (6P) (90890-03266). ECA14940

• If you already have Yamaha diagnostic tool (A/ NOTICE

I) (90890-03262), YDT sub harness (6P) Make sure the fuel tank breather hose is rout-
(90890-03266) is separately required. ed correctly.
3. Check: TIP
• DTC Before removing the fuel hoses, place a few
TIP rags in the area under where it will be removed.
Use the “Diagnosis of malfunction” function of
the YDT to check the DTC. For information
about using the YDT, refer to the operation man-
ual that is included with the tool.
DTC No. is displayed → Check and repair the
probable cause of the malfunction.
Refer to “SELF-DIAGNOSTIC FUNCTION 1
AND DIAGNOSTIC CODE TABLE” on 2
page 9-41.
4. Perform: 3
• Dynamic inspection
TIP
Use the “Dynamic inspection” function of the
YDT version 3.0 and after to perform the dynam-
ic inspection. For information about using the
YDT, refer to the operation manual that is includ-
ed with the tool.
2
5. Install:
• Rider seat
Refer to “GENERAL CHASSIS (1)” on
page 4-1.

3-4
 PERIODIC MAINTENANCE

3. Install: 5. Clean:
• Fuel tank • Spark plug
Refer to “FUEL TANK” on page 7-1. (with a spark plug cleaner or wire brush)
• Air scoop 6. Measure:
• Fuel tank center cover • Spark plug gap “a”
Refer to “GENERAL CHASSIS (1)” on (with a wire thickness gauge)
page 4-1. Out of specification → Regap.
• Rider seat
• Passenger seat Spark plug gap
Refer to “GENERAL CHASSIS (1)” on 0.8–0.9 mm (0.031–0.035 in)
page 4-1.
EAS30620

CHECKING THE SPARK PLUGS

The following procedure applies to all of the
spark plugs.
1. Remove:
• Passenger seat
• Rider seat
Refer to “GENERAL CHASSIS (1)” on
page 4-1. G088879
• Fuel tank center cover 7. Install:
• Air scoop • Spark plug
Refer to “GENERAL CHASSIS (1)” on • Ignition coil
page 4-1.
• Fuel tank Spark plug
Refer to “FUEL TANK” on page 7-1. 13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.

• Air filter case

Refer to “GENERAL CHASSIS (2)” on TIP
page 4-14. Before installing the spark plug, clean the spark
2. Remove: plug and gasket surface.
• Ignition coil
• Spark plug 8. Install:
ECA13320 • Air filter case
NOTICE Refer to “GENERAL CHASSIS (2)” on
Before removing the spark plugs, blow away page 4-14.
any dirt accumulated in the spark plug wells • Fuel tank
with compressed air to prevent it from falling Refer to “FUEL TANK” on page 7-1.
into the cylinders. • Air scoop
• Fuel tank center cover
3. Check: Refer to “GENERAL CHASSIS (1)” on
• Spark plug type page 4-1.
Incorrect → Change. • Rider seat
• Passenger seat
Manufacturer/model Refer to “GENERAL CHASSIS (1)” on
NGK/LMAR9A-9 page 4-1.
4. Check: EAS30622

• Electrode “1” ADJUSTING THE VALVE CLEARANCE

Damage/wear → Replace the spark plug. The following procedure applies to all of the
• Insulator “2” valves.
Abnormal color → Replace the spark plug. TIP
Normal color is medium-to-light tan. Valve clearance adjustment should be made on
a cold engine, at room temperature.

3-5
 PERIODIC MAINTENANCE

1. Remove: a. Turn the crankshaft counterclockwise.

• Passenger seat b. When piston #1 is at TDC on the compres-
• Rider seat sion stroke, align the TDC mark “a” on the
Refer to “GENERAL CHASSIS (1)” on generator rotor with the generator rotor cov-
page 4-1. er mark “b”.
• Fuel tank center cover
• Air scoop b
Refer to “GENERAL CHASSIS (1)” on
page 4-1. a
• Fuel tank
Refer to “FUEL TANK” on page 7-1.
• Air filter case
Refer to “GENERAL CHASSIS (2)” on
page 4-14.
• Front side panel
Refer to “GENERAL CHASSIS (1)” on TIP
page 4-1. TDC on the compression stroke can be found
• Radiator when the camshaft lobes are turned away from
Refer to “RADIATOR” on page 6-3. each other.
2. Remove:
• Ignition coil c. Measure the valve clearance with a thick-
• Spark plug ness gauge.
• Cylinder head cover
• Cylinder head cover gasket Thickness gauge
90890-03268
Refer to “CAMSHAFTS” on page 5-16.
Feeler gauge set
3. Remove:
YU-26900-9
• Timing mark accessing bolt “1”
• Crankshaft end cover “2” TIP
• If the valve clearance is incorrect, record the
2 measured reading.
1 • Measure the valve clearance in the following
sequence.

Valve clearance measuring sequence

Cylinder #1 → #2 → #3

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

Valve clearance (cold)

Intake
0.11–0.20 mm (0.0043–0.0079
in)
Exhaust G088882

0.28–0.32 mm (0.0110–0.0126 A. Front

in)
d. To measure the valve clearances of the
other cylinders, starting with cylinder #1 at
TDC, turn the crankshaft counterclockwise
as specified in the following table.

3-6
 PERIODIC MAINTENANCE

Example:
B Specified valve clearance = 0.11–0.20 mm
(0.004–0.008 in)
Measured valve clearance = 0.25 mm
(0.010 in)
D 0.25 mm (0.010 in) - 0.20 mm (0.008 in) =
C D 0.05 mm (0.002 in)
c. Check the thickness of the current valve
D pad.
TIP
B. Degrees that the crankshaft is turned coun-
terclockwise The thickness “a” of each valve pad is marked in
C. Cylinder hundredths of millimeters on the side that touch-
D. Combustion cycle es the valve lifter.
Example:
Cylinder #2 240°
If the valve pad is marked “158”, the pad
Cylinder #3 480° thickness is 1.58 mm (0.062 in).

5. Remove:
• Camshaft a
TIP
• Refer to “CAMSHAFTS” on page 5-16.
• When removing the timing chain and cam-
shafts, fasten the timing chain with a wire to re-
trieve it if it falls into the crankcase.
G088885
6. Adjust:
• Valve clearance d. Calculate the sum of the values obtained in
steps (b) and (c) to determine the required
a. Remove the valve lifter and the valve pad valve pad thickness and the valve pad num-
with a valve lapper. ber.
Example:
Valve lapper (ø14) 1.58 mm (0.062 in) + 0.05 mm (0.002 in) =
90890-04101
1.63 mm (0.064 in)
Valve lapper (ø14)
The valve pad number is 163.
YM-A8998
e. Round off the valve pad number according
TIP to the following table, and then select the
suitable valve pad.
• Cover the timing chain opening with a rag to
prevent the valve pad from falling into the Last digit Rounded value
crankcase. 0, 1, 2 0
• Make a note of the position of each valve lifter
3, 4, 5, 6 5
and valve pad so that they can be installed in
the correct place. 7, 8, 9 10

b. Calculate the difference between the spec-

TIP
ified valve clearance and the measured
valve clearance. Refer to the following table for the available
valve pads.

3-7
 PERIODIC MAINTENANCE

EAS31017
Valve pad range Nos. 150–240 CHECKING THE ENGINE IDLING SPEED
Valve pad thickness 1.50–2.40 mm TIP
(0.0590–0.0944 in) Prior to checking the engine idling speed, the
Available valve pads 19 thicknesses in throttle body synchronization should be adjusted
0.05 mm (0.002 in) in- properly, the air filter element should be clean,
crements and the engine should have adequate compres-
sion.
Example:
Valve pad number = 163 1. Start the engine and let it warm up for several
Rounded value = 165 minutes.
New valve pad number = 165 2. Check:
f. Install the new valve pad and the valve lift- • Engine idling speed
er. Out of specification → Go to next step.
TIP
Engine idling speed
• Lubricate the valve pad with molybdenum di- 1200–1400 r/min
sulfide oil.
• Lubricate the valve lifter (Top side) with molyb- 3. Check:
denum disulfide oil. • ISC (idle speed control) learning value
• Lubricate the valve lifter (Outer side) with en- “00” or “01” → Check the intake system.
gine oil. “02” → Clean the throttle bodies.
• Install the valve lifter and the valve pad in the Refer to “CHECKING AND CLEANING THE
correct place. THROTTLE BODIES” on page 7-8.
• The valve lifter must turn smoothly when rotat- a. Connect the YDT.
ed by hand. Use the diagnostic code number “67”.
g. Install the exhaust and intake camshafts, Refer to “DIAGNOSTIC CODE: SENSOR
timing chain and camshaft caps. OPERATION TABLE” on page 9-66.
b. Check the ISC (idle speed control) leaning
Camshaft cap bolt value.
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.

EAS30797
R.

SYNCHRONIZING THE THROTTLE BODIES

TIP
TIP
• Refer to “CAMSHAFTS” on page 5-16. Before synchronizing the throttle bodies, check
• Lubricate the camshaft lobes and camshaft the following items:
journals. • Valve clearance
• First, install the exhaust camshaft. • Spark plug
• Align the camshafts marks with the camshaft • Air filter element
cap marks. • Throttle body joint
• Turn the crankshaft counterclockwise several • Fuel hose
full turns to seat the parts. • Exhaust system
h. Measure the valve clearance again. • Breather hose
i. If the valve clearance is still out of specifica-
tion, repeat all of the valve clearance ad- Checking the throttle body synchronization
justment steps until the specified clearance 1. Stand the vehicle on a level surface.
is obtained.
TIP
7. Install: Place the vehicle on a maintenance stand.
• All removed parts
TIP
For installation, reverse the removal procedure.

3-8
 PERIODIC MAINTENANCE

2. Remove: a. Start the engine, warm it up for several min-

• Passenger seat utes, and then let it run at the specified en-
• Rider seat gine idling speed.
Refer to “GENERAL CHASSIS (1)” on
page 4-1. Engine idling speed
• Fuel tank center cover 1200–1400 r/min
• Air scoop
Refer to “GENERAL CHASSIS (1)” on b. Check the vacuum pressure.
page 4-1.
• Fuel tank Difference in vacuum pressure
Refer to “FUEL TANK” on page 7-1. between the cylinders
• Air filter case 0–1.3 kPa (10 mmHg, 0.4 inHg)
Refer to “GENERAL CHASSIS (2)” on
If out of specification → Adjust the throttle
page 4-14.
body synchronization.
3. Remove:
• Service hose cap “1” Adjusting the throttle body synchronization
1. Adjust:
1 1 • Throttle body synchronization
a. Start the engine, warm it up for several min-
utes, and then let it run at the specified en-
gine idling speed.

Engine idling speed

1200–1400 r/min

b. Using the throttle body that has the bypass

4. Install:
air screw “1” with a white paint mark as the
• Vacuum gauge “1”
standard, adjust the other throttle bodies by
turning its bypass air screw in or out.
Vacuum gauge ECA21300
90890-03094 NOTICE
Vacuummate Do not turn the bypass air screw (white paint
YU-44456
mark) of the throttle body that is the stan-
dard. Otherwise, the engine may run roughly
at idle and the throttle bodies may not oper-
1 ate properly.

TIP
• Turn the bypass air screw using the carburetor
angle driver.
• After each step, rev the engine two or three
times, each time for less than a second, and
check the synchronization again.
5. Install: • If a bypass air screw was removed, turn the
• Air filter case screw in fully and be sure to synchronize the
Refer to “GENERAL CHASSIS (2)” on throttle bodies.
page 4-14. • If the throttle body synchronization can not be
• Fuel tank adjusted using the bypass air screw, clean or
Refer to “FUEL TANK” on page 7-1. replace the throttle bodies.
6. Check: • The difference in vacuum pressure between
• Throttle body synchronization the throttle bodies should not exceed 1.3 kPa
(10 mmHg).

3-9
 PERIODIC MAINTENANCE

• Air scoop
Carburetor angle driver 2 Refer to “GENERAL CHASSIS (1)” on
90890-03173 page 4-1.
• Fuel tank
Refer to “FUEL TANK” on page 7-1.
• Air filter case
Refer to “GENERAL CHASSIS (2)” on
page 4-14.
2. Check:
• Cylinder head breather hose “1”
1 Cracks/damage → Replace.
Loose connection → Connect properly.
ECA14920

NOTICE
2. Stop the engine and remove the measuring Make sure the cylinder head breather hose is
equipment. routed correctly.
3. Install:
• Service hose cap
4. Install: 1
• Air filter case
Refer to “GENERAL CHASSIS (2)” on
page 4-14.
• Fuel tank
Refer to “FUEL TANK” on page 7-1.
• Air scoop
• Fuel tank center cover
Refer to “GENERAL CHASSIS (1)” on 3. Install:
page 4-1. • Air filter case
• Rider seat Refer to “GENERAL CHASSIS (2)” on
• Passenger seat page 4-14.
Refer to “GENERAL CHASSIS (1)” on • Fuel tank
page 4-1. Refer to “FUEL TANK” on page 7-1.
EAS30798
• Air scoop
CHECKING THE THROTTLE BODY JOINTS • Fuel tank center cover
1. Remove: Refer to “GENERAL CHASSIS (1)” on
• Throttle body page 4-1.
Refer to “THROTTLE BODIES” on page 7-6. • Rider seat
2. Check: • Passenger seat
• Throttle body joint Refer to “GENERAL CHASSIS (1)” on
Cracks/damage → Replace. page 4-1.
3. Install: EAS30625
• Throttle body CHECKING THE EXHAUST SYSTEM
Refer to “THROTTLE BODIES” on page 7-6. 1. Check:
EAS30623
• Muffler assembly “1”
CHECKING THE CYLINDER HEAD Cracks/damage → Replace.
BREATHER HOSE • Gasket “2”
1. Remove: Exhaust gas leaks → Replace.
• Passenger seat 2. Check:
• Rider seat Tightening torque
Refer to “GENERAL CHASSIS (1)” on • Exhaust pipe nut “3”
page 4-1. • Muffler bolt “4”
• Fuel tank center cover

3-10
 PERIODIC MAINTENANCE

• Fuel tank center cover

Exhaust pipe nut Refer to “GENERAL CHASSIS (1)” on
T.
R. 20 N·m (2.0 kgf·m, 15 lb·ft) page 4-1.
Muffler bolt • Rider seat
20 N·m (2.0 kgf·m, 15 lb·ft) • Passenger seat
Refer to “GENERAL CHASSIS (1)” on
page 4-1.
EAS33546

4 CHECKING THE PURGE CUT VALVE

SOLENOID (for California only)
2 Refer to “CHECKING THE PURGE CUT VALVE
SOLENOID (for California only)” on page 7-5.
EAS30628

REPLACING THE AIR FILTER ELEMENT

1. Remove:
• Passenger seat
• Rider seat
3 Refer to “GENERAL CHASSIS (1)” on
1
page 4-1.
• Fuel tank center cover
4
• Air scoop
Refer to “GENERAL CHASSIS (1)” on
page 4-1.
• Fuel tank
Refer to “FUEL TANK” on page 7-1.
2. Remove:
EAS30626 • ECU (Engine Control Unit) “1”
CHECKING THE CANISTER (for California • Air filter case cover “2”
only) Refer to “GENERAL CHASSIS (2)” on
1. Remove: page 4-14.
• Passenger seat
• Rider seat
Refer to “GENERAL CHASSIS (1)” on
page 4-1. 1
• Fuel tank center cover 2
• Air scoop
Refer to “GENERAL CHASSIS (1)” on
page 4-1.
• Fuel tank
Refer to “FUEL TANK” on page 7-1.
2. Check: 3. Check:
• Canister • Air filter element “1”
• Canister purge hose • Air filter seal
• Fuel tank breather hose Damage → Replace.
• Canister breather hose TIP
Cracks/damage → Replace. • Replace the air filter element every 24000 mi
Loose connection → Connect properly. (37000 km) of operation.
Refer to “FUEL TANK” on page 7-1. • The air filter needs more frequent service if you
3. Install: are riding in unusually wet or dusty areas.
• Fuel tank
Refer to “FUEL TANK” on page 7-1.
• Air scoop

3-11
 PERIODIC MAINTENANCE

1
a

4. Install: a. Push the clutch lever forward.

• Air filter element b. Turn the adjusting knob “1” until the clutch
• Air filter case cover lever is in the desired position.
• ECU (Engine Control Unit)
Refer to “REPLACING THE ECU (Engine
Control Unit)” on page 8-74.
ECA20710

NOTICE
Never operate the engine without the air filter
element installed. Unfiltered air will cause
rapid wear of engine parts and may damage
the engine. Operating the engine without the
air filter element will also affect throttle body 1
synchronization, leading to poor engine per-
EAS30629
formance and possible overheating.
ADJUSTING THE CLUTCH LEVER FREE
TIP PLAY
When installing the air filter element into the air 1. Check:
filter case cover, make sure that the sealing sur- • Clutch lever free play “a”
faces are aligned to prevent any air leaks. Out of specification → Adjust.

5. Install: Clutch lever free play

• Fuel tank 5.0–10.0 mm (0.20–0.39 in)
Refer to “FUEL TANK” on page 7-1.
• Air scoop
• Fuel tank center cover a
Refer to “GENERAL CHASSIS (1)” on
page 4-1.
• Rider seat
• Passenger seat
Refer to “GENERAL CHASSIS (1)” on
page 4-1.
EAS31485 G088887
ADJUSTING THE CLUTCH LEVER POSITION 2. Adjust:
1. Adjust: • Clutch lever free play
• Clutch lever position Handlebar side
(distance “a” from the handlebar grip to the a. Loosen the locknut “1”.
clutch lever) b. Turn the adjusting bolt “2” until the specified
clutch lever free play is obtained.

3-12
 PERIODIC MAINTENANCE

EAS30632

CHECKING THE BRAKE FLUID LEVEL

1. Stand the vehicle on a level surface.
1 TIP
2 • Place the vehicle on a maintenance stand.
• Make sure the vehicle is upright.
2. Check:
• Brake fluid level
Below the minimum level mark → Add the
c. Tighten the locknut. specified brake fluid to the proper level.
TIP
Front brake
If the specified clutch lever free play cannot be Specified brake fluid
obtained on the handlebar side of the cable, use DOT 4
the adjusting nut on the engine side. Rear brake
Specified brake fluid
Engine side DOT 4
a. Loosen the locknut “1”. EWA13090
b. Turn the adjusting nut “2” until the specified WARNING
clutch lever free play is obtained. • Use only the designated brake fluid. Other
c. Tighten the locknut “1”. brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
Clutch cable locknut brake performance.
7 N·m (0.7 kgf·m, 5.2 lb·ft)
• Refill with the same type of brake fluid that
T.
R.

is already in the system. Mixing brake fluids

may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
2 the brake fluid and could cause vapor lock.
ECA13540
1
NOTICE
Brake fluid may damage painted surfaces
EAS30801 and plastic parts. Therefore, always clean up
CHECKING THE BRAKE OPERATION any spilt brake fluid immediately.
1. Check:
• Brake operation TIP
Brake not working properly → Check the In order to ensure a correct reading of the brake
brake system. fluid level, make sure the top of the brake fluid
Refer to “FRONT BRAKE” on page 4-31 and reservoir is horizontal.
“REAR BRAKE” on page 4-49.
TIP EAS30630

ADJUSTING THE FRONT DISC BRAKE

Drive on the dry road, operate the front and rear
1. Adjust:
brakes separately and check to see if the brakes
• Front brake lever position
are operating properly.
(distance “a” from the throttle grip to the brake
lever)

3-13
 PERIODIC MAINTENANCE

a 1 1

G088889

a. Push the brake lever forward.

b. Turn the adjusting knob “1” until the brake For MT09SPR/MT09SPRC
lever is in the desired position. Wear indicator grooves “1” almost disap-
peared → Replace the brake pads as a set.
Refer to “FRONT BRAKE” on page 4-31.

1
1

1 1
1
EWA18170

WARNING
A soft or spongy feeling in the brake lever EAS30631
can indicate the presence of air in the brake ADJUSTING THE REAR DISC BRAKE
system. Before the vehicle is operated, the 1. Adjust:
air must be removed by bleeding the brake • Brake pedal position
system. Air in the brake system will consid- a. Loosen the locknut “1”.
erably reduce brake performance resulting b. Turn the adjusting bolt “2” until the specified
in loss of control and possibly cause an ac- brake pedal position is obtained.
cident. Therefore, check and if necessary, EWA18830

bleed the brake system. WARNING

ECA13490 After adjusting the brake pedal position,
NOTICE check that the end of the adjusting bolt “a” is
After adjusting the brake lever position, visible through the hole “b”.
make sure there is no brake drag. c. Tighten the locknut “1” to specification.
EAS30633
Rear brake master cylinder lock-
CHECKING THE FRONT BRAKE PADS nut
T.

The following procedure applies to all of the

R.

18 N·m (1.8 kgf·m, 13 lb·ft)

brake pads.
1. Operate the brake. EWA17030

2. Check: WARNING
• Front brake pad A soft or spongy feeling in the brake pedal
For MT09R/MT09RC can indicate the presence of air in the brake
Wear indicators “1” almost touch the brake system. Before the vehicle is operated, the
disc → Replace the brake pads as a set. air must be removed by bleeding the brake
Refer to “FRONT BRAKE” on page 4-31. system. Air in the brake system will consid-
erably reduce braking performance.

3-14
 PERIODIC MAINTENANCE

ECA13510
4. Check:
NOTICE • Brake hose
After adjusting the brake pedal position, Brake fluid leakage → Replace the damaged
make sure there is no brake drag. hose.
Refer to “FRONT BRAKE” on page 4-31.
EAS30636

CHECKING THE REAR BRAKE HOSE

1. Check:
a • Brake hose
2 Cracks/damage/wear → Replace.
2. Check:
b 1 • Brake hose holder
Loose Connection → Tighten the holder bolt.
3. Hold the vehicle upright and apply the rear
2. Adjust: brake several times.
• Rear brake light switch 4. Check:
Refer to “ADJUSTING THE REAR BRAKE • Brake hose
LIGHT SWITCH” on page 3-34. Brake fluid leakage → Replace the damaged
hose.
EAS30634
Refer to “REAR BRAKE” on page 4-49.
CHECKING THE REAR BRAKE PADS
The following procedure applies to all of the EAS30893

brake pads. BLEEDING THE HYDRAULIC BRAKE

1. Operate the brake. SYSTEM (ABS)
EWA14000
2. Check:
WARNING
• Rear brake pad
Always bleed the brake system when the
Wear indicator grooves “1” almost touch the
brake related parts are removed.
brake disc → Replace the brake pads as a
set. ECA22640

Refer to “REAR BRAKE” on page 4-49. NOTICE

• Bleed the brake system in the following or-
der.
• 1st step: Front brake master cylinder
• 2nd step: Front brake calipers
• 3rd step: Rear brake caliper
1 1
EWA16530

WARNING
Bleed the ABS whenever:
• the system is disassembled.
• a brake hose is loosened, disconnected or
EAS30635 replaced.
CHECKING THE FRONT BRAKE HOSE • the brake fluid level is very low.
The following procedure applies to all of the • brake operation is faulty.
brake hoses and brake hose holders.
1. Check:
• Brake hose
Cracks/damage/wear → Replace.
2. Check:
• Brake hose holder
Loose → Tighten the holder bolt.
3. Hold the vehicle upright and apply the brake
several times.

3-15
 PERIODIC MAINTENANCE

TIP d. Place the other end of the hose into a con-

• Be careful not to spill any brake fluid or allow tainer.
the brake fluid reservoir to overflow. e. Slowly apply the brake several times.
• When bleeding the ABS, make sure that there f. Fully squeeze the brake lever or fully de-
is always enough brake fluid before applying press the brake pedal and hold it in position.
the brake. Ignoring this precaution could allow g. Loosen the bleed screw.
air to enter the ABS, considerably lengthening TIP
the bleeding procedure. Loosening the bleed screw will release the pres-
• If bleeding is difficult, it may be necessary to let sure and cause the brake lever to contact the
the brake fluid settle for a few hours. throttle grip or the brake pedal to fully extend.
• Repeat the bleeding procedure when the tiny
bubbles in the hose have disappeared. h. Tighten the bleed screw and then release
the brake lever or brake pedal.
1. Bleed: i. Repeat steps (e) to (h) until all of the air
• ABS bubbles have disappeared from the brake
a. Fill the brake fluid reservoir to the proper fluid in the plastic hose.
level with the specified brake fluid. j. Check the operation of the hydraulic unit.
b. Install the brake fluid reservoir diaphragm. Refer to “HYDRAULIC UNIT OPERATION
c. Connect a clear plastic hose “1” tightly to TESTS” on page 4-66.
ECA17061
the bleed screw “2”.
NOTICE
A
Make sure that the main switch is turned to
“OFF” before checking the operation of the
hydraulic unit.
1
k. After operating the ABS, repeat steps (e) to
2 (i), and then fill the brake fluid reservoir to
the proper level with the specified brake flu-
id.
l. Tighten the bleed screw to specification.

B Front brake master cylinder

bleed screw
T.
R.

6 N·m (0.6 kgf·m, 4.4 lb·ft)

Front brake caliper bleed screw
2 (MT09R/MT09RC)
5 N·m (0.5 kgf·m, 3.7 lb·ft)
Front brake caliper bleed screw
1
(MT09SPR/MT09SPRC)
8 N·m (0.8 kgf·m, 5.9 lb·ft)
Rear brake caliper bleed screw
C 5 N·m (0.5 kgf·m, 3.7 lb·ft)
2
m. Fill the brake fluid reservoir to the proper
1
level with the specified brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-13.
EWA13110

WARNING
After bleeding the hydraulic brake system,
check the brake operation.
A. Front brake master cylinder
B. Front brake caliper (left/right)
C. Rear brake caliper

3-16
 PERIODIC MAINTENANCE

EAS30638

CHECKING THE WHEELS

Tire air pressure (measured on
The following procedure applies to both of the cold tires)
wheels. Up to 90 kg (198 lb) load
1. Check: Front
• Wheel 250 kPa (2.50 kgf/cm², 36 psi)
Damage/out-of-round → Replace. Rear
EWA13260
290 kPa (2.90 kgf/cm², 42 psi)
WARNING
90 kg (198 lb) load - maximum
Never attempt to make any repairs to the load
wheel. Front
250 kPa (2.50 kgf/cm², 36 psi)
TIP
Rear
After a tire or wheel has been changed or re- 290 kPa (2.90 kgf/cm², 42 psi)
placed, always balance the wheel. Maximum load
167 kg (368 lb) (MT09SPR,
EAS30640 MT09SPRC)
CHECKING THE TIRES 168 kg (372 lb) (MT09R,
The following procedure applies to both of the MT09RC)
tires. * Maximum load: Total weight of rider, pas-
1. Check: senger, cargo and accessories
• Tire air pressure
Out of specification → Regulate. 2. Check:
EWA13181
• Tire surfaces
WARNING Damage/wear → Replace the tire.
• The tire pressure should only be checked EWA13190

and regulated when the tire temperature WARNING

equals the ambient air temperature. It is dangerous to ride with a worn-out tire.
• The tire pressure and the suspension must When the tire tread reaches the wear limit, re-
be adjusted according to the total weight place the tire immediately.
(including cargo, rider, passenger and ac-
cessories) and the anticipated riding
Wear limit (front)
speed.
1.0 mm (0.04 in)
• Operation of an overloaded vehicle could
Wear limit (rear)
cause tire damage, an accident or an injury. 1.0 mm (0.04 in)
NEVER OVERLOAD THE VEHICLE.
EWA14090

WARNING
After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Ltd. for this model. The front and rear tires
should always be by the same manufacturer
and of the same design. No guarantee con-
cerning handling characteristics can be giv-
en if a tire combination other than one
approved by Yamaha is used on this vehicle.

Front tire
Size
120/70ZR17M/C (58W)
Manufacturer/model
BRIDGESTONE/BATTLAX HY-
PERSPORT S23F

3-17
 PERIODIC MAINTENANCE

EAS30643

Rear tire LUBRICATING THE SWINGARM PIVOT

Size 1. Lubricate:
180/55ZR17M/C (73W) • Dust cover
Manufacturer/model • Pivot shaft
BRIDGESTONE/BATTLAX HY- • Bearing
PERSPORT S23R • Oil seal
• Collar
EWA13210

WARNING
Recommended lubricant
New tires have a relatively low grip on the Lithium-soap-based grease
road surface until they have been slightly
worn. Therefore, approximately 100 km Refer to “INSTALLING THE SWINGARM” on
should be traveled at normal speed before page 4-100.
any high-speed riding is done.
EAS31923

TIP DRIVE CHAIN SLACK

For tires with a direction of rotation mark “1”:
Checking the drive chain slack
• Install the tire with the mark pointing in the di- EWA13120

rection of wheel rotation. WARNING

• Align the mark “2” with the valve installation Securely support the vehicle so that there is
point. no danger of it falling over.
ECA13550

NOTICE
1
A drive chain that is too tight will overload
the engine and other vital parts, and one that
2 is too loose can skip and damage the swing-
arm or cause an accident. Therefore, keep
the drive chain slack within the specified lim-
its.
G088891 1. Shift the transmission into the neutral posi-
EAS30641
tion.
CHECKING THE WHEEL BEARINGS 2. Check:
The following procedure applies to all of the • Drive chain slack
wheel bearing. Out of specification → Adjust.
1. Check: TIP
• Wheel bearing • Measure the distance “a” between the rib end
Refer to “CHECKING THE FRONT WHEEL” on the drive chain guide “1” and the center
on page 4-18 and “CHECKING THE REAR point of the drive chain “2”.
WHEEL” on page 4-26. • The center point “b” of the drive chain is ap-
EAS30802
prox. 32 mm (1.26 in) “c” forward from the edge
CHECKING THE SWINGARM OPERATION “d” of the drive chain guide.
1. Check:
• Swingarm operation Drive chain slack (Maintenance
Swingarm not working properly → Check the Stand)
swingarm. 36.0–41.0 mm (1.42–1.61 in)
Refer to “SWINGARM” on page 4-98. Drive chain slack (Sidestand)
2. Check: 36.0–41.0 mm (1.42–1.61 in)
• Swingarm excessive play Drive chain slack limit (Side-
Refer to “SWINGARM” on page 4-98. stand)
46.0 mm (1.81 in)

3-18
 PERIODIC MAINTENANCE

1
2
a 1

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

Rear wheel axle nut

105 N·m (10.5 kgf·m, 77 lb·ft)

T.
R.
ECA20870

NOTICE d. Tighten the locknuts to specification.

Improper drive chain slack will overload the
engine as well as other vital parts of the mo- Chain puller adjusting bolt lock-
torcycle and can lead to chain slippage or nut
T.
R.

breakage. If the drive chain slack is more 16 N·m (1.6 kgf·m, 12 lb·ft)
than the specified limit, the chain can dam-
age the frame, swingarm, and other parts. To EAS30803

prevent this from occurring, keep the drive LUBRICATING THE DRIVE CHAIN
chain slack within the specified limits. The drive chain consists of many interacting
parts. If the drive chain is not maintained proper-
ly, it will wear out quickly. Therefore, the drive
Adjusting the drive chain slack chain should be serviced, especially when the
EWA13120

WARNING vehicle is used in dusty areas.

This vehicle has a drive chain with small rubber
Securely support the vehicle so that there is
O-rings between each side plate. Steam clean-
no danger of it falling over.
ing, high-pressure washing, certain solvents,
1. Loosen: and the use of a coarse brush can damage
• Wheel axle nut these O-rings. Therefore, use only kerosene to
Refer to “REAR WHEEL” on page 4-23. clean the drive chain. Wipe the drive chain dry
2. Adjust: and thoroughly lubricate it with engine oil or
• Drive chain slack chain lubricant that is suitable for O-ring chains.
a. Loosen both locknuts “1”. Do not use any other lubricants on the drive
b. Turn both adjusting bolts “2” until the spec- chain since they may contain solvents that could
ified drive chain slack is obtained. damage the O-rings.

Recommended lubricant
Chain lubricant suitable for O-
ring chains

3-19
 PERIODIC MAINTENANCE

EAS30645

CHECKING AND ADJUSTING THE

Steering nut wrench
STEERING HEAD 90890-01403
1. Stand the vehicle on a level surface. Exhaust flange nut wrench
EWA13120
YU-A9472
WARNING
Securely support the vehicle so that there is
no danger of it falling over. Lower ring nut (initial tightening
torque)

T.
R.
TIP 52 N·m (5.2 kgf·m, 38 lb·ft)
Place the vehicle on a maintenance stand so
that the front wheel is elevated. c. Loosen the lower ring nut completely, then
tighten it to specification.
2. Check: EWA13140

• Steering head WARNING

Grasp the bottom of the front fork legs and Do not overtighten the lower ring nut.
gently rock the front fork.
Blinding/looseness → Adjust the steering
Lower ring nut (final tightening
head.
torque)

T.
3. Remove:

R.
14 N·m (1.4 kgf·m, 10 lb·ft)
• Upper bracket
4. Adjust: d. Check the steering head for looseness or
• Steering head binding by turning the front fork all the way
a. Remove the lock washer “1”, the upper ring in both directions. If any binding is felt, re-
nut “2”, and the rubber washer “3”. move the lower bracket and check the up-
per and lower bearings.
Refer to “STEERING HEAD” on page 4-88.
e. Install the rubber washer “3”.
f. Install the upper ring nut “2”.
g. Finger tighten the upper ring nut, then align
the slots of both ring nuts. If necessary, hold
the lower ring nut and tighten the upper ring
nut until their slots are aligned.
h. Install the lock washer “1”.
G088892
TIP
b. Loosen the lower ring nut “4” and then tight- Make sure the lock washer tabs “a” sit correctly
en it to specification with a steering nut in the ring nut slots “b”.
wrench “5”.
TIP
• Set the torque wrench at a right angle to the
steering nut wrench.
• Move the steering to the left and right a couple
of times to check that it moves smoothly.

G088894

5. Install:
• Upper bracket
Refer to “HANDLEBAR” on page 4-70.

G088893

3-20
 PERIODIC MAINTENANCE

EAS30646

LUBRICATING THE STEERING HEAD

Recommended lubricant
1. Lubricate: Molybdenum disulfide grease
• Upper bearing
• Lower bearing EAS30652

• Bearing cover CHECKING THE SIDESTAND SWITCH

Refer to “ELECTRICAL COMPONENTS” on
Recommended lubricant page 8-65.
Lithium-soap-based grease
EAS30653

EAS31186
CHECKING THE FRONT FORK
CHECKING THE CHASSIS FASTENERS 1. Stand the vehicle on a level surface.
EWA13120
Make sure that all nuts, bolts, and screws are
WARNING
properly tightened.
Securely support the vehicle so that there is
Refer to “CHASSIS TIGHTENING TORQUES”
no danger of it falling over.
on page 2-12.
EAS30804
2. Check:
LUBRICATING THE BRAKE LEVER • Inner tube
Lubricate the pivoting point and metal-to-metal Damage/scratches → Replace.
moving parts of the lever. • Front fork leg
Oil leaks between inner tube and outer tube
Recommended lubricant → Replace the oil seal.
Silicone grease 3. Hold the vehicle upright and apply the front
brake.
EAS30805
4. Check:
LUBRICATING THE CLUTCH LEVER • Front fork operation
Lubricate the pivoting point and metal-to-metal Push down hard on the handlebar several
moving parts of the lever. times and check if the front fork rebounds
smoothly.
Recommended lubricant Rough movement → Repair.
Lithium-soap-based grease
Refer to “FRONT FORK” on page 4-77.
EAS30649 EAS30806
LUBRICATING THE PEDAL ADJUSTING THE FRONT FORK LEGS (for
Lubricate the pivoting point and metal-to-metal MT09R/MT09RC)
moving parts of the pedal. The following procedure applies to both of the
front fork legs.
Recommended lubricant EWA13120

Lithium-soap-based grease WARNING

Securely support the vehicle so that there is
EAS30851
no danger of it falling over.
ADJUSTING THE SHIFT PEDAL
Refer to “ADJUSTING THE SHIFT PEDAL” on
page 4-106. Spring preload
EWA17040

EAS30650
WARNING
CHECKING THE SIDESTAND
Always adjust both front fork legs evenly.
1. Check:
Uneven adjustment can result in poor han-
• Sidestand operation
dling and loss of stability.
Check that the sidestand moves smoothly.
Rough movement → Repair or replace. ECA13590

NOTICE
EAS30651
Never go beyond the maximum or minimum
LUBRICATING THE SIDESTAND
adjustment positions.
Lubricate the pivoting point, metal-to-metal mov-
ing parts and spring contact point of the side-
stand.

3-21
 PERIODIC MAINTENANCE

1. Adjust: Rebound damping (right side only)

• Spring preload ECA13590

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

Rebound damping
Adjustment value from the start
1 position (Soft)
11
TIP Adjustment value from the start
The spring preload setting is determined by position (STD)
measuring the distance “c” shown in the illustra- 6
tion. The shorter distance “c” is, the higher the Adjustment value from the start
spring preload; the longer distance “c” is, the position (Hard)
lower the spring preload. 1
* Start position: With the adjusting screw
fully turned in direction “a”

TIP
Although the total number of clicks of a damping
c force adjusting mechanism may not exactly
match the above specifications due to small dif-
ferences in production, the actual number of
clicks always represents the entire adjusting
range. To obtain a precise adjustment, it would
be advisable to check the number of clicks of
each damping force adjusting mechanism and
Spring preload to modify the specifications as necessary.
Adjustment value (Soft)
19.0 mm (0.75 in)
Adjustment value (STD) 1
16.0 mm (0.63 in)
Adjustment value (Hard)
4.0 mm (0.16 in) a b

3-22
 PERIODIC MAINTENANCE

Compression damping (left side only) EAS32009

ECA13590 ADJUSTING THE FRONT FORK LEGS (for

NOTICE MT09SPR/MT09SPRC)
Never go beyond the maximum or minimum The following procedure applies to both of the
adjustment positions. front fork legs.
EWA13120

1. Adjust: WARNING
• Compression damping Securely support the vehicle so that there is
a. Turn the adjusting screw “1” in direction “a” no danger of it falling over.
or “b”.
Spring preload
Direction “a” EWA17040

Compression damping is increased WARNING

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

NOTICE
Compression damping Never go beyond the maximum or minimum
Adjustment value from the start adjustment positions.
position (Soft)
11 (MT09R, MT09RC) 1. Adjust:
Adjustment value from the start • Spring preload
position (STD) a. Turn the adjusting bolt “1” in direction “a” or
6 (MT09R, MT09RC) “b”.
Adjustment value from the start
position (Hard) Direction “a”
1 (MT09R, MT09RC) Spring preload is increased (suspen-
* Start position: With the adjusting screw sion is harder).
fully turned in direction “a” Direction “b”
Spring preload is decreased (suspen-
TIP sion is softer).
Although the total number of clicks of a damping
force adjusting mechanism may not exactly
match the above specifications due to small dif-
ferences in production, the actual number of a b a b
clicks always represents the entire adjusting
range. To obtain a precise adjustment, it would
be advisable to check the number of clicks of
each damping force adjusting mechanism and
to modify the specifications as necessary.
1

TIP
1 The spring preload setting is determined by
measuring the distance “c” shown in the illustra-
a b tion. The shorter distance “c” is, the higher the
spring preload; the longer distance “c” is, the
lower the spring preload.

3-23
 PERIODIC MAINTENANCE

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

Spring preload
Adjustment value (Soft)
1
19.0 mm (0.75 in)
Adjustment value (STD)
14.0 mm (0.55 in) a b
Adjustment value (Hard)
4.0 mm (0.16 in)

Rebound damping
ECA13590

NOTICE Compression damping

Never go beyond the maximum or minimum ECA13590

adjustment positions. NOTICE

Never go beyond the maximum or minimum
1. Adjust: adjustment positions.
• Rebound damping
a. Turn the adjusting screw “1” in direction “a” 1. Adjust:
or “b”. • Compression damping (fast compression
damping)
Direction “a” a. Turn the adjusting screw “1” in direction “a”
Rebound damping is increased (sus- or “b”.
pension is harder).
Direction “b” Direction “a”
Rebound damping is decreased (sus- Compression damping is increased
pension is softer). (suspension is harder).
Direction “b”
Compression damping is decreased
Rebound damping (suspension is softer).
Adjustment value from the start
position (Soft)
26 Fast compression damping
Adjustment value from the start Adjustment value from the start
position (STD) position (Soft)
11 5+1/2 (MT09SPR, MT09SPRC)
Adjustment value from the start Adjustment value from the start
position (Hard) position (STD)
1 2+3/4 (MT09SPR, MT09SPRC)
* Start position: With the adjusting screw Adjustment value from the start
fully turned in direction “a” position (Hard)
0 (MT09SPR, MT09SPRC)
* Start position: With the adjusting screw
fully turned in direction “a”

3-24
 PERIODIC MAINTENANCE

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

a a
1 1

b b

2. Adjust: EAS30808

• Compression damping (slow compression CHECKING THE REAR SHOCK ABSORBER

damping) ASSEMBLY
a. Turn the adjusting bolt “1” in direction “a” or Refer to “CHECKING THE REAR SHOCK AB-
“b”. SORBER ASSEMBLY” on page 4-95.
EAS30655

Direction “a” ADJUSTING THE REAR SHOCK ABSORBER

Compression damping is increased ASSEMBLY (for MT09R/MT09RC)
(suspension is harder). EWA13120

Direction “b” WARNING

Compression damping is decreased Securely support the vehicle so that there is
(suspension is softer). no danger of it falling over.

Slow compression damping Spring preload

Adjustment value from the start ECA13590

position (Soft) NOTICE

18 (MT09SPR, MT09SPRC) Never go beyond the maximum or minimum
Adjustment value from the start adjustment positions.
position (STD)
9 (MT09SPR, MT09SPRC) 1. Adjust:
Adjustment value from the start • Spring preload
position (Hard) a. Adjust the spring preload with the special
1 (MT09SPR, MT09SPRC) wrench “1” and extension bar “2” included
* Start position: With the adjusting bolt ful- in the owner’s tool kit.
ly turned in direction “a” b. Turn the adjusting ring “3” in direction “a” or
“b”.
c. Align the desired position on the adjusting
ring with the stopper “4”.

3-25
 PERIODIC MAINTENANCE

Direction “a” Rebound damping

Spring preload is increased (suspen- Adjustment value from the start
sion is harder). position (Soft)
Direction “b” 2+1/2
Spring preload is decreased (suspen- Adjustment value from the start
sion is softer). position (STD)
1
Adjustment value from the start
Spring preload position (Hard)
Adjustment value (Soft) 0
1 (MT09R, MT09RC) * Start position: With the adjusting screw
Adjustment value (STD) fully turned in direction “a”
4 (MT09R, MT09RC)
Adjustment value (Hard) TIP
7 (MT09R, MT09RC)
Although the total number of turns of a damping
force adjusting mechanism may not exactly
21
match the above specifications due to small dif-
76543 ferences in production, the actual number of
3
2 4 turns always represents the entire adjusting
range. To obtain a precise adjustment, it would
a be advisable to check the number of turns of
each damping force adjusting mechanism and
to modify the specifications as necessary.
1 b

Rebound damping
ECA13590
1
NOTICE b a
2
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
• Rebound damping
a. Remove the cap “1”. EAS31609
b. Turn the adjusting screw “2” in direction “a” ADJUSTING THE REAR SHOCK ABSORBER
or “b”. ASSEMBLY (for MT09SPR/MT09SPRC)
EWA13120

Direction “a” WARNING

Rebound damping is increased (sus- Securely support the vehicle so that there is
pension is harder). no danger of it falling over.
Direction “b”
Rebound damping is decreased (sus-
pension is softer). Spring preload
ECA13590

NOTICE
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
• Spring preload
a. Turn the adjusting knob “1” in direction “a”
or “b”.

3-26
 PERIODIC MAINTENANCE

1. Adjust:
Direction “a” • Rebound damping
Spring preload is increased (suspen- a. Turn the adjusting knob “1” in direction “a”
sion is harder). or “b”.
Direction “b”
Spring preload is decreased (suspen-
Direction “a”
sion is softer).
Rebound damping is increased (sus-
pension is harder).
Direction “b”
Rebound damping is decreased (sus-
1 b pension is softer).

Rebound damping
Adjustment value from the start
a position (Soft)
30
Adjustment value from the start
TIP position (STD)
The spring preload setting is determined by 18
measuring the distance “c” shown in the illustra- Adjustment value from the start
position (Hard)
tion. The shorter distance “c” is, the higher the
0
spring preload; the longer distance “c” is, the
lower the spring preload. * Start position: With the adjusting screw
fully turned in direction “a”

TIP
Although the total number of clicks of a damping
force adjusting mechanism may not exactly
match the above specifications due to small dif-
c ferences in production, the actual number of
clicks always represents the entire adjusting
range. To obtain a precise adjustment, it would
be advisable to check the number of clicks of
each damping force adjusting mechanism and
to modify the specifications as necessary.
Adjustment value (Soft)
154.5 mm (6.08 in) (MT09SPR,
MT09SPRC)
Adjustment value (STD)
150.0 mm (5.91 in) (MT09SPR,
MT09SPRC)
a
Adjustment value (Hard)
146.5 mm (5.77 in) (MT09SPR,
MT09SPRC) 1
b
Rebound damping
ECA13590

NOTICE Compression damping

Never go beyond the maximum or minimum ECA13590

adjustment positions. NOTICE

Never go beyond the maximum or minimum
adjustment positions.

3-27
 PERIODIC MAINTENANCE

1. Adjust: EAS30656

CHECKING THE ENGINE OIL LEVEL

• Compression damping
1. Stand the vehicle on a level surface.
a. Turn the adjusting knob “1” in direction “a”
TIP
or “b”.
• Place the vehicle on a maintenance stand.
Direction “a” • Make sure the vehicle is upright.
Compression damping is increased 2. Start the engine, warm it up for several min-
(suspension is harder). utes, and then turn it off.
Direction “b” 3. Check:
Compression damping is decreased • Engine oil level
(suspension is softer).
The engine oil level should be between the
minimum level mark “a” and maximum level
Compression damping mark “b”.
Adjustment value from the start Below the minimum level mark → Add the
position (Soft) recommended engine oil to the proper level.
20 (MT09SPR, MT09SPRC)
Adjustment value from the start
position (STD)
14 (MT09SPR, MT09SPRC)
Adjustment value from the start
position (Hard)
0 (MT09SPR, MT09SPRC)
* Start position: With the adjusting knob b
fully turned in direction “a” a
TIP
Although the total number of clicks of a damping Recommended brand
force adjusting mechanism may not exactly YAMALUBE
match the above specifications due to small dif- SAE viscosity grades
ferences in production, the actual number of 10W-40, 10W-50, 15W-40, 20W-
clicks always represents the entire adjusting 40 or 20W-50
range. To obtain a precise adjustment, it would Recommended engine oil grade
be advisable to check the number of clicks of API service SG type or higher,
each damping force adjusting mechanism and JASO standard MA
to modify the specifications as necessary. ECA13361

NOTICE
• Engine oil also lubricates the clutch and the
wrong oil types or additives could cause
b clutch slippage. Therefore, do not add any
chemical additives or use engine oils with a
grade of “CD” or higher and do not use oils
labeled “ENERGY CONSERVING II”.
1 • Do not allow foreign materials to enter the
a
crankcase.

TIP
EAS30809
Before checking the engine oil level, wait a few
CHECKING THE CONNECTING ARM AND
minutes until the oil has settled.
RELAY ARM
Refer to “CHECKING THE CONNECTING ARM 4. Start the engine, warm it up for several min-
AND RELAY ARM” on page 4-96. utes, and then turn it off.
5. Check the engine oil level again.

3-28
 PERIODIC MAINTENANCE

TIP
Before checking the engine oil level, wait a few
minutes until the oil has settled.

EAS30657

CHANGING THE ENGINE OIL

1. Start the engine, warm it up for several min-
utes, and then turn it off.
2. Place a container under the engine oil drain 2 1
bolt.
3. Remove: b. Lubricate the O-ring of the new oil filter car-
• Engine oil filler cap “1” tridge with a thin coat of engine oil.
ECA25890
• Engine oil drain bolt “2” NOTICE
• Gasket “3” Make sure the O-ring is positioned correctly
in the groove of the oil filter cartridge.
1 c. Tighten the new oil filter cartridge to specifi-
cation with an oil filter wrench.

Oil filter cartridge

17 N·m (1.7 kgf·m, 13 lb·ft)
T.
R.

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

Engine oil drain bolt

43 N·m (4.3 kgf·m, 32 lb·ft)
T.
R.

2 3 7. Fill:
• Crankcase
(with the specified amount of the recom-
mended engine oil)
4. Drain:
Engine oil quantity
• Engine oil
Quantity (disassembled)
(completely from the crankcase) 3.50 L (3.70 US qt, 3.08 Imp.qt)
5. If the oil filter cartridge is also to be replaced, Oil change
perform the following procedure. 2.80 L (2.96 US qt, 2.46 Imp.qt)
a. Remove the oil filter cartridge “1” with an oil With oil filter removal
filter wrench “2”. 3.20 L (3.38 US qt, 2.82 Imp.qt)

Oil filter wrench 8. Install:

90890-01426 • Engine oil filler cap
Oil filter wrench (along with the O-ring New )
YU-38411 9. Start the engine, warm it up for several min-
utes, and then turn it off.
10.Check:
• Engine
(for engine oil leaks)

3-29
 PERIODIC MAINTENANCE

11.Check:
• Engine oil level Oil pressure gauge joint 18 mm
Refer to “CHECKING THE ENGINE OIL 90890-04176
LEVEL” on page 3-28. YU-04176
EAS30810

MEASURING THE ENGINE OIL PRESSURE Oil pressure switch joint bolt
1. Check: 10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.
R.
• Engine oil level
Below the minimum level mark “a” → Add the
recommended engine oil to the proper level.

1
2

a 5. Install:
• Oil pressure gauge “1”
2. Start the engine, warm it up for several min- • Adapter C “2”
utes, and then turn it off.
ECA13410 Oil pressure gauge set
NOTICE 90890-03120
When the engine is cold, the engine oil will
have a higher viscosity, causing the engine
oil pressure to increase. Therefore, be sure 1
to measure the engine oil pressure after
warming up the engine.
2
3. Remove:
• Oil pressure switch joint bolt “1”
• Oil pressure switch joint (with the oil pressure
switch) “2”
EWA12980

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

The engine, muffler and engine oil are ex- utes.
tremely hot. ECA13410

NOTICE
When the engine is cold, the engine oil will
have a higher viscosity, causing the engine
oil pressure to increase. Therefore, be sure
to measure the engine oil pressure after
warming up the engine.
2 7. Measure:
• Engine oil pressure
1 (at the following conditions)

4. Install: Oil pressure

• Oil pressure gauge joint 18 mm “1” 200.0 kPa/5000 r/min (2.00 kgf/
• Oil pressure switch joint bolt “2” cm²/5000 r/min, 29.0 psi/5000 r/
min)

Out of specification → Check.

3-30
 PERIODIC MAINTENANCE

Engine oil pressure Possible causes

Below specification • Faulty oil pump
• Clogged oil filter
• Leaking oil passage
• Broken or damaged
oil seal a
Above specification • Faulty oil filter b
• Oil viscosity too high

8. Remove: ECA21281

• Oil pressure gauge NOTICE

• Adapter C • Adding water instead of coolant dilutes the
• Oil pressure switch joint bolt antifreeze concentration of the coolant. If
• Oil pressure switch joint (with the O-ring) water is used instead of coolant; check,
9. Install: and if necessary, correct the antifreeze
• O-ring “1” New concentration of the coolant.
• Oil pressure switch joint (with the oil pressure • Use only distilled water. However, if dis-
switch) “2” tilled water is not available, soft water may
• Oil pressure switch joint bolt “3” be used.
3. Start the engine, warm it up for several min-
Oil pressure switch joint bolt utes, and then turn it off.
10 N·m (1.0 kgf·m, 7.4 lb·ft) 4. Check:
T.
R.

• Coolant level
TIP
Before checking the coolant level, wait a few
2 minutes until it settles.

EAS30812

CHECKING THE COOLING SYSTEM

3 1. Check:
• Radiator “1”
1 New • Water pump inlet hose “2”
EAS30811
• Thermostat assembly “3”
CHECKING THE COOLANT LEVEL • Radiator outlet hose “4”
1. Stand the vehicle on a level surface. • Water pump “5”
TIP • Radiator inlet hose “6”
• Oil cooler outlet hose “7”
• Place the vehicle on a maintenance stand.
• Water jacket joint “8”
• Make sure the vehicle is upright.
• Oil cooler inlet hose “9”
2. Check: • Oil cooler “10”
• Coolant level Cracks/damage → Replace.
The coolant level should be between the Refer to “RADIATOR” on page 6-3, “OIL
maximum level mark “a” and minimum level COOLER” on page 6-7, “THERMOSTAT” on
mark “b”. page 6-9, and “WATER PUMP” on page 6-
Below the minimum level mark → Add the 11.
recommended coolant to the proper level.

3-31
 PERIODIC MAINTENANCE

2. Remove:
1 2 • Coolant reservoir bolt
• Coolant reservoir cover “1”
• Coolant reservoir “2”
• Collar
Refer to “RADIATOR” on page 6-3.
3

8
4
6

9
2 1
7
5 3. Remove:
10 • Coolant reservoir cap “1”

1
EAS30813

CHANGING THE COOLANT

1. Remove:
• Front side panel (right side)
Refer to “GENERAL CHASSIS (1)” on
page 4-1.
• Radiator cap “1”
EWA13030 4. Drain:
WARNING • Coolant
A hot radiator is under pressure. Therefore, (from the coolant reservoir)
do not remove the radiator cap when the en- 5. Remove:
gine is hot. Scalding hot fluid and steam may • Water pump drain bolt “1”
be blown out, which could cause serious in- • Copper washer “2”
jury. When the engine has cooled, open the
radiator cap as follows:
Place a thick rag or a towel over the radiator
cap and slowly turn the radiator cap counter-
clockwise toward the detent to allow any re- 1 2
sidual pressure to escape. When the hissing
sound has stopped, press down on the radi-
ator cap and turn it counterclockwise to re-
move.
6. Drain:
1 • Coolant
(from the engine and radiator)
7. Install:
• Water pump drain bolt
• Copper washer New

Water pump drain bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

3-32
 PERIODIC MAINTENANCE

8. Install: ECA21291

• Collar NOTICE
• Coolant reservoir • Adding water instead of coolant dilutes the
• Coolant reservoir cover antifreeze concentration of the coolant. If
• Coolant reservoir bolt water is used instead of coolant; check,
Refer to “RADIATOR” on page 6-3. and if necessary, correct the antifreeze
concentration of the coolant.
Coolant reservoir bolt (M5) • Use only distilled water. However, if dis-
0.5 N·m (0.05 kgf·m, 0.37 lb·ft) tilled water is not available, soft water may
T.
R.

Coolant reservoir bolt (M6) be used.

9 N·m (0.9 kgf·m, 6.6 lb·ft) • If coolant comes into contact with painted
LOCTITE® surfaces, immediately wash them with wa-
ter.
9. Fill: • Do not mix different types of antifreeze.
• Cooling system
(with the specified amount of the recom- 10.Install:
mended coolant) • Radiator cap
11.Fill:
Recommended antifreeze • Coolant reservoir
High-quality ethylene glycol anti- (with the recommended coolant to the maxi-
freeze containing corrosion mum level mark “a”)
inhibitors for aluminum engines
Mixing ratio
1:1 (antifreeze:water)
Radiator (including all routes)
1.72 L (1.82 US qt, 1.51 Imp.qt)
Coolant reservoir (up to the max- a
imum level mark)
0.28 L (0.30 US qt, 0.25 Imp.qt)

Handling notes for coolant

Coolant is potentially harmful and should be
12.Install:
handled with special care.
EWA13040
• Coolant reservoir cap
WARNING 13.Start the engine, warm it up for several min-
• If coolant splashes in your eyes, thorough- utes, and then turn it off.
ly wash them with water and consult a doc- 14.Check:
tor. • Coolant level
• If coolant splashes on your clothes, quickly Refer to “CHECKING THE COOLANT LEV-
wash it away with water and then with soap EL” on page 3-31.
and water. TIP
• If coolant is swallowed, induce vomiting Before checking the coolant level, wait a few
and get immediate medical attention. minutes until the coolant has settled.

EAS30814

CHECKING THE FRONT BRAKE LIGHT

SWITCH
Refer to “ELECTRICAL COMPONENTS” on
page 8-65.

3-33
 PERIODIC MAINTENANCE

EAS30659
TIP
ADJUSTING THE REAR BRAKE LIGHT
SWITCH Hold the cable end upright and pour a few drops
TIP
of lubricant into the cable sheath or use a suit-
able lubricating device.
The rear brake light switch is operated by move-
ment of the brake pedal. The rear brake light
EAS30815
switch is properly adjusted when the brake light CHECKING THE THROTTLE GRIP
comes on just before the braking effect starts. 1. Check:
1. Check: • Throttle grip movement
• Rear brake light operation timing Rough movement → Lubricate or replace the
Incorrect → Adjust. defective part(s).
2. Adjust: TIP
• Rear brake light operation timing With the engine stopped, turn the throttle grip
a. Hold the main body “1” of the rear brake slowly and release it. Make sure that the throttle
light switch so that it does not rotate and grip turns smoothly and returns properly when
turn the adjusting nut “2” until the rear brake released.
light comes on at the proper time.
EAS32558

LUBRICATING THE THROTTLE GRIP

1 1. Remove:
• Throttle grip
Refer to “HANDLEBAR” on page 4-70.
2. Lubricate:
• Throttle grip

2 Recommended lubricant
YAMAHA GREASE “R”
(Fluorine-based grease)
EAS30660

CHECKING AND LUBRICATING THE

CABLES
The following procedure applies to all of the in-
ner and outer cables.
EWA13270

WARNING
Damaged outer cable may cause the cable to
corrode and interfere with its movement. Re-
place damaged outer cable and inner cables
as soon as possible.
3. Install:
1. Check:
• Outer cable • Throttle grip
Damage → Replace. Refer to “INSTALLING THE HANDLEBAR”
on page 4-74.
2. Check:
• Cable operation EAS30816

Rough movement → Lubricate. CHECKING AND CHARGING THE BATTERY

Refer to “CHECKING AND CHARGING THE
Recommended lubricant BATTERY” on page 8-75.
Engine oil or a suitable cable lu- EAS30662
bricant CHECKING THE FUSES
Refer to “CHECKING THE FUSES” on page 8-
73.

3-34
 PERIODIC MAINTENANCE

EAS30664

ADJUSTING THE HEADLIGHT BEAMS

1. Remove: a
• Cover “1”

a. Turn the adjusting screw “1”.

2. Adjust:
• Headlight beam (vertically)
TIP
To adjust the headlight beam (vertically), insert a 1
crosshead screwdriver “a” into the hole in the
meter bracket, and then turn the adjusting
screw.

a. Turn the adjusting screw “1”.

1

3. Adjust:
• Headlight beam (horizontally)
TIP
To adjust the headlight beam (horizontally), in-
sert a crosshead screwdriver “a” into the hole in
the meter bracket, and then turn the adjusting
screw.

3-35
 PERIODIC MAINTENANCE

3-36
 CHASSIS

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

REMOVING THE PASSENGER SEAT ...................................................4-10
REMOVING THE RIDER SEAT ..............................................................4-10
REMOVING THE HEADLIGHT FRONT COVER .................................... 4-10
REMOVING THE FUEL TANK CENTER COVER ..................................4-10
REMOVING THE FUEL TANK LOWER COVER .................................... 4-10
INSTALLING THE FUEL TANK LOWER COVER................................... 4-11
INSTALLING THE FUEL TANK CENTER COVER .................................4-11
INSTALLING THE HEADLIGHT FRONT COVER................................... 4-11
INSTALLING THE IMU............................................................................4-12
INSTALLING THE RIDER SEAT............................................................. 4-12
INSTALLING THE PASSENGER SEAT.................................................. 4-12

GENERAL CHASSIS (2) ............................................................................... 4-14

FRONT WHEEL............................................................................................. 4-16

REMOVING THE FRONT WHEEL.......................................................... 4-18
DISASSEMBLING THE FRONT WHEEL................................................ 4-18
CHECKING THE FRONT WHEEL .......................................................... 4-18
ASSEMBLING THE FRONT WHEEL......................................................4-19
4
MAINTENANCE OF THE FRONT WHEEL SENSOR AND
SENSOR ROTOR .................................................................................. 4-20
ADJUSTING THE FRONT WHEEL STATIC BALANCE ......................... 4-20
INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS) ............... 4-21

REAR WHEEL ...............................................................................................4-23

REMOVING THE REAR WHEEL ............................................................ 4-26
DISASSEMBLING THE REAR WHEEL .................................................. 4-26
CHECKING THE REAR WHEEL............................................................. 4-26
CHECKING THE REAR WHEEL DRIVE HUB ........................................ 4-26
CHECKING AND REPLACING THE REAR WHEEL SPROCKET .........4-27
ASSEMBLING THE REAR WHEEL ........................................................ 4-27
MAINTENANCE OF THE REAR WHEEL SENSOR AND
SENSOR ROTOR .................................................................................. 4-28
ADJUSTING THE REAR WHEEL STATIC BALANCE............................ 4-28
INSTALLING THE REAR WHEEL (REAR BRAKE DISC) ......................4-28
FRONT BRAKE ............................................................................................. 4-31
INTRODUCTION .....................................................................................4-40
CHECKING THE FRONT BRAKE DISCS............................................... 4-40
REPLACING THE FRONT BRAKE PADS (for MT09R/MT09RC) ..........4-40
REPLACING THE FRONT BRAKE PADS
(for MT09SPR/MT09SPRC) ................................................................... 4-42
REMOVING THE FRONT BRAKE CALIPERS ....................................... 4-43
DISASSEMBLING THE FRONT BRAKE CALIPERS..............................4-43
CHECKING THE FRONT BRAKE CALIPERS ........................................ 4-43
ASSEMBLING THE FRONT BRAKE CALIPERS.................................... 4-44
INSTALLING THE FRONT BRAKE CALIPERS
(for MT09R/MT09RC) ............................................................................. 4-44
INSTALLING THE FRONT BRAKE CALIPERS
(for MT09SPR/MT09SPRC) ................................................................... 4-45
REMOVING THE FRONT BRAKE MASTER CYLINDER .......................4-46
CHECKING THE FRONT BRAKE MASTER CYLINDER........................ 4-46
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ................... 4-46
INSTALLING THE FRONT BRAKE MASTER CYLINDER......................4-47

REAR BRAKE ...............................................................................................4-49

ADJUSTING THE FOOTREST POSITION ............................................. 4-56
INTRODUCTION .....................................................................................4-56
CHECKING THE REAR BRAKE DISC....................................................4-56
REPLACING THE REAR BRAKE PADS................................................. 4-57
REMOVING THE REAR BRAKE CALIPER ............................................4-58
DISASSEMBLING THE REAR BRAKE CALIPER ..................................4-58
CHECKING THE REAR BRAKE CALIPER............................................. 4-58
ASSEMBLING THE REAR BRAKE CALIPER ........................................ 4-59
INSTALLING THE REAR BRAKE CALIPER...........................................4-59
REMOVING THE REAR BRAKE MASTER CYLINDER ......................... 4-60
CHECKING THE REAR BRAKE MASTER CYLINDER .......................... 4-60
ASSEMBLING THE REAR BRAKE MASTER CYLINDER......................4-60
INSTALLING THE REAR BRAKE MASTER CYLINDER ........................ 4-60

ABS (ANTI-LOCK BRAKE SYSTEM)........................................................... 4-62

REMOVING THE HYDRAULIC UNIT ASSEMBLY .................................4-64
CHECKING THE HYDRAULIC UNIT ASSEMBLY..................................4-65
INSTALLING THE HYDRAULIC UNIT ASSEMBLY................................4-65
HYDRAULIC UNIT OPERATION TESTS................................................ 4-66
CHECKING THE ABS WARNING LIGHT ............................................... 4-69

HANDLEBAR ................................................................................................4-70
ADJUSTING THE HANDLEBAR POSITION...........................................4-73
REMOVING THE HANDLEBAR..............................................................4-73
CHECKING THE HANDLEBAR ..............................................................4-74
INSTALLING THE HANDLEBAR ............................................................ 4-74
FRONT FORK................................................................................................4-77
REMOVING THE FRONT FORK LEGS.................................................. 4-80
DISASSEMBLING THE FRONT FORK LEGS ........................................ 4-80
CHECKING THE FRONT FORK LEGS .................................................. 4-81
ASSEMBLING THE FRONT FORK LEGS .............................................. 4-82
INSTALLING THE FRONT FORK LEGS ................................................ 4-86

STEERING HEAD.......................................................................................... 4-88

REMOVING THE LOWER BRACKET.....................................................4-90
CHECKING THE STEERING HEAD .......................................................4-90
INSTALLING THE STEERING HEAD .....................................................4-91

REAR SHOCK ABSORBER ASSEMBLY ....................................................4-92

HANDLING THE REAR SHOCK ABSORBER ........................................ 4-95
DISPOSING OF A REAR SHOCK ABSORBER
(for MT09R/MT09RC) ............................................................................. 4-95
DISPOSING OF A REAR SHOCK ABSORBER
(for MT09SPR/MT09SPRC) ................................................................... 4-95
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY................... 4-95
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 4-95
CHECKING THE CONNECTING ARM AND RELAY ARM.....................4-96
INSTALLING THE RELAY ARM..............................................................4-96
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ................. 4-96

SWINGARM................................................................................................... 4-98
REMOVING THE SWINGARM..............................................................4-100
CHECKING THE SWINGARM ..............................................................4-100
INSTALLING THE SWINGARM ............................................................4-100

CHAIN DRIVE..............................................................................................4-102
REMOVING THE DRIVE CHAIN........................................................... 4-103
CHECKING THE DRIVE CHAIN ........................................................... 4-103
CHECKING THE DRIVE SPROCKET...................................................4-104
CHECKING THE REAR WHEEL SPROCKET...................................... 4-104
CHECKING THE REAR WHEEL DRIVE HUB ...................................... 4-104
INSTALLING THE DRIVE CHAIN ......................................................... 4-105
ADJUSTING THE SHIFT PEDAL.......................................................... 4-106
INSTALLING THE SHIFT PEDAL COVER ........................................... 4-107
 GENERAL CHASSIS (1)

EAS20026

GENERAL CHASSIS (1)

Removing the seats and battery

11 N•m (1.1 kgf•m, 8.1 lb•ft)

T.R
.
2
1

2.2 N•m (0.22 kgf•m, 1.6 lb•ft)

4
T.R
.

Order Job/Parts to remove Q’ty Remarks

1 Passenger seat 1
2 Rider seat 1
3 Battery holding bracket 1
4 Negative battery lead 1 Disconnect.
5 Positive battery lead 1 Disconnect.
6 Battery 1

4-1
 GENERAL CHASSIS (1)

Removing the rear side covers

4.0 N•m (0.40 kgf•m, 3.0 lb•ft) 1.5 N•m (0.15 kgf•m, 1.1 lb•ft)

T.R

T.R
.

.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
11 N•m (1.1 kgf•m, 8.1 lb•ft)

T.R
.
5 1

11
10
4 28 N•m (2.8 kgf•m, 21 lb•ft)

T.R
.
9 1.5 N•m (0.15 kgf•m, 1.1 lb•ft)

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

12
LT LT

8
7
7
6

28 N•m (2.8 kgf•m, 21 lb•ft)

T.R
.

4.0 N•m (0.40 kgf•m, 3.0 lb•ft)

T.R
.

2
1.5 N•m (0.15 kgf•m, 1.1 lb•ft)
3
T.R
.

4.0 N•m (0.40 kgf•m, 3.0 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (1)” on
Passenger seat/Rider seat page 4-1.
Refer to “GENERAL CHASSIS (1)” on
Battery page 4-1.
1 Tail cover 1
2 Rear side cover (left) 1
3 Rear side outer cover (left) 1
4 Rear side cover (right) 1
5 Rear side outer cover (right) 1
6 License plate light coupler 1 Disconnect.
7 Rear turn signal light coupler 2 Disconnect.
8 Mudguard assembly 1
9 Tail/brake light coupler 1 Disconnect.
10 Tail/brake light bracket 1
11 Tail/brake light 1
12 Lower fender cover 1

4-2
 GENERAL CHASSIS (1)

Removing the IMU and GCU

2.0 N•m (0.20 kgf•m, 1.5 lb•ft)

T.R
.
(4)
2 (4)
(4)
4
(4) S

1
3

(4)
(4)
S 6
7

7 N•m (0.7 kgf•m, 5.2 lb•ft) 5

T.
R.

LT
7 N•m (0.7 kgf•m, 5.2 lb•ft)
(4)
T.
R.

Order Job/Parts to remove Q’ty Remarks

1 Relay unit 1
2 IMU cover 1
3 IMU coupler 1 Disconnect.
4 IMU (Inertial Measurement Unit) 1
5 Stay 1
6 GCU coupler 3 Disconnect.
7 GCU (Generator Control Unit) 1

4-3
 GENERAL CHASSIS (1)

Removing the rear frame

T.
R.

7 N•m (0.7 kgf•m, 5.2 lb•ft)

11 N•m (1.1 kgf•m, 8.1 lb•ft)

T.
R.
1

3.8 N•m (0.38 kgf•m, 2.8 lb•ft)

T.R
.
2

28 N•m (2.8 kgf•m, 21 lb•ft)

T.
R.
5 3

55 N•m (5.5 kgf•m, 41 lb•ft)

T.
R.

LT
4

LT
LT

55 N•m (5.5 kgf•m, 41 lb•ft) 28 N•m (2.8 kgf•m, 21 lb•ft)

T.

T.
R.

R.

Order Job/Parts to remove Q’ty Remarks

1 Rider seat bracket 1
2 Brake fluid reservoir 1
3 Rear frame 1
4 Passenger footrest (left) 1
5 Passenger footrest (right) 1

4-4
 GENERAL CHASSIS (1)

Removing the footrest (left)

2
New

3
21 N·m (2.1 kgf·m, 15 lb·ft)

28 N·m (2.8 kgf·m, 21 lb·ft) LT

10 N·m (1.0 kgf·m, 7.4 lb·ft)

Order Job/Parts to remove Q’ty Remarks

1 Footrest plate (left) 1
2 Footrest bracket (left) 1
3 Footrest (left) 1

4-5
 GENERAL CHASSIS (1)

Removing the headlight assembly, auxiliary light and meter assembly

7 N•m (0.7 kgf•m, 5.2 lb•ft)

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

1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.

7 8
1

1.5 N•m (0.15 kgf•m, 1.1 lb•ft) 3 6

T.R
.

5 N•m (0.5 kgf•m, 3.7 lb•ft) 1.2 N•m (0.12 kgf•m, 0.88 lb•ft)
T.R
.

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft) 5 1.5 N•m (0.15 kgf•m, 1.1 lb•ft)

T.R
T.R

.
.

4
2

7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Disconnect.
Brake hose (front brake master cylinder side) 1 Refer to “FRONT BRAKE” on page 4-31.
Handlebar switch couplers (left)/Clutch switch Disconnect.
connectors/Handlebar switch coupler (right)/ 1 Refer to “HANDLEBAR” on page 4-70.
Front brake light switch connectors
1 Meter cover 1
2 Headlight front cover 1
3 Auxiliary light coupler 1
4 Headlight cover 1
5 Auxiliary light 1
Headlight control unit coupler (wire harness
6 1 Disconnect.
side)
7 Headlight assembly 1
Headlight control unit coupler (headlight assem-
8 1 Disconnect.
bly side)

4-6
 GENERAL CHASSIS (1)

Removing the headlight assembly, auxiliary light and meter assembly

7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
11
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.

13

12
10
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.

1.5 N•m (0.15 kgf•m, 1.1 lb•ft) 9

T.R
.

5 N•m (0.5 kgf•m, 3.7 lb•ft) 1.2 N•m (0.12 kgf•m, 0.88 lb•ft)
T.R
.

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft) 1.5 N•m (0.15 kgf•m, 1.1 lb•ft)

T.R
T.R

.
.

7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

9 Headlight control unit 1
10 Meter assembly coupler 1 Disconnect.
11 Meter assembly 1
12 Wire harness clamp 1 Disconnect.
13 Meter assembly bracket 1

4-7
 GENERAL CHASSIS (1)

Removing the front side panel

1.5 N•m (0.15 kgf•m, 1.1 lb•ft)
T.R
.

7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
2 LT
7
6

7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

1.5 N•m (0.15 kgf•m, 1.1 lb•ft)

T.R
.

LT
LT
3 1

1.5 N•m (0.15 kgf•m, 1.1 lb•ft)

T.R
.

7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

1.5 N•m (0.15 kgf•m, 1.1 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

1 Radiator cover (left) 1
2 Radiator cover (right) 1
3 O2 sensor coupler 1 Disconnect.
4 Front turn signal/position light coupler (left) 1 Disconnect.
5 Front side panel (left) 1
6 Front turn signal/position light coupler (right) 1 Disconnect.
7 Front side panel (right) 1

4-8
 GENERAL CHASSIS (1)

Removing the fuel tank center cover and air scoop

1.5 N•m (0.15 kgf•m, 1.1 lb•ft)

T.R
.
0.4 N•m (0.04 kgf•m, 0.30 lb•ft)
1.5 N•m (0.15 kgf•m, 1.1 lb•ft) 5

T.R
.
T.R
.

2
4

0.4 N•m (0.04 kgf•m, 0.30 lb•ft)

T.R
.
3
6
1

0.4 N•m (0.04 kgf•m, 0.30 lb•ft) 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R

T.R
.

Order Job/Parts to remove Q’ty Remarks

1 Fuel tank center cover 1
2 Air scoop (left) 1
3 Air scoop (right) 1
4 Fuel tank lower cover (left) 1
5 Fuel tank lower cover (right) 1
6 Fuel tank upper cover (left) 1
7 Fuel tank upper cover (right) 1
8 Fuel tank center cover inner panel 1

4-9
 GENERAL CHASSIS (1)

EAS34050

REMOVING THE PASSENGER SEAT a a

1. Remove: b
• Passenger seat “1” a
a. Insert the key into the seat lock “2”, and
then turn it counterclockwise “a”. b
b. Lift the front of the passenger seat and pull d a
it forward. c
1
1
EAS34052

REMOVING THE FUEL TANK CENTER

2 COVER
a 1. Remove:
• Fuel tank center cover “1”
a. Remove the fuel tank center cover bolts “2”.
b. Remove the fuel tank center cover.
TIP
EAS34051

REMOVING THE RIDER SEAT Remove the projection “a” on the fuel tank cen-
1. Remove: ter cover from hole on the fuel tank center cover
• Rider seat “1” inner panel.
a. Remove the passenger seat.
b. Lift the rider seat rearward and up to re- 2
move it. 1

2 a

EAS34053

REMOVING THE FUEL TANK LOWER

COVER
EAS33544 The following procedure applies to both of the
REMOVING THE HEADLIGHT FRONT fuel tank lower cover.
COVER 1. Remove:
1. Remove: • Fuel tank lower cover (left) “1”
• Headlight front cover “1” a. Remove the quick fastener “2” and fuel tank
a. Remove the projections “a” on the headlight lower cover screw “3”.
front cover from the headlight cover. b. Remove the fuel tank lower cover (left).
b. Remove the projections “b” on the headlight TIP
front cover from holes on the headlight cov- Remove the projection “a” on the fuel tank lower
er. cover from the hole on the fitting plate.
c. Remove the projection “c” on the headlight
front cover from grommet “d” on the head-
light cover.

4-10
 GENERAL CHASSIS (1)

2
1
2

1 2 a
3 a

EAS34054 EAS33545

INSTALLING THE FUEL TANK LOWER INSTALLING THE HEADLIGHT FRONT

COVER COVER
The following procedure applies to both of the 1. Install:
fuel tank lower cover. • Headlight front cover “1”
1. Install: a. Insert the projection “a” on the headlight
• Fuel tank lower cover (left) “1” front cover into the grommet “b” on the
a. Insert the projection “a” on the fuel tank low- headlight cover.
er cover into the hole on the fitting plate. b. Insert the projections “c” on the headlight
b. Install the quick fastener “2” and fuel tank front cover from holes into the headlight
lower cover screw “3”, and then tighten the cover.
screw to specification. c. Fit the projections “d” on the headlight front
cover to the headlight cover.
Fuel tank lower cover screw d d
1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
T.

c
R.

c
2 b d
a
1
1
3 a

EAS34055

INSTALLING THE FUEL TANK CENTER

COVER
1. Install:
• Fuel tank center cover “1”
a. Insert the projection “a” on the fuel tank
center cover into hole on the fuel tank cen-
ter cover inner panel.
b. Install the fuel tank center cover bolts “2”.

4-11
 GENERAL CHASSIS (1)

EAS31636

INSTALLING THE IMU (4)

ECA22611
(4) 1
NOTICE
• Do not perform angle adjustment of the IMU S
and battery box by pinching the washer (4)
and related parts. (4)
• When installing the IMU, apply a thin coat of
silicone grease onto the washer where con-
tacting the IMU grommet.
• When installing the IMU, use only a genuine
bolt and washer, and tighten the bolt to the
specified torque.
• Pay attention not to expose the IMU to
2
strong shocks, such as striking or drop-
ping it.
• Do not place any foreign objects in and
around the battery box.
• Do not obstruct breather opening “a” of the
IMU. (4) S
• Do not clean the breather opening and do (4)
not blow it with compressed air.
• When replacing the collar or grommet, re- EAS31125

place all four collars and grommets. INSTALLING THE RIDER SEAT
1. Install:
• Rider seat “1”
a a. Insert the projection “a” on the front of the
rider seat into the seat holder “b” and the
projections “c” on the rear of the rider seat
into the holes “d” on the rider seat bracket.

1 a
c

b a
1. Install:
• IMU (Inertial Measurement Unit) “1”
d
a. Connect the IMU coupler “2” to the IMU.
b. Install the grommets, collars, IMU “1”,
washers, IMU nuts and IMU bolts, and then
tighten the bolts to specification. EAS31126

TIP INSTALLING THE PASSENGER SEAT

Apply a thin coat of silicone grease onto the col- 1. Install:
lars and washers where contacting the grom- • Passenger seat “1”
mets. a. Insert the projections “a” on the front and
rear of the passenger seat into the seat
holders “b”.
Recommended lubricant
Silicone grease

IMU bolt
2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
T.
R.

4-12
 GENERAL CHASSIS (1)

a a

4-13
 GENERAL CHASSIS (2)

EAS20155

GENERAL CHASSIS (2)

Removing the air filter case
7 N•m (0.7 kgf•m, 5.2 lb•ft) 1.6 N•m (0.16 kgf•m, 1.2 lb•ft)

T.R

T.R
.

.
2.0 N•m (0.20 kgf•m, 1.5 lb•ft) 4

T.R
.
(10)
New

(3)
(3)
10 11

8 5

(3)
3 7

2
9
6
6
1

2.8 N•m (0.28 kgf•m, 2.1 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (1)” on
Passenger seat/Rider seat page 4-1.
Refer to “GENERAL CHASSIS (1)” on
Fuel tank center cover/Air scoop page 4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
1 ECU coupler 3 Disconnect.
2 ECU (Engine Control Unit) 1
3 Intake air temperature sensor 1 Disconnect.
4 Air filter case cover 1
5 Air filter element 1
6 Air filter case joint clamp screw 3 Loosen.
7 Cylinder head breather hose 1 Disconnect.
8 BCM coupler 1 Disconnect.
9 Air filter case 1
10 BCM cover 1
11 BCM (Body Control Module) 1

4-14
 GENERAL CHASSIS (2)

Removing the remote control unit and buzzer (for MT09SPR/MT09SPRC)

5

3 6 7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

4.3 N•m (0.43 kgf•m, 3.2 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (1)” on
Passenger seat/Rider seat page 4-1.
Refer to “GENERAL CHASSIS (1)” on
Fuel tank center cover/Air scoop page 4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
1 Remote control unit cover 1
2 Remote control unit coupler 1 Disconnect.
3 Rubber band 1
4 Remote control unit 1
5 Buzzer 1
6 Remote control unit bracket 1

4-15
 FRONT WHEEL

EAS20028

FRONT WHEEL
Removing the front wheel and brake discs
35 N•m (3.5 kgf•m, 26 lb•ft)

2
72 N•m (7.2 kgf•m, 53 lb•ft)

23 N•m (2.3 kgf•m, 17 lb•ft) 1 35 N•m (3.5 kgf•m, 26 lb•ft)

5
18 N•m (1.8 kgf•m, 13 lb•ft)

New
LT

(5) 4
2
7

1
3
8 LT

(5) 7 N•m (0.7 kgf•m, 5.2 lb•ft)

New 35 N•m (3.5 kgf•m, 26 lb•ft)

6
18 N•m (1.8 kgf•m, 13 lb•ft)
8
7

Order Job/Parts to remove Q’ty Remarks

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

4-16
 FRONT WHEEL

Disassembling the front wheel

2 New
3 New
4

LT

New 3
New 2
New
1 (5)

8 N•m (0.8 kgf•m, 5.9 lb•ft)

D
FW

Order Job/Parts to remove Q’ty Remarks

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

4-17
 FRONT WHEEL

EAS31148
1. Remove:
REMOVING THE FRONT WHEEL
ECA20981
• Oil seal
NOTICE • Wheel bearing
• Keep any type of magnets (including mag- a. Clean the surface of the front wheel hub.
netic pick-up tools, magnetic screwdrivers, b. Remove the oil seals “1” with a flat-head
etc.) away from the front wheel sensor or screwdriver.
front wheel sensor rotor; otherwise, the TIP
sensor or rotor may be damaged, resulting To prevent damaging the wheel, place a rag “2”
in improper performance of the ABS sys- between the screwdriver and the wheel surface.
tem.
• Do not drop the front wheel sensor rotor or 2
subject it to shocks.
• If any solvent gets on the front wheel sen-
sor rotor, wipe it off immediately.
1
1. Stand the vehicle on a level surface.
EWA13120

WARNING
Securely support the vehicle so that there is
no danger of it falling over. G088896

c. Remove the wheel bearings with a general

2. Remove:
bearing puller.
• Brake caliper (left)
• Brake caliper (right) EAS30147

• Front wheel sensor CHECKING THE FRONT WHEEL

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

to any metal part when removing the front WARNING

wheel sensor from the sensor housing. Do not attempt to straighten a bent wheel ax-
le.
3. Elevate:
• Front wheel 2. Check:
TIP • Tire
Place the vehicle on a maintenance stand so • Front wheel
that the front wheel is elevated. Damage/wear → Replace.
Refer to “CHECKING THE TIRES” on
4. Loosen: page 3-17 and “CHECKING THE WHEELS”
• Wheel axle pinch bolt on page 3-17.
5. Remove: 3. Measure:
• Wheel axle • Radial wheel runout “1”
• Front wheel • Lateral wheel runout “2”
Over the specified limits → Replace.
EAS31149

DISASSEMBLING THE FRONT WHEEL

ECA21340 Radial wheel runout limit
NOTICE 1.0 mm (0.04 in)
• Do not drop the wheel sensor rotor or sub- Lateral wheel runout limit
ject it to shocks. 0.5 mm (0.02 in)
• If any solvent gets on the wheel sensor ro-
tor, wipe it off immediately.

4-18
 FRONT WHEEL

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

G088897

4. Check:
• Wheel bearing
Front wheel turns roughly or is loose → Re-
place the wheel bearings.
• Oil seal
Damage/wear → Replace.
G088899
EAS31150
d. Install the new oil seals.
ASSEMBLING THE FRONT WHEEL
ECA21340
2. Install:
NOTICE • Front wheel sensor rotor
• Do not drop the wheel sensor rotor or sub-
ject it to shocks. Wheel sensor rotor bolt
• If any solvent gets on the wheel sensor ro- 8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.
R.

tor, wipe it off immediately. LOCTITE®

1. Install: ECA17200

• Wheel bearing New NOTICE

• Oil seal New Replace the wheel sensor rotor bolts with
new ones.
a. Install the new wheel bearing (left side).
ECA18110
TIP
NOTICE
Install the wheel sensor rotor with the stamped
Do not contact the wheel bearing inner race
mark “1” facing outward.
“1” or balls “2”. Contact should be made
only with the outer race “3”.

TIP 1
Use a socket “4” that matches the diameter of
the wheel bearing outer race.

G088900

3. Measure:
• Wheel sensor rotor runout
Out of specification → Correct the wheel sen-
sor rotor runout or replace the wheel sensor
G088898
rotor.
Refer to “MAINTENANCE OF THE FRONT
b. Install the spacer.
WHEEL SENSOR AND SENSOR ROTOR”
c. Install the new wheel bearing (right side).
on page 4-20.

4-19
 FRONT WHEEL

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

EAS31151
a. Hold the dial gauge at a right angle against
MAINTENANCE OF THE FRONT WHEEL the wheel sensor rotor surface.
SENSOR AND SENSOR ROTOR b. Measure the wheel sensor rotor runout.
ECA21070

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

Iron powder/dust → Clean. NOTICE

Replace the wheel sensor rotor bolts with
new ones.
d. If the runout is still above specification, re-
place the wheel sensor rotor.
1
EAS30152

ADJUSTING THE FRONT WHEEL STATIC

BALANCE
TIP
• After replacing the tire, wheel or both, the front
2. Check:
wheel static balance should be adjusted.
• Front wheel sensor rotor
• Adjust the front wheel static balance with the
Cracks/damage/scratches → Replace the
brake disc installed.
front wheel sensor rotor.
• Refer to “ADJUSTING THE WHEEL STATIC
Iron powder/dust/solvent → Clean.
BALANCE” in “BASIC INFORMATION” (sepa-
TIP
rate volume).
• The wheel sensor rotor is installed on the inner
side of the wheel hub. 1. Remove:
• When cleaning the wheel sensor rotor, be • Balancing weight(s)
careful not to damage the surface of the sensor 2. Find:
rotor. • Front wheel’s heavy spot
3. Adjust:
3. Measure: • Front wheel static balance
• Wheel sensor rotor runout 4. Check:
Out of specification → Clean the installation • Front wheel static balance
surface of the wheel sensor rotor and correct
the wheel sensor rotor runout, or replace the
wheel sensor rotor.

4-20
 FRONT WHEEL

EAS31327

INSTALLING THE FRONT WHEEL (FRONT

BRAKE DISCS)
1. Install:
• Front brake disc

Front brake disc bolt

18 N·m (1.8 kgf·m, 13 lb·ft)
T.
R.

LOCTITE® a
ECA19150
b
NOTICE 6. Install:
Replace the brake disc bolts with new ones. • Front wheel sensor

TIP Front wheel sensor bolt

Tighten the brake disc bolts in stages and in a 7 N·m (0.7 kgf·m, 5.2 lb·ft)

T.
R.
crisscross pattern. ECA21020

2. Check: NOTICE
• Front brake disc Make sure there are no foreign materials in
Refer to “CHECKING THE FRONT BRAKE the front wheel sensor rotor and front wheel
DISCS” on page 4-40. sensor. Foreign materials cause damage to
3. Lubricate: the front wheel sensor rotor and front wheel
• Oil seal lip sensor.

TIP
Recommended lubricant
Lithium-soap-based grease When installing the front wheel sensor, check
the wheel sensor lead for twists.
4. Install:
• Collar 7. Measure:
• Front wheel • Distance “a”
• Wheel axle (between the wheel sensor rotor “1” and
5. Tighten: wheel sensor “2”)
• Wheel axle Out of specification → Check the wheel bear-
• Wheel axle pinch bolt ing for looseness, and the front wheel sensor
and sensor rotor installation conditions
Front wheel axle (warpage caused by overtorque, wrong in-
72 N·m (7.2 kgf·m, 53 lb·ft) stallation direction, rotor decentering, LOC-
T.

TITE® on the mounting surface of the rotor,

R.

Front wheel axle pinch bolt

23 N·m (2.3 kgf·m, 17 lb·ft) deformation caused by an impact during ser-
vice and caught foreign materials). If there is
ECA19760
any defective part, repair or replace the de-
NOTICE fective part.
Before tightening the wheel axle, push down
hard on the handlebars several times and Distance “a” (between the wheel
check if the front fork rebounds smoothly. sensor rotor and front wheel sen-
sor)
TIP 0.6–1.8 mm (0.02–0.07 in)
Check that wheel axle end “a” is flush with front
fork surface “b” and then tighten the wheel axle
pinch bolt. If wheel axle end “a” is not flush with
surface “b”, align the ends manually or with a
plastic hammer.

4-21
 FRONT WHEEL

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

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

a
1

2
2
1

G088903

8. Install:
• Front brake caliper

Front brake caliper bolt

35 N·m (3.5 kgf·m, 26 lb·ft)
T.
R.

EWA13500

WARNING
Make sure the brake hose is routed properly.

4-22
 REAR WHEEL

EAS20029

REAR WHEEL
Removing the rear wheel
105 N•m (10.5 kgf•m, 77 lb•ft) 4 7 N•m (0.7 kgf•m, 5.2 lb•ft)
5
8
LS
1 9

10

3 2 2 3

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

Order Job/Parts to remove Q’ty Remarks

Rear brake caliper Refer to “REAR BRAKE” on page 4-49.
1 Rear wheel sensor 1
2 Locknut 2 Loosen.
3 Adjusting bolt 2 Loosen.
4 Wheel axle nut 1
5 Washer 1
6 Wheel axle 1
7 Adjusting block (left) 1
8 Adjusting block (right) 1
9 Rear wheel 1
10 Brake caliper bracket assembly 1

4-23
 REAR WHEEL

Removing the brake disc and rear wheel sprocket

30 N•m (3.0 kgf•m, 22 lb•ft) 8 N•m (0.8 kgf•m, 5.9 lb•ft)

LT

(5) New
LT
13
(5) 1

2 6 LS

12
11 New 80 N•m (8.0 kgf•m, 59 lb•ft)
10
9
14
LS 4
3
5 – 10 mm 17 – 18 mm (5)
(0.19 – 0.39 in) (0.67 – 0.71 in) 7 New

New 8
LT
LS

5
F WD

Order Job/Parts to remove Q’ty Remarks

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

4-24
 REAR WHEEL

Disassembling the rear wheel

1 New

2 New

4 New

D
FW

Order Job/Parts to remove Q’ty Remarks

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

4-25
 REAR WHEEL

EAS30910
TIP
REMOVING THE REAR WHEEL
ECA21030 Push the rear wheel forward and remove the
NOTICE drive chain from the rear wheel sprocket.
• Keep any type of magnets (including mag-
netic pick-up tools, magnetic screwdrivers, EAS31154

etc.) away from the rear wheel sensor or DISASSEMBLING THE REAR WHEEL
ECA21340
rear wheel sensor rotor; otherwise, the sen-
NOTICE
sor or rotor may be damaged, resulting in
improper performance of the ABS system. • Do not drop the wheel sensor rotor or sub-
• Do not drop the rear wheel sensor rotor or ject it to shocks.
subject it to shocks. • If any solvent gets on the wheel sensor ro-
• If any solvent gets on the rear wheel sensor tor, wipe it off immediately.
rotor, wipe it off immediately. 1. Remove:
1. Stand the vehicle on a level surface. • Oil seal
EWA13120 • Wheel bearing
WARNING Refer to “DISASSEMBLING THE FRONT
Securely support the vehicle so that there is WHEEL” on page 4-18.
no danger of it falling over. EAS30159

CHECKING THE REAR WHEEL

TIP
1. Check:
Place the vehicle on a maintenance stand so • Wheel axle
that the rear wheel is elevated. • Wheel bearing
2. Remove: • Oil seal
• Rear brake caliper Refer to “CHECKING THE FRONT WHEEL”
• Rear wheel sensor on page 4-18.
ECA27270 2. Check:
NOTICE • Tire
• Do not depress the brake pedal when re- • Rear wheel
moving the brake caliper. Damage/wear → Replace.
• Be sure not to contact the sensor electrode Refer to “CHECKING THE TIRES” on
to any metal part when removing the rear page 3-17 and “CHECKING THE WHEELS”
wheel sensor from the rear brake caliper on page 3-17.
bracket assembly. 3. Measure:
• Radial wheel runout
3. Loosen: • Lateral wheel runout
• Locknut Refer to “CHECKING THE FRONT WHEEL”
• Adjusting bolt on page 4-18.
4. Remove:
• Wheel axle nut EAS30160

• Washer CHECKING THE REAR WHEEL DRIVE HUB

• Wheel axle 1. Check:
• Rear wheel • Rear wheel drive hub
• Brake caliper bracket assembly Cracks/damage → Replace.
ECA27280 • Rear wheel drive hub damper
NOTICE Damage/wear → Replace.
Be sure to remove the rear wheel sensor be- • Rear wheel drive hub stud bolt
fore removing the brake caliper bracket as- Bends/damage/wear → Replace.
sembly, otherwise the sensor could be 2. Replace:
damaged. • Rear wheel drive hub stud bolt “1”
a. Remove the rear wheel drive hub stud
bolts.
b. Clean the threaded holes on the rear wheel
drive hub “2”.

4-26
 REAR WHEEL

c. Apply LOCTITE® to the drive hub side of TIP

the new stud bolts in the area shown in the Tighten the rear wheel sprocket nuts in stages
illustration. and in a crisscross pattern.
d. Install the new stud bolts to specification.
EAS30163

ASSEMBLING THE REAR WHEEL

B ECA21340

NOTICE
1 • Do not drop the wheel sensor rotor or sub-
ject it to shocks.
A • If any solvent gets on the wheel sensor ro-
2
tor, wipe it off immediately.
LT
1. Install:
A. 5–10 mm (0.19–0.39 in) • Wheel bearing New
B. 17–18 mm (0.67–0.71 in) • Oil seal New
a. Install the new wheel bearing (right side).
EAS30161 ECA18110
CHECKING AND REPLACING THE REAR NOTICE
WHEEL SPROCKET Do not contact the wheel bearing inner race
1. Check: “1” or balls “2”. Contact should be made
• Rear wheel sprocket only with the outer race “3”.
More than 1/4 tooth “a” wear → Replace the
drive sprocket, the rear wheel sprocket and TIP
the drive chain as a set. Use a socket “4” that matches the diameter of
Bent teeth → Replace the drive sprocket, the the wheel bearing outer race.
rear wheel sprocket and the drive chain as a
set.

G088898

G088904 b. Install the spacer.

b. Correct c. Install the new wheel bearing (left side).
TIP
1. Drive chain roller
Place a suitable washer “1” between the socket
2. Rear wheel sprocket
“2” and the bearing so that both the inner race
2. Replace: “3” and outer race “4” are pressed at the same
• Rear wheel sprocket time, and then press the bearing until the inner
a. Remove the rear wheel sprocket nuts and race makes contact with the spacer “5”.
the rear wheel sprocket.
b. Clean the rear wheel drive hub with a clean
cloth, especially the surfaces that contact
the sprocket.
c. Install the new rear wheel sprocket.

Rear wheel sprocket nut

80 N·m (8.0 kgf·m, 59 lb·ft)
T.
R.

4-27
 REAR WHEEL

EAS30164

ADJUSTING THE REAR WHEEL STATIC

BALANCE
TIP
• After replacing the tire, wheel or both, the rear
wheel static balance should be adjusted.
• Adjust the rear wheel static balance with the
brake disc and rear wheel drive hub installed.

G088899 1. Adjust:
d. Install the new oil seals. • Rear wheel static balance
Refer to “ADJUSTING THE FRONT WHEEL
EAS31156 STATIC BALANCE” on page 4-20.
MAINTENANCE OF THE REAR WHEEL
SENSOR AND SENSOR ROTOR EAS31157

ECA21060 INSTALLING THE REAR WHEEL (REAR

NOTICE BRAKE DISC)
• Handle the ABS components with care 1. Install:
since they have been accurately adjusted. • Rear brake disc
Keep them away from dirt and do not sub-
ject them to shocks. Rear brake disc bolt
• The rear wheel sensor cannot be disassem- 30 N·m (3.0 kgf·m, 22 lb·ft)
T.
R.
bled. Do not attempt to disassemble it. If LOCTITE®
faulty, replace with a new one. ECA19150

• Keep any type of magnets (including mag- NOTICE

netic pick-up tools, magnetic screwdrivers, Replace the brake disc bolts with new ones.
etc.) away from the rear wheel sensor or
rear wheel sensor rotor. TIP
• Do not drop or shock the wheel sensor or Tighten the brake disc bolts in stages and in a
the wheel sensor rotor. crisscross pattern.
1. Check: 2. Check:
• Rear wheel sensor • Rear brake disc
Refer to “MAINTENANCE OF THE FRONT Refer to “CHECKING THE REAR BRAKE
WHEEL SENSOR AND SENSOR ROTOR” DISC” on page 4-56.
on page 4-20. 3. Lubricate:
2. Check: • Oil seal lip
• Rear wheel sensor rotor
Refer to “MAINTENANCE OF THE FRONT Recommended lubricant
WHEEL SENSOR AND SENSOR ROTOR” Lithium-soap-based grease
on page 4-20.
3. Measure: 4. Install:
• Wheel sensor rotor runout • Brake caliper bracket assembly
Refer to “MAINTENANCE OF THE FRONT • Rear wheel
WHEEL SENSOR AND SENSOR ROTOR” • Adjusting block
on page 4-20. • Wheel axle
• Washer
• Wheel axle nut

4-28
 REAR WHEEL

TIP
• Do not install the brake caliper. Drive chain slack (Maintenance
• Align the projection “a” in the swingarm with the Stand)
36.0–41.0 mm (1.42–1.61 in)
slot “b” of the brake caliper bracket assembly.
Drive chain slack (Sidestand)
• Install the adjusting block (left) so that projec-
36.0–41.0 mm (1.42–1.61 in)
tion “c” faces to the front of the vehicle.
Drive chain slack limit
• Install the adjusting block (right) with the cham- 46.0 mm (1.81 in)
fered “d” facing the inside.
7. Tighten:
• Wheel axle nut
• Rear brake caliper bolt
b
a Rear wheel axle nut
105 N·m (10.5 kgf·m, 77 lb·ft)

T.
R.
Rear brake caliper bolt (front)
27 N·m (2.7 kgf·m, 20 lb·ft)
Rear brake caliper bolt (rear)
22 N·m (2.2 kgf·m, 16 lb·ft)
LOCTITE®
A
EWA13500

c WARNING
Make sure the brake hose is routed properly.

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

A
B a

2 1

A. Left side B
B. Right side
a

5. Install:
• Rear brake caliper
• Rear brake caliper bolt
6. Adjust:
• Drive chain slack
Refer to “DRIVE CHAIN SLACK” on page 3- 1 2
18.
A. Left side
B. Right side

4-29
 REAR WHEEL

8. Install:
• Rear wheel sensor 1

Rear wheel sensor bolt 2

7 N·m (0.7 kgf·m, 5.2 lb·ft) 2
T.
R.

ECA21080

NOTICE a
Make sure there are no foreign materials in
the rear wheel sensor rotor and rear wheel 1
G088906
sensor. Foreign materials cause damage to
the rear wheel sensor rotor and rear wheel
sensor.

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

Distance “a” (between the wheel

sensor rotor and rear wheel sen-
sor)
0.6–1.7 mm (0.02–0.07 in)

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

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

4-30
 FRONT BRAKE

EAS20030

FRONT BRAKE
Removing the front brake pads (for MT09R/MT09RC)

5 N•m (0.5 kgf•m, 3.7 lb•ft)

T.R
.
7

6
5

4 3

0.5 mm
(0.02 in)

2 1

35 N•m (3.5 kgf•m, 26 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

The following procedure applies to both of
the front brake calipers.
1 Brake pad clip 2
2 Brake pad pin 1
3 Brake pad spring 1
4 Brake pad 2
5 Reflector bracket 1
6 Front brake caliper 1
7 Bleed screw 1

4-31
 FRONT BRAKE

Removing the front brake pads (for MT09SPR/MT09SPRC)

35 N•m (3.5 kgf•m, 26 lb•ft)

T.R
.
8 N•m (0.8 kgf•m, 5.9 lb•ft)

T.R
.
5
3 2
1
4

1.0 mm
(0.04 in)

1.0 mm
(0.04 in)

Order Job/Parts to remove Q’ty Remarks

The following procedure applies to both of
the front brake calipers.
1 Reflector bracket 1
2 Front brake caliper 1
3 Brake pad 2
4 Brake pad spring 1
5 Bleed screw 1

4-32
 FRONT BRAKE

Removing the front brake master cylinder

1.2 N•m (0.12 kgf•m, 0.88 lb•ft)

T.R
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)

T.R
.
22 N•m (2.2 kgf•m, 16 lb•ft) 6 2

T.R
.
1.0 N•m (0.10 kgf•m, 0.73 lb•ft) 3
T.R
.

4
1
S
5

* 8

New
S

6 N•m (0.6 kgf•m, 4.4 lb•ft)

T.R
.

1.2 N•m (0.12 kgf•m, 0.88 lb•ft)

T.R

16 N•m (1.6 kgf•m, 12 lb•ft)

.

T.R
.

30 N•m (3.0 kgf•m, 22 lb•ft)

T.R
.

* This collar is press-fitted in the brake lever. When press-fitting the collar into the brake lever, press-fit it from
the chamfered side where the collar mounting hole.
Order Job/Parts to remove Q’ty Remarks
Rearview mirror (right) Refer to “HANDLEBAR” on page 4-70.
Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-15.
1 Brake fluid reservoir cap stopper 1
2 Brake fluid reservoir cap 1
3 Brake fluid reservoir diaphragm holder 1
4 Brake fluid reservoir diaphragm 1
5 Brake fluid reservoir 1
6 Rearview mirror (right) 1
7 Brake fluid reservoir bracket 1
8 Brake fluid reservoir hose 1

4-33
 FRONT BRAKE

Removing the front brake master cylinder

1.2 N•m (0.12 kgf•m, 0.88 lb•ft)

T.R
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)

T.R
.
22 N•m (2.2 kgf•m, 16 lb•ft)

T.R
.
1.0 N•m (0.10 kgf•m, 0.73 lb•ft)
T.R
.

16

17
15
*

17 11 New
S 14 10

9
S 12
13
6 N•m (0.6 kgf•m, 4.4 lb•ft)
T.R
.

1.2 N•m (0.12 kgf•m, 0.88 lb•ft)

T.R

16 N•m (1.6 kgf•m, 12 lb•ft)

.

T.R
.

30 N•m (3.0 kgf•m, 22 lb•ft)

T.R
.

* This collar is press-fitted in the brake lever. When press-fitting the collar into the brake lever, press-fit it from
the chamfered side where the collar mounting hole.
Order Job/Parts to remove Q’ty Remarks
9 Brake hose union bolt 1
10 Brake hose 1
11 Brake hose gasket 2
12 Front brake light switch cover 1
13 Front brake light switch 1
14 Front brake light switch connector 2 Disconnect.
15 Front brake master cylinder holder 1
16 Brake lever 1
17 Front brake master cylinder 1

4-34
 FRONT BRAKE

Disassembling the front brake master cylinder

BF

2
3
New
1 New
BF 6 N•m (0.6 kgf•m, 4.4 lb•ft)

T.
R.
4
S

1 New

Order Job/Parts to remove Q’ty Remarks

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

4-35
 FRONT BRAKE

Removing the front brake calipers (for MT09R/MT09RC)

30 N•m (3.0 kgf•m, 22 lb•ft)

T.R
.
3.7 N•m (0.37 kgf•m, 2.7 lb•ft)

T.R
.
3 6

2 New
1

35 N•m (3.5 kgf•m, 26 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

The following procedure applies to both of
the front brake calipers.
Drain.
Brake fluid Refer to“BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-15.
1 Brake hose union bolt 1
2 Brake hose gasket 3
3 Brake hose 2
4 Reflector bracket 1
5 Reflector 1
6 Front brake caliper 1

4-36
 FRONT BRAKE

Removing the front brake calipers (for MT09SPR/MT09SPRC)

30 N•m (3.0 kgf•m, 22 lb•ft)

T.R
.
1
3.7 N•m (0.37 kgf•m, 2.7 lb•ft)

T.R
3

.
2 6
New

4
5

35 N•m (3.5 kgf•m, 26 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

The following procedure applies to both of
the front brake calipers.
Drain.
Brake fluid Refer to“BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-15.
1 Brake hose union bolt 1
2 Brake hose gasket 3
3 Brake hose 2
4 Reflector bracket 1
5 Reflector 1
6 Front brake caliper 1

4-37
 FRONT BRAKE

Disassembling the front brake calipers (for MT09R/MT09RC)

5 N•m (0.5 kgf•m, 3.7 lb•ft)
FW
D 8

7 New
New 6
BF

2 New 5
1
6
New 7
S
S
7
6 New
New
5
BF
6 New
7 New
Order Job/Parts to remove Q’ty Remarks
The following procedure applies to both of
the front brake calipers.
1 Brake pad clip 2
2 Brake pad pin 1
3 Brake pad spring 1
4 Brake pad 2
5 Brake caliper piston 4
6 Brake caliper piston dust seal 4
7 Brake caliper piston seal 4
8 Bleed screw 1

4-38
 FRONT BRAKE

Disassembling the front brake calipers (for MT09SPR/MT09SPRC)

FW
D 6 8 N•m (0.8 kgf•m, 5.9 lb•ft)

2
1

5 New
New 4
BF
3

New 4
New 5 BF

BF 5
4 New
New

3
BF
4 New
5 New
Order Job/Parts to remove Q’ty Remarks
The following procedure applies to both of
the front brake calipers.
1 Brake pad 2
2 Brake pad spring 1
3 Brake caliper piston 4
4 Brake caliper piston dust seal 4
5 Brake caliper piston seal 4
6 Bleed screw 1

4-39
 FRONT BRAKE

EAS30168

INTRODUCTION
EWA14101

WARNING
Disc brake components rarely require disas-
sembly. Therefore, always follow these pre-
ventive measures:
• Never disassemble brake components un-
less absolutely necessary.
• If any connection on the hydraulic brake G088908
system is disconnected, the entire brake
system must be disassembled, drained, 3. Measure:
cleaned, properly filled, and bled after reas- • Brake disc thickness
sembly. Measure the brake disc thickness at a few dif-
• Never use solvents on internal brake com- ferent locations.
ponents. Out of specification → Replace.
• Use only clean or new brake fluid for clean-
ing brake components. Brake disc thickness limit
• Brake fluid may damage painted surfaces 4.0 mm (0.16 in)
and plastic parts. Therefore, always clean
4. Replace:
up any spilt brake fluid immediately.
• Brake disc
• Avoid brake fluid coming into contact with
Refer to “FRONT WHEEL” on page 4-16.
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING
Front brake disc bolt
THE EYES:
18 N·m (1.8 kgf·m, 13 lb·ft)
T.

• Flush with water for 15 minutes and get im-

R.

LOCTITE®
mediate medical attention.
ECA19150

EAS30169 NOTICE
CHECKING THE FRONT BRAKE DISCS Replace the brake disc bolts with new ones.
The following procedure applies to both brake
discs. TIP
1. Check: Tighten the brake disc bolts in stages and in a
• Front brake disc crisscross pattern.
Damage/galling → Replace.
2. Measure: EAS30170

• Brake disc runout REPLACING THE FRONT BRAKE PADS (for

Out of specification → Replace. MT09R/MT09RC)
The following procedure applies to both brake
Brake disc runout limit (as mea- calipers.
sured on wheel) TIP
0.10 mm (0.0039 in) When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disassem-
a. Place the vehicle on a maintenance stand ble the brake caliper.
so that the front wheel is elevated.
b. Remove the brake caliper. 1. Remove:
c. Hold the dial gauge at a right angle against • Brake pad clip “1”
the brake disc surface. • Brake pad pin “2”
d. Measure the runout 1.5 mm (0.06 in) below • Brake pad spring “3”
the edge of the brake disc.

4-40
 FRONT BRAKE

b. Loosen the bleed screw and push the brake

3 caliper pistons into the brake caliper with
your finger.

1
2

2
1
2. Remove:
• Brake pad “1”

c. Tighten the bleed screw.

Front brake caliper bleed screw

(MT09R/MT09RC)

T.
R.
5 N·m (0.5 kgf·m, 3.7 lb·ft)
1
d. Install the brake pads and brake pad spring.
TIP
The arrow mark “a” on the brake pad spring
3. Measure: must point in the direction of disc rotation.
• Brake pad wear limit “a”
Out of specification → Replace the brake
pads as a set.

Brake pad lining thickness limit

0.5 mm (0.02 in) (MT09R/
MT09RC)

a 6. Install:
• Brake pad pin
• Brake pad clip
• Front brake caliper

Front brake caliper bolt

35 N·m (3.5 kgf·m, 26 lb·ft)
4. Remove:
T.
R.

• Brake caliper bolt 7. Check:

5. Install: • Brake fluid level
• Brake pad Below the minimum level mark → Add the
• Brake pad spring specified brake fluid to the proper level.
TIP Refer to “CHECKING THE BRAKE FLUID
Always install new brake pads and new brake LEVEL” on page 3-13.
pad spring as a set. 8. Check:
• Brake lever operation
a. Connect a clear plastic hose “1” tightly to Soft or spongy feeling → Bleed the brake sys-
the bleed screw “2”. Put the other end of the tem.
hose into an open container. Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-15.

4-41
 FRONT BRAKE

EAS34056

REPLACING THE FRONT BRAKE PADS (for

Brake pad lining thickness limit
MT09SPR/MT09SPRC) 1.0 mm (0.04 in) (MT09SPR/
The following procedure applies to both brake MT09SPRC)
calipers.
TIP
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disassem-
ble the brake caliper. a a
1. Remove:
• Brake caliper bolt “1”
• Brake caliper “2”

5. Install:
• Brake pad spring
2
• Brake pad
1 TIP
Always install new brake spring and new brake
pads as a set.

a. Connect a clear plastic hose “1” tightly to

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

1
2
1

3. Remove:
• Brake pad spring “1”

c. Tighten the bleed screw.

1
Front brake caliper bleed screw
(MT09SPR/MT09SPRC)
T.
R.

8 N·m (0.8 kgf·m, 5.9 lb·ft)

d. Install the brake spring and brake pads.

TIP
The arrow mark “a” on the brake pad spring
4. Measure: must point in the direction of disc rotation.
• Brake pad wear limit “a”
Out of specification → Replace the brake
pads as a set.

4-42
 FRONT BRAKE

a. Secure the right side brake caliper pistons

with a piece of wood “a”.
a b. Blow compressed air into the brake hose
joint opening “b” to force out the left side
pistons from the brake caliper.
EWA17060

WARNING
• Never try to pry out the brake caliper pis-
tons.
• Do not loosen the bolts “4”.
6. Install: Bolts “4”: for MT09R/MT09RC
• Front brake caliper

Front brake caliper bolt

35 N·m (3.5 kgf·m, 26 lb·ft) 4
T.
R.

7. Check:
• Brake fluid level
Below the minimum level mark → Add the
specified brake fluid to the proper level. a b
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-13.
c. Remove the brake caliper piston dust seals
8. Check:
and brake caliper piston seals.
• Brake lever operation
d. Repeat the previous steps to force out the
Soft or spongy feeling → Bleed the brake sys-
right side pistons from the brake caliper.
tem.
Refer to “BLEEDING THE HYDRAULIC EAS30173

BRAKE SYSTEM (ABS)” on page 3-15. CHECKING THE FRONT BRAKE CALIPERS
The following procedure applies to both of the
EAS30724
brake calipers.
REMOVING THE FRONT BRAKE CALIPERS
The following procedure applies to both of the Recommended brake component
brake calipers. replacement schedule
TIP Brake pads If necessary
Before removing the brake caliper, drain the Piston seals Every two years
brake fluid from the entire brake system.
Piston dust seals Every two years
1. Remove: Brake hoses Every four years
• Brake hose union bolt
• Brake hose gasket Brake fluid Every two years and
whenever the brake is
• Brake hose
disassembled
TIP
Put the end of the brake hose into a container 1. Check:
and pump out the brake fluid carefully. • Brake caliper piston
Rust/scratches/wear → Replace the brake
EAS30172
caliper pistons.
DISASSEMBLING THE FRONT BRAKE • Brake caliper cylinder
CALIPERS Scratches/wear → Replace the brake caliper
The following procedure applies to both of the assembly.
brake calipers.
1. Remove:
• Brake caliper piston
• Brake caliper piston dust seal
• Brake caliper piston seal

4-43
 FRONT BRAKE

• Brake caliper body ECA21410

Cracks/damage → Replace the brake caliper NOTICE

assembly. • When installing the brake hose onto the
• Brake fluid delivery passages brake caliper “1”, make sure the brake pipe
(brake caliper body) “a” touches the projection “b” on the brake
Obstruction → Blow out with compressed air. caliper.
EWA13611 • Install the brake pipe “c” so that it is
WARNING aligned with the brake pipe “a”.
Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seals A
b
and brake caliper piston seals. 2

EAS30174
a
ASSEMBLING THE FRONT BRAKE
CALIPERS 3
EWA16560

WARNING
• Before installation, all internal brake com- 1
ponents should be cleaned and lubricated
with clean or new brake fluid. B
• Never use solvents on internal brake com-
c
ponents as they will cause the brake caliper
2
piston dust seals and brake caliper piston
seals to swell and distort. 3 a
• Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seals b
and brake caliper piston seals.
1

Specified brake fluid A. Right side

DOT 4 B. Left side

EAS30175
2. Remove:
INSTALLING THE FRONT BRAKE CALIPERS • Front brake caliper
(for MT09R/MT09RC) 3. Install:
The following procedure applies to both of the • Brake pad
brake calipers. • Brake pad spring
1. Install: • Brake pad pin
• Front brake caliper “1” • Brake pad clip
(temporarily) • Front brake caliper
• Brake hose gasket New
• Brake hose “2” Front brake caliper bolt
• Brake hose union bolt “3” 35 N·m (3.5 kgf·m, 26 lb·ft)
T.
R.

Refer to “REPLACING THE FRONT BRAKE

Front brake hose union bolt PADS (for MT09R/MT09RC)” on page 4-40.
30 N·m (3.0 kgf·m, 22 lb·ft) 4. Fill:
T.
R.

EWA13531 • Brake master cylinder reservoir

WARNING (with the specified amount of the specified
Proper brake hose routing is essential to in- brake fluid)
sure safe vehicle operation.
Specified brake fluid
DOT 4

4-44
 FRONT BRAKE

EWA13090
• Brake hose (front brake caliper (left) to front
WARNING brake caliper (right)) “3”
• Use only the designated brake fluid. Other • Brake hose union bolt “4”
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor Front brake caliper bolt
brake performance. 35 N·m (3.5 kgf·m, 26 lb·ft)

T.
R.
• Refill with the same type of brake fluid that Front brake hose union bolt
is already in the system. Mixing brake fluids 30 N·m (3.0 kgf·m, 22 lb·ft)
may result in a harmful chemical reaction,
EWA13531
leading to poor brake performance.
WARNING
• When refilling, be careful that water does
Proper brake hose routing is essential to in-
not enter the brake fluid reservoir. Water
sure safe vehicle operation.
will significantly lower the boiling point of
the brake fluid and could cause vapor lock. ECA28620

NOTICE
ECA13540

NOTICE • When installing the brake hose to the brake

Brake fluid may damage painted surfaces caliper, make sure that the projection “a” of
the brake hose (front brake caliper (left) to
and plastic parts. Therefore, always clean up
front brake caliper (right)) “3” is in contact
any spilt brake fluid immediately.
with the brake hose (hydraulic unit to front
5. Bleed: brake caliper (left)) “2” as shown. (Left side
• Brake system only)
Refer to “BLEEDING THE HYDRAULIC • When installing the brake hose to the brake
BRAKE SYSTEM (ABS)” on page 3-15. caliper, view at the brake hose union bolt
6. Check: from top side and make sure that the brake
• Brake fluid level caliper bolt and brake hose are parallel “b”
Below the minimum level mark → Add the as shown.
specified brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID A 2
LEVEL” on page 3-13. 3
7. Check: b
a
• Brake lever operation
b
Soft or spongy feeling → Bleed the brake sys-
tem. 4 1
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-15.
EAS34057

INSTALLING THE FRONT BRAKE CALIPERS

B
(for MT09SPR/MT09SPRC)
3
The following procedure applies to both of the
brake calipers. b
1. Install: 4
• Brake pad spring
• Brake pad 1
Refer to “REPLACING THE FRONT BRAKE
PADS (for MT09SPR/MT09SPRC)” on
page 4-42.
2. Install: A. Left side
• Front brake caliper “1” B. Right side
• Brake hose gasket New 3. Fill:
• Brake hose (hydraulic unit to front brake cali- • Brake master cylinder reservoir
per (left)) “2” (with the specified amount of the specified
brake fluid)

4-45
 FRONT BRAKE

2. Remove:
Specified brake fluid • Brake hose union bolt
DOT 4 • Brake hose gasket
EWA13090
• Brake hose
WARNING TIP
• Use only the designated brake fluid. Other To collect any remaining brake fluid, place a
brake fluids may cause the rubber seals to container under the master cylinder and the end
deteriorate, causing leakage and poor of the brake hose.
brake performance.
• Refill with the same type of brake fluid that EAS30725

is already in the system. Mixing brake fluids CHECKING THE FRONT BRAKE MASTER
may result in a harmful chemical reaction, CYLINDER
leading to poor brake performance. 1. Check:
• When refilling, be careful that water does • Brake master cylinder
not enter the brake fluid reservoir. Water Damage/scratches/wear → Replace.
will significantly lower the boiling point of • Brake fluid delivery passages
the brake fluid and could cause vapor lock. (brake master cylinder body)
Obstruction → Blow out with compressed air.
ECA13540
2. Check:
NOTICE
• Brake master cylinder kit
Brake fluid may damage painted surfaces Damage/scratches/wear → Replace.
and plastic parts. Therefore, always clean up 3. Check:
any spilt brake fluid immediately. • Brake master cylinder reservoir
4. Bleed: • Brake master cylinder reservoir diaphragm
• Brake system holder
Refer to “BLEEDING THE HYDRAULIC Cracks/damage → Replace.
BRAKE SYSTEM (ABS)” on page 3-15. • Brake master cylinder reservoir diaphragm
5. Check: Damage/wear → Replace.
• Brake fluid level 4. Check:
Below the minimum level mark → Add the • Brake hose
specified brake fluid to the proper level. Cracks/damage/wear → Replace.
Refer to “CHECKING THE BRAKE FLUID EAS30181

LEVEL” on page 3-13. ASSEMBLING THE FRONT BRAKE MASTER

6. Check: CYLINDER
• Brake lever operation EWA13520

Soft or spongy feeling → Bleed the brake sys- WARNING

tem. • Before installation, all internal brake com-
Refer to “BLEEDING THE HYDRAULIC ponents should be cleaned and lubricated
BRAKE SYSTEM (ABS)” on page 3-15. with clean or new brake fluid.
• Never use solvents on internal brake com-
EAS30179
ponents.
REMOVING THE FRONT BRAKE MASTER
CYLINDER
TIP Specified brake fluid
Before removing the front brake master cylinder, DOT 4
drain the brake fluid from the entire brake sys-
1. Install:
tem.
• Cylinder cup “1” New
1. Disconnect: • Master cylinder piston “2”
• Brake light switch connector Use the cylinder cup installer “3” for the instal-
(from the front brake light switch) lation.

4-46
 FRONT BRAKE

Cylinder cup installer

90890-01996

1
3

New 1 a

c b
2
2. Install:
• Master cylinder piston 2
• Circlip “1” New
• Dust boot “2” New
• Push rod “3”
2. Install:
1 New
• Brake hose gasket New
2 New • Brake hose
• Brake hose union bolt
3
Front brake hose union bolt
30 N·m (3.0 kgf·m, 22 lb·ft)
T.
R.

EWA13531

WARNING
EAS30182
Proper brake hose routing is essential to in-
INSTALLING THE FRONT BRAKE MASTER
sure safe vehicle operation.
CYLINDER
1. Install: ECA14160

• Front brake master cylinder “1” NOTICE

• Front brake master cylinder holder “2” When installing the brake hose onto the
brake master cylinder, make sure the brake
Front brake master cylinder hold- pipe touches the projection “a” as shown.
er bolt
T.

TIP
R.

16 N·m (1.6 kgf·m, 12 lb·ft)

Turn the handlebar to the left and right to make
TIP sure the brake hose does not touch other parts
• Align the end of the front brake master cylinder (e.g., wire harness, cables, leads). Correct if
“1” with the punch mark “a” on the handlebar. necessary.
• First, tighten the upper bolt, then the lower bolt.
• Align the pin “b” of the front brake master cylin-
der holder with the groove “c” of the brake fluid
reservoir bracket.

4-47
 FRONT BRAKE

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

Specified brake fluid

DOT 4
EWA13540

WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake master cylinder reser-
voir. Water will significantly lower the boil-
ing point of the brake fluid and could cause
vapor lock.
ECA13540

NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
4. Bleed:
• Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-15.
5. Check:
• Brake fluid level
Below the minimum level mark → Add the
specified brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-13.
6. Check:
• Brake lever operation
Soft or spongy feeling → Bleed the brake sys-
tem.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-15.

4-48
 REAR BRAKE

EAS20031

REAR BRAKE
Removing the rear brake pads
9
*
5 N•m (0.5 kgf•m, 3.7 lb•ft)

T.R
.
27 N•m (2.7 kgf•m, 20 lb•ft)

T.R
.
3

S
8

7 2
6 1
5
LT
S
6
22 N•m (2.2 kgf•m, 16 lb•ft)
T.R
.

17 N•m (1.7 kgf•m, 13 lb•ft)

T.R
.

4 2.5 N•m (0.25 kgf•m, 1.8 lb•ft)

T.R
.

1.0 mm (0.04 in) 5

* Three Bond No. 1521.
Order Job/Parts to remove Q’ty Remarks
1 Screw plug 1
2 Brake pad retaining bolt 1
3 Rear brake caliper 1
4 Brake pad 2
5 Brake pad shim 2
6 Brake pad insulator 2
7 Brake pad spring 1
8 Bleed screw 1
9 Brake caliper bracket assembly 1

4-49
 REAR BRAKE

Removing the rear brake master cylinder

22 N•m (2.2 kgf•m, 16 lb•ft)

T.R
.

7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
28 N•m (2.8 kgf•m, 21 lb•ft)

T.R
.
21 N•m (2.1 kgf•m, 15 lb•ft)

T.R
.
LT

2
3 9
New 8 7
4
1
5 6 23 N•m (2.1 kgf•m, 17 lb•ft)

T.R
1.5 N•m (0.15 kgf•m, 1.1 lb•ft)

.
T.R
.

30 N•m (3.0 kgf•m, 22 lb•ft)

T.R
.

3.8 N•m (0.38 kgf•m, 2.8 lb•ft)

T.R
.

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

4-50
 REAR BRAKE

Removing the rear brake master cylinder

14
22 N•m (2.2 kgf•m, 16 lb•ft)
T.R
.

7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
28 N•m (2.8 kgf•m, 21 lb•ft)

T.R
.
15 21 N•m (2.1 kgf•m, 15 lb•ft)

T.R
.
16
10
12
LT

13

New

23 N•m (2.1 kgf•m, 17 lb•ft)

T.R
1.5 N•m (0.15 kgf•m, 1.1 lb•ft)

.
T.R
.

11 30 N•m (3.0 kgf•m, 22 lb•ft)

T.R
.

3.8 N•m (0.38 kgf•m, 2.8 lb•ft)

T.R
.

New
Order Job/Parts to remove Q’ty Remarks
10 Footrest plate (right) 1
11 Rear brake master cylinder assembly 1
12 Footrest assembly (right) 1
13 Rear brake light switch bracket 1
14 Rear brake light switch coupler 1 Disconnect.
15 Rear brake light switch 1
16 Brake pedal 1

4-51
 REAR BRAKE

Disassembling the rear brake master cylinder

New

BF
New

New BF

18 N m (1.8 kgf m, 13 lb ft)

Order Job/Parts to remove Q’ty Remarks

1 Brake master cylinder yoke 1
2 Brake master cylinder kit 1
3 Hose joint 1
4 Bushing 1
5 Brake master cylinder body 1

4-52
 REAR BRAKE

Disassembling the footrest assembly (right)

D
FW
New

LT

10 N·m (1.0 kgf·m, 7.4 lb·ft)

Order Job/Parts to remove Q’ty Remarks

1 Footrest (right) 1
2 Footrest bracket (right) 1

4-53
 REAR BRAKE

Removing the rear brake caliper

30 N m (3.0 kgf m, 22 lb ft)

New 2
3

LT

S
4

22 N•m (2.2 kgf•m, 16 lb•ft)

T.R
.

27 N•m (2.7 kgf•m, 20 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-15.
1 Brake hose union bolt 1
2 Brake hose gasket 2
3 Brake hose 1
4 Rear brake caliper 1

4-54
 REAR BRAKE

Disassembling the rear brake caliper

D
FW
S
5 N•m (0.5 kgf•m, 3.7 lb•ft)

New
New
BF

17 N•m (1.7 kgf•m, 13 lb•ft)

2.5 N•m (0.25 kgf•m, 1.8 lb•ft)

Order Job/Parts to remove Q’ty Remarks

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

4-55
 REAR BRAKE

EAS33521 EAS30183

ADJUSTING THE FOOTREST POSITION INTRODUCTION

1. Check: EWA14101

• Footrest position WARNING

TIP Disc brake components rarely require disas-
sembly. Therefore, always follow these pre-
The rider footrests can be adjusted to one of two
ventive measures:
positions. From the factory, the footrests are in
• Never disassemble brake components un-
the low position.
less absolutely necessary.
2. Adjust: • If any connection on the hydraulic brake
a. Remove the footrest assembly (left and system is disconnected, the entire brake
right) “1”. system must be disassembled, drained,
b. Adjust the footrest position (low or high po- cleaned, properly filled, and bled after reas-
sition). sembly.
c. Install the footrest assembly (left and right). • Never use solvents on internal brake com-
ponents.
Footrest assembly bolt • Use only clean or new brake fluid for clean-
28 N·m (2.8 kgf·m, 21 lb·ft) ing brake components.
T.
R.

• Brake fluid may damage painted surfaces

A and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
• Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING
1
THE EYES:
• Flush with water for 15 minutes and get im-
mediate medical attention.

EAS30184
B CHECKING THE REAR BRAKE DISC
1. Check:
• Rear brake disc
Damage/galling → Replace.
1 2. Measure:
• Brake disc runout
Out of specification → Replace.
Refer to “CHECKING THE FRONT BRAKE
DISCS” on page 4-40.
A. Left side
B. Right side Brake disc runout limit (as mea-
sured on wheel)
0.15 mm (0.0059 in)

3. Measure:
• Brake disc thickness
Measure the brake disc thickness at a few dif-
ferent locations.
Out of specification → Replace.
Refer to “CHECKING THE FRONT BRAKE
DISCS” on page 4-40.

Brake disc thickness limit

4.5 mm (0.18 in)

4-56
 REAR BRAKE

4. Replace: 1
• Brake disc 2
Refer to “REAR WHEEL” on page 4-23.

Rear brake disc bolt

30 N·m (3.0 kgf·m, 22 lb·ft)
T.
R.

LOCTITE®

EAS30185

REPLACING THE REAR BRAKE PADS

TIP c. Tighten the bleed screw.
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disassem- Rear brake caliper bleed screw
ble the brake caliper. 5 N·m (0.5 kgf·m, 3.7 lb·ft)

T.
R.
1. Measure: d. Install the brake pad insulators and brake
• Brake pad wear limit “a” pad shims onto each brake pads.
Out of specification → Replace the brake TIP
pads as a set.
Apply silicone grease between the brake pad in-
sulator and brake pad shim.
Brake pad lining thickness limit
1.0 mm (0.04 in) ECA14150

NOTICE
• Do not allow grease to contact the brake
pads.
• Remove any excess grease.
a e. Install the brake pads and brake pad spring.
TIP
The longer tangs “a” of the brake pad spring
must point in the direction of the brake caliper
piston.

2. Install:
• Brake pad insulator a
• Brake pad shim
(onto the brake pad)
• Brake pad spring
(into the rear brake caliper)
• Brake pad
TIP
Always install new brake pads, brake pad insu-
lators, brake pad shims, and brake pad spring as
a set. 3. Lubricate:
• Rear brake caliper bolt
a. Connect a clear plastic hose “1” tightly to
the bleed screw “2”. Put the other end of the Recommended lubricant
hose into an open container. Silicone grease
b. Loosen the bleed screw and push the brake ECA14150
caliper piston into the brake caliper with NOTICE
your finger.
• Do not allow grease to contact the brake
pads.
• Remove any excess grease.

4-57
 REAR BRAKE

4. Install: EWA13550

• Rear brake caliper WARNING

• Brake pad retaining bolt • Cover the brake caliper piston with a rag.
• Screw plug Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
Rear brake caliper bolt (front) • Never try to pry out the brake caliper pis-
27 N·m (2.7 kgf·m, 20 lb·ft) ton.
T.
R.

Rear brake caliper bolt (rear)

22 N·m (2.2 kgf·m, 16 lb·ft)
LOCTITE®
Rear brake pad retaining bolt
17 N·m (1.7 kgf·m, 13 lb·ft)
Rear brake caliper screw plug
2.5 N·m (0.25 kgf·m, 1.8 lb·ft)

5. Check: a
• Brake fluid level
Below the minimum level mark → Add the
specified brake fluid to the proper level. b. Remove the brake caliper piston dust seal
Refer to “CHECKING THE BRAKE FLUID and brake caliper piston seal.
LEVEL” on page 3-13. EAS30188
6. Check: CHECKING THE REAR BRAKE CALIPER
• Brake pedal operation
Soft or spongy feeling → Bleed the brake sys- Recommended brake component
replacement schedule
tem.
Refer to “BLEEDING THE HYDRAULIC Brake pads If necessary
BRAKE SYSTEM (ABS)” on page 3-15. Piston seal Every two years
EAS30186 Piston dust seal Every two years
REMOVING THE REAR BRAKE CALIPER
Brake hoses Every four years
TIP
Brake fluid Every two years and
Before disassembling the brake caliper, drain
whenever the brake is
the brake fluid from the entire brake system. disassembled
1. Remove:
• Brake hose union bolt 1. Check:
• Brake hose gasket • Brake caliper piston
• Brake hose Rust/scratches/wear → Replace the brake
TIP caliper piston.
Put the end of the brake hose into a container • Brake caliper cylinder
and pump out the brake fluid carefully. Scratches/wear → Replace the brake caliper
assembly.
• Brake caliper body
EAS30187

DISASSEMBLING THE REAR BRAKE Cracks/damage → Replace the brake caliper

CALIPER assembly.
1. Remove: • Brake fluid delivery passages
• Brake caliper piston (brake caliper body)
• Brake caliper piston dust seal Obstruction → Blow out with compressed air.
EWA13601
• Brake caliper piston seal
WARNING
a. Blow compressed air into the brake hose Whenever a brake caliper is disassembled,
joint opening “a” to force out the piston from replace the brake caliper piston dust seal
the brake caliper. and brake caliper piston seal.

4-58
 REAR BRAKE

2. Check:
• Rear brake caliper bracket a
• Rear brake caliper bracket retainer
Cracks/damage → Replace the rear brake
caliper bracket assembly.
Refer to “REAR WHEEL” on page 4-23.
EAS30189

ASSEMBLING THE REAR BRAKE CALIPER

EWA17080
1 b
WARNING
• Before installation, all internal brake com- 2. Remove:
ponents should be cleaned and lubricated • Rear brake caliper
with clean or new brake fluid. 3. Install:
• Never use solvents on internal brake com- • Brake pad insulator
ponents as they will cause the brake caliper • Brake pad shim
piston dust seal and brake caliper piston (onto the brake pad)
seal to swell and distort. • Brake pad spring
• Whenever a brake caliper is disassembled, (into the rear brake caliper)
replace the brake caliper piston dust seal • Brake pad
and brake caliper piston seal. • Rear brake caliper
Refer to “REPLACING THE REAR BRAKE
PADS” on page 4-57.
Specified brake fluid
DOT 4 Rear brake caliper bolt (front)
27 N·m (2.7 kgf·m, 20 lb·ft)
T.
R.

EAS30190
Rear brake caliper bolt (rear)
INSTALLING THE REAR BRAKE CALIPER
22 N·m (2.2 kgf·m, 16 lb·ft)
1. Install: LOCTITE®
• Brake caliper bracket retainer Rear brake pad retaining bolt
• Rear brake caliper 17 N·m (1.7 kgf·m, 13 lb·ft)
(temporarily) Rear brake caliper screw plug
• Brake hose gasket New 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
• Brake hose
• Brake hose union bolt 4. Fill:
• Brake fluid reservoir
Rear brake hose union bolt (with the specified amount of the specified
30 N·m (3.0 kgf·m, 22 lb·ft) brake fluid)
T.
R.

EWA13531
Specified brake fluid
WARNING DOT 4
Proper brake hose routing is essential to in-
sure safe vehicle operation.
ECA19080

NOTICE
When installing the brake hose onto the
brake caliper “1”, make sure the brake pipe
“a” passes between the projections “b” on
the brake caliper.

TIP
Apply Three Bond No. 1521 onto the mating sur-
faces of the brake caliper bracket and brake cal-
iper bracket retainer.

4-59
 REAR BRAKE

EWA13090 EAS30194

WARNING CHECKING THE REAR BRAKE MASTER

• Use only the designated brake fluid. Other CYLINDER
brake fluids may cause the rubber seals to 1. Check:
deteriorate, causing leakage and poor • Brake master cylinder
brake performance. Damage/scratches/wear → Replace.
• Refill with the same type of brake fluid that • Brake fluid delivery passages
is already in the system. Mixing brake fluids (brake master cylinder body)
may result in a harmful chemical reaction, Obstruction → Blow out with compressed air.
leading to poor brake performance. 2. Check:
• When refilling, be careful that water does • Brake master cylinder kit
not enter the brake fluid reservoir. Water Damage/scratches/wear → Replace.
will significantly lower the boiling point of 3. Check:
the brake fluid and could cause vapor lock. • Brake fluid reservoir
• Brake fluid reservoir diaphragm holder
Cracks/damage → Replace.
ECA13540

NOTICE
• Brake fluid reservoir diaphragm
Brake fluid may damage painted surfaces Damage/wear → Replace.
and plastic parts. Therefore, always clean up 4. Check:
any spilt brake fluid immediately. • Brake hose
5. Bleed: • Brake fluid reservoir hose
• Brake system Cracks/damage/wear → Replace.
Refer to “BLEEDING THE HYDRAULIC EAS30195
BRAKE SYSTEM (ABS)” on page 3-15. ASSEMBLING THE REAR BRAKE MASTER
6. Check: CYLINDER
• Brake fluid level EWA13520

Below the minimum level mark → Add the WARNING

specified brake fluid to the proper level. • Before installation, all internal brake com-
Refer to “CHECKING THE BRAKE FLUID ponents should be cleaned and lubricated
LEVEL” on page 3-13. with clean or new brake fluid.
7. Check: • Never use solvents on internal brake com-
• Brake pedal operation ponents.
Soft or spongy feeling → Bleed the brake sys-
tem.
Specified brake fluid
Refer to “BLEEDING THE HYDRAULIC DOT 4
BRAKE SYSTEM (ABS)” on page 3-15.
EAS30193
1. Install:
REMOVING THE REAR BRAKE MASTER • Brake master cylinder kit New
CYLINDER
EAS30196
1. Remove: INSTALLING THE REAR BRAKE MASTER
• Brake hose union bolt CYLINDER
• Brake hose gasket 1. Install:
• Brake hose
• Brake hose gasket New
TIP
• Brake hose
To collect any remaining brake fluid, place a • Brake fluid reservoir hose
container under the master cylinder and the end • Brake hose union bolt
of the brake hose.
Rear brake hose union bolt
30 N·m (3.0 kgf·m, 22 lb·ft)
T.
R.

4-60
 REAR BRAKE

EWA13531
4. Check:
WARNING • Brake fluid level
Proper brake hose routing is essential to in- Below the minimum level mark → Add the
sure safe vehicle operation. specified brake fluid to the proper level.
ECA14160 Refer to “CHECKING THE BRAKE FLUID
NOTICE LEVEL” on page 3-13.
When installing the brake hose onto the 5. Adjust:
brake master cylinder, make sure the brake • Brake pedal position
pipe touches the projection “a” as shown. Refer to “ADJUSTING THE REAR DISC
BRAKE” on page 3-14.
6. Adjust:
a • Rear brake light operation timing
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” on page 3-34.

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

Specified brake fluid

DOT 4
EWA13090

WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
ECA13540

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

4-61
 ABS (ANTI-LOCK BRAKE SYSTEM)

EAS20032

ABS (ANTI-LOCK BRAKE SYSTEM)

Removing the hydraulic unit assembly
2 30 N•m (3.0 kgf•m, 22 lb•ft)

T.R
.
4 30 N•m (3.0 kgf•m, 22 lb•ft)
5 2

T.R
.
2 New
New

7 N•m (0.7 kgf•m, 5.2 lb•ft)

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

3
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (1)” on
Passenger seat/Rider seat page 4-1.
Refer to “GENERAL CHASSIS (1)” on
Fuel tank center cover/Air scoop page 4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-15.
1 ABS ECU coupler 1 Disconnect.
2 Brake hose union bolt 4
3 Hydraulic unit bracket bolt 3
Brake hose (front brake master cylinder to
4 1 Disconnect.
hydraulic unit)
Brake hose (hydraulic unit to front brake cali-
5 1 Disconnect.
pers)

4-62
 ABS (ANTI-LOCK BRAKE SYSTEM)

Removing the hydraulic unit assembly

30 N•m (3.0 kgf•m, 22 lb•ft)

T.R
.
30 N•m (3.0 kgf•m, 22 lb•ft)

T.R
.
New
New
7
6 7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
8

9 7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Brake hose (rear brake master cylinder to
6 1 Disconnect.
hydraulic unit)
7 Brake hose (hydraulic unit to rear brake caliper) 1 Disconnect.
8 Hydraulic unit assembly 1
9 Hydraulic unit bracket 1

4-63
 ABS (ANTI-LOCK BRAKE SYSTEM)

EAS30197
2. Remove:
REMOVING THE HYDRAULIC UNIT
• Brake hose union bolt “1
ASSEMBLY
ECA21091
• Brake hose
ECA28600
NOTICE
NOTICE
Unless necessary, avoid removing and in-
Loosen the brake hose union bolts while
stalling the brake hoses of the hydraulic unit
holding the hydraulic unit assembly with the
assembly.
HU holder.
EWA13930

WARNING TIP
Refill with the same type of brake fluid that is • Use the HU holder attachment A.
already in the system. Mixing fluids may re- • Do not operate the brake lever and brake pedal
sult in a harmful chemical reaction, leading while removing the brake hose union bolts.
to poor braking performance. • Do not bend the brake pipe when loosening the
ECA18241
brake hose union bolts.
NOTICE
• Handle the ABS components with care HU holder
since they have been accurately adjusted. 90890-01912
Keep them away from dirt and do not sub-
ject them to shocks.
• Do not turn the main switch to “ON” when
removing the hydraulic unit assembly.
• Do not clean with compressed air.
• Do not reuse the brake fluid.
• Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean 2
up any spilt brake fluid immediately. 1 1
• Do not allow any brake fluid to contact the
couplers. Brake fluid may damage the cou-
plers and cause bad contacts. 2. HU holder
• If the union bolts for the hydraulic unit as- ECA19800

sembly have been removed, be sure to NOTICE

tighten them to the specified torque and • When removing the brake hoses and brake
bleed the brake system. pipes, cover the area around the hydraulic
unit assembly to catch any spilt brake fluid.
1. Disconnect: Do not allow the brake fluid to contact other
• ABS ECU coupler “1” parts.
TIP • Before disconnecting the brake pipes from
While pushing the portion “a” of the ABS ECU the hydraulic unit assembly, do not lift up
coupler, pull the lock lever “2” up to release the or move the brake pipes.
lock.
3. Remove:
• Hydraulic unit assembly “1”
2 TIP
a
To avoid brake fluid leakage and to prevent for-
1 eign materials from entering the hydraulic unit
assembly, insert a rubber plug “a” or a bolt (M10
× 1.25) into each brake hose union bolt hole.

4-64
 ABS (ANTI-LOCK BRAKE SYSTEM)

ECA19810
3. Install:
NOTICE
• Gasket New
When using a bolt, do not tighten the bolt un- • Brake hose union bolt “1”
til the bolt head touches the hydraulic unit. • Brake hose
Otherwise, the brake pipe seating surface Refer to “CABLE ROUTING” on page 2-15.
could be deformed. ECA21121

NOTICE
If the brake hose union bolt does not turn
easily, replace the hydraulic unit assembly,
a brake hoses, and related parts as a set.

Brake hose union bolt

1 30 N·m (3.0 kgf·m, 22 lb·ft)

T.
R.
ECA28610

NOTICE
EAS30198
Tighten the brake hose union bolts while
CHECKING THE HYDRAULIC UNIT holding the hydraulic unit assembly with the
ASSEMBLY HU holder.
1. Check:
TIP
• Hydraulic unit assembly
Cracks/damage → Replace the hydraulic unit Use the HU holder attachment A.
assembly and the brake pipes that are con-
nected to the assembly as a set. HU holder
EAS30200
90890-01912
INSTALLING THE HYDRAULIC UNIT
ASSEMBLY
1. Install:
• Hydraulic unit assembly
ECA21110

NOTICE
Do not remove the rubber plugs or bolts
(M10 × 1.25) installed in the brake hose union 2
bolt holes before installing the hydraulic unit 1 1
assembly.

TIP 2. HU holder
Do not allow any foreign materials to enter the 4. Connect:
hydraulic unit assembly and brake hoses when • ABS ECU coupler “1”
installing the hydraulic unit assembly. TIP
Connect the ABS ECU coupler, and then push
Hydraulic unit assembly bolt the lock lever “a” of the coupler in the direction of
7 N·m (0.7 kgf·m, 5.2 lb·ft) the arrow shown.
T.
R.

Hydraulic unit bracket bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft)

2. Remove:
• Rubber plugs or bolt (M10 × 1.25)

4-65
 ABS (ANTI-LOCK BRAKE SYSTEM)

8. Delete the DTC.

Refer to “SELF-DIAGNOSTIC FUNCTION
a AND DIAGNOSTIC CODE TABLE” on
page 9-41.
1
9. Perform a trial run.
Refer to “CHECKING THE ABS WARNING
LIGHT” on page 4-69.
EAS30930

HYDRAULIC UNIT OPERATION TESTS

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

may result in a harmful chemical reaction, WARNING

leading to poor brake performance. Securely support the vehicle so that there is
• When refilling, be careful that water does no danger of it falling over.
not enter the brake master cylinder reser-
TIP
voir or brake fluid reservoir. Water will sig-
nificantly lower the boiling point of the • For the brake line routing confirmation, use the
brake fluid and could cause vapor lock. diagnosis of function of the YDT.
• Before performing the brake line routing confir-
ECA13540
mation, make sure that no malfunctions have
NOTICE been detected in the ABS ECU and that the
Brake fluid may damage painted surfaces wheels are not rotating.
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately. 1. Place the vehicle on a maintenance stand.
2. Turn the main switch to “OFF”.
6. Bleed: 3. Remove:
• Brake system • Rider seat
Refer to “BLEEDING THE HYDRAULIC Refer to “GENERAL CHASSIS (1)” on
BRAKE SYSTEM (ABS)” on page 3-15. page 4-1.
7. Check the operation of the hydraulic unit ac- 4. Check:
cording to the brake lever and the brake ped- • Battery voltage
al response. Lower than 12.8 V → Charge or replace the
Refer to “HYDRAULIC UNIT OPERATION battery.
TESTS” on page 4-66.
ECA14770
Battery voltage
NOTICE
Higher than 12.8 V
Always check the operation of the hydraulic
unit according to the brake lever and the
brake pedal response.

4-66
 ABS (ANTI-LOCK BRAKE SYSTEM)

TIP 9. Check:
If the battery voltage is lower than 12.8 V, charge • Hydraulic unit operation
the battery, and then perform brake line routing Click “Actuator Check”, a single pulse will be
confirmation. generated in the brake lever “1”, brake pedal
“2”, and again in the brake lever “1”, in this or-
5. Removing the protective cap, and then con- der.
nect the YDT to the YDT coupler (6P).
1
Yamaha diagnostic tool USB
(US)
90890-03275
Yamaha diagnostic tool (A/I)
90890-03273

TIP
• Yamaha diagnostic tool (A/I) (90890-03273) in- G088911 2
cludes YDT sub harness (6P) (90890-03266). TIP
• If you already have Yamaha diagnostic tool (A/ “ON” and “OFF” on the tool screen indicate
I) (90890-03262), YDT sub harness (6P) when the brakes are being applied and released
(90890-03266) is separately required. respectively.
Refer to “YDT” on page 9-3. ECA17371

6. Start the YDT and display the diagnosis of NOTICE

function screen. • Check that the pulse is felt in the brake le-
7. Select code No. 2, “Brake line routing confir- ver, brake pedal, and again in the brake le-
mation”. ver, in this order.
8. Click “Actuator Check”, and then operate the • If the pulse is felt in the brake pedal before
brake lever “1” and brake pedal “2” simulta- it is felt in the brake lever, check that the
neously. brake hoses and brake pipes are connected
TIP correctly to the hydraulic unit assembly.
• The hydraulic unit operates 1 second after the • If the pulse is hardly felt in either the brake
brake lever and brake pedal are operated si- lever or brake pedal, check that the brake
multaneously and continues for approximately hoses and brake pipes are connected cor-
5 seconds. rectly to the hydraulic unit assembly.
• The operation of the hydraulic unit can be con-
10.If the operation of the hydraulic unit is normal,
firmed using the indicator.
delete all of the DTC.
On: The hydraulic unit is operating.
Flashing: The conditions for operating the hy-
ABS reaction-force confirmation
draulic unit have not been met. EWA13120

Off: The brake lever and brake pedal are not WARNING
being operated. Securely support the vehicle so that there is
no danger of it falling over.
1
TIP
• For the ABS reaction-force confirmation, use
the diagnosis of function of the YDT. For more
information, refer to the operation manual of
the YDT.
• Before performing the ABS reaction-force con-
firmation, make sure that no malfunctions have
G088909 2 been detected in the ABS ECU and that the
wheels are not rotating.

4-67
 ABS (ANTI-LOCK BRAKE SYSTEM)

1. Place the vehicle on a maintenance stand. TIP

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

TIP 1
If the battery voltage is lower than 12.8 V, charge
the battery, and then perform ABS reaction-
force confirmation.
5. Removing the protective cap, and then con-
nect the YDT to the YDT coupler (6P).

Yamaha diagnostic tool USB G088909 2

(US) 9. A reaction-force pulsating action is generated
90890-03275 in the brake lever “1” and continues for a few
Yamaha diagnostic tool (A/I) seconds.
90890-03273
TIP
TIP • The reaction-force pulsating action consists of
• Yamaha diagnostic tool (A/I) (90890-03273) in- quick pulses.
cludes YDT sub harness (6P) (90890-03266). • Be sure to continue operating the brake lever
• If you already have Yamaha diagnostic tool (A/ and brake pedal even after the pulsating action
I) (90890-03262), YDT sub harness (6P) has stopped.
(90890-03266) is separately required. • “ON” and “OFF” on the tool screen indicate
when the brakes are being applied and re-
Refer to “YDT” on page 9-3. leased respectively.
6. Start the YDT and display the diagnosis of
function screen.
7. Select code No. 1, “ABS reaction-force con- 1
firmation”.
8. Click “Actuator Check”, and then operate the
brake lever “1” and brake pedal “2” simulta-
neously.

G088913

10.After the pulsating action has stopped in the

brake lever, it is generated in the brake pedal
“1” and continues for a few seconds.

4-68
 ABS (ANTI-LOCK BRAKE SYSTEM)

TIP 17.If the operation of the hydraulic unit is normal,

• The reaction-force pulsating action consists of delete all of the DTC.
quick pulses. EAS30202

• Be sure to continue operating the brake lever CHECKING THE ABS WARNING LIGHT
and brake pedal even after the pulsating action After all checks and servicing are completed, en-
has stopped. sure that the ABS warning light goes off by walk-
• “ON” and “OFF” on the tool screen indicate ing the vehicle at a speed of faster than 5 km/h
when the brakes are being applied and re- (3 mi/h) or performing a trial run.
leased respectively.

1
G088914

11.After the pulsating action has stopped in the

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

NOTICE
• Check that the pulse is felt in the brake le-
ver, brake pedal, and again in the brake le-
ver, in this order.
• If the pulse is felt in the brake pedal before
it is felt in the brake lever, check that the
brake hoses and brake pipes are connected
correctly to the hydraulic unit assembly.
• If the pulse is hardly felt in either the brake
lever or brake pedal, check that the brake
hoses and brake pipes are connected cor-
rectly to the hydraulic unit assembly.
12.Turn the main switch to “OFF”.
13.Remove the YDT from the YDT coupler, and
then install the protective cap.
14.Turn the main switch to “ON”.
15.Set the stop/run/start switch to “ ”.
16.Check for brake fluid leakage around the hy-
draulic unit.
Brake fluid leakage → Replace the hydraulic
unit, brake pipes, and related parts as a set.

4-69
 HANDLEBAR

EAS20033

HANDLEBAR
Removing the clutch lever and handlebar switch (left)
22 N•m (2.2 kgf•m, 16 lb•ft)

T.R
1

.
1.0 N•m (0.10 kgf•m, 0.73 lb•ft)

T.R
.
6 N•m (0.6 kgf•m, 4.4 lb•ft)

T.
R.
1.0 N•m (0.10 kgf•m, 0.73 lb•ft)

T.R
.
LS
LS
LS
10 N•m (1.0 kgf•m, 7.4 lb•ft)
7
T.
R.

2 5 New
LS
3
10 9
8
6

* 4 1.2 N•m (0.12 kgf•m, 0.88 lb•ft)

T.R
.
1.0 N•m (0.10 kgf•m, 0.73 lb•ft) LT
T.R
.

16 N•m (1.6 kgf•m, 12 lb•ft)

T.R
.

FW
D

* Rubber adhesive
Order Job/Parts to remove Q’ty Remarks
1 Rearview mirror (left) 1
2 Grip end (left) 1
3 Handlebar grip 1
4 Handlebar switch cover 1
5 Plastic locking tie 1
6 Handlebar switch coupler (left) 1 Disconnect.
7 Handlebar switch (left) 1
8 Handlebar switch clip 1
9 Clutch switch cover 1
10 Clutch switch 1

4-70
 HANDLEBAR

Removing the clutch lever and handlebar switch (left)

22 N•m (2.2 kgf•m, 16 lb•ft)

T.R
.
1.0 N•m (0.10 kgf•m, 0.73 lb•ft)

T.R
.
6 N•m (0.6 kgf•m, 4.4 lb•ft)

T.
R.
1.0 N•m (0.10 kgf•m, 0.73 lb•ft)

T.R
.
14
LS
LS
16 LS
10 N•m (1.0 kgf•m, 7.4 lb•ft) 12
T.

New
R.

LS
13
11

* 1.2 N•m (0.12 kgf•m, 0.88 lb•ft)

T.R
.
1.0 N•m (0.10 kgf•m, 0.73 lb•ft) LT
T.R
.

15
16 N•m (1.6 kgf•m, 12 lb•ft)
T.R
.

FW
D

* Rubber adhesive
Order Job/Parts to remove Q’ty Remarks
11 Clutch switch connector 4 Disconnect.
12 Clutch cable 1 Disconnect.
13 Adjusting bolt/Locknut 1/1
14 Clutch lever 1
15 Rearview mirror bracket 1
16 Clutch lever holder 1

4-71
 HANDLEBAR

Removing the handlebar switch (right) and handlebar

22 N•m (2.2 kgf•m, 16 lb•ft)

FW
T.
R.
D
8 2.5 N•m (0.25 kgf•m, 1.8 lb•ft)

T.R
.
5
7

40 N•m (4.0 kgf•m, 30 lb•ft)

T.
R.
3 New
9

5
4 *
3 New
2
6
1.0 N•m (0.10 kgf•m, 0.73 lb•ft)
T.R
.

1
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.

* YAMAHA GREASE “R” (Fluorine-based grease)

Order Job/Parts to remove Q’ty Remarks
Front brake master cylinder assembly Refer to “FRONT BRAKE” on page 4-31.
1 Grip end (right) 1
2 Handlebar switch cover 1
3 Plastic locking tie 2
4 Handlebar switch coupler 2 Disconnect.
5 Handlebar switch (right) 1
6 Throttle grip 1
7 Upper handlebar holder 2
8 Handlebar 1
9 Lower handlebar holder 2

4-72
 HANDLEBAR

EAS31396

ADJUSTING THE HANDLEBAR POSITION

Upper handlebar holder bolt
1. Check: 22 N·m (2.2 kgf·m, 16 lb·ft)

T.
• Handlebar position

R.
ECA18300
TIP
NOTICE
The handlebar position can be adjusted in two
positions to suit the rider’s preference. First, tighten the bolts on the front side of the
handlebar holder, and then on the rear side.

TIP
• Align the punch mark “a” on the handlebar with
the left side upper surface of the lower handle-
bar holder (left) “3”.
• The upper handlebar holders should be in-
stalled with the punch marks “b” facing for-
ward.

b
2. Remove:
• Air scoop (left and right) a
Refer to “GENERAL CHASSIS (1)” on 1
page 4-1.
3. Adjust: 2
• Handlebar position 3
a. Remove the upper handlebar holders “1”
3
and handlebar “2”.
e. Tighten the lower handlebar holder nuts.
1
Lower handlebar holder nut
2 40 N·m (4.0 kgf·m, 30 lb·ft)
T.
R.

EAS30203

REMOVING THE HANDLEBAR

1. Stand the vehicle on a level surface.
EWA13120

WARNING
b. Loosen the lower handlebar holder nuts. Securely support the vehicle so that there is
c. Adjust the handlebar position by rotating no danger of it falling over.
both of the lower handlebar holders “1” in
180°. 2. Remove:
• Handlebar grip “1”
1
TIP
1
Blow compressed air between the handlebar
and the handlebar grip, and gradually pull the
grip off the handlebar.

d. Install the handlebar “1” and upper handle-

bar holders “2”.

4-73
 HANDLEBAR

b
1
a
1

2
3
3

EAS30204
3. Tighten:
CHECKING THE HANDLEBAR • Lower handlebar holder nut
1. Check:
• Handlebar Lower handlebar holder nut
Bends/cracks/damage → Replace. 40 N·m (4.0 kgf·m, 30 lb·ft)

T.
R.
EWA13690

WARNING 4. Lubricate:
Do not attempt to straighten a bent handle- • Throttle grip
bar as this may dangerously weaken it. Refer to “LUBRICATING THE THROTTLE
GRIP” on page 3-34.
EAS30205
5. Install:
INSTALLING THE HANDLEBAR • Throttle grip “1”
1. Stand the vehicle on a level surface. • Handlebar switch (right)
EWA13120

WARNING Handlebar switch screw

Securely support the vehicle so that there is 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
T.
R.

no danger of it falling over.

a. Face the groove “a” in the throttle grip to the
2. Install: rear side of the vehicle, and then fit the
• Lower handlebar holder flange “b” on the throttle grip into the groove
(temporarily) “c” in the handlebar switch (right, front side)
• Handlebar “1” “2” and the throttle grip onto the handlebar
• Upper handlebar holder “2” “3”.
Upper handlebar holder bolt
22 N·m (2.2 kgf·m, 16 lb·ft)
T.
R.

ECA18300

NOTICE
First, tighten the bolts on the front side of the
handlebar holder, and then on the rear side.
1
a
TIP
• Align the punch mark “a” on the handlebar with
the left side upper surface of the lower handle- 2
bar holder (left) “3”. b c
• The upper handlebar holders should be in-
stalled with the punch marks “b” facing for-
ward.

4-74
 HANDLEBAR

b. Install the handlebar switch (right, rear side) a. Align the projection “a” on the handlebar
“4”. switch clip with the hole “b” in the handle-
TIP bar.
Align the projection “d” on the handlebar switch b. Insert the handlebar switch (left) into the
(right, rear side) with the hole “e” in the handle- handlebar switch clip, and tighten the han-
bar “3”. dlebar switch screw to the specified torque.
2

3 b
4 3
a

d e 1

c. Make sure that the throttle grip turns 9. Install:

smoothly. • Clutch lever holder “1”
• Rearview mirror bracket “2”
6. Install: • Clutch cable
• Grip end (right) “1”
• Grip end bolt Rearview mirror bracket bolt
16 N·m (1.6 kgf·m, 12 lb·ft)
T.

Grip end bolt

R.

10 N·m (1.0 kgf·m, 7.4 lb·ft) TIP

T.
R.

• Align the mating surfaces of the rearview mir-

TIP
ror bracket and clutch lever holder with the
There should be 1–3 mm (0.04–0.12 in) of clear- punch mark “a” on the handlebar.
ance “a” between the throttle grip and the grip • First, tighten the upper bolt, and then the lower
end. bolt.

a
2

a
1

7. Install: 10.Install:
• Front brake master cylinder assembly • Handlebar grip
Refer to “INSTALLING THE FRONT BRAKE • Grip end (left) “1”
MASTER CYLINDER” on page 4-47.
8. Install: Grip end bolt
• Handlebar switch clip “1” 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.

• Handlebar switch (left) “2”

R.

• Handlebar switch screw “3” a. Degrease the adhesive surfaces of the han-
dlebar grip and handlebar.
Handlebar switch screw b. Apply a thin coat of rubber adhesive onto
1.0 N·m (0.10 kgf·m, 4.4 lb·ft) the end of the handlebar (left).
T.
R.

4-75
 HANDLEBAR

c. Slide the handlebar grip over the end of the

handlebar (left).
d. Wipe off any excess rubber adhesive with a
clean rag.
EWA13700

WARNING
Do not touch the handlebar grip until the rub-
ber adhesive has fully dried.

TIP
There should be 1–3 mm (0.04–0.12 in) of clear-
ance “a” between the handlebar grip and the grip
end.

G088918 1
11.Adjust:
• Clutch lever free play
Refer to “ADJUSTING THE CLUTCH LEVER
FREE PLAY” on page 3-12.

Clutch lever free play

5.0–10.0 mm (0.20–0.39 in)

4-76
 FRONT FORK

EAS20034

FRONT FORK
Removing the front fork legs

23 N•m (2.3 kgf•m, 17 lb•ft)

2

3 26 N•m (2.6 kgf•m, 19 lb•ft)

4
23 N•m (2.3 kgf•m, 17 lb•ft)
1

211.5 mm
(8.33
33 in)
5

10 N•m (1.0 kgf•m, 7.4 lb•ft)

Order Job/Parts to remove Q’ty Remarks

The following procedure applies to both of
the front fork legs.
Front wheel Refer to “FRONT WHEEL” on page 4-16.
1 Front fender 1
2 Upper bracket pinch bolt 1 Loosen.
3 Cap bolt 1 Loosen.
4 Lower bracket pinch bolt 2 Loosen.
5 Front fork leg 1

4-77
 FRONT FORK

Disassembling the front fork leg

23 N•m (2.3 kgf•m, 17 lb•ft)

T.R
.
1 13 New
LS 15 N•m (1.5 kgf•m, 11 lb•ft)

T.R
.
New 2
6
3

12 New
11
10 New
LS New
8 New
7 New LT

23 N•m (2.3 kgf•m, 17 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

The following procedure applies to both of
the front fork legs.
1 Cap bolt 1
2 O-ring 1
3 Washer 1
4 Spacer 1
5 Fork spring 1
6 Locknut 1
7 Dust seal 1
8 Oil seal clip 1
9 Outer tube 1
10 Oil seal 1
11 Washer 1
12 Outer tube bushing 1
13 Inner tube bushing 1

4-78
 FRONT FORK

Disassembling the front fork leg

23 N•m (2.3 kgf•m, 17 lb•ft)

T.R
.
New
LS 15 N•m (1.5 kgf•m, 11 lb•ft)

T.R
.
New

18

17

New

New
14
LS New 16 New
New LT

15

23 N•m (2.3 kgf•m, 17 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

14 Wheel axle pinch bolt 1 Right side only.
15 Damper rod assembly bolt 1
16 Copper washer 1
17 Damper rod assembly 1
18 Inner tube 1

4-79
 FRONT FORK

EAS30206 EAS30207

REMOVING THE FRONT FORK LEGS DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the The following procedure applies to both of the
front fork legs. front fork legs.
TIP 1. Remove:
For MT09R/MT09RC: • Cap bolt “1”
Each front fork leg is equipped with a spring pre- (from the damper rod assembly)
load adjusting bolt, the fork leg (right) is • Washer “2”
equipped with a rebound damping force adjust- • Spacer “3”
ing screw, the fork leg (left) is equipped with a • Locknut “4”
compression damping force adjusting screw. a. Press down on the spacer with the fork
Pay attention not to mistake the right and left. spring compressor “5”.
b. Install the rod holder “6” between the lock-
1. Stand the vehicle on a level surface. nut “4” and the washer “2”.
EWA13120

WARNING
Fork spring compressor
Securely support the vehicle so that there is
90890-01441
no danger of it falling over.
Fork spring compressor
TIP YM-01441
Rod holder
Place the vehicle on a maintenance stand so
90890-01434
that the front wheel is elevated.
Damper rod holder double ended
2. Remove: YM-01434
• Front brake caliper
Refer to “FRONT BRAKE” on page 4-31. TIP
• Front wheel Use the side of the rod holder that is marked “B”.
Refer to “FRONT WHEEL” on page 4-16.
3. Loosen:
• Upper bracket pinch bolt “1”
• Cap bolt “2”
• Lower bracket pinch bolt “3”
EWA13640

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

c. Hold the cap bolt and loosen the locknut.

d. Remove the cap bolt.
2 e. Remove the rod holder and fork spring
compressor.
1 f. Remove the washer, spacer and locknut.
2. Drain:
3 • Fork oil
TIP
4. Remove: Stroke the damper rod assembly “1” several
• Front fork leg times while draining the fork oil.

4-80
 FRONT FORK

TIP
While holding the damper rod with the damper
rod holder “1”, loosen the damper rod assembly
bolt.

Damper rod holder (ø27)

90890-01582
Damper rod holder
G088919 YM-01582
3. Remove:
• Dust seal “1”
• Oil seal clip “2”
(with a flat-head screwdriver)
ECA19100

NOTICE
Do not scratch the outer tube.

1 1

EAS30208

CHECKING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
2 1. Check:
G088920 • Inner tube
4. Remove: • Outer tube
• Outer tube Bends/damage/scratches → Replace.
EWA13650
a. Hold the front fork leg horizontally. WARNING
b. Securely clamp the brake caliper bracket in
Do not attempt to straighten a bent inner
a vise with soft jaws.
tube as this may dangerously weaken it.
c. Separate the outer tube from the inner tube
by pulling the outer tube forcefully but care- 2. Measure:
fully. • Fork spring free length “a”
ECA19880
Out of specification → Replace.
NOTICE
Excessive force will damage the bushings. Fork spring free length limit
Damaged bushings must be replaced. 251.4 mm (9.90 in) (MT09R,
MT09RC)
261.7 mm (10.31 in) (MT09SPR,
MT09SPRC)

5. Remove:
• Damper rod assembly bolt
G088921
• Damper rod assembly

4-81
 FRONT FORK

3. Check: TIP
• Damper rod • When assembling the front fork leg, be sure to
Damage/wear → Replace. replace the following parts:
Obstruction → Blow out all of the oil passag- – Inner tube bushing
es with compressed air. – Outer tube bushing
ECA19110
– Oil seal
NOTICE
– Oil seal clip
• The front fork leg has a very sophisticated
– Dust seal
internal construction, which are particular-
– Copper washer
ly sensitive to foreign material.
– O-ring
• When disassembling and assembling the
• Before assembling the front fork leg, make
front fork leg, do not allow any foreign ma-
sure all of the components are clean.
terial to enter the front fork.
1. Install:
4. Check:
• Damper rod assembly
• Cap bolt “1” ECA22560

Cracks/damage → Replace. NOTICE

Allow the damper rod assembly to slide
slowly down the inner tube. Be careful not to
damage the inner tube.
2. Tighten:
• Damper rod assembly bolt
(along with the copper washer New )

Front fork damper rod assembly

bolt
T.
R.

23 N·m (2.3 kgf·m, 17 lb·ft)

EAS30209
LOCTITE®
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the TIP
front fork legs.
While holding the damper rod assembly with the
For MT09R/MT09RC:
EWA17090 damper rod holder “1”, tighten the damper rod
WARNING assembly bolt.
• Note that the amount of the fork oil is differ-
ent in the left and right front fork legs. Make Damper rod holder (ø27)
sure to fill each of the left and right front 90890-01582
fork legs with the specified amount of the Damper rod holder
fork oil. YM-01582
• If both front fork legs are not filled with the
specified amount of the fork oil, it may
cause poor handling and a loss of stability.
For MT09SPR/MT09SPRC:
EWA18360

WARNING
If both front fork legs are not filled with the
specified amount of the fork oil, it may cause
poor handling and a loss of stability.
1

4-82
 FRONT FORK

3. Lubricate:
• Inner tube’s outer surface Fork seal driver
90890-01442
Recommended oil Adjustable fork seal driver (36–
Yamaha Suspension Oil 01 46 mm)
YM-01442
4. Install:
• Dust seal “1” New
• Oil seal clip “2” New
• Oil seal “3” New
• Washer “4” 3
• Outer tube bushing “5” New 2
• Inner tube bushing “6” New
ECA19170 1
NOTICE
G088923
Make sure the numbered side of the oil seal
faces bottom side. 7. Install:
• Oil seal “1”
TIP (with the fork seal driver “2”)
• Before installing the oil seal, lubricate its lips
with lithium-soap-based grease. Fork seal driver
• Lubricate the outer surface of the inner tube 90890-01442
with fork oil. Adjustable fork seal driver (36–
• Before installing the oil seal, cover the top of 46 mm)
the front fork leg with a plastic bag to protect YM-01442
the oil seal during installation.

3 New
2
New 5 4
1
New 6
1 New
2 New G088924

8. Install:
• Oil seal clip “1”
TIP
Adjust the oil seal clip so that it fits into the outer
tube’s groove.

1
G088922

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

4-83
 FRONT FORK

9. Install:
• Dust seal “1” Recommended oil
(with the fork seal driver “2”) Yamaha Suspension Oil 01
Quantity (left)
Fork seal driver 456.0 cm³ (15.42 US oz, 16.08
90890-01442 Imp.oz) (MT09R, MT09RC)
Adjustable fork seal driver (36– 466.0 cm³ (15.76 US oz, 16.44
46 mm) Imp.oz) (MT09SPR, MT09SPRC)
YM-01442 Quantity (right)
460.0 cm³ (15.55 US oz, 16.22
Imp.oz) (MT09R, MT09RC)
466.0 cm³ (15.76 US oz, 16.44
Imp.oz) (MT09SPR, MT09SPRC)
2 ECA14230

NOTICE
• Be sure to use the recommended fork oil.
1 Other oils may have an adverse effect on
front fork performance.
G088926
• When disassembling and assembling the
10.Install: front fork leg, do not allow any foreign ma-
terial to enter the front fork.
• Rod puller “1”
• Rod puller attachment (M10) “2” 12.After filling the front fork leg, slowly stroke the
(onto the damper rod “3”) damper rod “1” up and down (at least ten
times) to distribute the fork oil.
Rod puller TIP
90890-01437
Be sure to stroke the damper rod slowly be-
Universal damping rod bleeding
tool set cause the fork oil may spurt out.
YM-A8703
Rod puller attachment (M10 long)
90890-01578
Universal damping rod bleeding
tool set
YM-A8703

G088929

13.Before measuring the fork oil level, wait ten

minutes until the oil has settled and the air
bubbles have dispersed.
TIP
Be sure to bleed the front fork leg of any residual
G088927 air.
11.Fill:
• Front fork leg 14.Measure:
(with the specified amount of the recom- • Front fork leg oil level “a”
mended fork oil) (from the top of the outer tube, with the outer
tube fully compressed and without the fork
spring)
Out of specification → Correct.

4-84
 FRONT FORK

g. Press down on the spacer with the fork

Level (left) spring compressor “1”.
105 mm (4.1 in) (MT09SPR, h. Pull up the rod puller and install the rod
MT09SPRC) holder “2” between the locknut “3” and the
109 mm (4.3 in) (MT09R, washer “4”.
MT09RC)
Level (right) Rod puller
105 mm (4.1 in) (MT09SPR, 90890-01437
MT09SPRC) Universal damping rod bleeding
109 mm (4.3 in) (MT09R, tool set
MT09RC) YM-A8703
Rod puller attachment (M10 long)
90890-01578
Universal damping rod bleeding
a tool set
YM-A8703
Fork spring compressor
90890-01441
Fork spring compressor
YM-01441
G088930
Rod holder
90890-01434
15.Install:
Damper rod holder double ended
• Fork spring YM-01434
• Spacer
• Locknut TIP
• Damper adjusting rod (damper rod assem- Use the side of the rod holder that is marked “B”.
bly)
• Washer
• Cap bolt
(along with the O-ring New )
a. Remove the rod puller and rod puller at-
tachment.
b. Install the fork spring.
TIP
Install the fork spring with the smaller diameter
“a” facing up “A”.
i. Remove the rod puller and rod puller at-
tachment.
j. Position the locknut “3” as distance “b”.

Distance “b”
12 mm (0.47 in)

3
b
G088931

c. Install the locknut all the way onto the

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

4-85
 FRONT FORK

k. Set the cap bolt distance “c” to specifica- 1. Install:

tion. • Front fork leg
Temporarily tighten the upper and lower
Distance “c” bracket pinch bolts.
13 mm (0.51 in)
Installed length (from the top of
the outer tube) “a”
211.5 mm (8.33 in)
EWA13680

WARNING
Make sure the brake hoses are routed prop-
erly.
c TIP
When installing the front fork, set the outer tube
l. Install the damper adjusting rod and cap with the specified length “a” from the top of the
bolt, and then finger tighten the cap bolt. outer tube to the top of the lower bracket.
EWA13670

WARNING
Always use a new cap bolt O-ring.
m. Hold the cap bolt “5” and tighten the locknut a
“3” to specification.

Front fork cap bolt locknut

15 N·m (1.5 kgf·m, 11 lb·ft)
T.
R.

2. Tighten:
5 • Lower bracket pinch bolt “1”

Lower bracket pinch bolt

3
23 N·m (2.3 kgf·m, 17 lb·ft)
T.
R.

• Cap bolt “2”

Front fork cap bolt

n. Remove the rod holder and fork spring 23 N·m (2.3 kgf·m, 17 lb·ft)
T.
R.

compressor.
• Upper bracket pinch bolt “3”
16.Install:
• Cap bolt Upper bracket pinch bolt
(to the outer tube) 26 N·m (2.6 kgf·m, 19 lb·ft)
T.
R.

TIP
• Temporarily tighten the cap bolt.
• When to tighten the cap bolt to the specified
torque is after installing the front fork leg to the 2
vehicle and tightening the lower bracket pinch
bolts.
3
EAS30210

INSTALLING THE FRONT FORK LEGS 1

The following procedure applies to both of the
front fork legs.

4-86
 FRONT FORK

TIP
For MT09SPR/MT09SPRC:
When installing the front fork legs, make sure
that the letters on the cap bolts are positioned
within the angle range shown in the illustration.

5 5 5 5

3. Check:
• Cable routing
TIP
Make sure the brake hoses, clutch cable, and
handlebar switch leads are routed properly.
Refer to “CABLE ROUTING” on page 2-15.
4. Adjust:
• Spring preload
• Rebound damping
• Compression damping
Refer to “ADJUSTING THE FRONT FORK
LEGS (for MT09R/MT09RC)” on page 3-21
and “ADJUSTING THE FRONT FORK LEGS
(for MT09SPR/MT09SPRC)” on page 3-23.

4-87
 STEERING HEAD

EAS20035

STEERING HEAD
Removing the lower bracket

110 N•m (11 kgf•m, 81 lb•ft) 5

T.R
.
6
7
1st 52 N m (5.2 kgf m, 38 lb ft)
*2nd 14 N m (1.4 kgf m, 10 lb ft) 8
9
LS
10

LS

1 2

LS

3 4

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

* Loosen the lower ring nut completely, and then tighten it to specification.
Order Job/Parts to remove Q’ty Remarks
Refer to “GENERAL CHASSIS (1)” on
Meter assembly bracket page 4-1.
Handlebar Refer to “HANDLEBAR” on page 4-70.
Front fork legs Refer to “FRONT FORK” on page 4-77.
1 Front brake hose bracket 1
2 Headlight bracket 1
3 Wire harness 1 Disconnect.
4 Lower bracket cap 1
5 Steering stem nut cap 1
6 Steering stem nut 1
7 Upper bracket 1
8 Lock washer 1
9 Upper ring nut 1
10 Rubber washer 1

4-88
 STEERING HEAD

Removing the lower bracket

110 N•m (11 kgf•m, 81 lb•ft)

T.R
.
1st 52 N m (5.2 kgf m, 38 lb ft)
*2nd 14 N m (1.4 kgf m, 10 lb ft)

LS
11
13
15

LS

12 16

14

LS

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

* Loosen the lower ring nut completely, and then tighten it to specification.
Order Job/Parts to remove Q’ty Remarks
11 Lower ring nut 1
12 Lower bracket 1
13 Bearing cover 1
14 Lower bearing dust seal 1
15 Upper bearing 1
16 Lower bearing 1

4-89
 STEERING HEAD

EAS30213
2. Check:
REMOVING THE LOWER BRACKET
• Bearing
1. Stand the vehicle on a level surface.
EWA13120
• Bearing race
WARNING Damage/pitting → Replace the bearings and
Securely support the vehicle so that there is bearing races as a set.
no danger of it falling over. 3. Replace:
• Bearing
2. Remove: • Bearing race
• Upper ring nut “1” a. Remove the bearing races from the steer-
• Rubber washer ing head pipe “1” with a long rod “2” and
• Lower ring nut “2” hammer.
• Lower bracket b. Remove the bearing race “3” from the lower
EWA13730

WARNING
bracket with a floor chisel “4” and hammer.
c. Install a new dust seal and new bearing rac-
Securely support the lower bracket so that
es.
there is no danger of it falling. ECA14270

NOTICE
TIP
If the bearing race is not installed properly,
• Hold the lower ring nut with ring nut wrench “3”,
the steering head pipe could be damaged.
and then remove the upper ring nut with the
steering nut wrench “4”. TIP
• Remove the lower ring nut with the steering nut • Always replace the bearings and bearing races
wrench. as a set.
• Whenever the steering head is disassembled,
Ring nut wrench replace the dust seal.
90890-01268
Spanner wrench
YU-01268
Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472

4 3
G088933

G088932 2
EAS30214

CHECKING THE STEERING HEAD G088934

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

4-90
 STEERING HEAD

EAS30216

INSTALLING THE STEERING HEAD

1. Lubricate:
• Upper bearing
• Lower bearing

Recommended lubricant
Lithium-soap-based grease

2. Install:
• Lower ring nut “1”
• Rubber washer “2”
• Upper ring nut “3”
• Lock washer “4”
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-20.

G088935

3. Install:
• Upper bracket
• Steering stem nut
TIP
Temporarily tighten the steering stem nut.
4. Install:
• Front fork legs
Refer to “FRONT FORK” on page 4-77.
TIP
Temporarily tighten the upper and lower bracket
pinch bolts.
5. Tighten:
• Steering stem nut

Steering stem nut

110 N·m (11 kgf·m, 81 lb·ft)
T.
R.

6. Tighten:
• Lower bracket pinch bolt

Lower bracket pinch bolt

23 N·m (2.3 kgf·m, 17 lb·ft)
T.
R.

• Upper bracket pinch bolt

Upper bracket pinch bolt

26 N·m (2.6 kgf·m, 19 lb·ft)
T.
R.

4-91
 REAR SHOCK ABSORBER ASSEMBLY

EAS20036

REAR SHOCK ABSORBER ASSEMBLY

Removing the rear shock absorber assembly (for MT09R/MT09RC)

44 N•m (4.4 kgf•m, 32 lb•ft)

T.R
.
1
7
5
6

3
44 N•m (4.4 kgf•m, 32 lb•ft)
T.R
.

LS
8

7 New
11
1 11 New
5
4
6 3
LS

9
10 2

44 N•m (4.4 kgf•m, 32 lb•ft) 8

T.R
.

Order Job/Parts to remove Q’ty Remarks

1 Rear shock absorber assembly lower nut/Bolt 1/1
2 Cap 1
Rear shock absorber assembly upper nut/
3 1/1/1
Washer/Bolt
4 Rear shock absorber assembly 1
5 Relay arm nut/Bolt 1/1
6 Connecting arm upper nut/Bolt 1/1
7 Relay arm 2
8 Connecting arm lower nut/Bolt 1/1
9 Connecting arm 1
10 Collar 1
11 Collar/Oil seal/Bearing 1/2/1

4-92
 REAR SHOCK ABSORBER ASSEMBLY

Removing the rear shock absorber assembly (for MT09SPR/MT09SPRC)

7 N•m (0.7 kgf•m, 5.2 lb•ft) 7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R

T.R
.

.
5
10 LT
8
9
7 N•m (0.7 kgf•m, 5.2 lb•ft) 1
T.R
.

7 N•m (0.7 kgf•m, 5.2 lb•ft) 2

T.R
.

11
3

10
5 14
8 7
14

9 New
LS

LS
6
New 4

12

13
11
44 N•m (4.4 kgf•m, 32 lb•ft)
T.R
.

44 N•m (4.4 kgf•m, 32 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

1 Gas cylinder bracket 1 1
2 Gas cylinder bracket 2 1
3 Spring preload adjuster bracket 1
4 Cap 1
5 Rear shock absorber assembly lower nut/Bolt 1/1
Rear shock absorber assembly upper nut/
6 1/1/1
Washer/Bolt
7 Rear shock absorber assembly 1
8 Relay arm nut/Bolt 1/1
9 Connecting arm upper nut/Bolt 1/1
10 Relay arm 2
11 Connecting arm lower nut/Bolt 1/1
12 Connecting arm 1
13 Collar 1
14 Collar/Oil seal/Bearing 1/2/1

4-93
 REAR SHOCK ABSORBER ASSEMBLY

Disassembling the bearing

4.0 mm (0.16 in)

LS

LS
LS

2 New
3
0.0-1.0 mm
2 New
1 (0.00-0.04 in)

LS

LS
LS
2 New

4.0 mm (0.16 in)

3
2 New
1

Order Job/Parts to remove Q’ty Remarks

1 Collar 2
2 Oil seal 4
3 Bearing 2

4-94
 REAR SHOCK ABSORBER ASSEMBLY

EAS30826 EWA13760

HANDLING THE REAR SHOCK ABSORBER WARNING

EWA13740
Wear eye protection to prevent eye damage
WARNING
from released gas or metal chips.
This rear shock absorber contains highly
compressed nitrogen gas. Before handling
the rear shock absorber, read and make sure
you understand the following information.
The manufacturer cannot be held responsi-
ble for property damage or personal injury
that may result from improper handling of
the rear shock absorber.
• Do not tamper or attempt to open the rear
shock absorber.
• Do not subject the rear shock absorber to
an open flame or any other source of high EAS30219

heat. High heat can cause an explosion due REMOVING THE REAR SHOCK ABSORBER
to excessive gas pressure. ASSEMBLY
• Do not deform or damage the rear shock 1. Stand the vehicle on a level surface.
EWA13120
absorber in any way. Rear shock absorber
damage will result in poor damping perfor- WARNING
mance. Securely support the vehicle so that there is
no danger of it falling over.
EAS33551
TIP
DISPOSING OF A REAR SHOCK ABSORBER
(for MT09R/MT09RC) • Place the vehicle on a maintenance stand so
1. Gas pressure must be released before dis- that the rear wheel is elevated.
posing of a rear shock absorber. To release • When removing the bolt, hold the swingarm so
the gas pressure, drill a 2–3 mm (0.08–0.12 that it does not drop down.
in) hole through the rear shock absorber at a
point 20–25 mm (0.79–0.98 in) from its end EAS30220

as shown. CHECKING THE REAR SHOCK ABSORBER

EWA13760 ASSEMBLY
WARNING 1. Check:
Wear eye protection to prevent eye damage • Rear shock absorber rod
from released gas or metal chips. Bends/damage → Replace the rear shock
absorber assembly.
20-25 mm • Rear shock absorber assembly
Gas leaks/oil leaks → Replace the rear shock
(0.79-0.98 in)
absorber assembly.
• Spring
• Bushing
Damage/wear → Replace the rear shock ab-
sorber assembly.
• Hose (for MT09SPR/MT09SPRC)
Cracks/damage/wear → Replace the rear
shock absorber assembly.
EAS30729 • Bolt
DISPOSING OF A REAR SHOCK ABSORBER Bends/damage/wear → Replace.
(for MT09SPR/MT09SPRC)
1. Gas pressure must be released before dis-
posing of a rear shock absorber. To release
the gas pressure, drill a 2–3 mm (0.08–0.12
in) hole through the flat portion of the gas cyl-
inder as shown.

4-95
 REAR SHOCK ABSORBER ASSEMBLY

EAS30221

CHECKING THE CONNECTING ARM AND

RELAY ARM 3 3
1. Check:
• Connecting arm 1 5
• Relay arm
Damage/wear → Replace. New 2 2 New
2. Check:
b b
• Bearing a a
Damage/pitting → Replace. 1
5
3. Check:
New 2 2 New
• Collar
A b b B
Damage/scratches → Replace. a a
EAS30222

INSTALLING THE RELAY ARM 4

1. Lubricate:
• Collar a a
b b
• Oil seal New

Recommended lubricant New 2 2 New

Lithium-soap-based grease 1
3. Relay arm
2. Install: 4. Connecting arm
• Bearing “1” 5. Swingarm
(to the connecting arm and swingarm)
A. Left side
• Oil seal “2” New B. Right side
(connecting arm and swingarm)
3. Tighten:
Installed depth “a” • Connecting arm upper nut
4.0 mm (0.16 in) • Relay arm nut
Installed depth “b”
0–1.0 mm (0–0.04 in) Connecting arm upper nut
44 N·m (4.4 kgf·m, 32 lb·ft)
T.
R.

TIP Relay arm nut

• When installing the oil seals “2” to the relay 44 N·m (4.4 kgf·m, 32 lb·ft)
arm, face the character stamp of the oil seals
EAS30225
outside. INSTALLING THE REAR SHOCK
• Install the connecting arm upper bolt and relay ABSORBER ASSEMBLY
arm bolt from the left. 1. Install:
• Gas cylinder bracket 1 and 2 bolt (for
MT09SPR/MT09SPRC)
• Gas cylinder bolt (for MT09SPR/
MT09SPRC)
• Rear shock absorber assembly
• Spring preload adjuster bracket bolt (for
MT09SPR/MT09SPRC)
• Spring preload adjuster bolt (for MT09SPR/
MT09SPRC)
• Rear shock absorber assembly upper bolt
• Rear shock absorber assembly upper nut
• Rear shock absorber assembly lower bolt
• Rear shock absorber assembly lower nut

4-96
 REAR SHOCK ABSORBER ASSEMBLY

TIP
• Install the rear shock absorber assembly upper
bolt and rear shock absorber assembly lower
bolt from the left.
• When installing the rear shock absorber as-
sembly, lift up the swingarm.
2. Tighten:
• Gas cylinder bracket 1 and 2 bolt (for
MT09SPR/MT09SPRC)
• Gas cylinder bolt (for MT09SPR/
MT09SPRC)
• Spring preload adjuster bracket bolt (for
MT09SPR/MT09SPRC)
• Spring preload adjuster bolt (for MT09SPR/
MT09SPRC)
• Rear shock absorber assembly upper nut
• Rear shock absorber assembly lower nut

Gas cylinder bracket 1 bolt (for

MT09SPR/MT09SPRC)
T.
R.

7 N·m (0.7 kgf·m, 5.2 lb·ft)

Gas cylinder bracket 2 bolt (for
MT09SPR/MT09SPRC)
7 N·m (0.7 kgf·m, 5.2 lb·ft)
LOCTITE®
Gas cylinder bolt (for MT09SPR/
MT09SPRC)
7 N·m (0.7 kgf·m, 5.2 lb·ft)
Spring preload adjuster bracket
bolt (for MT09SPR/MT09SPRC)
7 N·m (0.7 kgf·m, 5.2 lb·ft)
Spring preload adjuster bolt (for
MT09SPR/MT09SPRC)
7 N·m (0.7 kgf·m, 5.2 lb·ft)
Rear shock absorber assembly
upper nut
44 N·m (4.4 kgf·m, 32 lb·ft)
Rear shock absorber assembly
lower nut
44 N·m (4.4 kgf·m, 32 lb·ft)

4-97
 SWINGARM

EAS20037

SWINGARM
Removing the swingarm

7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

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

LS
8

LS

LS 7
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
LS

8 4
2 6
1
LS

115 N•m (11.5 kgf•m, 85 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Rear brake caliper Refer to “REAR BRAKE” on page 4-49.
Rear wheel Refer to “REAR WHEEL” on page 4-23.
Refer to “REAR SHOCK ABSORBER
Relay arm nut/Bolt ASSEMBLY” on page 4-92.
1 Pivot shaft nut 1
2 Washer 1
3 Pivot shaft 1
4 Swingarm 1
5 Rear fender 1
6 Drive chain guide 1
7 Bracket 1
8 Dust cover 2

4-98
 SWINGARM

Disassembling the bearing

0-1.0 mm 0-1.0 mm
0-1.0 mm (0-0.04 in) (0-0.04 in)
(0-0.04 in)

LS 5
LS 2 New
5
4 LS

LS 3

1 LS

New 2
LS

0-1.0 mm 4.0 mm
(0-0.04 in) (0.16 in)

Order Job/Parts to remove Q’ty Remarks

1 Collar 1
2 Oil seal 2
3 Bearing 1
4 Collar 1
5 Bearing 2

4-99
 SWINGARM

EAS30226 EWA13770

REMOVING THE SWINGARM WARNING

1. Stand the vehicle on a level surface. Do not attempt to straighten a bent pivot
EWA13120
shaft.
WARNING
Securely support the vehicle so that there is 3. Wash:
no danger of it falling over. • Pivot shaft
• Dust cover
TIP • Collar
Place the vehicle on a maintenance stand so
that the rear wheel is elevated. Recommended cleaning solvent
Kerosene
2. Measure:
• Swingarm side play 4. Check:
• Swingarm vertical movement • Dust cover “1”
a. Measure the tightening torque of the pivot • Oil seal “2”
shaft nut. Damage/wear → Replace.
• Collar “3”
Pivot shaft nut Damage/scratches → Replace.
115 N·m (11.5 kgf·m, 85 lb·ft) • Bearing “4”
T.
R.

Damage/pitting → Replace.
b. Check the swingarm side play “A” by mov- • Collar “5”
ing the swingarm from side to side. Damage/scratches → Replace.
If the swingarm has side-to-side play, check
the collars, bearings, and dust covers. 4 1
c. Check the swingarm vertical movement “B” 4
by moving the swingarm up and down. 2
5
If the swingarm vertical movement is not
smooth or if there is binding, check the pivot
shaft, collar, bearings, and dust covers.
2 4 3
1
B
A EAS30228

INSTALLING THE SWINGARM

1. Lubricate:
• Dust cover
• Pivot shaft
G088936
• Bearing
• Oil seal New
3. Remove: • Collar
• Swingarm
EAS30227 Recommended lubricant
CHECKING THE SWINGARM Lithium-soap-based grease
1. Check:
• Swingarm 2. Install:
Bends/cracks/damage → Replace. • Bearing “1”
2. Check: (to the swingarm)
• Pivot shaft • Oil seal “2” New
Roll the pivot shaft on a flat surface. (to the swingarm)
Bends → Replace.
Installed depth “a”
0–1.0 mm (0–0.04 in)

4-100
 SWINGARM

TIP 6. Adjust:
When installing the oil seals to the swingarm, • Drive chain slack
face the character stamp of the oil seals outside. Refer to “DRIVE CHAIN SLACK” on page 3-
18.

Drive chain slack (Maintenance

Stand)
36.0–41.0 mm (1.42–1.61 in)
1
New 2 2 N
New Drive chain slack (Sidestand)
36.0–41.0 mm (1.42–1.61 in)
A B Drive chain slack limit
46.0 mm (1.81 in)
a a

1 1
A B
a a
A. Left side
B. Right side
3. Install:
• Swingarm
• Pivot shaft

Relay arm nut

44 N·m (4.4 kgf·m, 32 lb·ft)
T.
R.

4. Install:
• Pivot shaft nut
a. Lubricate the pivot shaft nut mating surface
with lithium-soap-based grease, and then
tighten it to specification.

Pivot shaft nut

115 N·m (11.5 kgf·m, 85 lb·ft)
T.
R.

TIP
Do not allow grease to contact the pivot shaft nut
threads.

5. Install:
• Rear wheel
Refer to “REAR WHEEL” on page 4-23.

4-101
 CHAIN DRIVE

EAS20038

CHAIN DRIVE
Removing the drive chain

14 N•m (1.4 kgf•m, 10 lb•ft)

T.
R.

11

LS LT
13
10
1 5
LT
14 12 New
6
2 160 N•m (16 kgf•m, 118 lb•ft)

T.R
.
9

LT
3 LT
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.
R.

4 2 LT 8 N•m (0.8 kgf•m, 5.9 lb•ft)

T.
R.
LS
6 *
LS 7
8 28 N•m (2.8 kgf•m, 21 lb•ft)
LT
T.
R.

LT
10 N•m (1.0 kgf•m, 7.4 lb•ft) LS
T.
R.

* Rubber adhesive
Order Job/Parts to remove Q’ty Remarks
1 Shift sensor coupler 1 Disconnect.
2 Locknut 3
3 Shift sensor 1
4 Shift rod 1
5 Shift arm 1
6 Shift rod joint 2
7 Shift pedal 1
8 Shift pedal cover 1
9 Drive sprocket cover 1
10 Drive chain guide 1
11 Drive chain 1
12 Drive sprocket nut 1
13 Washer 1
14 Drive sprocket 1

4-102
 CHAIN DRIVE

EAS30229
a. Measure the length “a” between the inner
REMOVING THE DRIVE CHAIN
sides of the pins and the length “b” between
1. Stand the vehicle on a level surface.
EWA13120
the outer sides of the pins on a 15-link sec-
WARNING tion of the drive chain as shown in the illus-
Securely support the vehicle so that there is tration.
no danger of it falling over. b. Calculate the 15-link section length “c” of
the 15-link section of the drive chain using
2. Straighten the drive sprocket nut ribs “a”. the following formula.
Drive chain 15-link section length “c” =
(length “a” between pin inner sides + length
“b” between pin outer sides)/2
TIP
a • When measuring a 15-link section of the drive
chain, make sure that the drive chain is taut.
• Perform this procedure 2–3 times, at a different
location each time.

3. Loosen:
• Drive sprocket nut
TIP
Loosen the drive sprocket nut while pressing the
brake pedal.
4. Remove:
• Drive chain
ECA17410
G088937
NOTICE
Be sure to put on safety goggles when work-
ing.

TIP
Cut the drive chain with the drive chain cut & riv-
et tool.

Drive chain cut & rivet tool

G088938
90890-01550
Drive chain cut & rivet tool 2. Check:
YM-01550 • Drive chain
Stiffness → Clean and lubricate or replace.
EAS30230

CHECKING THE DRIVE CHAIN

1. Measure:
• 15-link section length “c” of the drive chain
Out of specification → Replace the drive
chain.

15-link length limit

239.3 mm (9.42 in)
G088939

4-103
 CHAIN DRIVE

3. Clean:
• Drive chain
a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosene and remove
any remaining dirt.
c. Remove the drive chain from the kerosene
and completely dry it.
ECA19090

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

G088940

G088904

b. Correct

1. Drive chain roller

2. Drive sprocket
EAS30232

CHECKING THE REAR WHEEL SPROCKET

G088941 Refer to “CHECKING AND REPLACING THE
REAR WHEEL SPROCKET” on page 4-27.
4. Check:
• O-ring “1” EAS30233

Damage → Replace the drive chain. CHECKING THE REAR WHEEL DRIVE HUB
• Drive chain roller “2” Refer to “CHECKING THE REAR WHEEL
Damage/wear → Replace the drive chain. DRIVE HUB” on page 4-26.
• Drive chain side plate “3”
Damage/wear/cracks → Replace the drive
chain.

4-104
 CHAIN DRIVE

EAS30234

INSTALLING THE DRIVE CHAIN

1. Install:
• Drive chain
ECA17410

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

TIP
Install the drive chain joint with the drive chain
cut & rivet tool. 2. Lubricate:
• Drive chain
Drive chain cut & rivet tool
90890-01550 Recommended lubricant
Chain lubricant suitable for O-
Drive chain cut & rivet tool
ring chains
YM-01550
3. Install:
a. When press fitting the connecting plate “1”, • Drive sprocket
make sure the space “a” between the end • Washer “1”
of the connecting pin “2” and the connecting
• Drive sprocket nut “2” New
plate is 1.2–1.4 mm (0.05–0.06 in).
Drive sprocket nut
160 N·m (16 kgf·m, 118 lb·ft)
T.
R.

LOCTITE®

TIP
• Thoroughly clean all the drive sprocket nut
seat and threads of drive axle.
• While applying the rear brake, tighten the drive
sprocket nut.
• Install washer “1” with the “OUT” mark “a” fac-
b. After riveting, make sure the diameter be-
ing out.
tween the edges “b” of the connecting pin
• Stake the drive sprocket nut “2” at cutouts “b” in
“2” is 5.7–6.0 mm (0.22–0.24 in).
the drive axle securely.

b
c. After riveting, make sure the space “c”, a
which is inside of the connecting link “3” and
inside of the connecting plate “1”, is 14.35–
14.55 mm (0.565–0.573 in).

4-105
 CHAIN DRIVE

a
c
2

3
1 b
b
4. Install: a. 24 mm (0.94 in)
• Shift arm “1” b. 24.4 mm (0.96 in)
TIP
6. Adjust:
Before installing, make sure to align the mark “a” • Installed shift rod length
of the shift shaft with the punch mark “b” of the Refer to “ADJUSTING THE SHIFT PEDAL”
shift arm. on page 4-106.
7. Adjust:
Shift arm bolt • Drive chain slack
14 N·m (1.4 kgf·m, 10 lb·ft) Refer to “DRIVE CHAIN SLACK” on page 3-
T.
R.

18.

Drive chain slack (Maintenance

b Stand)
36.0–41.0 mm (1.42–1.61 in)
Drive chain slack (Sidestand)
36.0–41.0 mm (1.42–1.61 in)
Drive chain slack limit
1 a 46.0 mm (1.81 in)
ECA13550

NOTICE
5. Install:
A drive chain that is too tight will overload
• Shift rod joint “1”
the engine and other vital parts, and one that
• Shift sensor “2”
is too loose can skip and damage the swing-
• Shift rod “3”
arm or cause an accident. Therefore, keep
TIP the drive chain slack within the specified lim-
• Install the shift rod joint and shift sensor in the its.
direction shown in the illustration.
• The allowable twist of the shift rod joint and EAS31729
shift sensor is ±5°. ADJUSTING THE SHIFT PEDAL
• Install the shift rod so that the side “c” faces up- TIP
ward as shown in the illustration. The shift pedal position is determined by the in-
stalled shift rod length.
Shift rod joint bolt 1. Measure:
10 N·m (1.0 kgf·m, 7.4 lb·ft)
• Installed shift rod length “a”
T.
R.

LOCTITE®
Incorrect → Adjust.
Shift sensor locknut
7 N·m (0.7 kgf·m, 5.2 lb·ft)
Installed shift rod length
236.4–238.4 mm (9.31–9.39 in)

4-106
 CHAIN DRIVE

a a

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

2 1 c. Insert the shift pedal cover into the shift

pedal, align the projections “b” of the shift
1 pedal cover with the grooves “c” of the shift
pedal.
c. Tighten both locknuts.
2
TIP
Be sure to place the shift rod joints in parallel. c 1
The allowable twist of the shift rod joints is ±5°.
c b
Shift rod locknut
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.

b
d. Make sure the installed shift rod length is
within specification. d. Wipe off any excess rubber adhesive with a
EAS34071
clean rag.
INSTALLING THE SHIFT PEDAL COVER
1. Install:
• Shift pedal cover “1”
a. Degrease the adhesive surfaces of the shift
pedal cover and shift pedal.
b. Apply a thin coat of rubber adhesive “a” to
the top and bottom surfaces of the shift
pedal “2” as shown.

4-107
 ENGINE

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

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

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

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

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

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

CAMSHAFTS.................................................................................................5-16
REMOVING THE CAMSHAFTS..............................................................5-19
CHECKING THE CAMSHAFTS ..............................................................5-20
CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET .........5-21
CHECKING THE TIMING CHAIN GUIDES............................................. 5-21
CHECKING THE TIMING CHAIN TENSIONER...................................... 5-21
INSTALLING THE CAMSHAFTS ............................................................ 5-22

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

REMOVING THE CYLINDER HEAD.......................................................5-27
CHECKING THE TIMING CHAIN GUIDE (EXHAUST SIDE) ................. 5-27
CHECKING THE CYLINDER HEAD .......................................................5-27
5
INSTALLING THE CYLINDER HEAD .....................................................5-27

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

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

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

REMOVING THE GENERATOR ............................................................. 5-38
REMOVING THE STARTER CLUTCH ...................................................5-38
CHECKING THE STARTER CLUTCH ....................................................5-38
INSTALLING THE STARTER CLUTCH .................................................. 5-39
INSTALLING THE GENERATOR............................................................ 5-39

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

CHECKING THE STARTER MOTOR .....................................................5-43
ASSEMBLING THE STARTER MOTOR................................................. 5-43
INSTALLING THE STARTER MOTOR ...................................................5-44
CLUTCH ........................................................................................................5-45
REMOVING THE CLUTCH ..................................................................... 5-49
CHECKING THE FRICTION PLATES.....................................................5-50
CHECKING THE CLUTCH PLATES .......................................................5-50
CHECKING THE CLUTCH SPRINGS.....................................................5-51
CHECKING THE CLUTCH HOUSING ....................................................5-51
CHECKING THE CLUTCH BOSS........................................................... 5-51
CHECKING THE PRESSURE PLATE ....................................................5-52
CHECKING THE PRIMARY DRIVE GEAR............................................. 5-52
CHECKING THE PRIMARY DRIVEN GEAR ..........................................5-52
CHECKING THE PULL LEVER SHAFT AND PULL ROD ......................5-52
INSTALLING THE CLUTCH.................................................................... 5-52

SHIFT SHAFT................................................................................................5-55
CHECKING THE SHIFT SHAFT ............................................................. 5-56
CHECKING THE STOPPER LEVER ......................................................5-56
INSTALLING THE SHIFT SHAFT ........................................................... 5-56

OIL PUMP...................................................................................................... 5-57

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

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

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

CRANKCASE ................................................................................................5-63
DISASSEMBLING THE CRANKCASE....................................................5-65
CHECKING THE CRANKCASE ..............................................................5-65
ASSEMBLING THE CRANKCASE.......................................................... 5-65
INSTALLING THE OIL PRESSURE SWITCH.........................................5-67
INSTALLING THE GEAR POSITION SENSOR...................................... 5-67

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

REMOVING THE CONNECTING RODS AND PISTONS.......................5-70
CHECKING THE CYLINDER AND PISTON ...........................................5-70
CHECKING THE PISTON RINGS........................................................... 5-71
CHECKING THE PISTON PIN ................................................................5-72
CHECKING THE CONNECTING RODS................................................. 5-72
INSTALLING THE CONNECTING ROD AND PISTON .......................... 5-75
CRANKSHAFT AND BALANCER SHAFT ...................................................5-80
REMOVING THE CRANKSHAFT AND BALANCER SHAFT.................. 5-81
CHECKING THE OIL NOZZLES ............................................................. 5-81
CHECKING THE CRANKSHAFT ............................................................ 5-81
CHECKING THE BALANCER SHAFT ....................................................5-83
INSTALLING THE CRANKSHAFT .......................................................... 5-84
INSTALLING THE BALANCER ASSEMBLY...........................................5-85

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

EAS20298

LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS32362

ENGINE OIL LUBRICATION CHART

16

15
14

13
12 12 12

11

7
6 2

4 3
5 1

8 8 8

10

1. Oil strainer 15. Intake camshaft

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

5-1
 LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS32363

LUBRICATION DIAGRAMS

3 5

2
1
1. Oil filter cartridge union bolt
2. Oil filter cartridge
3. Oil delivery pipe
4. Drive axle
5. Main axle

5-2
 LUBRICATION SYSTEM CHART AND DIAGRAMS

2 3

10

9 7
7
8

1. Timing chain tensioner

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

5-3
 LUBRICATION SYSTEM CHART AND DIAGRAMS

5
4

2 1

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

5-4
 LUBRICATION SYSTEM CHART AND DIAGRAMS

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

5-5
 LUBRICATION SYSTEM CHART AND DIAGRAMS

3
4 5

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

5-6
 ENGINE INSPECTION

EAS20041

ENGINE INSPECTION 1
EAS30249

MEASURE THE COMPRESSION PRESSURE

The following procedure applies to all of the cyl- 2
inders.
TIP
Insufficient compression pressure will result in a
loss of performance.
1. Measure: 5. Measure:
• Valve clearance • Compression pressure
Out of specification → Adjust. Out of specification → Refer to steps (c) and
Refer to “ADJUSTING THE VALVE CLEAR- (d).
ANCE” on page 3-5.
2. Start the engine, warm it up for several min- Compression pressure
utes, and then turn it off. 1392–1792 kPa/425 r/min (13.9–
3. Remove: 17.9 kgf/cm²/425 r/min, 198.0–
254.9 psi/425 r/min)
• Rider seat
Refer to “GENERAL CHASSIS (1)” on
a. Set the main switch to “ON”.
page 4-1.
b. With the throttle wide open, crank the en-
• Fuel tank center cover
gine until the reading on the compression
Refer to “GENERAL CHASSIS (1)” on
gauge stabilizes.
page 4-1. EWA17100

• Fuel tank WARNING

Refer to “FUEL TANK” on page 7-1. To prevent sparking the plug, remove all ig-
• Air filter case nition coil couplers and fuel injector cou-
Refer to “GENERAL CHASSIS (2)” on plers before cranking the engine.
page 4-14.
• Ignition coil TIP
• Spark plug The difference in compression pressure be-
Refer to “CAMSHAFTS” on page 5-16. tween cylinders should not exceed 100 kPa (1
ECA13340
kg/cm², 15 psi).
NOTICE
Before removing the spark plugs, use com- c. If the compression pressure is above the
pressed air to blow away any dirt accumulat- maximum specification, check the cylinder
ed in the spark plug wells to prevent it from head, valve surfaces and piston crown for
falling into the cylinders. carbon deposits.
Carbon deposits → Eliminate.
4. Install: d. If the compression pressure is below the
• Compression gauge “1” minimum specification, pour a teaspoonful
• Extension “2” of engine oil into the spark plug bore and
measure again.
Compression gauge Refer to the following table.
90890-03081
Engine compression tester
YU-33223
Compression gauge extension
122mm
90890-04136
Compression gauge extension
122mm
YM-04136

5-7
 ENGINE INSPECTION

Compression pressure (with oil applied into

the cylinder)
Reading Diagnosis
Higher than without Piston ring(s) wear or
oil damage → Repair.
Same as without oil Piston, valves, cylin-
der head gasket pos-
sibly defective →
Repair.

6. Install:
• Spark plug

Spark plug
13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.

7. Install:
• Ignition coil
Refer to “CAMSHAFTS” on page 5-16.
• Air filter case
Refer to “GENERAL CHASSIS (2)” on
page 4-14.
• Fuel tank
Refer to “FUEL TANK” on page 7-1.
• Fuel tank center cover
Refer to “GENERAL CHASSIS (1)” on
page 4-1.
• Rider seat
Refer to “GENERAL CHASSIS (1)” on
page 4-1.

5-8
 ENGINE REMOVAL

EAS20042

ENGINE REMOVAL
Removing the muffler and exhaust pipe

* 3 New

20 N•m (2.0 kgf•m, 15 lb•ft)

T.R
.
2

20 N•m (2.0 kgf•m, 15 lb•ft)

T.R
.

20 N•m (2.0 kgf•m, 15 lb•ft)

T.R
.

25 N•m (2.5 kgf•m, 18 lb•ft)

T.R
.

* YAMAHA GREASE “G” (Shell Sunlight Grease 3®)

Order Job/Parts to remove Q’ty Remarks
Radiator bracket Refer to “RADIATOR” on page 6-3.
1 O2 sensor coupler 1 Disconnect.
2 Muffler assembly 1
3 Exhaust gasket 3
Remove the O2 sensor only when neces-
4 O2 sensor 1 sary.

5-9
 ENGINE REMOVAL

Disconnecting the leads and hoses

7 N•m (0.5 kgf•m, 5.2 lb•ft)

T.R
.

7 N•m (0.7 kgf•m, 5.2 lb•ft) 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
T.R

.
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (1)” on
Passenger seat/Rider seat page 4-1.
Refer to “GENERAL CHASSIS (1)” on
Fuel tank center cover/Air scoop page 4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Refer to “GENERAL CHASSIS (2)” on
Air filter case page 4-14.
Throttle bodies Refer to “THROTTLE BODIES” on page 7-6.
Refer to “GENERAL CHASSIS (1)” on
Front side panel page 4-1.
Radiator Refer to “RADIATOR” on page 6-3.
Footrest assembly (right) Refer to “REAR BRAKE” on page 4-49.
Shift rod/Drive sprocket Refer to “CHAIN DRIVE” on page 4-102.

5-10
 ENGINE REMOVAL

Disconnecting the leads and hoses

8 3
9

5
7 N•m (0.5 kgf•m, 5.2 lb•ft)
T.R
.

1
6 10
2

7 N•m (0.7 kgf•m, 5.2 lb•ft) 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R

T.R
.

Order Job/Parts to remove Q’ty Remarks

1 Clutch cable 1 Disconnect.
2 Starter motor lead 1 Disconnect.
Canister purge hose (purge cut valve solenoid Disconnect.
3 1
to canister) For California only.
4 Ignition coil coupler 3 Disconnect.
5 Coolant temperature sensor coupler 1 Disconnect.
6 Neutral switch connector 1 Disconnect.
7 Gear position sensor coupler 1 Disconnect.
8 Crankshaft position sensor coupler 1 Disconnect.
9 Stator coil coupler 1 Disconnect.
10 Oil pressure switch lead 1 Disconnect.

5-11
 ENGINE REMOVAL

Removing the engine

25 N•m (2.5 kgf•m, 18 lb•ft) 25 N•m (2.5 kgf•m, 18 lb•ft)
45 N•m (4.5 kgf•m, 33 lb•ft)
4 2
1
1
2 3
8
LS 15
5 6 7
60 N•m (6.0 kgf•m, 44 lb•ft) 115 N•m (11.5 kgf•m, 85 lb•ft)

9 60 N•m (6.0 kgf•m, 44 lb•ft)

45 N•m (4.5 kgf•m, 33 lb•ft)
10 11
LT

LT

55 N•m (5.5 kgf•m, 41 lb•ft)

12

LT
LT

13

14
7 N•m (0.7 kgf•m, 5.2 lb•ft)
55 N•m (5.5 kgf•m, 41 lb•ft)
T.R
.

Order Job/Parts to remove Q’ty Remarks

Engine mounting bolt (right front upper side)/
1 1/1
Engine mounting bolt (left front upper side)
Engine bracket bolt (right)/Engine bracket bolt
2 2/2
(left)
3 Engine bracket (right) 1
4 Engine bracket (left) 1
5 Engine mounting bolt (right front lower side) 1
6 Collar 1
7 Collar 1
8 Engine mounting bolt (left front lower side) 1
9 Engine mounting nut (lower) 1
10 Muffler bracket bolt 1
11 Muffler bracket (right) 1
12 Sidestand switch coupler 1 Disconnect.
13 Muffler bracket bolt 1
14 Muffler bracket (left) 1
15 Pivot shaft nut 1 Loosen.

5-12
 ENGINE REMOVAL

Removing the engine

25 N•m (2.5 kgf•m, 18 lb•ft) 25 N•m (2.5 kgf•m, 18 lb•ft)
45 N•m (4.5 kgf•m, 33 lb•ft)

16
LS 18

115 N•m (11.5 kgf•m, 85 lb•ft)

60 N•m (6.0 kgf•m, 44 lb•ft)
17
60 N•m (6.0 kgf•m, 44 lb•ft)
45 N•m (4.5 kgf•m, 33 lb•ft)
LT

LT

55 N•m (5.5 kgf•m, 41 lb•ft)

LT
LT
20

7 N•m (0.7 kgf•m, 5.2 lb•ft) 20 55 N•m (5.5 kgf•m, 41 lb•ft)

T.R

19
.

Order Job/Parts to remove Q’ty Remarks

16 Engine mounting nut (upper) 1
17 Engine mounting bolt (rear lower side) 1
18 Engine mounting bolt (rear upper side) 1
19 Engine 1
20 Engine mounting adjust bolt 2

5-13
 ENGINE REMOVAL

EAS30250
4. Install:
REMOVING THE ENGINE
• Engine mounting bolt (rear lower side) “5”
1. Loosen:
• Engine mounting bolt (rear upper side) “6”
• Engine mounting adjust bolt (rear)
5. Install:
TIP • Engine mounting bolt (left front lower side) “7”
Loosen the engine mounting adjust bolts with (temporarily tighten)
the pivot shaft wrench “1” and pivot shaft wrench 6. Install:
adapter “2”. • Collar “8”
• Collar “9”
Pivot shaft wrench • Engine mounting bolt (right front lower side)
90890-01518 “10”
Frame spanner socket (temporarily tighten)
YM-01518 7. Tighten:
Pivot shaft wrench adapter • Engine mounting adjust bolt (lower) “1”
90890-01476 TIP
• Tighten the engine mounting adjust bolt to
specification with the pivot shaft wrench and
1 pivot shaft wrench adapter.
• Make sure that the flange on the engine
mounting adjust bolt contacts the engine.

Engine mounting adjust bolt

2 (lower)
T.
R.

7 N·m (0.7 kgf·m, 5.2 lb·ft)

Pivot shaft wrench

90890-01518
Frame spanner socket
YM-01518
Pivot shaft wrench adapter
90890-01476

1 8. Install:
2 • Muffler bracket “11”
• Muffler bracket bolt “12”
EAS30251 (temporarily tighten)
INSTALLING THE ENGINE 9. Tighten:
1. Install: • Engine mounting nut (lower) “13”
• Engine mounting adjust bolt (lower) “1” • Muffler bracket bolt “4”, “12”
(temporarily tighten)
• Engine mounting adjust bolt (upper) “2” Engine mounting nut (lower)
(temporarily tighten) 55 N·m (5.5 kgf·m, 41 lb·ft)
T.
R.

2. Install: Muffler bracket bolt

• Muffler bracket “3” 55 N·m (5.5 kgf·m, 41 lb·ft)
• Muffler bracket bolt “4” LOCTITE®
(temporarily tighten)
3. Install:
• Engine

5-14
 ENGINE REMOVAL

10.Tighten: 15.Install:
• Engine mounting bolt (left front lower side) “7” • Engine bracket (right) “19”
• Engine mounting bolt (right front lower side) • Engine bracket bolt (right) “20”
“10” (temporarily tighten)
• Engine mounting bolt (right front upper side)
Engine mounting bolt (left front “21”
lower side) (temporarily tighten)
T.
R.

60 N·m (6.0 kgf·m, 44 lb·ft) 16.Tighten:

Engine mounting bolt (right front • Engine bracket bolt (left) “17”
lower side) • Engine mounting bolt (left front upper side)
60 N·m (6.0 kgf·m, 44 lb·ft) “18”
• Engine bracket bolt (right) “20”
11.Tighten:
• Pivot shaft nut “14” • Engine mounting bolt (right front upper side)
“21”
Pivot shaft nut
115 N·m (11.5 kgf·m, 85 lb·ft) Engine bracket bolt (left)
T.

25 N·m (2.5 kgf·m, 18 lb·ft)

R.

T.
R.
12.Tighten: Engine mounting bolt (left front
• Engine mounting adjust bolt (upper) “2” upper side)
45 N·m (4.5 kgf·m, 33 lb·ft)
TIP
Engine bracket bolt (right)
• Tighten the engine mounting adjust bolt to 25 N·m (2.5 kgf·m, 18 lb·ft)
specification with the pivot shaft wrench and Engine mounting bolt (right front
pivot shaft wrench adapter. upper side)
• Make sure that the flange on the engine 45 N·m (4.5 kgf·m, 33 lb·ft)
mounting adjust bolt contacts the engine.

19
Engine mounting adjust bolt (up- 20
21 16
per) 17
T.
R.

7 N·m (0.7 kgf·m, 5.2 lb·ft) 18

15

Pivot shaft wrench 6

10 9 8 14 7
90890-01518 13
Frame spanner socket 5
YM-01518
Pivot shaft wrench adapter 11
90890-01476 12

13.Tighten:
• Engine mounting nut (upper) “15”
2
Engine mounting nut (upper)
45 N·m (4.5 kgf·m, 33 lb·ft) 4
T.
R.

14.Install: 1
• Engine bracket (left) “16” 3
• Engine bracket bolt (left) “17”
(temporarily tighten)
• Engine mounting bolt (left front upper side)
“18”
(temporarily tighten)

5-15
 CAMSHAFTS

EAS20043

CAMSHAFTS
Removing the cylinder head cover

10 N•m (1.0 kgf•m, 7.4 lb•ft)

1

T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
2 2 2

3 3 3

New 5

* 13 N•m (1.3 kgf•m, 9.6 lb•ft)

T.R
.

* Three Bond No. 1541C®

Order Job/Parts to remove Q’ty Remarks
Refer to “GENERAL CHASSIS (1)” on
Rider seat page 4-1.
Refer to “GENERAL CHASSIS (1)” on
Fuel tank center cover page 4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Refer to “GENERAL CHASSIS (2)” on
Air filter case page 4-14.
Refer to “GENERAL CHASSIS (1)” on
Front side panel page 4-1.
Radiator Refer to “RADIATOR” on page 6-3.
1 Ignition coil coupler 3 Disconnect.
2 Ignition coil 3
3 Spark plug 3
4 Cylinder head cover 1
5 Cylinder head cover gasket 1
6 Timing chain guide (top side) 1

5-16
 CAMSHAFTS

Removing the camshafts

10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
E

10 N•m (1.0 kgf•m, 7.4 lb•ft) E (8)

T.R
.

24 N•m (2.4 kgf•m, 18 lb•ft) (4)

(4)
T.R
.
8 9 6
5 New
4 7
9
9 9
E
10

(7) 11

1 2 3 New
M

12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Crankshaft end cover/Timing mark accessing Refer to “GENERATOR AND STARTER
bolt CLUTCH” on page 5-36.
1 Holder 2
2 Timing chain cover 1
3 Timing chain cover gasket 1
4 Timing chain tensioner 1
5 Timing chain tensioner gasket 1
6 Intake camshaft cap 1
7 Exhaust camshaft cap 1
8 Camshaft cap 1
9 Dowel pin 6
10 Intake camshaft 1
11 Exhaust camshaft 1

5-17
 CAMSHAFTS

Removing the camshafts

10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
E

10 N•m (1.0 kgf•m, 7.4 lb•ft) E (8)

T.R
.

24 N•m (2.4 kgf•m, 18 lb•ft) (4)

(4)
T.R
.

New
12

(7) 13

New M

12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R

14 15 16
.

Order Job/Parts to remove Q’ty Remarks

12 Intake camshaft sprocket 1
13 Exhaust camshaft sprocket 1
14 Dowel pin 1
15 Timing chain guide (intake side) 1
16 Timing chain 1

5-18
 CAMSHAFTS

EAS30256
4. Remove:
REMOVING THE CAMSHAFTS
• Camshaft cap
1. Remove:
• Intake camshaft cap
• Timing mark accessing bolt “1”
• Exhaust camshaft cap
• Crankshaft end cover “2” ECA13720

NOTICE
2 To prevent damage to the cylinder head,
1 camshafts or camshaft caps, loosen the
camshaft cap bolts in stages and in a criss-
cross pattern, working from the outside in.
5. Remove:
• Intake camshaft “1”
• Exhaust camshaft “2”
TIP
2. Align: To prevent the timing chain from falling into the
• Mark “a” on the generator rotor crankcase, fasten it with a wire “3”.
(with the generator rotor cover mark “b”)
a. Turn the crankshaft counterclockwise. 2
b. When piston #1 is at BTDC125° on the
compression stroke, align the BTDC125°
mark “a” on the generator rotor with the
generator rotor cover mark “b”.
TIP
BTDC125° on the compression stroke can be
found when the camshaft lobes are turned away
from each other. 1

3
6. Remove:
3. Remove: • Camshaft sprocket “1”
• Timing chain tensioner “1” TIP
• Timing chain tensioner gasket Use the camshaft wrench “2” and loosen the
camshaft sprocket bolt.

Camshaft wrench
90890-04162
Camshaft wrench
YM-04162
1

5-19
 CAMSHAFTS

4. Measure:
• Camshaft-journal-to-camshaft-cap clearance
Out of specification → Measure the camshaft
1 journal diameter.
2
Camshaft-journal-to-camshaft-
cap clearance limit
0.080 mm (0.0032 in)

a. Install the camshaft into the cylinder head

(without the camshaft caps).
EAS30257
b. Position strip of Plastigauge® “1” onto the
CHECKING THE CAMSHAFTS
camshaft journal as shown.
1. Check:
• Camshaft lobes
Blue discoloration/pitting/scratches → Re-
1
place the camshaft.
2. Measure:
• Camshaft lobe dimensions “a”
Out of specification → Replace the camshaft.

Camshaft lobe dimensions

Lobe height limit (Intake) G088947
35.590 mm (1.4012 in) c. Install the dowel pins and camshaft caps.
Lobe height limit (Exhaust) Refer to “INSTALLING THE CAMSHAFTS”
35.620 mm (1.4024 in) on page 5-22.
TIP
Do not turn the camshaft when measuring the
camshaft journal-to-camshaft cap clearance
with the Plastigauge®.
d. Remove the camshaft caps, and then mea-
sure the width of the Plastigauge® “1”.

G088946 1
3. Measure:
• Camshaft runout
Out of specification → Replace.

Camshaft runout limit

0.030 mm (0.0012 in)
G088948

5. Measure:
• Camshaft journal diameter “a”
Out of specification → Replace the camshaft.
Within specification → Replace the cylinder
head and the camshaft caps as a set.

Camshaft journal diameter

24.459–24.472 mm (0.9630–
0.9635 in)

5-20
 CAMSHAFTS

a. Using the valve spring compressor “1”,

push and insert timing chain tensioner rod
“2” into the timing chain tensioner housing.
TIP
Push the timing chain tensioner rod in direction
“a”, and turn the timing chain tensioner body “3”
in direction “b” until the circlip fits into the groove.

G088949 a
1
EAS30258

CHECKING THE TIMING CHAIN AND

CAMSHAFT SPROCKET
1. Check:
• Timing chain 2
Damage/stiffness → Replace the timing
chain and camshaft and camshaft sprocket b 3
as a set.
2. Check:
• Camshaft sprocket
More than 1/4 tooth wear “a” → Replace the
camshaft sprockets and the timing chain as a
set. 1

1
a

b
b. Lock the timing chain tensioner rod by set-
ting the circlip “4” to groove “5” while push-
2
ing the timing chain tensioner rod.
G088950

a. 1/4 tooth 4
b. Correct

1. Timing chain
2. Camshaft sprocket
5
EAS30265

CHECKING THE TIMING CHAIN GUIDES

1. Check:
• Timing chain guide (intake side) c. Push the timing chain tensioner rod “c”.
• Timing chain guide (top side) d. If the circlip does not unlock even though
Damage/wear → Replace the defective you press the timing chain tensioner rod in
part(s). the “c” direction, rotate the timing chain ten-
EAS30266 sioner rod clockwise.
CHECKING THE TIMING CHAIN TENSIONER e. Make sure that the timing chain tensioner
1. Check: rod comes out “d” of the timing chain ten-
• Timing chain tensioner sioner housing smoothly. If there is rough
Cracks/damage/rough movement → Re- movement, replace the timing chain ten-
place. sioner.

5-21
 CAMSHAFTS

TIP
c • Install the camshaft projection “a” at the posi-
tion shown in the illustration.
• Tighten the camshaft sprocket bolt with the
camshaft wrench “3”.

Camshaft wrench
d 90890-04162
Camshaft wrench
YM-04162
EAS30269

INSTALLING THE CAMSHAFTS

1. Remove: 1 2
a
• Timing mark accessing bolt “1”
• Crankshaft end cover “2”

2
1

2. Align: 3
• Mark “a” on the generator rotor
(with the generator rotor cover mark “b”)
a. Turn the crankshaft counterclockwise.
b. When piston #1 is at BTDC125°, align the
mark “a” on the generator rotor with the
generator rotor cover mark “b”. 4. Install:
• Exhaust camshaft “1”
b
• Intake camshaft “2”
TIP
a
Make sure the punch mark “a” on each camshaft
faces up.

2 a

3. Install:
• Intake camshaft sprocket “1”
• Exhaust camshaft sprocket “2”
a
Camshaft sprocket bolt 1
24 N·m (2.4 kgf·m, 18 lb·ft)
T.
R.

5. Install:
• Camshaft cap
• Intake camshaft cap
• Exhaust camshaft cap

5-22
 CAMSHAFTS

TIP TIP
• Make sure each camshaft cap is installed in its Tighten the camshaft cap bolts in stage and in a
original place. Refer to the identification marks crisscross pattern, working from the inner caps
as follows: out.
“IL”: Intake left side camshaft cap mark ECA17430
“EL”: Exhaust left side camshaft cap mark NOTICE
• Make sure the arrow mark “a” on each cam- • Lubricate the camshaft cap bolts with the
shaft points toward the right side of the engine. engine oil.
• The camshaft cap bolts must be tightened
a evenly or damage to the cylinder head,
IL
camshaft caps, and camshafts will result.
• Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.

1
EL
a
6. Tighten:
• Camshaft cap bolt

Camshaft cap bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

1
TIP
8. Check:
Tighten the camshaft cap bolts in the tightening
• Camshaft punch mark “a”
sequence as shown.
Make sure the camshaft punch mark “a” on
ECA17430 the camshaft is aligned with the camshaft cap
NOTICE alignment mark “b”.
• Lubricate the camshaft cap bolts with the
engine oil. b
a
• The camshaft cap bolts must be tightened
evenly or damage to the cylinder head,
camshaft caps, and camshafts will result. b
• Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.
a

8 5 9. Install:
• Timing chain tensioner gasket New
2 3 • Timing chain tensioner
a. Using the valve spring compressor “1”,
4 1
push and insert timing chain tensioner rod
6 7 “2” into the timing chain tensioner housing.
TIP
7. Tighten: Push the timing chain tensioner rod in direction
• Camshaft cap bolt “1” “a”, and turn the timing chain tensioner body “3”
in direction “b” until the circlip fits into the groove.
Camshaft cap bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

5-23
 CAMSHAFTS

12.Check:
a • Mark “a”
1
Make sure the mark “a” on the generator rotor
is aligned with the generator rotor cover mark
“b”.
• Camshaft punch mark “c”
2
Make sure the camshaft punch mark “c” on
the camshaft is aligned with the camshaft cap
b 3 alignment mark “d”.
Out of alignment → Adjust.
Refer to the installation steps above.

b
1
a

b. Lock the timing chain tensioner rod by set-

ting the circlip “4” into groove “5” while d
pushing the timing chain tensioner rod. c

4 d

5 c

13.Measure:
• Valve clearance
c. Install the timing chain tensioner to the cyl- Out of specification → Adjust.
inder block. Refer to “ADJUSTING THE VALVE CLEAR-
TIP ANCE” on page 3-5.
Always use a new gasket. 14.Install:
• Timing mark accessing bolt “1”
Timing chain tensioner bolt Timing mark accessing bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft) 15 N·m (1.5 kgf·m, 11 lb·ft)
T.
R.

T.
R.

d. Turn the crankshaft clockwise several times • Crankshaft end cover “2”
to release the timing chain tensioner rod.
10.Turn: Crankshaft end cover
• Crankshaft 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

(several turns counterclockwise)

11.Confirm the timing chain tension properly.

5-24
 CAMSHAFTS

TIP
2 Install the ignition coils “1” in the direction shown
1 in the illustration.

15.Install:
• Timing chain guide (top side)
• Cylinder head cover gasket “1” New
• Cylinder head cover 1

Cylinder head cover bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

TIP
• Apply Three Bond No. 1541C® onto the mat-
ing surfaces of the cylinder head cover and cyl-
inder head cover gasket.
• After installing the cylinder head cover gasket
“1” to the cylinder head cover, cut off the “a”
section.

1 New

16.Install:
• Spark plug
• Ignition coil “1”

Spark plug
13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.

5-25
 CYLINDER HEAD

EAS20044

CYLINDER HEAD
Removing the cylinder head
10 N•m (1.0 kgf•m, 7.4 lb•ft) (8) 1st 20 N•m (2.0 kgf•m, 15 lb•ft)
E 2nd 30 N•m (3.0 kgf•m, 22 lb•ft)
15 N•m (1.5 kgf•m, 11 lb•ft) 15 N•m (1.5 kgf•m, 11 lb•ft)
*3rd
Specified angle 120°

10 N•m (1.0 kgf•m, 7.4 lb•ft)

1

New
15 N•m (1.5 kgf•m, 11 lb•ft)

2 4 3 New
6

* Following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque and the
specified angle.
Order Job/Parts to remove Q’ty Remarks
Engine Refer to “ENGINE REMOVAL” on page 5-9.
Intake camshaft Refer to “CAMSHAFTS” on page 5-16.
Exhaust camshaft Refer to “CAMSHAFTS” on page 5-16.
Timing chain Refer to “CAMSHAFTS” on page 5-16.
1 Coolant temperature sensor 1
2 Cylinder head 1
3 Cylinder head gasket 1
4 Dowel pin 2
5 Timing chain guide (exhaust side) 1
6 Stud bolt 6

5-26
 CYLINDER HEAD

EAS30276
3. Measure:
REMOVING THE CYLINDER HEAD
• Cylinder head warpage
1. Remove:
Out of specification → Resurface the cylinder
• Intake camshaft
head.
• Exhaust camshaft
Refer to “REMOVING THE CAMSHAFTS”
Warpage limit
on page 5-19. 0.10 mm (0.0039 in)
2. Remove:
• Cylinder head bolt (M6) (×4)
• Cylinder head bolt (M9) (×8)
TIP
• Loosen the bolts in the proper sequence as
shown.
• Loosen each bolt 1/2 of a turn at a time. After
all of the bolts are fully loosened, remove them.

G088955
5 11 9 7
1 4 a. Place a straightedge “1” and a thickness
gauge “2” across the cylinder head.

Thickness gauge
3 2 90890-03268
4
8 10 12 6 Feeler gauge set
YU-26900-9
8

EAS30278

CHECKING THE TIMING CHAIN GUIDE

1 2
(EXHAUST SIDE)
1. Check:
• Timing chain guide (exhaust side)
Damage/wear → Replace.
EAS30277

CHECKING THE CYLINDER HEAD

1. Eliminate: G088957
• Combustion chamber carbon deposits b. Measure the warpage.
(with a rounded scraper) c. If the limit is exceeded, resurface the cylin-
TIP der head as follows.
Do not use a sharp instrument to avoid damag- d. Place a 400–600 grit wet sandpaper on the
ing or scratching: surface plate and resurface the cylinder
• Spark plug bore threads head using a figure-eight sanding pattern.
• Valve seats TIP
2. Check: To ensure an even surface, rotate the cylinder
• Cylinder head head several times.
Damage/scratches → Replace.
• Cylinder head water jacket EAS30282

Mineral deposits/rust → Eliminate. INSTALLING THE CYLINDER HEAD

1. Install:
• Timing chain guide (exhaust side) “1”
• Cylinder head gasket “2” New
• Dowel pin “3”

5-27
 CYLINDER HEAD

4. Install:
3 2 New • Exhaust camshaft
• Intake camshaft
3 Refer to “INSTALLING THE CAMSHAFTS”
on page 5-22.

2. Install:
• Cylinder head
• Cylinder head bolt (M6) (×4)
• Cylinder head bolt (M9) (×8)
TIP
• Pass the timing chain through the timing chain
cavity.
• Lubricate the cylinder head bolt (M9) thread
and mating surface with engine oil.
3. Tighten:
• Cylinder head bolt “1”–“8”
• Cylinder head bolt “9”–“12”

Cylinder head bolt “1”–“8”

1st: 20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.

2nd: 30 N·m (3.0 kgf·m, 22 lb·ft)

*3rd: 15 N·m (1.5 kgf·m, 11 lb·ft)
Specified angle 120°
Cylinder head bolt “9”–“12”
10 N·m (1.0 kgf·m, 7.4 lb·ft)

* Following the tightening order, loosen the

bolt one by one and then retighten it to the
specified torque and the specified angle.
TIP
Tighten the cylinder head bolts “1”–“8” in the
tightening sequence as shown and torque them
in 3 stages.

8 2 4 6
12 9

10 11 4
5 3 1 7
8

5-28
 VALVES AND VALVE SPRINGS

EAS20045

VALVES AND VALVE SPRINGS

Removing the valves and valve springs

10
11 E
E
12
13 M M
14
M

New M
1
2
3
4
5
7 New
8

9
6

Order Job/Parts to remove Q’ty Remarks

Cylinder head Refer to “CYLINDER HEAD” on page 5-26.
1 Intake valve lifter 6
2 Intake valve pad 6
3 Intake valve cotter 12
4 Intake valve spring retainer 6
5 Intake valve spring 6
6 Intake valve 6
7 Intake valve stem seal 6
8 Intake valve spring seat 6
9 Intake valve guide 6
10 Exhaust valve lifter 6
11 Exhaust valve pad 6
12 Exhaust valve cotter 12
13 Exhaust valve spring retainer 6
14 Exhaust valve spring 6

5-29
 VALVES AND VALVE SPRINGS

Removing the valves and valve springs

E
E

M M

M
New 16
M
17

New

18

15

Order Job/Parts to remove Q’ty Remarks

15 Exhaust valve 6
16 Exhaust valve stem seal 6
17 Exhaust valve spring seat 6
18 Exhaust valve guide 6

5-30
 VALVES AND VALVE SPRINGS

EAS30283

REMOVING THE VALVES

Valve spring compressor
The following procedure applies to all of the 90890-04200
valves and related components. Valve spring compressor
TIP YM-04019
Before removing the internal parts of the cylinder Valve spring compressor attach-
head (e.g., valves, valve springs, valve seats), ment (ø23)
make sure the valves properly seal. 90890-04179
Valve spring compressor adapter
1. Remove: (ø23)
• Valve lifter YM-04179
• Valve pad
TIP
Make a note of the position of each valve lifter
and valve pad so that they can be reinstalled in
their original place.
2. Check:
• Valve sealing
Leakage at the valve seat → Check the valve
face, valve seat, and valve seat width.
G088959
Refer to “CHECKING THE VALVE SEATS”
on page 5-33. 4. Remove:
• Valve spring retainer
a. Pour a clean solvent “a” into the intake and
• Valve spring
exhaust ports.
• Valve
b. Check that the valves properly seal.
• Valve stem seal
TIP
• Valve spring seat
There should be no leakage at the valve seat “1”. TIP
Identify the position of each part very carefully so
that it can be reinstalled in its original place.

EAS30284

CHECKING THE VALVES AND VALVE

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

5-31
 VALVES AND VALVE SPRINGS

G088960 G088963

a. Valve guide position

c. After installing the valve guide, bore the
valve guide with the valve guide reamer “3”
to obtain the proper valve-stem-to-valve-
guide clearance.

G088961

2. Replace:
• Valve guide
TIP
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder G088964
head to 100 °C (212 °F) in an oven. TIP
a. Remove the valve guide with the valve After replacing the valve guide, reface the valve
guide remover “1”. seat.

Valve guide remover (ø4.5)

90890-04116
Valve guide remover (4.5 mm)
YM-04116
Valve guide installer (ø4.5)
90890-04117
Valve guide installer (4.5 mm)
YM-04117
G088962
Valve guide reamer (ø4.5)
b. Install the new valve guide with the valve 90890-04118
guide installer “2” and valve guide remover Valve guide reamer (4.5 mm)
“1”. YM-04118

Valve guide position 3. Eliminate:

13.3–13.7 mm (0.52–0.54 in) • Carbon deposits
(from the valve face and valve seat)
4. Check:
• Valve face
Pitting/wear → Grind the valve face.
• Valve stem end
Mushroom shape or diameter larger than the
body of the valve stem → Replace the valve.

5-32
 VALVES AND VALVE SPRINGS

5. Measure: a. Apply blue layout fluid “b” onto the valve

• Valve stem runout face.
Out of specification → Replace the valve.
TIP
• When installing a new valve, always replace
the valve guide.
• If the valve is removed or replaced, always re-
place the valve stem seal.

Valve stem runout

0.020 mm (0.0008 in) G088967

b. Install the valve into the cylinder head.

c. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
d. Measure the valve seat contact width.
TIP
Where the valve seat and valve face contacted
one another, the blue layout fluid will have been
removed.
G088965

EAS30285 4. Lap:
CHECKING THE VALVE SEATS • Valve face
The following procedure applies to all of the • Valve seat
valves and valve seats. TIP
1. Eliminate: After replacing the cylinder head or replacing the
• Carbon deposits valve and valve guide, the valve seat and valve
(from the valve face and valve seat) face should be lapped.
2. Check:
• Valve seat a. Apply a coarse lapping compound “a” to the
Pitting/wear → Replace the cylinder head. valve face.
3. Measure: ECA13790

• Valve seat contact width “a” NOTICE

Out of specification → Replace the cylinder Do not let the lapping compound enter the
head. gap between the valve stem and the valve
guide.
Valve seat contact width limit (in-
take)
1.6 mm (0.06 in)
Valve seat contact width limit
(exhaust)
1.8 mm (0.07 in)

G088968

b. Apply molybdenum disulfide oil onto the

valve stem.
c. Install the valve into the cylinder head.

G088966

5-33
 VALVES AND VALVE SPRINGS

d. Turn the valve until the valve face and valve EAS30286

CHECKING THE VALVE SPRINGS

seat are evenly polished, then clean off all
The following procedure applies to all of the
of the lapping compound.
valve springs.
TIP
1. Measure:
For the best lapping results, lightly tap the valve • Valve spring free length “a”
seat while rotating the valve back and forth be- Out of specification → Replace the valve
tween your hands. spring.
ECA27780

NOTICE
When replacing even one light green ex-
haust valve spring, replace all six exhaust
valve springs as a set.

Free length limit (intake)

39.18 mm (1.54 in)
Free length limit (exhaust)
G088969
38.58 mm (1.52 in)
e. Apply a fine lapping compound to the valve
face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from
the valve face and valve seat.
g. Apply blue layout fluid “b” onto the valve
face.

G088971

EAS30287

CHECKING THE VALVE LIFTERS

The following procedure applies to all of the
valve lifters.
1. Check:
G088967 • Valve lifter
h. Install the valve into the cylinder head. Damage/scratches → Replace the valve lift-
i. Press the valve through the valve guide and ers and cylinder head.
onto the valve seat to make a clear impres- EAS30288
sion. INSTALLING THE VALVES
j. Measure the valve seat contact width “c” The following procedure applies to all of the
again. If the valve seat width is out of spec- valves and related components.
ification, reface and lap the valve seat. 1. Deburr:
• Valve stem end
(with an oil stone)

G088970

G088972

5-34
 VALVES AND VALVE SPRINGS

2. Lubricate:
• Valve stem
• Valve stem seal
(with the recommended lubricant)

Recommended lubricant
Molybdenum disulfide oil

3. Install:
• Valve spring seat “1” G088959

• Valve stem seal “2” New 5. To secure the valve cotters onto the valve
• Valve “3” stem, lightly tap the valve tip with a soft-face
• Valve spring “4” hammer.
ECA13800
• Valve spring retainer “5”
NOTICE
(into the cylinder head)
Hitting the valve tip with excessive force
TIP
could damage the valve.
• Make sure each valve is installed in its original
place.
• Install the valve springs with the larger pitch “a”
facing up.

G088975

6. Lubricate:
• Valve pad
(with the recommended lubricant)
G088973

b. Smaller pitch Recommended lubricant

4. Install: Molybdenum disulfide oil
• Valve cotter
• Valve lifter
TIP (with the recommended lubricant)
Install the valve cotters by compressing the
valve spring with the valve spring compressor Recommended lubricant
“1” and the valve spring compressor attachment Engine oil
“2”.
7. Install:
• Valve pad
Valve spring compressor • Valve lifter
90890-04200
TIP
Valve spring compressor
YM-04019 • The valve lifter must move smoothly when ro-
Valve spring compressor attach- tated with a finger.
ment (ø23) • Each valve lifter and valve pad must be rein-
90890-04179 stalled in its original position.
Valve spring compressor adapter
(ø23)
YM-04179

5-35
 GENERATOR AND STARTER CLUTCH

EAS20140

GENERATOR AND STARTER CLUTCH

Removing the stator coil, generator rotor and starter clutch

E
E
New
E New
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
75 N•m (7.5 kgf•m, 55 lb•ft) (3) New 2
5 New
32 N•m (3.2 kgf•m, 24 lb•ft) 1
LT
15 N•m (1.5 kgf•m, 11 lb•ft)

3
*
(6) (3) LT
4
12 N•m (1.2 kgf•m, 8.9 lb•ft)

LT
New
11 N•m (1.1 kgf•m, 8.1 lb•ft)
LT LT
10 N•m (1.0 kgf•m, 7.4 lb•ft)

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

Order Job/Parts to remove Q’ty Remarks
Refer to “GENERAL CHASSIS (1)” on
Rider seat page 4-1.
Refer to “GENERAL CHASSIS (1)” on
Fuel tank center cover/Air scoop page 4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Water pump Refer to “WATER PUMP” on page 6-11.
Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-29.
1 Stator coil coupler 1 Disconnect.
2 Crankshaft position sensor coupler 1 Disconnect.
3 Shift sensor lead bracket 3
4 Generator cover 1
5 Generator cover gasket 1

5-36
 GENERATOR AND STARTER CLUTCH

Removing the stator coil, generator rotor and starter clutch

E
14
13 12
E 6

10
11 6
9
E
E
New
E New
10 N•m (1.0 kgf•m, 7.4 lb•ft)
17

T.R
.
75 N•m (7.5 kgf•m, 55 lb•ft) (3) New
32 N•m (3.2 kgf•m, 24 lb•ft) LT New
15 N•m (1.5 kgf•m, 11 lb•ft)
16
*
(6) 15 7 (3) LT

12 N•m (1.2 kgf•m, 8.9 lb•ft)

LT
New 8
11 N•m (1.1 kgf•m, 8.1 lb•ft)
LT LT
10 N•m (1.0 kgf•m, 7.4 lb•ft)

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

Order Job/Parts to remove Q’ty Remarks
6 Dowel pin 2
7 Stator coil lead holder 1
Stator coil assembly (stator coil/crankshaft posi-
8 1
tion sensor)
9 Generator rotor 1
10 Starter clutch 1
11 Starter clutch gear 1
12 Woodruff key 1
13 Starter clutch idle gear shaft 1
14 Starter clutch idle gear 1
15 Crankshaft end cover 1
16 Timing mark accessing bolt 1
17 Water pump outlet pipe 1

5-37
 GENERATOR AND STARTER CLUTCH

EAS30867

REMOVING THE GENERATOR

1. Remove:
• Generator rotor bolt “1”
• Washer 1
TIP 2
While holding the generator rotor “2” with the
sheave holder “3”, loosen the generator rotor
bolt.

EAS30868
Sheave holder
90890-01903 REMOVING THE STARTER CLUTCH
Primary clutch holder 1. Remove:
YS-01880-A • Starter clutch bolt
• Starter clutch
TIP
While holding the generator rotor “1” with the
sheave holder “2”, loosen the starter clutch
bolts.

3 Sheave holder
90890-01903
2 Primary clutch holder
1 YS-01880-A
2. Remove:
• Generator rotor “1” 1
(with the flywheel puller “2”) 2
• Woodruff key
ECA13880

NOTICE
To protect the end of the crankshaft, place an
appropriate sized socket between the fly-
wheel puller set center bolt and the crank-
shaft.

TIP EAS30869

• Install the flywheel puller bolts to the threaded CHECKING THE STARTER CLUTCH
holes of the starter clutch. 1. Check:
• Make sure the flywheel puller is centered over • Starter clutch roller
the generator rotor. Damage/wear → Replace.
2. Check:
• Starter clutch idle gear
Flywheel puller • Starter clutch gear
90890-01362 Burrs/chips/roughness/wear → Replace the
Heavy duty puller defective part(s).
YU-33270-B
3. Check:
• Starter clutch gear contact surfaces
Damage/pitting/wear → Replace the starter
clutch gear.

5-38
 GENERATOR AND STARTER CLUTCH

4. Check:
• Starter clutch operation a
a. Install the starter clutch gear “1” onto the
generator rotor “2” and hold the generator
rotor.
b. When turning the starter clutch gear clock-
wise “A”, the starter clutch and the starter 1
clutch gear should engage, otherwise the
starter clutch is faulty and must be re- 2
placed.
c. When turning the starter clutch gear coun-
2
terclockwise “B”, it should turn freely, other- 3
wise the starter clutch is faulty and must be
replaced.
1
A

EAS30872

INSTALLING THE GENERATOR

B 1. Install:
G088978
2 • Woodruff key
• Generator rotor
EAS30871
• Washer New
INSTALLING THE STARTER CLUTCH
1. Install: • Generator rotor bolt
• Starter clutch “1” TIP
• Clean the tapered portion of the crankshaft and
Starter clutch bolt the generator rotor hub.
32 N·m (3.2 kgf·m, 24 lb·ft) • When installing the generator rotor, make sure
T.
R.

LOCTITE® the woodruff key is properly seated in the key-

way of the crankshaft.
TIP • Lubricate the washer with engine oil.
• Install the starter clutch so that the side of the • Lubricate the generator rotor bolt threads and
starter clutch roller assembly with the arrow washer mating surfaces with engine oil.
mark “a” is toward the generator rotor “2”.
• While holding the generator rotor with the 2. Tighten:
sheave holder “3”, tighten the starter clutch • Generator rotor bolt “1”
bolts.
Generator rotor bolt
75 N·m (7.5 kgf·m, 55 lb·ft)
T.
R.

Sheave holder
90890-01903 TIP
Primary clutch holder While holding the generator rotor “2” with the
YS-01880-A sheave holder “3”, tighten the generator rotor
bolt.

Sheave holder
90890-01903
Primary clutch holder
YS-01880-A

5-39
 GENERATOR AND STARTER CLUTCH

5. Connect:
• Stator coil coupler
• Crankshaft position sensor coupler
TIP
To route the stator coil lead, refer to “CABLE
ROUTING” on page 2-15.
3

2
1
3. Apply:
• Sealant
(onto the stator coil assembly lead grommet)

Yamaha bond No. 1215

90890-85505
Three bond No. 1215®

G088980

4. Install:
• Generator cover gasket New
• Generator cover

Generator cover bolt “1”

12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.

LOCTITE®
Generator cover bolt “2”
12 N·m (1.2 kgf·m, 8.9 lb·ft)

TIP
Tighten the generator cover bolts in stages and
in a crisscross pattern.

5-40
 ELECTRIC STARTER

EAS20052

ELECTRIC STARTER
Removing the starter motor

LS
New 12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.
R.
2

7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

1 Starter motor lead 1 Disconnect.
2 Starter motor 1

5-41
 ELECTRIC STARTER

Disassembling the starter motor

11 N•m (1.1 kgf•m, 8.1 lb•ft)
7

New

6
3

4
5 New

5 New

1 New

New

5 N•m (0.5 kgf•m, 3.7 lb•ft)

Order Job/Parts to remove Q’ty Remarks

1 O-ring 1
2 Starter motor front cover 1
3 Starter motor yoke 1
4 Armature assembly 1
5 Gasket 2
6 Brush holder set 1
7 Starter motor rear cover 1

5-42
 ELECTRIC STARTER

EAS30325
4. Measure:
CHECKING THE STARTER MOTOR
• Brush length “a”
1. Check:
Out of specification → Replace the brush
• Commutator
holder set.
Dirt → Clean with 600 grit sandpaper.
2. Measure:
Brush overall length limit
• Mica undercut “a” 6.5 mm (0.26 in)
Out of specification → Scrape the mica to the
proper measurement with a hacksaw blade
that has been grounded to fit the commutator.

Mica undercut (depth)

0.70 mm (0.03 in)

TIP
The mica of the commutator must be undercut to
ensure proper operation of the commutator.
G088989

5. Check:
• Gear teeth
Damage/wear → Replace the starter motor
assembly.
6. Check:
• Bearing
• Oil seal
Damage/wear → Replace the starter motor
G088986
assembly.
3. Check: EAS30326

• Armature assembly ASSEMBLING THE STARTER MOTOR

a. Connect the digital circuit tester and check 1. Install:
the continuity. • Brush holder set
• Insulator “1”
Digital circuit tester (CD732) TIP
90890-03243 Install the insulator as shown in the illustration.
Model 88 Multimeter with ta-
chometer
YU-A1927 1

b. If there is no continuity, replace the starter

motor.

2. Install:
• Starter motor rear cover “1”
• Starter motor yoke “2”
• Starter motor front cover “3”
TIP
Align the match marks “a” on the starter motor
yoke with the match marks “b” on the front and
rear cover.

5-43
 ELECTRIC STARTER

b a b

1 2 3
EAS30327

INSTALLING THE STARTER MOTOR

1. Install:
• Starter motor
• Starter motor bolt
TIP
Tighten the starter motor bolts in the tightening
sequence as shown.

Starter motor bolt

12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.

1
2

2. Connect:
• Starter motor lead

Starter motor lead nut

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.

5-44
 CLUTCH

EAS20055

CLUTCH
Removing the clutch cover
1
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
12 N•m (1.2 kgf•m, 8.9 lb•ft)
4 New
T.R
.

1.5 N•m (0.15 kgf•m, 1.1 lb•ft)

T.R

5
.

5
New

6
(8) 3
2 LS
47.1–54.8 mm
12 N•m (1.2 kgf•m, 8.9 lb•ft) (1.85–2.16 in)
T.R
.

12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-29.
1 Clutch cable 1 Disconnect.
2 Cover 1
3 Clutch cover 1
4 Clutch cover gasket 1
5 Dowel pin 2
6 Oil filler cap 1

5-45
 CLUTCH

Removing the pull lever shaft

4 New

0 mm (0 in)

8
7
New 6

0 mm (0 in)
5
E

3
LS

1 New 2

Order Job/Parts to remove Q’ty Remarks

1 Circlip 1
2 Pull lever 1
3 Pull lever spring 1
4 Circlip 1
5 Pull lever shaft 1
6 Oil seal 1
7 Bearing 1
8 Bearing 1

5-46
 CLUTCH

Removing the clutch

125 N•m (12.5 kgf•m, 92 lb•ft)

11 10
E

11
6 10

9
12 New
14 13
6

E
4 8
5

E 3 2 7
1
42.7–43.5 mm(1.68–1.71 in)

10 N•m (1.0 kgf•m, 7.4 lb•ft)

Order Job/Parts to remove Q’ty Remarks

Oil pump driven sprocket Refer to “OIL PUMP” on page 5-57.
1 Pressure plate 1 1
2 Clutch spring 3
3 Pressure plate 2 1
4 Pull rod 1
5 Bearing 1
6 Friction plate 2 3 Inside diameter: 126 mm (4.96 in)
7 Clutch plate 1 1 Inside diameter: 116 mm (4.57 in)
8 Clutch plate 2 7 Inside diameter: 105 mm (4.13 in)
9 Friction plate 1 6 Inside diameter: 119 mm (4.69 in)
10 Clutch damper spring 1
11 Clutch damper spring seat 1
12 Clutch boss nut 1
13 Conical spring washer 1
14 Washer 1

5-47
 CLUTCH

Removing the clutch

125 N•m (12.5 kgf•m, 92 lb•ft)

22 20
E
21
19
18 17

E 16 15

New

42.7–43.5 mm(1.68–1.71 in)

10 N•m (1.0 kgf•m, 7.4 lb•ft)

Order Job/Parts to remove Q’ty Remarks

15 Clutch boss 1
16 Thrust plate 1
17 Clutch housing 1
18 Oil pump drive chain 1
19 Bearing 1
20 Spacer 1
21 Thrust plate 1
22 Thrust plate 1

5-48
 CLUTCH

EAS30346
4. Remove:
REMOVING THE CLUTCH
• Friction plate 2 “1”
1. Remove:
• Cover “1”
• Clutch cover “2”
• Gasket
TIP
Loosen each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern.
After all of the bolts are fully loosened, remove
them.
1

1 5. Remove:
• Clutch plate 1 “1”
• Clutch plate 2
• Friction plate 1
• Clutch damper spring
• Clutch damper spring seat

2
2. Remove:
• Oil pump driven sprocket “1”
Refer to “OIL PUMP” on page 5-57.

6. Straighten the clutch boss nut rib “a”.

1
3. Remove:
• Clutch spring bolt “1”
• Pressure plate 1 “2”
• Clutch spring G088992
• Pressure plate 2 “3” 7. Loosen:
• Pull rod “4” • Clutch boss nut “1”
4 TIP
While holding the clutch boss “2” with the univer-
1 sal clutch holder “3”, loosen the clutch boss nut.

Clutch holder
3 1 90890-04199
Universal clutch holder
2 YM-91042

5-49
 CLUTCH

A. Friction plate 1
B. Friction plate 2
3 1 EAS30349

CHECKING THE CLUTCH PLATES

The following procedure applies to all of the
clutch plates.
1. Check:
2 • Clutch plate 1, 2
G088993 Damage → Replace the clutch plates as a
8. Remove: set.
• Clutch boss nut 2. Measure:
• Conical spring washer • Clutch plate 1, 2 thickness
• Washer (with a surface plate and thickness gauge)
• Clutch boss Out of specification → Replace the clutch
• Thrust plate plates as a set.
• Clutch housing
• Oil pump drive chain Thickness gauge
90890-03268
EAS30348 Feeler gauge set
CHECKING THE FRICTION PLATES YU-26900-9
The following procedure applies to all of the fric-
tion plates.
1. Check: Clutch plate 1 thickness
• Friction plate 1, 2 2.18–2.42 mm (0.086–0.095 in)
Damage/wear → Replace the friction plates Warpage limit
0.10 mm (0.004 in)
as a set.
Clutch plate 2 thickness
2. Measure:
1.90–2.10 mm (0.075–0.083 in)
• Friction plate 1, 2 thickness
Warpage limit
Out of specification → Replace the friction 0.10 mm (0.004 in)
plates as a set.
TIP 3. Measure:
Measure the friction plate at four places. • Assembly width “a” of the friction plates and
clutch plates
Out of specification → Adjust.
Friction plate 1 thickness
2.92–3.08 mm (0.115–0.121 in) Assembly width
Wear limit 42.7–43.5 mm (1.68–1.71 in)
2.82 mm (0.111 in)
Friction plate 2 thickness TIP
2.92–3.08 mm (0.115–0.121 in) • Perform the thickness measurement without
Wear limit applying the oil.
2.82 mm (0.111 in)
• This step should be performed only if the fric-
tion plates and clutch plates were replaced.
• To measure the total width of the friction plates
and clutch plates, combine 9 friction plates and
8 clutch plates as shown.

5-50
 CLUTCH

2. Measure:
• Clutch spring free length
Out of specification → Replace the clutch
a springs as a set.

a Clutch spring free length limit

42.53 mm (1.67 in)

EAS30352

CHECKING THE CLUTCH HOUSING

1. Check:
a. Assembly width adjusted by clutch plate 2
• Clutch housing dogs
“1” and “2”.
Damage/pitting/wear → Deburr the clutch
b. Select the clutch plate 2 from the following
housing dogs or replace the clutch housing.
table.
TIP
Clutch plate 2 “1” Pitting on the clutch housing dogs will cause er-
BR9-16324-00 1.6 mm (0.063 in) ratic clutch operation.
5VY-16325-00 2.0 mm (0.079 in) STD
4B1-16325-00 2.3 mm (0.091 in)

Clutch plate 2 “2”

BR9-16324-00 1.6 mm (0.063 in)
5VY-16325-00 2.0 mm (0.079 in) STD
4B1-16325-00 2.3 mm (0.091 in)
G088994
TIP 2. Check:
When adjusting the clutch assembly width [by • Oil pump drive sprocket “1”
replacing the clutch plate(s)], be sure to replace Cracks/damage/wear → Replace the oil
the clutch plate 2 “1” first. pump drive chain and clutch housing as a set.
After replacing the clutch plate 2 “1”, if specifica-
tions cannot be met, replace the clutch plate 2 1
“2”.

3. Check:
• Bearing
Damage/wear → Replace the bearing and
2 1 clutch housing.
EAS30351 EAS30353

CHECKING THE CLUTCH SPRINGS CHECKING THE CLUTCH BOSS

The following procedure applies to all of the 1. Check:
clutch springs. • Clutch boss splines
1. Check: Damage/pitting/wear → Replace the clutch
• Clutch spring boss.
Damage → Replace the clutch springs as a
set.

5-51
 CLUTCH

EAS30363
TIP
INSTALLING THE CLUTCH
Pitting on the clutch boss splines will cause er- 1. Install:
ratic clutch operation. • Oil pump drive chain “1”
• Clutch housing “2”
TIP
Install the oil pump drive chain onto the oil pump
drive sprocket “a”.

G088995

EAS30354

CHECKING THE PRESSURE PLATE

1. Check:
• Pressure plate 1 a 1
• Pressure plate 2
2. Install:
Cracks/damage → Replace.
• Thrust plate
• Bearing
• Clutch boss “1”
Damage/wear → Replace.
• Washer
EAS30356 • Conical spring washer “2”
CHECKING THE PRIMARY DRIVE GEAR • Clutch boss nut “3” New
1. Check:
• Primary drive gear Clutch boss nut
Damage/wear → Replace the crankshaft and 125 N·m (12.5 kgf·m, 92 lb·ft)
T.

clutch housing as a set.

R.

Excessive noise during operation → Replace TIP

the crankshaft and clutch housing as a set. • Install the conical spring washer on the main
EAS30357 axle with the “OUT” mark “a” facing away from
CHECKING THE PRIMARY DRIVEN GEAR the vehicle.
1. Check: • While holding the clutch boss “1” with the uni-
• Primary driven gear versal clutch holder “4”, tighten the clutch boss
Damage/wear → Replace the clutch housing nut.
and crankshaft as a set. • Stake the clutch boss nut at cutouts “b” in the
Excessive noise during operation → Replace main axle.
the clutch housing and crankshaft as a set.
EAS30358 Clutch holder
CHECKING THE PULL LEVER SHAFT AND 90890-04199
PULL ROD Universal clutch holder
1. Check: YM-91042
• Pull lever shaft pinion gear teeth
• Pull rod teeth
Damage/wear → Replace the pull rod and
pull lever shaft as a set.
2. Check:
• Pull rod bearing
Damage/wear → Replace.

5-52
 CLUTCH

3 New Clutch spring bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.
R.
4 1
• Oil pump driven sprocket “2”

2 Oil pump driven sprocket bolt

15 N·m (1.5 kgf·m, 11 lb·ft)

T.
R.
LOCTITE®
a TIP
• Tighten the clutch spring bolts in stages and in
b a crisscross pattern.
• Apply lithium-soap-based grease onto the pull
rod.
• Position the pull rod so that the teeth “a” face
towards the hole “b”. Then, install the clutch
cover.

3. Install:
• Clutch damper spring seat 1
• Clutch damper spring
• Friction plate 2
• Clutch plate 2 1
• Friction plate 1
• Clutch plate 1
TIP
• First, install a friction plate and then alternate
between a clutch plate and a friction plate.
• Install the last friction plate “1” offset from the
other friction plates “2”, making sure to align a
projection on the friction plate with the punch
mark “a” on the clutch housing. a

2
b
2 5. Install:
• Dowel pin
• Clutch cover gasket New
a
• Clutch cover
• Cover
1
4. Install: Clutch cover bolt
• Pull rod 12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.

• Pressure plate 2
• Clutch spring TIP
• Pressure plate 1 • Apply engine oil onto the bearing.
• Clutch spring bolt “1” • Tighten the clutch cover bolts in stages and in
a crisscross pattern.

5-53
 CLUTCH

6. Install: 8. Adjust:
• Pull lever • Clutch lever free play
TIP Refer to “ADJUSTING THE CLUTCH LEVER
• Install the pull lever with the “O” mark “a” facing FREE PLAY” on page 3-12.
toward lower side.
• When installing the pull lever, push the pull le- Clutch lever free play
ver and check that the punch mark “a” on the 5.0–10.0 mm (0.20–0.39 in)
pull lever aligns with the mark “b” on the clutch
cover. Make sure that the pull rod teeth and
pull lever shaft pinion gear are engaged.

a
b

7. Connect:
• Clutch cable “1”
TIP
• For the clutch cable “1”, turn the nut “2” in fully
and then adjust the length “a” by using the nut
“3” so that the cable length is 47.1–54.8 mm
(1.85–2.16 in).
• Measure the length while keeping the measur-
ing surface “b” parallel.
• After installing the clutch cable, bend the pro-
jection “c” on the pull lever.

c
a
2

3
b
1

5-54
 SHIFT SHAFT

EAS20057

SHIFT SHAFT
Removing the shift shaft and stopper lever

0.60-1.10 mm
(0.02-0.04 in)

12 New
13
2

LT

1 New
E
LS
8
New 11
22 N•m (2.2 kgf•m, 16 lb•ft)
T.
R.

4
5
6
7
E 9 3
10
E E

Order Job/Parts to remove Q’ty Remarks

Clutch assembly Refer to “CLUTCH” on page 5-45.
Shift arm Refer to “CHAIN DRIVE” on page 4-102.
1 Circlip 1
2 Washer 1
3 Shift shaft 1
4 Washer 1
5 Circlip 1
6 Washer 1
7 Stopper lever 1
8 Stopper lever spring 1
9 Collar 1
10 Shift shaft spring 1
11 Shift shaft spring stopper 1
12 Oil seal 1
13 Bearing 1

5-55
 SHIFT SHAFT

EAS30377
TIP
CHECKING THE SHIFT SHAFT
1. Check: Lubricate the oil seal lips with lithium-soap-
• Shift shaft based grease.
Bends/damage/wear → Replace.
• Shift shaft spring
• Collar
Damage/wear → Replace.
EAS30378 2
CHECKING THE STOPPER LEVER 1
1. Check:
• Stopper lever
Bends/damage → Replace.
Roller turns roughly → Replace the stopper
lever.
EAS30381

INSTALLING THE SHIFT SHAFT

1. Install:
• Shift shaft spring stopper “1”
• Shift shaft assembly
• Stopper lever spring “2”

Shift shaft spring stopper

22 N·m (2.2 kgf·m, 16 lb·ft)
T.
R.

LOCTITE®

TIP
• Hook the end of the shift shaft spring “3” onto
the shift shaft spring stopper “1”.
• Hook the ends of the stopper lever spring “2”
onto the stopper lever “4” and the crankcase
boss “5”.
• Mesh the stopper lever with the shift drum seg-
ment assembly.

3
1
4
5

2. Install:
• Bearing
• Oil seal New
• Washer “1”
• Circlip “2” New

5-56
 OIL PUMP

EAS20054

OIL PUMP
Removing the oil pump

D
FW

LT

10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
1
T
LL
T

15 N•m (1.5 kgf•m, 11 lb•ft)

T.R
.

LT
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.

Order Job/Parts to remove Q’ty Remarks

Clutch cover Refer to “CLUTCH” on page 5-45.
1 Oil pump driven sprocket 1
2 Oil pump assembly 1

5-57
 OIL PUMP

Disassembling the oil pump

T.R
.
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
6
1

3
8
2

4
5
9

E
9

Order Job/Parts to remove Q’ty Remarks

1 Oil pump cover 1
2 Oil pump shaft 1
3 Pin 1
4 Oil pump inner rotor 1
5 Oil pump outer rotor 1
6 Washer 1
7 Spring 1
8 Relief valve 1
9 Dowel pin 2

5-58
 OIL PUMP

EAS30336

CHECKING THE SPROCKET AND CHAIN

1. Check:
• Oil pump drive sprocket
Refer to “CHECKING THE CLUTCH HOUS- 1
ING” on page 5-51.
2. Check:
• Oil pump drive chain 2
Damage/stiffness → Replace the oil pump
drive chain and oil pump drive sprocket
(clutch housing) as a set.
EAS30342

EAS30337 ASSEMBLING THE OIL PUMP

CHECKING THE OIL PUMP 1. Lubricate:
1. Check: • Inner rotor
• Oil pump driven sprocket • Outer rotor
Cracks/damage/wear → Replace the oil • Oil pump shaft
pump drive chain and oil pump driven sprock-
et as a set. Recommended lubricant
• Oil pump housing Engine oil
• Oil pump cover
• Oil pump shaft 2. Install:
• Oil pump inner rotor • Outer rotor “1”
• Oil pump outer rotor • Inner rotor “2”
Cracks/damage/wear → Replace the oil • Pin “3”
pump assembly. • Oil pump cover “4”
2. Check: • Oil pump cover screw
• Oil pump operation
Rough movement → Replace the oil pump Oil pump cover screw
assembly. 3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
T.
R.

TIP
Align the pin “3” in the oil pump shaft with the
groove in the inner rotor “2”.

2
G088997
1
4
EAS30338

CHECKING THE RELIEF VALVE

1. Check:
• Relief valve “1”
• Spring “2” 3. Check:
Damage/wear → Replace the oil pump as- • Oil pump operation
sembly. Refer to “CHECKING THE OIL PUMP” on
page 5-59.

5-59
 OIL PUMP

EAS30343

INSTALLING THE OIL PUMP

1. Install:
• Oil pump “1”
• Oil pump bolt “2”

Oil pump bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

• Oil pump driven sprocket “3”

Oil pump driven sprocket bolt

15 N·m (1.5 kgf·m, 11 lb·ft)
T.
R.

LOCTITE®
ECA20940

NOTICE
After installing the oil pump drive chain and
driven sprocket, make sure the oil pump
turns smoothly.

TIP
• 1RC mark of the oil pump driven sprocket is in-
stalled at oil pump side.
• Install the oil pump drive chain onto the oil
pump driven sprocket.

2
3

2 1

5-60
 OIL PAN

EAS20177

OIL PAN
Removing the oil pan

FW
D

43 N•m (4.3 kgf•m, 32 lb•ft)

T.R
.

New

New 2

New

(15)
LT
LT

LT
3
13 N•m (1.3 kgf•m, 9.6 lb•ft) 10 N•m (1.0 kgf•m, 7.4 lb•ft) 10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R

T.R

T.R
.

Order Job/Parts to remove Q’ty Remarks

Muffler assembly Refer to “ENGINE REMOVAL” on page 5-9.
Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-29.
1 Oil pan 1
2 Oil pan gasket 1
3 Oil strainer 1

5-61
 OIL PAN

EAS31068

REMOVING THE OIL PAN

1. Remove:
• Oil pan
• Oil pan gasket
TIP
Loosen each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern. After all of the
bolts are fully loosened, remove them.

EAS31069

CHECKING THE OIL STRAINER

1. Check:
• Oil strainer
Damage → Replace.
Contaminants → Clean with solvent.
EAS31070

INSTALLING THE OIL PAN

1. Install:
• Oil pan gasket New
• Oil pan

Oil pan bolt

13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.

LOCTITE®

TIP
Tighten the oil pan bolts in stages and in a criss-
cross pattern.
2. Install:
• Gasket New
• Engine oil drain bolt

Engine oil drain bolt

43 N·m (4.3 kgf·m, 32 lb·ft)
T.
R.

5-62
 CRANKCASE

EAS20059

CRANKCASE
Separating the crankcase
10 N•m (1.0 kgf•m, 7.4 lb•ft) 1st 25 N•m (2.5 kgf•m, 18 lb•ft)

T.R
.
New 20 N•m (2.0 kgf•m, 15 lb•ft)

T.R
*2nd

.
1st 25 N•m (2.5 kgf•m, 18 lb•ft) Specified angle 60°
16 N•m (1.6 kgf•m, 12 lb•ft) New (2)
T.R

*2nd
.

22 N•m (2.2 kgf•m, 16 lb•ft)

Specified angle 60° (4)

T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft) E 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
T.R
.

24 N•m (2.4 kgf•m, 18 lb•ft) (6) New

T.R
.

E E E 13 N•m (1.3 kgf•m, 9.6 lb•ft)

T.R
.
(2)
(2) **
E
LS
(12)
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
E

17 N•m (1.7 kgf•m, 13 lb•ft)

T.R
.
LS

LS
E

New 70 N•m (7.0 kgf•m, 52 lb•ft)

T.R
.

LT
LT
New
LT

LT
T
LL
T 12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
.

4.0 N•m (0.40 kgf•m, 3.0 lb•ft) 17 N•m (1.7 kgf•m, 13 lb•ft)
T.R

T.R
.

* Following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque and the
specified angle.
** YAMAHA Bond No. 1215B®
Order Job/Parts to remove Q’ty Remarks
Engine Refer to “ENGINE REMOVAL” on page 5-9.
Cylinder head Refer to “CYLINDER HEAD” on page 5-26.
Water pump Refer to “WATER PUMP” on page 6-11.
Oil cooler Refer to “OIL COOLER” on page 6-7.
Water jacket joint Refer to “OIL COOLER” on page 6-7.
Thermostat assembly Refer to “THERMOSTAT” on page 6-9.
Refer to “GENERATOR AND STARTER
Starter clutch CLUTCH” on page 5-36.
Refer to “ELECTRIC STARTER” on page 5-
Starter motor 41.
Clutch housing Refer to “CLUTCH” on page 5-45.
Oil strainer Refer to “OIL PAN” on page 5-61.

5-63
 CRANKCASE

Separating the crankcase

10 N•m (1.0 kgf•m, 7.4 lb•ft) 1st 25 N•m (2.5 kgf•m, 18 lb•ft)

T.R
.
New 20 N•m (2.0 kgf•m, 15 lb•ft)

T.R
*2nd

.
1st 25 N•m (2.5 kgf•m, 18 lb•ft) Specified angle 60°
16 N•m (1.6 kgf•m, 12 lb•ft) New (2)
T.R

*2nd
.

22 N•m (2.2 kgf•m, 16 lb•ft)

Specified angle 60° (4)

T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft) E 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
T.R
.

24 N•m (2.4 kgf•m, 18 lb•ft) (6) New 3

T.R
.

4
E E E 13 N•m (1.3 kgf•m, 9.6 lb•ft)

T.R
.
(2)
(2) **
E
LS
(12)
8 10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
2 E
9 9
17 N•m (1.7 kgf•m, 13 lb•ft)

T.R
.
9
1
LS

5 LS
E

New 70 N•m (7.0 kgf•m, 52 lb•ft)

T.R
.

7
LT
LT
New
LT

LT
6 T
LL
T 12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
.

4.0 N•m (0.40 kgf•m, 3.0 lb•ft) 17 N•m (1.7 kgf•m, 13 lb•ft)
T.R

T.R
.

* Following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque and the
specified angle.
** YAMAHA Bond No. 1215B®
Order Job/Parts to remove Q’ty Remarks
1 Oil filter cartridge 1
2 Oil filter cartridge union bolt 1
3 Oil pressure switch 1
4 Oil pressure switch joint 1
5 Gear position sensor 1
6 Neutral switch 1
7 Clutch cable holder 1
8 Lower crankcase 1
9 Dowel pin 3

5-64
 CRANKCASE

EAS30389 EAS30390

DISASSEMBLING THE CRANKCASE CHECKING THE CRANKCASE

1. Place the engine upside down. 1. Thoroughly wash the crankcase halves in a
2. Remove: mild solvent.
• Crankcase bolt (×31) 2. Thoroughly clean all the gasket surfaces and
TIP crankcase mating surfaces.
• Loosen each bolt 1/4 of a turn at a time, in stag- 3. Check:
es and in a crisscross pattern. After all of the • Crankcase
bolts are fully loosened, remove them. Cracks/damage → Replace.
• Loosen the bolts in the proper sequence as • Oil delivery passages
shown. Obstruction → Blow out with compressed air.
• The numbers embossed on the crankcase in- EAS30397

dicate the crankcase tightening sequence. ASSEMBLING THE CRANKCASE

1. Lubricate:
• Crankshaft journal bearing inner surface
(with the recommended lubricant)
13 12 7
11 9 8 Recommended lubricant
10
17 23 20 Engine oil
22 21 2. Apply:
25 31 29 27 • Sealant
(onto the crankcase mating surfaces)
14 24 28 30 26
Yamaha bond No. 1215
19 6 16 90890-85505
15 Three bond No. 1215®

2 TIP
1 3 4 5 18 • Do not allow any sealant to come into contact
with the oil gallery or crankshaft journal bear-
ings, or balancer shaft journal bearings.
• Make sure that the sealant does not get into
31
the groove “a” in the crankcase.
3. Remove:
• Lower crankcase
ECA13900

NOTICE
Tap on one side of the crankcase with a soft-
face hammer. Tap only on reinforced por-
tions of the crankcase, not on the crankcase
mating surfaces. Work slowly and carefully
and make sure the crankcase halves sepa-
rate evenly.
4. Remove:
• Dowel pin
5. Remove:
• Crankshaft journal lower bearing
• Balancer shaft journal bearing
(from the lower crankcase)
TIP
Identify the position of each part very carefully so
that it can be reinstalled in its original place. a

5-65
 CRANKCASE

3. Install:
• Dowel pin
4. Set the shift drum assembly and transmission
19 20 25
gears in the neutral position. 21
5. Install: 22 23 24
15 9 12
• Lower crankcase “1”
(onto the upper crankcase “2”) 10 11
ECA13980

NOTICE
7 1 3 5
Before tightening the crankcase bolts, make 18 8 4 2 6
sure the transmission gears shift correctly
when the shift drum assembly is turned by
26 16
hand. 17
13
30
1
31 29 28 27 14

2
31
7. Tighten:
• Crankcase bolt “1”–“8”

Crankcase bolts “1”–“6”

6. Install: 1st: 25 N·m (2.5 kgf·m, 18 lb·ft)
T.

• Crankcase bolt (×31)

R.

*2nd: 16 N·m (1.6 kgf·m, 12 lb·ft)

TIP Specified angle 60°
• Lubricate the bolts “1”–“8” thread, mating sur- Crankcase bolts “7”–“8”
faces and washers with engine oil. 1st: 25 N·m (2.5 kgf·m, 18 lb·ft)
• Lubricate the bolts “9”–“12” thread, mating sur- *2nd: 20 N·m (2.0 kgf·m, 15 lb·ft)
faces and O-rings with engine oil. Specified angle 60°
• Lubricate the bolts “13”–“31” thread and mat- * Following the tightening order, loosen the
ing surfaces with engine oil. bolt one by one and then retighten it to the
• M9 × 100 mm (3.94 in) bolt with washer: “7”, specified torque and the specified angle.
EWA16610
“8” New WARNING
• M9 × 85 mm (3.35 in) bolt with washer: “1”– If the bolt is tightened more than the speci-
“6” New fied angle, do not loosen the bolt and then re-
• M8 × 78 mm (3.07 in) bolt with new O-ring: tighten it. Instead, replace the bolt with a new
“9”–“12” one and perform the procedure again.
• M8 × 60 mm (2.36 in) bolt: “13”, “14”
• M6 × 85 mm (3.35 in) bolt: “18”
ECA20890

NOTICE
• M6 × 65 mm (2.56 in) bolt: “15”, “16”
• M6 × 65 mm (2.56 in) bolt: “26” Do not use a torque wrench to tighten the
• M6 × 50 mm (1.97 in) bolt: “17”, “19”–“21”, bolt to the specified angle.
“23”–“25”, “27”–“31” TIP
• M6 × 40 mm (1.57 in) bolt: “22”
Tighten the bolts in the tightening sequence cast
on the crankcase.

5-66
 CRANKCASE

EAS31071

INSTALLING THE OIL PRESSURE SWITCH

1. Install:
• Oil pressure switch “1”
• Oil pressure switch lead “2”

Oil pressure switch

7 1 3 5 13 N·m (1.3 kgf·m, 9.6 lb·ft)

T.
R.
Oil pressure switch lead bolt
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
8 4 2 6 TIP
• Apply Three Bond No. 1215B® to the threads
“a” of the oil pressure switch. However, do not
apply Three Bond No. 1215B® to the portion
“b” of the oil pressure switch.
• Install the oil pressure switch lead so that it is
routed within the range shown in the illustra-
tion.
8
8. Tighten:
• Crankcase bolt “9”–“31”
1
Crankcase bolts “9”–“12”
22 N·m (2.2 kgf·m, 16 lb·ft)
T.
R.

Crankcase bolts “13”–“14”

24 N·m (2.4 kgf·m, 18 lb·ft) a
Crankcase bolts “15”–“31” b
10 N·m (1.0 kgf·m, 7.4 lb·ft)

TIP 2
Tighten the bolts in the tightening sequence cast
on the crankcase.
26°

19 20 25
21 1
22 23 24
15 9 12
10 11
EAS31658

INSTALLING THE GEAR POSITION SENSOR

ECA22630

18 NOTICE
To prevent damage to the gear position sen-
26 16 sor, keep magnets (including any pickup tool
17 13 with a magnet, magnetized screwdrivers,
etc.) away from the gear position sensor.
30
1. Install:
31 29 28 27 14
• O-ring New
• Gear position sensor “1”

23

5-67
 CRANKCASE

Gear position sensor bolt

T.
R. 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
LOCTITE®

TIP
• Lubricate the O-ring with lithium-soap-based
grease.
• Fit the end “a” of the shift drum assembly into
the opening “b” in the gear position sensor “1”.

a
b

5-68
 CONNECTING RODS AND PISTONS

EAS20132

CONNECTING RODS AND PISTONS

Removing the connecting rods and pistons

1st 20 N·m (2.0 kgf·m, 15 lb·ft)

7
2nd Specified angle 180°

6 New
E 3
New
5

E
M
4
M 1 New 3 10

9
2
8
E E

Order Job/Parts to remove Q’ty Remarks

Lower crankcase Refer to “CRANKCASE” on page 5-63.
1 Connecting rod cap 3
2 Big end lower bearing 3
3 Piston pin clip 6
4 Piston pin 3
5 Piston 3
6 Connecting rod 3
7 Big end upper bearing 3
8 Top ring 3
9 2nd ring 3
10 Oil ring 3

5-69
 CONNECTING RODS AND PISTONS

EAS30745
TIP
REMOVING THE CONNECTING RODS AND
PISTONS When removing a piston ring, open the end gap
The following procedure applies to all of the con- with your fingers and lift the other side of the ring
necting rods and pistons. over the piston crown.
1. Remove:
• Connecting rod cap
• Connecting rod
• Big end bearing
TIP
• Identify the position of each big end bearing so
that it can be reinstalled in its original place.
• After removing the connecting rods and con-
necting rod caps, care should be taken not to
G088999
damage the mating surfaces of the connecting
rods and connecting rod caps. EAS30747

CHECKING THE CYLINDER AND PISTON

2. Remove: 1. Check:
• Piston pin clip • Piston wall
• Piston pin “1” • Cylinder wall
• Piston “2” Vertical scratches → Replace the cylinder,
ECA13810

NOTICE and replace the piston and piston rings as a

set.
Do not use a hammer to drive the piston pin
2. Measure:
out.
• Piston-to-cylinder clearance
TIP a. Measure cylinder bore “C” with the cylinder
• For reference during installation, put identifica- bore gauge.
tion marks on the piston crown. TIP
• Before removing the piston pin, deburr the pis- Measure cylinder bore “C” by taking side-to-side
ton pin clip groove and the piston pin bore ar- and front-to-back measurements of the cylinder.
ea. If both areas are deburred and the piston
pin is still difficult to remove, remove it with the
piston pin puller set “3”. Bore
78.000–78.010 mm (3.0709–
3.0713 in)
Piston pin puller set Wear limit
90890-01304 78.060 mm (3.0732 in)
Piston pin puller
YU-01304 “C” = maximum of D1, D2, D3, D4, D5, D6

2 1

G088998 3
G089000
3. Remove:
b. If out of specification, replace the cylinder,
• Top ring
and replace the piston and piston rings as a
• 2nd ring
set.
• Oil ring

5-70
 CONNECTING RODS AND PISTONS

c. Measure piston skirt diameter “b” with the

micrometer.

Piston
Diameter
77.975–77.990 mm (3.0699–
3.0705 in)

G089002

2. Install:
a • Piston ring
(into the cylinder)
b TIP
Use the piston crown to level the piston ring near
bottom of cylinder, where cylinder wear is low-
G089001 est.
a. 9.0 mm (0.35 in) from the bottom edge of the 3. Measure:
piston
• Piston ring end gap
d. If out of specification, replace the piston and Out of specification → Replace the piston
piston rings as a set. ring.
e. Calculate the piston-to-cylinder clearance TIP
with the following formula. The oil ring expander spacer’s end gap cannot
Piston-to-cylinder clearance = Cylinder bore be measured. If the oil ring rail’s gap is exces-
“C” - Piston skirt diameter “b” sive, replace all three piston rings.

Top ring
Piston-to-cylinder clearance
End gap limit
0.010–0.035 mm (0.0004–0.0014
0.50 mm (0.0197 in)
in)
2nd ring
f. If out of specification, replace the cylinder, End gap limit
and replace the piston and piston rings as a 1.15 mm (0.0453 in)
set.
EAS30748 a
CHECKING THE PISTON RINGS
1. Measure:
• Piston ring side clearance
Out of specification → Replace the piston
and piston rings as a set. b
TIP
Before measuring the piston ring side clearance, G089003
eliminate any carbon deposits from the piston
ring grooves and piston rings. a. Bottom of cylinder
b. Upper of cylinder

Top ring
Side clearance limit
0.115 mm (0.0045 in)
2nd ring
Side clearance limit
0.115 mm (0.0045 in)

5-71
 CONNECTING RODS AND PISTONS

EAS30749

CHECKING THE PISTON PIN The following procedure applies to all of the con-
The following procedure applies to all of the pis- necting rods.
ECA13930
ton pins. NOTICE
1. Check:
Do not interchange the big end bearings and
• Piston pin
connecting rods. To obtain the correct
Blue discoloration/grooves → Replace the
crankshaft-pin-to-big-end-bearing clear-
piston pin and then check the lubrication sys-
ance and prevent engine damage, the big
tem.
end bearings must be installed in their origi-
2. Measure:
nal positions.
• Piston pin outside diameter “a”
Out of specification → Replace the piston pin. a. Clean the big end bearings, crankshaft
pins, and the inside of the connecting rods
Piston pin outside diameter limit halves.
16.970 mm (0.6681 in) b. Install the big end upper bearing into the
connecting rod and the big end lower bear-
ing into the connecting rod cap with the
connecting rod big end metal installer “1”.
TIP
• From the 3 types, choose the connecting rod
big end metal installer “1” that fits exactly, and
install it to the connecting rod and connecting
rod cap as shown in the illustration.
• Align the projections “a” on the big end bear-
G089004 ings with the notches “b” in the connecting rod
3. Measure: and connecting rod cap.
• Piston pin bore inside diameter “b” • Push the big end bearing “2” down and install it
Out of specification → Replace the piston. to the connecting rod and connecting rod cap.

Piston pin bore inside diameter

limit Connecting rod big end bearing
17.043 mm (0.6710 in) installer
90890-04193
Connecting rod big end bearing
installer
YM-04193

b
G089005

EAS30750

CHECKING THE CONNECTING RODS

1. Measure: 1
• Crankshaft-pin-to-big-end-bearing clearance
Out of specification → Replace the big end
bearings.

Oil clearance
0.027–0.051 mm (0.0011–0.0020
in)

5-72
 CONNECTING RODS AND PISTONS

a b
b

1
a

TIP
Install by carrying out the following procedures in
order to assemble in the most suitable condition.
e. Tighten the connecting rod bolt while
checking that the sections shown “a” and
1 “b” are flush with each other by touching the
surface.
2
Connecting rod bolt
c. Put a piece of Plastigauge® “1” on the 30 N·m (3.0 kgf·m, 22 lb·ft)

T.
R.
crankshaft pin.
TIP
To install the big end bearing, care should be
1 taken not to install it at an angle and the position
should not be out of alignment.

a
G089008
b
d. Assemble the connecting rod halves.
ECA18390

NOTICE
Tighten the connecting rod bolts using the
plastic-region tightening angle method. Al-
ways install new bolts. a. Side machined face
b. Thrusting faces
TIP
f. Loosen the connecting rod bolt, remove the
• Clean the connecting rod bolts and lubricate
connecting rod and connecting rod cap and
the bolt threads and seats with molybdenum
install these parts to the crankshaft with the
disulfide oil.
big end bearing kept in the current condi-
• Make sure that the projection “a” on the con-
tion.
necting rod cap faces the same direction as the
“Y” mark “b” on the connecting rod.
• After installing the big end bearing, assemble
the connecting rod and connecting rod cap
without installing them onto the crankshaft.

5-73
 CONNECTING RODS AND PISTONS

TIP
• Do not move the connecting rod or crankshaft
until the clearance measurement has been
completed.
• Make sure that the projection “a” on the con-
necting rod cap faces the same direction as the
“Y” mark “b” on the connecting rod.
• Make sure the “Y” marks “b” on the connecting
180˚
rods face towards the left side of the crank-
shaft. EWA16610

WARNING
If the bolt is tightened more than the speci-
b 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
a Do not use a torque wrench to tighten the
bolt to the specified angle.
g. Tighten the connecting rod bolts with a j. After the installation, check that the section
torque wrench. shown “a” is flush with each other by touch-
ing the surface.
Connecting rod bolt (1st)
20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.

h. Put a mark “1” on the corner of the connect-

ing rod bolt “2” and the connecting rod cap
“3”.

k. Remove the connecting rod and big end

bearings.
l. Measure the compressed Plastigauge®
width “e” on the crankshaft pin. If the crank-
shaft-pin-to-big-end-bearing clearance is
out of specification, select replacement big
i. Tighten the connecting rod bolts further to end bearings.
reach the specified angle 180°.

Connecting rod bolt (final)

Specified angle 180°
T.
R.

G089010

5-74
 CONNECTING RODS AND PISTONS

2. Select:
• Big end bearing (P1–P3)
TIP
• The numbers “A” stamped into the crankshaft
web and the numbers “1” on the connecting
rods are used to determine the replacement
big end bearings sizes.
• “P1”–“P3” refer to the bearings shown in the
crankshaft illustration. 1
For example, if the connecting rod “P1” and EAS30751

the crankshaft web “P1” numbers are 5 and 2 INSTALLING THE CONNECTING ROD AND
respectively, then the bearing size for “P1” is: PISTON
The following procedure applies to all of the con-
“P1” (connecting rod) - “P1” (crankshaft) = 5 - 2 necting rods and pistons.
= 3 (brown) 1. Install:
• Big end bearing
• Connecting rod cap
Bearing color code (onto the connecting rod)
Code 1 TIP
Blue
• Be sure to reinstall each big end bearing in its
Code 2
Black original place.
Code 3 • From the 3 types, choose the connecting rod
Brown big end metal installer “1” that fits exactly, and
Code 4 install it to the connecting rod and connecting
Yellow green rod cap as shown in the illustration.
• Align the projections “a” on the big end bear-
ings with the notches “b” in the connecting rods
and connecting rod caps.
• Push the big end bearing “2” down and install it
P3 to the connecting rod and connecting rod cap.
• Make sure that the projection “c” on the con-
P1 P2 necting rod cap faces the same direction as the
“Y” mark “d” on the connecting rod.

Connecting rod big end bearing

installer
A P1 P 2 P3 90890-04193
Connecting rod big end bearing
installer
YM-04193

5-75
 CONNECTING RODS AND PISTONS

d. Tighten the connecting rod bolt while

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

Connecting rod bolt

1 30 N·m (3.0 kgf·m, 22 lb·ft)

T.
R.
TIP
To install the big end bearing, care should be
taken not to install it at an angle and the position
should not be out of alignment.

1
a
b
2

d
a. Side machined face
b. Thrusting faces
e. Loosen the connecting rod bolt, remove the
connecting rod and connecting rod cap and
c install these parts to the crankshaft with the
big end bearing kept in the current condi-
tion.
2. Tighten:
• Connecting rod bolt New 3. Install:
ECA18390 • Oil ring expander “1”
NOTICE • Lower oil ring rail “2”
Tighten the connecting rod bolts using the • Upper oil ring rail “3”
plastic-region tightening angle method. Al- • 2nd ring “4”
ways install new bolts. • Top ring “5”
(into the piston)
TIP
TIP
Install by carrying out the following procedures in Be sure to install the piston rings so that the
order to assemble in the most suitable condition. manufacturer’s marks or numbers “a” face up.
a. Replace the connecting rod bolts with new
ones.
b. Clean the connecting rod bolts and lubri-
cate the bolt threads and seats with molyb-
denum disulfide oil.
c. After installing the big end bearing, assem-
ble the connecting rod and connecting rod
cap without installing them onto the crank-
shaft.

5-76
 CONNECTING RODS AND PISTONS

4. Install:
• Piston “1” 90˚
(onto the respective connecting rod “2”) b,e c
• Piston pin “3”
• Piston pin clip “4” New
TIP 90˚
• Apply engine oil onto the piston pin.
• Make sure that the “Y” mark “a” on the connect-
ing rod faces left when the punch mark “b” on a,d
45˚
the piston is pointing up as shown.
a. Top ring
• Make sure that the clip ends “c” are positioned
b. 2nd ring
away from the cutout “d” in the piston as shown
c. Upper oil ring rail
in the illustration.
d. Oil ring expander
• Reinstall each piston into its original cylinder.
e. Lower oil ring rail

4 New A. Exhaust side

a
7. Lubricate:
2 1 • Crankshaft pin
• Connecting rod big end bearing inner surface
(with the recommended lubricant)
3
b
New 4 Recommended lubricant
Engine oil
G089013
8. Install:
• Piston assembly “1”
(into the cylinder “2” and onto the crankshaft
pin)

Piston installing tool

c 90890-04161
d Piston installing tool
YM-04161
4 New ECA21490

5. Lubricate: NOTICE
• Piston If the projection “a” of the piston installing
• Piston ring tool damages, you cannot use it. Please han-
• Cylinder dle with care.
(with the recommended lubricant)
TIP
Recommended lubricant Fit the projection “a” of the piston installing tool
Engine oil “3” and blunt-edged part “b” of the cylinder, fix
the position of the piston installing tool, and then
6. Offset:
push the piston up to the cylinder.
• Piston ring end gap

5-77
 CONNECTING RODS AND PISTONS

2
2
b
a 1

3 1
9. Install: c. Tighten the connecting rod bolts further to
• Connecting rod cap reach the specified angle 180°.
• Connecting rod bolt
TIP Connecting rod bolt (final)
• Make sure the “Y” marks “a” on the connecting Specified angle 180°

T.
R.
rods face towards the left side of the crank-
shaft.
• Make sure that the projection “b” on the con-
necting rod cap faces the same direction as the
“Y” mark “a” on the connecting rod.
• Apply Molybdenum disulfide oil to the bolt
threads and seats.

a 180˚

EWA16610

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

10.Tighten: NOTICE
• Connecting rod bolt Do not use a torque wrench to tighten the
TIP bolt to the specified angle.
Tighten the connecting rod bolts using the fol- d. After the installation, check that the section
lowing procedure. shown “a” is flush with each other by touch-
ing the surface.
a. Tighten the connecting rod bolts with a EWA17120

torque wrench. WARNING

If the connecting rod and cap are not flush
Connecting rod bolt (1st) with each other, remove the connecting rod
20 N·m (2.0 kgf·m, 15 lb·ft) bolts and big end bearing and restart from
T.
R.

b. Put a mark “1” on the corner of the connect- step (1). In this case, make sure to replace
ing rod bolt “2” and the connecting rod cap the connecting rod bolts.
“3”.

5-78
 CONNECTING RODS AND PISTONS

5-79
 CRANKSHAFT AND BALANCER SHAFT

EAS20178

CRANKSHAFT AND BALANCER SHAFT

Removing the crankshaft and balancer shaft

4
New 7
New 1 4
7
E

6 2

1
2

E
3
E
3

Order Job/Parts to remove Q’ty Remarks

Lower crankcase Refer to “CRANKCASE” on page 5-63.
Refer to “REMOVING THE CONNECTING
Connecting rod RODS AND PISTONS” on page 5-70.
1 Balancer shaft 1
2 Balancer shaft journal lower bearing 2
3 Balancer shaft journal upper bearing 2
4 Crankshaft 1
5 Crankshaft journal lower bearing 4
6 Crankshaft journal upper bearing 4
7 Oil nozzle 3

5-80
 CRANKSHAFT AND BALANCER SHAFT

EAS31171
2. Check:
REMOVING THE CRANKSHAFT AND
• Crankshaft journal surfaces
BALANCER SHAFT
• Crankshaft pin surfaces
1. Remove:
• Bearing surfaces
• Balancer shaft “1”
Scratches/wear → Replace the crankshaft.
• Balancer shaft journal bearing
3. Measure:
• Crankshaft assembly “2”
• Crankshaft-journal-to-crankshaft-journal-
• Crankshaft journal bearing
bearing clearance
TIP Out of specification → Replace the crank-
Identify the position of each balancer shaft jour- shaft journal bearings.
nal bearings and crankshaft journal bearings so
that it can be reinstalled in its original place. Journal oil clearance
0.013–0.037 mm (0.0005–0.0015
2 in)
ECA13920

NOTICE
Do not interchange the crankshaft journal
bearings. To obtain the correct crankshaft-
journal-to-crankshaft-journal-bearing clear-
ance and prevent engine damage, the crank-
1 shaft journal bearings must be installed in
their original positions.
EAS31174

CHECKING THE OIL NOZZLES a. Clean the crankshaft journal bearings,

The following procedure applies to all of the oil crankshaft journals, and bearing portions of
nozzles. the crankcase.
1. Check: b. Place the upper crankcase upside down on
• Oil nozzle a bench.
Damage/wear → Replace the oil nozzle. c. Install the crankshaft journal upper bear-
• Oil passage ings “1” and the crankshaft into the upper
Obstruction → Blow out with compressed air. crankcase.
TIP
EAS31075

CHECKING THE CRANKSHAFT Align the projections “a” on the crankshaft jour-
1. Measure: nal upper bearings with the notches “b” in the up-
• Crankshaft runout per crankcase.
Out of specification → Replace the crank-
shaft.

Runout limit 1
0.030 mm (0.0012 in) a
b

G089019

d. Put a piece of Plastigauge® “1” on each

crankshaft journal.
TIP
Do not put the Plastigauge® over the oil hole in
G089017 the crankshaft journal.

5-81
 CRANKSHAFT AND BALANCER SHAFT

4. Select:
1 • Crankshaft journal bearing (J1–J4)
TIP
• The numbers “A” stamped into the crankshaft
web and the numbers “B” stamped into the
lower crankcase are used to determine the re-
placement crankshaft journal bearing sizes.
• “J1”–“J4” refer to the bearings shown in the
G089020 crankshaft and lower crankcase illustration.
e. Install the crankshaft journal lower bearings For example, if the crankcase “J1” and crank-
“1” into the lower crankcase and assemble shaft web “J1” numbers are 6 and 2 respec-
the crankcase halves. tively, then the bearing size for “J1” is:
TIP
“J1” (crankcase) - “J1” (crankshaft web) -1 = 6
• Align the projections “a” of the crankshaft jour-
nal lower bearings with the notches “b” in the - 2 - 1 = 3 (Brown)
lower crankcase.
• Do not move the crankshaft until the clearance
measurement has been completed. Bearing color code
Code 0
White
Code 1
Blue
1
Code 2
a Black
b Code 3
Brown
Code 4
Yellow green
G089019

f. Tighten the bolts to specification in the tight-

ening sequence cast on the crankcase.
Refer to “CRANKCASE” on page 5-63.
g. Remove the lower crankcase and the
crankshaft journal lower bearings. J1 J2 J3 J4
h. Measure the compressed Plastigauge®
width “a” on each crankshaft journal.
If the crankshaft-journal-to-crankshaft-jour-
nal-bearing clearance is out of specifica-
tion, select replacement crankshaft journal
bearings. A J1 J2 J3 J4

G089021

5-82
 CRANKSHAFT AND BALANCER SHAFT

a. Clean the balancer shaft journal bearings,

balancer shaft journals, and bearing por-
tions of the crankcase.
b. Place the upper crankcase upside down on
a bench.
c. Install the balancer shaft journal upper
bearings “1” and the balancer shaft into the
upper crankcase.
B J1 J2 J3 J4 TIP
Align the projections “a” on the balancer shaft
EAS31076

CHECKING THE BALANCER SHAFT journal upper bearings with the notches “b” in the
1. Measure: upper crankcase.
• Balancer shaft runout
Out of specification → Replace the balancer
shaft.
1
Balancer shaft runout limit a
0.030 mm (0.0012 in) b

G089019

d. Put a piece of Plastigauge® “1” on each

balancer shaft journal.
TIP
Do not put the Plastigauge® over the oil hole in
the balancer shaft journal.

2. Check:
• Balancer shaft journal surfaces
• Bearing surfaces
Scratches/wear → Replace the balancer
shaft. 1
3. Measure:
• Balancer shaft journal-to-balancer shaft bear-
ing clearance
Out of specification → Replace the balancer
shaft journal bearings. e. Install the balancer shaft journal lower bear-
ings “1” into the lower crankcase and as-
Balancer shaft journal to balanc- semble the crankcase halves.
er shaft bearing clearance TIP
0.023–0.047 mm (0.0009–0.0019
in) • Align the projections “a” of the balancer shaft
journal lower bearings with the notches “b” in
ECA18400
the crankcase.
NOTICE • Do not move the balancer shaft until the clear-
Do not interchange the balancer shaft jour- ance measurement has been completed.
nal bearings. To obtain the correct balancer
shaft-journal-to-balancer shaft-journal-bear-
ing clearance and prevent engine damage,
the balancer shaft journal bearings must be
installed in their original positions.

5-83
 CRANKSHAFT AND BALANCER SHAFT

Bearing color code

Code 1
1
Blue
a
Code 2
b Black
Code 3
Brown
Code 4
G089019 Green
f. Tighten the bolts to specification in the tight- Code 5
ening sequence cast on the crankcase. Yellow
Refer to “CRANKCASE” on page 5-63.
g. Remove the lower crankcase and the bal-
ancer shaft journal lower bearings.
h. Measure the compressed Plastigauge®
width “a” on each balancer shaft journal.
If the balancer shaft-journal-to-balancer J1 J2
shaft-journal-bearing clearance is out of
specification, select replacement balancer
shaft journal bearings.

a
J1 J2

4. Select:
• Balancer shaft journal bearing (J1–J2)
TIP
• The numbers “A” stamped into the balancer
shaft web and the numbers “B” stamped into
the lower crankcase are used to determine the
replacement balancer shaft journal bearing siz-
es.
• “J1”–“J2” refer to the bearings shown in the bal-
ancer shaft and lower crankcase illustration. B J1 J2
For example, if the crankcase “J1” and bal- EAS31077

ancer shaft web “J1” numbers are 5 and 2 re- INSTALLING THE CRANKSHAFT
spectively, then the bearing size for “J1” is: 1. Install:
• Crankshaft journal upper bearing
“J1” (crankcase) - “J1” (balancer shaft web) = (into the upper crankcase)
5 - 2 = 3 (brown) • Crankshaft journal lower bearing
(into the lower crankcase)
• Crankshaft

5-84
 CRANKSHAFT AND BALANCER SHAFT

TIP
b a
• Align the projections “a” on the crankshaft jour-
nal bearings “1” with the notches “b” in the
crankcase.
• Be sure to install each crankshaft journal bear-
ings in its original place.

1
a
b

G089019

EAS31172

INSTALLING THE BALANCER ASSEMBLY

1. Install:
• Balancer shaft journal upper bearing
(into the upper crankcase)
• Balancer shaft journal lower bearing
(into the lower crankcase)
TIP
• Align the projections “a” on the balancer shaft
journal bearings “1” with the notches “b” in the
crankcases.
• Be sure to install each balancer shaft journal
bearing in its original place.

1
a
b

G089019

2. Install:
• Balancer shaft
TIP
Install by aligning the crankshaft match mark “a”
and the balancer shaft match mark “b”.

5-85
 TRANSMISSION

EAS20062

TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks
12 N·m (1.2 kgf·m, 8.9 lb·ft)
E 2 New
LT 4 New 1

LT E
5
3
LT E

14 N·m (1.4 kgf·m, 10 lb·ft) E

New

10 N·m (1.0 kgf·m, 7.4 lb·ft)

0.5 N·m (0.05 kgf·m, 0.37 lb·ft)
8
E
8
E
8
7
6
8
6
E
LT LT

10 N·m (1.0 kgf·m, 7.4 lb·ft)

Order Job/Parts to remove Q’ty Remarks

Lower crankcase Refer to “CRANKCASE” on page 5-63.
Shift shaft Refer to “SHIFT SHAFT” on page 5-55.
1 Drive axle assembly 1
2 Oil seal 1
3 Bearing 1
4 Circlip 1
5 Washer 1
6 Shift drum retainer 2
7 Shift fork guide bar 2 1
8 Spring 4

5-86
 TRANSMISSION

Removing the transmission, shift drum assembly, and shift forks

12 N·m (1.2 kgf·m, 8.9 lb·ft)
E 19 New
LT New
14 18

LT E
9
13
LT E
10
14 N·m (1.4 kgf·m, 10 lb·ft) E
17
New

16
15
10 N·m (1.0 kgf·m, 7.4 lb·ft)
0.5 N·m (0.05 kgf·m, 0.37 lb·ft)
11
E
E

12
E
LT LT

10 N·m (1.0 kgf·m, 7.4 lb·ft)

Order Job/Parts to remove Q’ty Remarks

9 Shift fork-L 1
10 Shift fork-R 1
11 Shift fork guide bar 1 1
12 Shift drum assembly 1
13 Shift fork-C 1
14 Main axle assembly 1
15 Oil delivery pipe 1
16 O-ring 1
17 Oil nozzle 1
18 Bearing cover plate 1
19 Bearing 1

5-87
 TRANSMISSION

Disassembling the main axle assembly

New 9
14 10
E

13 11
12
15

10
9

M 6
7
M 1
2
3
New 7
M
8 4
5
M
6 2

M
3

Order Job/Parts to remove Q’ty Remarks

1 2nd pinion gear 1
2 Toothed lock washer 1
3 Toothed lock washer retainer 1
4 6th pinion gear 1
5 Collar 1
6 Washer 1
7 Circlip 1
8 3rd pinion gear 1
9 Circlip 1
10 Washer 1
11 5th pinion gear 1
12 Collar 1
13 Bearing housing 1
14 Bearing 1
15 Main axle 1

5-88
 TRANSMISSION

Disassembling the drive axle assembly

6
M 5
5 4
New 4
M

1 2

15
3
M

14
12 M
13
10 11 15 New
M

9 12 13 New
8
7
M E

M
New
M

8 9

Order Job/Parts to remove Q’ty Remarks

1 1st wheel gear 1
2 Collar 1
3 5th wheel gear 1
4 Circlip 1
5 Washer 1
6 3rd wheel gear 1
7 Collar 1
8 Toothed lock washer 1
9 Toothed lock washer retainer 1
10 4th wheel gear 1
11 Collar 1
12 Washer 1
13 Circlip 1
14 6th wheel gear 1
15 Circlip 1

5-89
 TRANSMISSION

Disassembling the drive axle assembly

M
New

17
16

M 18

16 M

New
M

New 19
22
20
M E
New 21
M
M

Order Job/Parts to remove Q’ty Remarks

16 Washer 1
17 2nd wheel gear 1
18 Collar 1
19 Collar 1
20 Bearing 1
21 Circlip 1
22 Drive axle 1

5-90
 TRANSMISSION

EAS30430

REMOVING THE TRANSMISSION 2 4

1. Remove: 1
• Drive axle assembly “1”
3
• Shift drum retainer “2”
• Shift fork guide bar 2
• Spring
• Shift fork-L
• Shift fork-R
• Shift fork guide bar 1
• Spring
• Shift drum assembly EAS30431

CHECKING THE SHIFT FORKS

• Shift fork-C
The following procedure applies to all of the shift
1 forks.
1. Check:
• Shift fork cam follower “1”
• Shift fork pawl “2”
Bends/damage/scoring/wear → Replace the
shift fork.

2
2. Remove:
• Bearing housing “1”
• Main axle assembly “2”
a. Insert two bolts “3” of the proper size, as
shown in the illustration, into the main axle
assembly bearing housing. G089022

2. Check:
• Shift fork guide bar 1
2 • Shift fork guide bar 2
1
Roll the shift fork guide bar on a flat surface.
Bends → Replace.
EWA12840

WARNING
Do not attempt to straighten a bent shift fork
guide bar.
3
b. Tighten the bolts until they contact the 3. Check:
crankcase surface. • Shift fork movement
c. Continue tightening the bolts until the main (along the shift fork guide bar)
axle assembly comes free from the upper Rough movement → Replace the shift forks
crankcase. and shift fork guide bar as a set.

3. Remove:
• Oil delivery pipe “1”
• Oil nozzle “2”
• Bearing cover plate “3”
• Bearing “4”

G089023

5-91
 TRANSMISSION

EAS30432

CHECKING THE SHIFT DRUM ASSEMBLY

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

G089024

EAS30433

CHECKING THE TRANSMISSION

1. Measure:
• Main axle runout
(with a centering device and dial gauge “1”) G089025
Out of specification → Replace the main axle. 4. Check:
• Transmission gear engagement
Main axle runout limit (each pinion gear to its respective wheel
0.08 mm (0.0032 in) gear)
Incorrect → Reassemble the transmission
axle assemblies.
5. Check:
1 • Transmission gear movement
Rough movement → Replace the defective
part(s).
6. Check:
• Circlip
Bends/damage/looseness → Replace.
EAS30435

2. Measure: ASSEMBLING THE MAIN AXLE AND DRIVE

• Drive axle runout AXLE
(with a centering device and dial gauge “1”) 1. Install:
Out of specification → Replace the drive axle. • Toothed washer “1”
• Circlip “2” New
Drive axle runout limit
0.08 mm (0.0032 in)

5-92
 TRANSMISSION

TIP TIP
• Be sure the circlip sharp-edged corner “a” is • With the toothed lock washer retainer in the
positioned opposite side to the toothed washer groove “a” in the axle, align the projection on
and gear. the retainer with an axle spline, and then install
• Align the opening between the ends “b” of the the toothed lock washer.
circlip with a groove “c” in the axle. • Be sure to align the projection on the toothed
• Install the circlip so that a spline “d” is in the lock washer that is between the alignment
center of the gap between the circlip ends “e” marks “b” with the alignment mark “c” on the re-
as shown. tainer.

A
1
2
2
1

b B c
1
2 b
1
2
b

a
c

A. Main axle
e B. Drive axle
EAS30438

INSTALLING THE TRANSMISSION

1. Install:
• Bearing “1”
• Bearing cover plate “2”
• Oil nozzle “3”
d • Oil delivery pipe “4”
A. Main axle TIP
B. Drive axle • Face the seal side of bearing to the outside.
• Install bearing cover plate “2” with the “OUT”
2. Install: mark “a” facing out.
• Toothed lock washer retainer “1”
• Toothed lock washer “2”
Bearing cover plate screw
12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.

LOCTITE®
Oil nozzle
0.5 N·m (0.05 kgf·m, 0.37 lb·ft)

5-93
 TRANSMISSION

3 4. Install:
1 a • Shift fork-R “1”
4
• Shift fork-L “2”
• Spring
2 • Shift fork guide bar 2
• Shift drum retainer “3”
• Bearing “4”
2 • Circlip “5” New
• Oil seal New
• Drive axle assembly “6”
2. Install:
• Main axle assembly “1”
Shift drum retainer bolt
• Bearing housing “2”
10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.
R.
LOCTITE®
Main axle bearing housing bolt
14 N·m (1.4 kgf·m, 10 lb·ft) TIP
T.
R.

LOCTITE®
• Install shift fork-R into the groove “a” in the 5th
wheel gear and shift fork-L into the groove “b”
in the 6th wheel gear on the drive axle.
• Face the seal side of bearing “4” to the outside.
2 1 • Install the shift drum retainer with its “OUT”
mark “c” facing outward.
• Make sure that the projection “d” on the drive
axle assembly is inserted into the slot in the
crankcase.
• Make sure that the drive axle bearing circlips
“5” is inserted into the grooves “e” in the upper
3. Install: crankcase.
• Shift fork-C “1”
• Shift drum assembly “2” a b 6
• Spring
• Shift fork guide bar 1 “3”
TIP
4
• The embossed marks on the shift forks should
face towards the right side of the engine and be
5 5
in the following sequence: “R”, “C”, “L”. New New
• Carefully position the shift forks so that they
e
are installed correctly into the transmission 1 2 d e
gears.
3
• Install shift fork-C into the groove “a” in the 3rd c
pinion gear on the main axle.

c
a

2
3
1

5-94
 TRANSMISSION

5. Check:
• Transmission
Rough movement → Repair.
TIP
Oil each gear, shaft, and bearing thoroughly.

5-95
 COOLING SYSTEM

COOLING SYSTEM DIAGRAMS .................................................................... 6-1

RADIATOR ...................................................................................................... 6-3

CHECKING THE RADIATOR.................................................................... 6-5
INSTALLING THE RADIATOR..................................................................6-5

OIL COOLER...................................................................................................6-7
CHECKING THE OIL COOLER ................................................................6-8
INSTALLING THE OIL COOLER .............................................................. 6-8

THERMOSTAT ................................................................................................6-9
CHECKING THE THERMOSTAT ASSEMBLY ....................................... 6-10
INSTALLING THE THERMOSTAT ASSEMBLY ..................................... 6-10

WATER PUMP...............................................................................................6-11
DISASSEMBLING THE WATER PUMP.................................................. 6-13
CHECKING THE WATER PUMP ............................................................ 6-13
ASSEMBLING THE WATER PUMP........................................................ 6-13

6
 COOLING SYSTEM DIAGRAMS

EAS20299

COOLING SYSTEM DIAGRAMS

1. Water pump
2. Thermostat
3. Radiator

6-1
 COOLING SYSTEM DIAGRAMS

1 2 3

4
1. Water jacket
2. Thermostat
3. Water pump
4. Oil cooler
5. Coolant reservoir

6-2
 RADIATOR

EAS20063

RADIATOR
Removing the radiator
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.
R.
10
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
8 N•m (0.8 kgf•m, 5.9 lb•ft)

T.
R.
LT

LT
2
4

5 6
8 9
7 3

0.5 N•m (0.05 kgf•m, 0.37 lb•ft)

T.R
.

9 N•m (0.9 kgf•m, 6.6 lb•ft)

T.
R.

10 N•m (1.0 kgf•m, 7.4 lb•ft)

7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.

T.
R.

2.0 N•m (0.20 kgf•m, 1.5 lb•ft)

T.R

7 N•m (0.7 kgf•m, 5.2 lb•ft)

.

T.
R.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (2)” on
Air filter case page 4-14.
Refer to “GENERAL CHASSIS (1)” on
Front side panel page 4-1.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-32.
1 Horn connector 2 Disconnect.
2 Horn 1
3 Horn bracket 1
4 Coolant reservoir hose 1 Disconnect.
5 Coolant reservoir cover 1
6 Coolant reservoir 1
7 Coolant reservoir cap 1
8 Coolant reservoir breather hose 1
9 Radiator cap 1
10 Radiator fan motor coupler 1 Disconnect.

6-3
 RADIATOR

Removing the radiator

7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.
R.
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
8 N•m (0.8 kgf•m, 5.9 lb•ft)

T.
R.
11
13

15

LT

12
16
LT

14

0.5 N•m (0.05 kgf•m, 0.37 lb•ft) 17

T.R
.

9 N•m (0.9 kgf•m, 6.6 lb•ft)

T.
R.

10 N•m (1.0 kgf•m, 7.4 lb•ft)

7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.

T.
R.

2.0 N•m (0.20 kgf•m, 1.5 lb•ft)

T.R

7 N•m (0.7 kgf•m, 5.2 lb•ft)

.

T.
R.

Order Job/Parts to remove Q’ty Remarks

11 Radiator hose (cylinder head to radiator) 1 Disconnect.
12 Radiator inlet hose 1 Disconnect.
13 Radiator outlet hose 1 Disconnect.
14 Radiator 1
15 Radiator fan cover 1
16 Radiator fan 1
17 Radiator bracket 1

6-4
 RADIATOR

EAS30439

CHECKING THE RADIATOR

1. Check:
• Radiator fin
Obstruction → Clean.
Apply compressed air to the rear of the radia-
tor.
Damage → Repair or replace.
TIP
Straighten any flattened fins with a thin, flat-head G089029

screwdriver. b. Apply specified pressure to the radiator cap

and then, make sure to check the specified
pressure for at least 10 seconds. If it is not
keep the pressure, replace it.
4. Check:
• Radiator fan
Damage → Replace.
Malfunction → Check and repair.
Refer to “COOLING SYSTEM” on page 8-39.
EAS30440
G089028
INSTALLING THE RADIATOR
2. Check: 1. Install:
• Radiator hose • All removed parts
Cracks/damage → Replace. 2. Fill:
3. Measure: • Cooling system
• Radiator cap valve opening pressure (with the specified amount of the recom-
Below the specified pressure → Replace the mended coolant)
radiator cap. Refer to “CHANGING THE COOLANT” on
page 3-32.
Radiator cap valve opening pres- 3. Check:
sure
• Cooling system
107.9–137.3 kPa (1.08–1.37 kgf/
cm², 15.6–19.9 psi) Leaks → Repair or replace any faulty part.
a. Attach the radiator cap tester “1” and radia-
a. Install the radiator cap tester “1” and radia- tor cap tester adapter “2” to the radiator.
tor cap tester adapter “2” to the radiator cap
“3”. Radiator cap tester
90890-01325
Radiator cap tester Mityvac cooling system tester kit
90890-01325 YU-24460-A
Mityvac cooling system tester kit Radiator cap tester adapter
YU-24460-A 90890-01352
Radiator cap tester adapter Pressure tester adapter
90890-01352 YU-33984
Pressure tester adapter
YU-33984

6-5
 RADIATOR

G089031 1
b. Apply the specified pressure.

Cooling system leak test pres-

sure
137.3 kPa (1.37 kgf/cm², 19.9
psi)
ECA24270

NOTICE
• Do not apply such a high pressure as ex-
ceeds the test pressure.
• Make sure that a checkup after the cylinder
head gasket is replaced is made after 3 min-
utes of warm-up.
• Make sure that coolant is filled up to the up-
per level beforehand.

4. Check:
• Pressure value
No stay for 5 to 10 seconds at the test pres-
sure value → Repair.
• Radiator
• Radiator hose connections
Coolant leaks → Repair or replace.
• Radiator hose
Bulges → Replace.
EWA19090

WARNING
When the radiator cap tester is removed,
coolant will spout; therefore, cover it with a
cloth beforehand.

6-6
 OIL COOLER

EAS20064

OIL COOLER
Removing the oil cooler

5
LS
1
2.0 N•m (0.20 kgf•m, 1.5 lb•ft)

T.R
New

.
LT
LT
2 10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
3

LS

New 4
LT

LT

Order Job/Parts to remove Q’ty Remarks

Coolant reservoir Refer to “RADIATOR” on page 6-3.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-32.
Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-29.
1 Radiator inlet hose 1
2 Oil cooler inlet hose 1
3 Oil cooler outlet hose 1
4 Oil cooler 1
5 Water jacket joint 1

6-7
 OIL COOLER

EAS30441
5. Measure:
CHECKING THE OIL COOLER
• Radiator cap valve opening pressure
1. Check:
Below the specified pressure → Replace the
• Oil cooler
radiator cap.
Cracks/damage → Replace.
Refer to “CHECKING THE RADIATOR” on
2. Check:
page 6-5.
• Oil cooler inlet hose
• Oil cooler outlet hose
Cracks/damage/wear → Replace.
EAS30442

INSTALLING THE OIL COOLER

1. Clean:
• Mating surfaces of the oil cooler and the
crankcase
(with a cloth dampened with lacquer thinner)
2. Install:
• O-ring New
• Oil cooler
• Oil cooler bolt “1”

Oil cooler bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

TIP
• Before installing the oil cooler, apply lithium-
soap-based grease to the O-ring.
• Make sure the O-ring is positioned properly.

3. Fill:
• Cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-32.
• Crankcase
(with the specified amount of the recom-
mended engine oil)
Refer to “CHANGING THE ENGINE OIL” on
page 3-29.
4. Check:
• Cooling system
Leaks → Repair or replace any faulty part.
Refer to “INSTALLING THE RADIATOR” on
page 6-5.

6-8
 THERMOSTAT

EAS20065

THERMOSTAT
Removing the thermostat assembly

1
4

2.0 N·m (0.20 kgf·m, 1.5 lb·ft)

2
10 N·m (1.0 kgf·m, 7.4 lb·ft)

Order Job/Parts to remove Q’ty Remarks

Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-32.
Radiator Refer to “RADIATOR” on page 6-3.
Muffler assembly Refer to “ENGINE REMOVAL” on page 5-9.
1 Oil cooler outlet hose 1
2 Radiator outlet hose 1
3 Water pump inlet hose 1
4 Thermostat assembly 1

6-9
 THERMOSTAT

EAS31248

CHECKING THE THERMOSTAT ASSEMBLY

1. Check:
• Thermostat assembly “1”
Cracks/damage → Replace.

EAS30445

INSTALLING THE THERMOSTAT

ASSEMBLY
1. Install:
• Thermostat assembly
2. Fill:
• Cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-32.
3. Check:
• Cooling system
Leaks → Repair or replace any faulty part.
Refer to “INSTALLING THE RADIATOR” on
page 6-5.
4. Measure:
• Radiator cap valve opening pressure
Below the specified pressure → Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-5.

6-10
 WATER PUMP

EAS20066

WATER PUMP
Removing the water pump

New
LS

New
1 LS

2.0 N•m (0.20 kgf•m, 1.5 lb•ft)

T.R
.

12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-32.
1 Water pump inlet hose 1 Disconnect.
2 Water pump assembly 1

6-11
 WATER PUMP

Disassembling the water pump

5
6
9
10

4 7
E 2

0.5–1.0 mm (0.02–0.04 in)

E

10 N·m (1.0 kgf·m, 7.4 lb·ft)

Order Job/Parts to remove Q’ty Remarks

1 Water pump housing cover 1
2 O-ring 1
3 Circlip 1
4 Water pump driven gear 1
5 Pin 1
6 Washer 1
7 Impeller shaft 1
8 Mechanical seal 1
9 Bearing 1
10 Oil seal 1

6-12
 WATER PUMP

EAS30446 EAS30447

DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP

1. Remove: 1. Check:
• Mechanical seal (housing side) “1” • Water pump housing cover “1”
TIP • Impeller shaft “2”
Remove the mechanical seal (housing side) Cracks/damage/wear → Replace.
from the inside of the water pump housing “2”. • Water pump housing “3”
Cracks/damage/wear → Replace the water
pump assembly.

3
2
1

1 2

2. Remove:
• Bearing “1” 2. Check:
• Oil seal “2” • Bearing
TIP Rough movement → Replace.
Remove the oil seal and bearing from the out- 3. Check:
side of the water pump housing “3”. • Water pump inlet hose
Cracks/damage/wear → Replace.
EAS30448

ASSEMBLING THE WATER PUMP

1. Install:
• Oil seal “1” New
• Bearing “2” New
2
(into the water pump housing “3”)

1 3 Installed depth “a”

0.5–1.0 mm (0.02–0.04 in)
3. Remove:
• Mechanical seal (impeller side) “1” TIP
(from the impeller, with a thin, flat-head Install the oil seal with a socket that matches its
screwdriver) outside diameter.
TIP
Do not scratch the impeller shaft.

2 3
a

2. Install:
G089034 • Mechanical seal (housing side) “1” New

6-13
 WATER PUMP

ECA20330

NOTICE
Never lubricate the mechanical seal (hous-
ing side) surface with oil or grease.

TIP
Use the special tools and a press to press the
mechanical seal (housing side) straight in until it
touches the water pump housing.
G089035

Mechanical seal installer

90890-04078
Water pump seal installer
YM-33221-A
Middle driven shaft bearing driv-
er
90890-04058
Middle drive bearing installer 40
& 50 mm
YM-04058

2. Water pump housing

3. Mechanical seal installer
4. Middle driven shaft bearing driver

A. Push down
3. Install:
• Mechanical seal (impeller side) “1” New
ECA20340

NOTICE
Make sure the mechanical seal (impeller
side) is flush with the impeller.

TIP
• Before installing the mechanical seal (impeller
side), apply tap water or coolant onto its outer
surface.
• If the top of the mechanical seal is dirty, clean
it.

6-14
 WATER PUMP

6-15
 FUEL SYSTEM

FUEL TANK..................................................................................................... 7-1

REMOVING THE FUEL TANK ..................................................................7-4
REMOVING THE FUEL PUMP .................................................................7-4
CHECKING THE FUEL PUMP BODY.......................................................7-4
CHECKING THE FUEL PUMP OPERATION............................................7-4
CHECKING THE PURGE CUT VALVE SOLENOID
(for California only) ................................................................................... 7-5
INSTALLING THE CANISTER (for California only)...................................7-5
INSTALLING THE FUEL PUMP................................................................7-5
INSTALLING THE FUEL TANK.................................................................7-5

THROTTLE BODIES .......................................................................................7-6

CHECKING THE INJECTORS (BEFORE REMOVING) ........................... 7-8
REMOVING THE FUEL HOSE (FUEL RAIL SIDE) ..................................7-8
REMOVING THE INJECTORS .................................................................7-8
CHECKING THE INJECTORS ..................................................................7-8
CHECKING AND CLEANING THE THROTTLE BODIES.........................7-8
REPLACING THE THROTTLE BODIES ................................................. 7-10
INSTALLING THE INJECTORS ..............................................................7-10
CHECKING THE INJECTOR PRESSURE.............................................. 7-11
CHECKING THE FUEL PRESSURE ......................................................7-11
INSTALLING THE FUEL HOSE (FUEL RAIL SIDE) ...............................7-12
ADJUSTING THE THROTTLE POSITION SENSOR..............................7-12

7
 FUEL TANK

EAS20067

FUEL TANK
Removing the fuel tank
6 N•m (0.6 kgf•m, 4.4 lb•ft)

T.R
.
(5) 11
6
13
12

5 4.0 N•m (0.40 kgf•m, 3.0 lb•ft)

T.R
.
7
11 N•m (1.1 kgf•m, 8.1 lb•ft)
9

T.
R.
1
10
8

(3) (3)
(3)

2 4 3 4.0 N•m (0.40 kgf•m, 3.0 lb•ft) 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.
T.R

R.
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (1)” on
Passenger seat/Rider seat page 4-1.
Fuel tank center cover/Air scoop/Fuel tank lower Refer to “GENERAL CHASSIS (1)” on
cover/Fuel tank upper cover page 4-1.
1 Fuel tank bracket bolt 4
2 Fuel hose connector 1 Disconnect.
3 Fuel pump coupler 1 Disconnect.
4 Fuel tank drain hose 1 Disconnect.
5 Fuel tank breather hose 1 Disconnect.
6 Fuel tank cap coupler 1 Disconnect. (for MT09SPR/MT09SPRC)
7 Fuel tank 1
8 Fuel tank bracket 1
9 Fitting plate (front) (left) 1
10 Fitting plate (rear) (left) 1
11 Fitting plate (front) (right) 1
12 Fitting plate (rear) (right) 1
13 Fuel tank cap 1

7-1
 FUEL TANK

Removing the fuel pump

New 3

1
(4)
4.0 N•m (0.40 kgf•m, 3.0 lb•ft)
T.R
.

Order Job/Parts to remove Q’ty Remarks

1 Fuel pump bracket 1
2 Fuel pump 1
3 Fuel pump gasket 1

7-2
 FUEL TANK

Removing the canister (for California only)

1 2

Order Job/Parts to remove Q’ty Remarks

Fuel tank Refer to “FUEL TANK” on page 7-1.
Refer to “ELECTRIC STARTER” on page 5-
Starter motor 41.
1 Purge cut valve solenoid coupler 1 Disconnect.
2 Purge cut valve solenoid 1
Canister purge hose (purge cut valve solenoid
3 1
to hose joint)
Canister purge hose (purge cut valve solenoid
4 1
to canister)
Fuel tank breather hose (fuel tank cap to canis-
5 1
ter)
6 Canister holder 1
7 Canister 1
8 Canister breather hose 1

7-3
 FUEL TANK

EAS30450

REMOVING THE FUEL TANK

1. Extract the fuel in the fuel tank through the 1 c
fuel tank cap with a pump.
2. Remove:
• Passenger seat
• Rider seat
• Fuel tank center cover
• Air scoop
Refer to “GENERAL CHASSIS (1)” on
page 4-1.
• Bracket bolt
3. Disconnect: a
• Fuel hose (fuel tank side) “1” b
• Fuel pump coupler “2”
• Fuel tank breather hose “3”
• Fuel tank drain hose “4”
b

2
4. Remove:
• Fuel tank
TIP
1
3 Do not set the fuel tank down so that the instal-
lation surface of the fuel pump is directly under
4 the tank. Be sure to lean the fuel tank in an up-
EWA17320
right position.
WARNING
Cover fuel hose connections with a cloth EAS30451

when disconnecting them. Residual pres- REMOVING THE FUEL PUMP

sure in the fuel lines could cause fuel to 1. Remove:
spurt out when removing the hose. • Fuel pump
ECA14721
ECA17490
NOTICE
NOTICE
• Do not drop the fuel pump or give it a
Be sure to disconnect the fuel hose by hand.
strong shock.
Do not forcefully disconnect the hose with
• Do not touch the base section of the fuel
tools.
sender.
TIP
EAS30454
• While pushing the ends “a” of the fuel hose
CHECKING THE FUEL PUMP BODY
connector cover “1” in direction “b”, slide the
1. Check:
fuel hose connector cover in direction “c”, and
• Fuel pump body
then remove the hose from the fuel pump.
Obstruction → Clean.
• Before removing the hose, place a few rags in
Cracks/damage → Replace fuel pump as-
the area under where it will be removed.
sembly.
• It is prohibited to wear the cotton work gloves
or equivalent coverings. EAS30455

CHECKING THE FUEL PUMP OPERATION

1. Check:
• Fuel pump operation
Refer to “CHECKING THE FUEL PRES-
SURE” on page 7-11.

7-4
 FUEL TANK

EAS33542

CHECKING THE PURGE CUT VALVE

SOLENOID (for California only)
1. Check: 2
• Canister purge hose
Loose connection → Connect properly. a
Cracks/damage/wear → Replace. 1 New
2. Check:
• Purge cut valve solenoid resistance
Refer to “CHECKING THE PURGE CUT
VALVE SOLENOID (for California only)” on
page 8-83. c

EAS31330 4
INSTALLING THE CANISTER (for California 1
only)
1. Install: 2
• Canister 3
• Canister holder
• Canister purge hose b
• Canister breather hose
• Fuel tank breather hose EAS30457

Refer to “CABLE ROUTING” on page 2-15. INSTALLING THE FUEL TANK

1. Connect:
EAS30456
• Fuel hose (fuel tank side)
INSTALLING THE FUEL PUMP ECA17500

1. Install: NOTICE
• Fuel pump gasket “1” New When installing the fuel hose, make sure that
• Fuel pump “2” it is securely connected, and that the fuel
• Fuel pump bracket hose connector cover on the fuel hose is in
• Fuel pump bolt the correct position, otherwise the fuel hose
will not be properly installed.
Fuel pump bolt
4.0 N·m (0.40 kgf·m, 3.0 lb·ft) TIP
T.
R.

• Install the fuel hose onto the fuel pump secure-

TIP ly, and slide the fuel hose connector cover “1”
• Do not damage the installation surfaces of the in the direction shown in the illustration.
fuel tank when installing the fuel pump. • It is prohibited to wear the cotton work gloves
• Always use a new fuel pump gasket. or equivalent coverings.
• When installing the fuel pump gasket, make
sure that there is no foreign material between
the gasket and the surrounding parts.
• The gasket lip “a” shall face toward the fuel 1
tank.
• Align the projection “b” on the fuel pump with
the slot in the fuel pump bracket.
• Align the projection “b” on the fuel pump with
the punch mark “c” on the fuel tank.
• Tighten the fuel pump bolts in stages and in a
crisscross pattern.
2. Connect:
• Fuel tank drain hose
• Fuel tank breather hose
• Fuel pump coupler

7-5
 THROTTLE BODIES

EAS20070

THROTTLE BODIES
Removing the throttle bodies

2
6
3
4
9 5
4
1

12 7
11

(6)
10 10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
LT

8 3 N•m (0.30 kgf•m, 2.2 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (2)” on
Air filter case page 4-14.
1 Fuel hose 1
2 Intake air pressure sensor 1 coupler 1 Disconnect.
3 Intake air pressure sensor 2 coupler 1 Disconnect.
4 Injector coupler 3 Disconnect.
5 Throttle servo motor coupler 1 Disconnect.
6 Throttle position sensor coupler 1 Disconnect.
Canister purge hose (purge cut valve solenoid Disconnect.
7 1
to hose joint) For California only.
8 Throttle body joint clamp screw 3 Loosen.
9 Throttle body assembly 1
10 Throttle body joint 1
11 Throttle body joint 1
12 Throttle body joint clamp 3

7-6
 THROTTLE BODIES

Removing the injectors

3.5 N·m (0.35 kgf·m, 2.6 lb·ft)

New
New
3.5 N·m (0.35 kgf·m, 2.6 lb·ft) 1

4 2 New
2
New
6 2
New
3
6
5
3.5 N·m (0.35 kgf·m, 2.6 lb·ft)

6
6
8
6 7
6 7

8
9
8
9

Order Job/Parts to remove Q’ty Remarks

1 Fuel rail 1
2 Injector 3
3 Intake air pressure sensor 2 1
4 Intake air pressure sensor 1 1
5 Throttle position sensor 1
6 Negative pressure hose 6
7 Hose joint 2
8 Canister purge hose 4 For California only.
9 Hose joint 2 For California only.

7-7
 THROTTLE BODIES

EAS30475 EAS30476

CHECKING THE INJECTORS (BEFORE REMOVING THE INJECTORS

REMOVING) EWA17330

1. Check: WARNING
• Injector • Check the injectors in a well-ventilated area
Use the diagnostic code numbers “36”–“38”. free of combustible materials. Make sure
Refer to “DIAGNOSTIC CODE: ACTUATOR that there is no smoking or use of electric
OPERATION TABLE” on page 9-70. tools in the vicinity of the injectors.
• Be careful when disconnecting the fuel
EAS31158
hose. Any remaining pressure in the fuel
REMOVING THE FUEL HOSE (FUEL RAIL
hose may cause the fuel to spray out. Place
SIDE)
a container or rag under the hose to catch
1. Remove:
any fuel that spills. Always clean up any
• Fuel tank
spilt fuel immediately.
Refer to “REMOVING THE FUEL TANK” on
• Turn the main switch to “OFF” and discon-
page 7-4.
nect the negative battery lead from the bat-
2. Remove:
tery terminal before removing the injectors.
• Fuel hose (fuel rail side)
ECA17490
1. Remove:
NOTICE • Fuel rail
Be sure to disconnect the fuel hose by hand.
a. Remove the fuel rail bolts.
Do not forcefully disconnect the hose with
tools. EAS30477

CHECKING THE INJECTORS

TIP 1. Check:
• While pushing the ends “a” of the fuel hose • Injector
connector cover “1” in direction “b”, slide the Obstruction → Replace and check the fuel
fuel hose connector cover in direction “c”, and pump/fuel supply system.
then remove the hose from the fuel pump. Deposit → Replace.
• Before removing the hose, place a few rags in Damage → Replace.
the area under where it will be removed. 2. Check:
• It is prohibited to wear the cotton work gloves • Injector resistance
or equivalent coverings. Refer to “CHECKING THE FUEL INJEC-
TORS” on page 8-83.
EAS30769
1 c CHECKING AND CLEANING THE THROTTLE
BODIES
TIP
Clean the throttle bodies only if they cannot be
synchronized using the bypass air screws. Be-
fore cleaning the throttle bodies, check the fol-
lowing items:
• Valve clearance
• Spark plug
a • Air filter element
• Throttle body joint
b
• Fuel hose
• Exhaust system
• Cylinder head breather hose

7-8
 THROTTLE BODIES

EWA17340
A
WARNING
If the throttle bodies are subjected to strong
shocks or dropped during cleaning, replace
them as a set.
1. Check:
• Throttle bodies
Cracks/damage → Replace the throttle bod- a
ies as a set. a
a
2. Clean:
• Throttle bodies B
ECA21540

NOTICE
• Observe the following precautions; other-
wise, the throttle bodies may not operate
properly.
• Do not subject the throttle bodies to exces-
sive force. a
• Clean the throttle bodies in the recom- a
a
mended cleaning solvent.
A. Except for California
• Do not use any caustic carburetor cleaning
B. For California
solution.
• Do not apply cleaning solvent directly to c. Hold the throttle valves in the open position.
EWA15940
any plastic parts, sensors, or seals.
• Be careful not to remove the white paint WARNING
mark that identifies the standard throttle When cleaning the throttle bodies, be careful
body. not to injure yourself on the throttle valves or
• Do not turn the bypass air screws “a”; oth- other components of the throttle bodies.
erwise, the throttle body synchronization ECA20380

will be affected. NOTICE

• Do not open the throttle valves by supply-
ing electrical power to the throttle bodies.
Recommended cleaning solvent
• Do not use tools to open the throttle valves
Yamaha Oil & Brake Cleaner
or to keep them in the open position.
• Do not open the throttle valves quickly.

a
a. Place the throttle bodies on a flat surface
with the air filter case side facing up. d. Apply the recommended cleaning solvent
b. Install the caps (895-14169-00) onto the to the throttle valves and the inside of the
hose fittings “a”. throttle bodies to remove any carbon de-
posits.

7-9
 THROTTLE BODIES

TIP 5. Adjust:
• Do not allow any cleaning solvent to enter the • Throttle bodies synchronizing
opening for the injectors. Out of specification → Replace the throttle
• Do not apply any cleaning solvent to the por- bodies.
tions of the throttle valve shafts between the Refer to “SYNCHRONIZING THE THROT-
throttle bodies. TLE BODIES” on page 3-8.
EAS31160
e. Remove the carbon deposits from the in-
REPLACING THE THROTTLE BODIES
side of each throttle body in a downward di-
1. Remove the throttle bodies from the vehicle.
rection, from the air filter case side of the
2. Install a new throttle bodies to the vehicle.
throttle body to the engine side.
ECA17590
3. Reset:
NOTICE • ISC (idle speed control) learning values
• Do not use a tool, such as a wire brush, to Use the diagnostic code number “67”.
remove the carbon deposits; otherwise, the Refer to “DIAGNOSTIC CODE: SENSOR
inside of the throttle bodies may be dam- OPERATION TABLE” on page 9-66.
aged. • A/F control learning value
• Do not allow carbon deposits or other for- Use the diagnostic code number “87”.
eign materials to enter any of the passages Refer to “DIAGNOSTIC CODE: SENSOR
in each throttle body or in the space be- OPERATION TABLE” on page 9-66.
tween the throttle valve shaft and the throt- 4. Adjust:
tle body. • Throttle bodies synchronizing
Refer to “SYNCHRONIZING THE THROT-
f. After removing the carbon deposits, clean TLE BODIES” on page 3-8.
the inside of the throttle bodies with the rec- 5. Place the vehicle on a maintenance stand so
ommended cleaning solvent, and then dry that the rear wheel is elevated.
the throttle bodies using compressed air. 6. Check:
g. Make sure that there are no carbon depos- • Engine idling speed
its or other foreign materials in any of the Start the engine, warm it up, and then mea-
passages “a” in each throttle body or in the sure the engine idling speed.
space “b” between the throttle valve shaft
and the throttle body. Engine idling speed
1200–1400 r/min
A a B a
EAS30480

INSTALLING THE INJECTORS

ECA19400

NOTICE
• Always use new O-rings.
• When installing the injectors, do not allow
any foreign material to enter or adhere to
b the injectors, fuel rails, or O-rings.
• Be careful not to twist or pinch the O-rings
A. Air filter case side when installing the injectors.
B. Throttle body joint side • When installing the injector, install it at the
same position as the removed cylinder.
3. Install the throttle bodies. • If an injector is subject to strong shocks or
4. Reset: excessive force, replace it.
• ISC (idle speed control) learning values
Use the diagnostic code number “67”. 1. Install a new seal onto the end of each injec-
Refer to “DIAGNOSTIC CODE: SENSOR tor.
OPERATION TABLE” on page 9-66. 2. Install the injectors to the fuel rail, making
sure to install them in the correct direction.
3. Install the injector assemblies to the throttle
bodies.

7-10
 THROTTLE BODIES

ECA17600

Fuel rail bolt NOTICE

T.
R. 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) Never exceed the specified air pressure or
damage could occur.
4. Check the injector pressure after the injectors
are installed. f. Close the valve on the fuel injector pressure
Refer to “CHECKING THE INJECTOR adapter.
PRESSURE” on page 7-11. g. Check that the specified air pressure is held
at least one minute.
EAS30481
Pressure drops → Check the pressure
CHECKING THE INJECTOR PRESSURE
gauge and adapter.
TIP Check the seals and O-rings and then rein-
• After installing the injectors, perform the follow- stall.
ing steps to check the injector pressure. Out of specification → Replace the fuel in-
• Do not allow any foreign materials to enter the jectors.
fuel lines.
EAS30482

1. Check: CHECKING THE FUEL PRESSURE

• Injector pressure 1. Check:
a. Connect the fuel injector pressure adapter • Fuel pressure
“1” to the fuel rail joint “2”, and then connect a. Remove the passenger seat, rider seat, fuel
an air compressor “3” to the adapter. tank center cover and air scoops.
b. Connect the pressure gauge “4” to the fuel Refer to “GENERAL CHASSIS (1)” on
injector pressure adapter “1”. page 4-1.
b. Remove the fuel bracket bolt and hold up
Pressure gauge the fuel tank.
90890-03153 c. Disconnect the fuel hose “1” from the fuel
Pressure gauge pump.
YU-03153 Refer to “REMOVING THE FUEL TANK”
Fuel injector pressure adapter on page 7-4.
90890-03210 EWA17320

Fuel injector pressure adapter WARNING

YU-03210 Cover fuel hose connections with a cloth
when disconnecting them. Residual pres-
sure in the fuel lines could cause fuel to
spurt out when removing the hose.
ECA17490

NOTICE
Be sure to disconnect the fuel hose by hand.
Do not forcefully disconnect the hose with
tools.

G089041

c. Close the valve on the fuel injector pressure

adapter. 1
d. Apply air pressure with the air compressor.
e. Open the valve on the fuel injector pressure
adapter until the specified air pressure is
reached.

Specified air pressure

490 kPa (5.0 kgf/cm², 71.1 psi)

7-11
 THROTTLE BODIES

d. Connect the pressure gauge “2” and fuel

pressure adapter “3” to the fuel hose.

Pressure gauge 1
90890-03153
Pressure gauge
YU-03153
Fuel pressure adapter
90890-03176
Fuel pressure adapter
YM-03176
EAS30485

ADJUSTING THE THROTTLE POSITION

SENSOR
ECA17540

NOTICE
2 3 • Handle the throttle position sensor with
special care.
• Never subject the throttle position sensor
to strong shocks. If the throttle position
sensor is dropped, replace it.
1. Check:
e. Start the engine.
• Throttle position sensor
f. Measure the fuel line pressure.
Refer to “DIAGNOSTIC CODE: SENSOR
Faulty → Replace the fuel pump.
OPERATION TABLE” on page 9-66.
2. Adjust:
Fuel line pressure (at idle)
300–390 kPa (3.0–3.9 kgf/cm², • Throttle position sensor angle
43.5–56.6 psi) TIP
Before adjusting the throttle position sensor, the
EAS31159
throttle bodies must be removed.
INSTALLING THE FUEL HOSE (FUEL RAIL
SIDE) a. Temporary tighten the throttle position sen-
1. Connect: sor screws “1”.
• Fuel hose (fuel rail side) b. Check that the throttle valves are fully
ECA17500 closed.
NOTICE c. Connect the throttle position sensor to the
When installing the fuel hose, make sure that wire harness.
it is securely connected, and that the fuel d. Remove the protective cap, and then con-
hose connector cover on the fuel hose is in nect the YDT to coupler.
the correct position, otherwise the fuel hose
will not be properly installed. Yamaha diagnostic tool USB
(US)
TIP 90890-03275
• Install the fuel hose onto the fuel pump secure- Yamaha diagnostic tool (A/I)
ly, and slide the fuel hose connector cover “1” 90890-03273
in the direction shown in the illustration.
• It is prohibited to wear the cotton work gloves TIP
or equivalent coverings. • Yamaha diagnostic tool (A/I) (90890-03273) in-
cludes YDT sub harness (6P) (90890-03266).
• If you already have Yamaha diagnostic tool (A/
I) (90890-03262), YDT sub harness (6P)
(90890-03266) is separately required.
e. Diagnostic code number “01” is selected.

7-12
 THROTTLE BODIES

f. Adjust the position of the throttle position

sensor angle so that 11–21 can appear in
the YDT screen.
g. After adjusting the throttle position sensor
angle, tighten the throttle position sensor
screws.

Throttle position sensor screw

3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
T.
R.

7-13
 ELECTRICAL SYSTEM

IGNITION SYSTEM ......................................................................................... 8-1

CIRCUIT DIAGRAM .................................................................................. 8-1
ENGINE STOPPING DUE TO SIDESTAND OPERATION.......................8-5
TROUBLESHOOTING ..............................................................................8-6

ELECTRIC STARTING SYSTEM .................................................................... 8-9

CIRCUIT DIAGRAM .................................................................................. 8-9
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ........................ 8-13
TROUBLESHOOTING ............................................................................8-14

CHARGING SYSTEM....................................................................................8-17
CIRCUIT DIAGRAM ................................................................................ 8-17
TROUBLESHOOTING ............................................................................8-21

LIGHTING SYSTEM ......................................................................................8-23

CIRCUIT DIAGRAM ................................................................................ 8-23
TROUBLESHOOTING ............................................................................8-27

SIGNALING SYSTEM ...................................................................................8-29

CIRCUIT DIAGRAM ................................................................................ 8-29
TROUBLESHOOTING ............................................................................8-33

COOLING SYSTEM....................................................................................... 8-39

CIRCUIT DIAGRAM ................................................................................ 8-39
TROUBLESHOOTING ............................................................................8-43

FUEL PUMP SYSTEM...................................................................................8-45

CIRCUIT DIAGRAM ................................................................................ 8-45
TROUBLESHOOTING ............................................................................8-49

SMART KEY SYSTEM (for MT09SPR/MT09SPRC) .................................... 8-51

CIRCUIT DIAGRAM ................................................................................ 8-51
TROUBLESHOOTING ............................................................................8-53
SMART KEY SYSTEM SELF-DIAGNOSIS............................................. 8-56
SMART KEY SYSTEM EMERGENCY MODE ........................................ 8-58
REGISTERING A SMART KEY...............................................................8-59
DISABLING A SMART KEY .................................................................... 8-60
8
DISABLING THE POWER-ON ALARM...................................................8-61
REPLACING THE REMOTE CONTROL UNIT AND ECU ......................8-62
REPLACING THE REMOTE CONTROL UNIT ....................................... 8-62
REPLACING THE ECU ...........................................................................8-62
REPLACEMENT PARTS LIST ................................................................8-63
ELECTRICAL COMPONENTS...................................................................... 8-65
RELAY LOCATION CHART .................................................................... 8-67
CHECKING THE SWITCHES .................................................................8-68
CHECKING THE HANDLEBAR SWITCH (LEFT) ................................... 8-70
CHECKING THE HANDLEBAR SWITCH (RIGHT).................................8-72
CHECKING THE FUSES ........................................................................8-73
REPLACING THE ECU (Engine Control Unit) ........................................ 8-74
CHECKING AND CHARGING THE BATTERY....................................... 8-75
CHECKING THE RELAYS ...................................................................... 8-75
CHECKING THE RELAY UNIT (DIODE) ................................................ 8-77
CHECKING THE IGNITION COILS......................................................... 8-78
CHECKING THE IGNITION SPARK GAP............................................... 8-78
CHECKING THE CRANKSHAFT POSITION SENSOR.......................... 8-79
CHECKING THE STARTER MOTOR OPERATION ...............................8-79
CHECKING THE STATOR COIL ............................................................ 8-79
CHECKING THE GCU (Generator Control Unit)..................................... 8-80
CHECKING THE HORN..........................................................................8-80
CHECKING THE FUEL SENDER ........................................................... 8-80
CHECKING THE FUEL LEVEL WARNING LIGHT .................................8-81
CHECKING THE RADIATOR FAN MOTOR ...........................................8-81
CHECKING THE COOLANT TEMPERATURE SENSOR.......................8-81
CHECKING THE THROTTLE SERVO MOTOR ..................................... 8-82
CHECKING THE INTAKE AIR TEMPERATURE SENSOR ....................8-82
CHECKING THE FUEL INJECTORS......................................................8-83
CHECKING THE PURGE CUT VALVE SOLENOID
(for California only) ................................................................................. 8-83
CHECKING THE SMART KEY BATTERY
(for MT09SPR/MT09SPRC) ................................................................... 8-84
CHECKING THE BUZZER (for MT09SPR/MT09SPRC)......................... 8-84
CHECKING THE FUEL TANK CAP (for MT09SPR/MT09SPRC)...........8-84
CHECKING THE MAIN SWITCH SOLENOID
(for MT09SPR/MT09SPRC) ................................................................... 8-85
 EAS30490
EAS20072

MT09R/MT09RC

R
R/W 47 O R/W
R O O
ON 1 Br/W
OFF 50 (B)
R/G
CIRCUIT DIAGRAM

L/B R R/W
Br/L L/Y
26 48 Gy/R R/W
Br Br/R L/R B R Gy/R Gy/R
Br/R W L/W P L/B L Sb Y Sb/W 50 (B)
R L/B Br/L L/Y B W L/R
L/Y Br/L L/B
31 R/W
49 O/G R/W
O/G O/G
IGNITION SYSTEM

32 50 (B)
R/B
P BY Sb L L/B R/W
L/Y R/W
B/Y R/W
L/G R/W
R/W R/W
R/B

L Y W L/G
Br/L Br/L Br/L P Br/L Sb L/B B/Y Br
Br/L P R/W
Br/L Br/L **
R R/W L/B L L/Y B/Y Y Sb L/G L/W W Br
Br
R/L 34
B B B Lg/W Lg/W Lg/W Lg/W
R/W L/B

Br/L
Br/L 8 29 35 B
Lg/W
R/W Lg/L Lg/L Lg/L Lg/L
B B Lg/W
(B)
R/W
11 Br/L
L/B B B
R R Lg/L 46
(B)
Lg/L
13 Gy B Gy B/L
R/G
41 (B)
(B)
B Gy Gy
B/L
Gy B/L
R B/L
R B/L
B/L
Br/L B/L B/L
Br/L L/W R
83 R B/L B/L
Y/R W/R L Br/Y Br/W Y/R P/W P/B O O/G Gy/R
R Lg/R R/B L/B G/B B
85 Y W Gy/W
R R/L G/Y B
OFF B/L Br
RUN Y/B B W/B R/G * Y/B L/W R B/W B/W
START (B) (B)
19 Br/L B/L

8-1
Br/L
L/R B/W Br/W B/L B/L
L/B Lg/L W/L Y P/W P V L L/R Gy
L/R B/W L/W
L/W Lg/W W/Y B/Y Gy/G Br/W B/L B/R
Br/L G/W B/L 20 L/Y L/G Lg/B G/W G/B W/G W/B

(B)
L/R
R/B R/W
L/R L/R L/R B

R/W
Br/L Lg/W
79 R/B Br/L Lg/L
B L/R

Br/R Br
Br/L
L/W
Br
80 Br/R
Br/L L/W

B/W Lg/W Lg/L R/W B/W B

61 B/W B
(B)
Lg/W R/W
Lg/L B/W
B B B

B B

B B B B

B B
BB
B B B/W
B B B
B B
B B B/W
B B B B/W
B
B/W B
B B/W
B B/W
B B B
B/W B/W
B
B
B B
B/W

B/W
IGNITION SYSTEM
 IGNITION SYSTEM

1. Main switch
8. Fuse box
11. Main fuse
13. Backup fuse 2
19. Ignition fuse 1
20. Ignition fuse 2
26. Battery
29. Frame ground
31. Relay unit
32. Starting circuit cut-off relay
34. Neutral switch
35. Sidestand switch
41. Crankshaft position sensor
46. ECU (Engine Control Unit)
47. Ignition coil #1
48. Ignition coil #2
49. Ignition coil #3
50. Spark plug
61. IMU (Inertial Measurement Unit)
79. Engine stop relay
80. Starting circuit cut-off relay 2
83. Handlebar switch (right)
85. Stop/run/start switch

*. For California only: Y

Except for California: blank

**. For California only: R/W

Except for California: blank

8-2
 R
R/W 47
Y/L O R/W
R O O
MT09SPR/MT09SPRC

ON Br/W
OFF 1 50 (B)
R/G
R R/W
26 L/B L/B B/R Br Br/L B/G Br Br/R L/R B R 48
Br/L Gy/R R/W
G L/W Y/L B/W O R/G W L/W P L/B L Sb Y Sb/W Gy/R Gy/R
Br/R
(B) 50 (B)
Br/L R B W L/R
Br/L Y/L
31 R/W
49 O/G R/W
R/G
Br/L O/G O/G
L/B 32 (B)
101 50
R/B
B/W P BY Sb L L/B R/W
L/Y R/W
B/Y R/W
L/G R/W
R/W R/W
R/B

L/B
L/B

L/B
L Y W L/G
Br/L Br/L Br/L P Br/L Sb L/Y B/Y Br
Br/L P R/W
Br/L Br/L **
R R/W L/Y L L/Y B/Y Y Sb L/G L/W W Br
Br
Br/L R/L 34
B B B Lg/W Lg/W Lg/W Lg/W
R/W L/B

Br/L
Br/L 8 29 35 B
Lg/W
R/W Lg/L Lg/L Lg/L Lg/L
Br/L B B Lg/W
(B) B
R/W
11 Br/L
L/B B B
R R Lg/L 46
(B)
Lg/L
13 R/G
R/G Gy B Gy B/L
41 (B)
B Gy Gy
B/L
Gy B/L
R B/L
R B/L
B/L
Br/L B/L B/L
Br/L L/W R
83 R B/L B/L
Y/R W/R L Br/Y Br/W Y/R P/B O/G Gy/R O
R Lg/R L/B G/B R/B B
85 Y W Gy/W
R R/L G/Y B
OFF B/L Br
RUN Y/B B W/B R/G * Y/B L/W R B/W B/W
START (B) (B)
19 Br/L B/L
Br/L
L/R B/W Br/W B/L B/L
L/B Lg/L W/L Y/L Y P/W P V L L/R Gy

8-3
L/R B/W L/W
L/W Lg/W W/Y B/Y Gy/G Br/W B/L B/R
Br/L G/W B/L 20 L/Y L/G Lg/B G/W G/B W/G W/B

(B)
L/R
R/B R/W
L/R L/R L/R B

R/W
Br/L Lg/W
79 R/B Br/L Lg/L
B L/R

Br/R Br
Br/L
L/W
Br
80 Br/R
Br/L L/W

B/W Lg/W Lg/L R/W

61 B/W B
(B) B/W B
Lg/W R/W
Lg/L B/W

B B B

B B B B B B

BB
B B
B B B/W
B B B
B B
B B B/W
B B B B/W
B
B/W B
B B/W
B B/W
B B B
B/W B/W
B
B
B B
B/W
B/W B/W
B/W
IGNITION SYSTEM
 IGNITION SYSTEM

1. Main switch
8. Fuse box
11. Main fuse
13. Backup fuse 2
19. Ignition fuse 1
20. Ignition fuse 2
26. Battery
29. Frame ground
31. Relay unit
32. Starting circuit cut-off relay
34. Neutral switch
35. Sidestand switch
41. Crankshaft position sensor
46. ECU (Engine Control Unit)
47. Ignition coil #1
48. Ignition coil #2
49. Ignition coil #3
50. Spark plug
61. IMU (Inertial Measurement Unit)
79. Engine stop relay
80. Starting circuit cut-off relay 2
83. Handlebar switch (right)
85. Stop/run/start switch
101.Remote control unit

*. For California only: Y

Except for California: blank

**. For California only: R/W

Except for California: blank

8-4
 IGNITION SYSTEM

EAS30491

ENGINE STOPPING DUE TO SIDESTAND OPERATION

When the engine is running and the transmission is in gear, the engine will stop if the sidestand is
moved down. This is because the electric current from the ECU does not flow to the ignition coils or fuel
injectors when the neutral switch or sidestand switch is open. However, the engine continues to run un-
der the following conditions:
• The transmission is in gear (the neutral switch is open) and the sidestand is up (the sidestand switch
circuit is closed).
• The transmission is in neutral (the neutral switch is closed) and the sidestand is down (the sidestand
switch circuit is open).
2

1
3

12
9
8
6
13

11 10 7

1. Battery
2. Main fuse
3. Main switch
4. Ignition fuse 1
5. Stop/run/start switch
6. Ignition coil
7. Spark plug
8. ECU (Engine Control Unit)
9. Relay unit (diode)
10. Sidestand switch
11. Neutral switch
12. Engine stop relay
13. Remote control unit

8-5