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Yamaha TMAX 2020, Service Manual


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XP560D 2020

1. Battery charger terminal
2. Remote control unit
3. OFF/LOCK switch
4. Parking/Unlock switch
5. Buzzer
6. Steering lock relay
7. Turn signal/hazard relay
8. Storage box light
9. Windshield motor fuse
10. Joint coupler
11. Crankshaft position sensor
12. AC magneto
13. Rectifier/regulator
14. Ignition system relay
15. Signaling system fuse
16. Ignition fuse
17. Taillight fuse
18. Radiator fan motor fuse
19. Fuel injection system fuse
20. Backup fuse
21. Diode 3
22. Battery
23. Engine ground
24. Main fuse
25. Starter relay
26. Starter motor
27. Diode 1
28. Sidestand relay
29. Diode 2
30. Fuel injection system relay
31. Starting circuit cut-off relay
32. Sidestand switch
33. Diode 4
34. Handlebar switch (right)
35. Engine stop switch
36. ON/start switch
37. Hazard switch
38. Mode switch
39. Headlight relay (dimmer)
40. Brake light relay
41. Brake light fuse
42. Front brake light switch
43. Rear brake light switch
44. Grip cancel switch
45. Smart key system relay 

(unlock)

46. Storage compartment lid lock 

solenoid

47. Seat/fuel lid lock solenoid
48. Smart key system relay (lock)
49. Windshield drive unit relay 

(down)

50. Windshield drive unit
51. Windshield drive unit relay (up)
52. Seat heater relay (control)
53. Seat heater relay (power)
54. Seat heater
55. Meter assembly

56. Smart key system indicator 

light

57. Meter light
58. Tachometer
59. Fuel level warning light
60. MIL (Malfunction indicator light)
61. Traction control system indica-

tor light

62. Turn signal indicator light (left)
63. Turn signal indicator light (right)
64. Cruise control system indicator 

light

65. Cruise control setting indicator 

light

66. Steering damper and suspen-

sion warning light

67. ABS warning light
68. High beam indicator light
69. Multi-function display
70. ECU (Engine Control Unit)
71. Ignition coil
72. Spark plug
73. Grip warmer connector
74. Grip warmer (left)
75. Grip warmer (right)
76. Coolant temperature sensor
77. Intake air temperature sensor
78. Intake air pressure sensor
79. Lean angle sensor
80. O

2

 sensor

81. Injector #1
82. Injector #2
83. Throttle servo motor
84. Accelerator position sensor
85. Throttle position sensor
86. Fuel sender
87. Fuel pump
88. Front wheel sensor
89. Rear wheel sensor
90. ABS ECU (Electronic Control 

Unit)

91. YDT coupler
92. Radiator fan motor
93. Radiator fan motor relay
94. Horn
95. Handlebar switch (left)
96. Cruise control power switch
97. Cruise control setting switch
98. Dimmer/pass switch
99. Horn switch
100.Menu switch
101.Select switch
102.Turn signal switch
103.Tail/brake light
104.License plate light
105.Rear turn signal light (right)
106.Rear turn signal light (left)
107.Front turn signal light (right)
108.Front turn signal light (left)
109.Auxiliary light

110.Headlight (high)
111.Headlight (low)
112.Headlight control unit
113.Cruise control fuse
114.Auxiliary DC jack
115.ABS solenoid fuse
116.ABS motor fuse
117.Electronic throttle valve fuse
118.Headlight fuse
119.Auxiliary DC jack fuse
120.ABS ECU fuse
121.Storage box light switch
122.Anti-theft alarm (OPTION)
123.Steering lock unit
124.Centerstand lock solenoid

A. Wire harness
B. Negative battery sub-wire har-

ness

C. Headlight sub-wire harness

Summary of Contents for TMAX 2020

Page 1: ...2020 SERVICE MANUAL TMAX TMAX TECH MAX XP560EL XP560D B3T 28197 20...

Page 2: ......

Page 3: ...ill 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 Designs and specifications are...

Page 4: ...itle 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...

Page 5: ...TION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clea...

Page 6: ......

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

Page 8: ......

Page 9: ...1 GENERAL INFORMATION IDENTIFICATION 1 1 VEHICLE IDENTIFICATION NUMBER 1 1 MODEL LABEL 1 1 FEATURES 1 2 MULTI FUNCTION DISPLAY 1 2 CANCELING THE SIDESTAND ALARM BEEPER 1 11 SPECIAL TOOLS 1 12...

Page 10: ...AS30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped onto the right side of the frame EAS30003 MODEL LABEL The model label 1 is affixed to the storage box This informat...

Page 11: ...is detected in the fuel meter electri cal circuit the fuel meter will flash repeatedly Check the vehicle Coolant temperature meter The coolant temperature varies with changes in the weather and engine...

Page 12: ...before the V belt re placement indicator flashes the indicator must be reset in order for the next periodic V belt change to be indicated at the correct time Oil change indicator This indicator flashe...

Page 13: ...the handlebar grip or throttle grip be comes worn or damaged stop using the grip warmers and replace the grips Adjusting the seat heater This vehicle can be equipped with a seat heater which can only...

Page 14: ...traveled from that point In this case push the select switch to switch the display in the following order F TRIP Display 1 Display 2 Dis play 3 F TRIP If you do not reset the fuel reserve tripmeter ma...

Page 15: ...ttings 1 Use the select switch to highlight Grip Warmer 1 Setting mode display 1 Display Description Grip Warmer This function allows you to set the low middle and high settings to 10 temperature leve...

Page 16: ...o return to the menu screen Seat heater settings 1 Use the select switch to highlight Seat Heat er 2 Push the MENU switch The seat heater setting display will be shown 3 Push the MENU switch The tempe...

Page 17: ...hen you finished changing the settings push the MENU switch to return to the menu screen Resetting the maintenance counters 1 Use the select switch to highlight Mainte nance 2 Push the MENU switch and...

Page 18: ...e display to change and then push the MENU switch again 3 Use the select switch to highlight the item to change and then push the MENU switch TIP Display item order is as follows 4 Use the select swit...

Page 19: ...he clock TIP The clock uses a 12 hour time system 1 Use the select switch to highlight Clock 2 Push the MENU switch 3 When the hour digits are highlighted use the select switch to set the hours 4 Push...

Page 20: ...e will stop and the beeper will sound to prevent you from forgetting to turn off the vehicle power The sidestand alarm beeper can be set to not activate Setting procedure 1 Set the engine stop switch...

Page 21: ...provided below to avoid any mistakes TIP For U S A and Canada use part numbers starting with YM YU or ACC For others use part numbers starting with 90890 Tool name Tool No Illustration Reference page...

Page 22: ...90890 01426 Oil filter wrench YU 38411 3 27 6 8 Oil pressure gauge set 90890 03120 3 29 Oil pressure adapter B 90890 03124 3 29 Pressure gauge 90890 03153 Pressure gauge YU 03153 3 29 7 12 7 13 Fork...

Page 23: ...90890 01437 Universal damping rod bleeding tool set YM A8703 4 87 Rod puller attachment M10 90890 01436 Universal damping rod bleeding tool set YM A8703 4 87 Compression gauge 90890 03081 Engine compr...

Page 24: ...guide installer 4 0 mm YM 04112 5 25 Valve guide reamer 4 90890 04113 Valve guide reamer 4 0 mm YM 04113 5 25 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 31 Digital circuit tester...

Page 25: ...ve spring compressor 90890 04134 Sheave spring compressor YM 04134 5 43 5 46 Sheave fixed block 90890 04135 Sheave fixed bracket YM 04135 5 43 5 46 Yamaha bond No 1215 90890 85505 Three bond No 1215 5...

Page 26: ...holder YU 01235 5 58 5 61 Clutch spring compressor 90890 01482 5 58 5 61 Universal clutch holder 90890 04086 Universal clutch holder YM 91042 5 58 5 60 Plane bearing installer 90890 04139 5 75 5 79 Ra...

Page 27: ...6 14 Fuel injector pressure adapter 90890 03210 Fuel injector pressure adapter YU 03210 7 12 Fuel pressure adapter 90890 03186 Fuel pressure adapter YM 03186 7 13 Ignition checker 90890 06754 Oppama p...

Page 28: ...stic tool A I 90890 03264 This special tool includes the YDT sub harness 6P 90890 03266 TIP YDT sub harness 6P 90890 03266 If you already have Yamaha diagnostic tool A I 90890 03262 YDT sub harness 6P...

Page 29: ...GENERAL SPECIFICATIONS 2 1 ENGINE SPECIFICATIONS 2 2 CHASSIS SPECIFICATIONS 2 7 ELECTRICAL SPECIFICATIONS 2 9 TIGHTENING TORQUES 2 11 ENGINE TIGHTENING TORQUES 2 11 CHASSIS TIGHTENING TORQUES 2 11 CA...

Page 30: ...n Overall width 765 mm 30 1 in Overall height 1420 1475 mm 55 9 58 1 in XP560E 1420 1555 mm 55 9 61 2 in XP560D Wheelbase 1575 mm 62 0 in Ground clearance 125 mm 4 92 in Minimum turning radius 2 8 m 9...

Page 31: ...gal Engine oil Recommended brand YAMALUBE SAE viscosity grades 10W 40 Recommended engine oil grade API service SG type or higher JASO standard MA Lubrication system Dry sump Engine oil quantity Oil ch...

Page 32: ...intake 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Valve seat contact width exhaust 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Valve stem diameter intake 3 975 3 990 mm 0 1565 0 1571 i...

Page 33: ...0 0026 in Side clearance limit 0 115 mm 0 0045 in 2nd ring End gap limit 0 85 mm 0 0335 in Ring side clearance 0 020 0 055 mm 0 0008 0 0022 in Side clearance limit 0 115 mm 0 0045 in Connecting rod Oi...

Page 34: ...ity 7 pcs Clutch spring plate height 4 70 mm 0 19 in Minimum height 4 40 mm 0 17 in Spring quantity 1 pcs Clutch in revolution 1650 2250 r min Clutch stall revolution 3500 4500 r min V belt V belt wid...

Page 35: ...2 feedback control Active Coolant temperature 85 105 C 185 221 F Intake vacuum 34 0 kPa 255 mmHg 10 0 inHg Difference in vacuum pressure between the cylinders 0 kPa 1 3 kPa 0 mmHg 10 mmHg 0 inHg 0 4 i...

Page 36: ...TLAX SCF Rear tire Type Tubeless Size 160 60R15M C 67H Manufacturer model BRIDGESTONE BATTLAX SCR Tire air pressure measured on cold tires 1 person Front 225 kPa 2 25 kgf cm 33 psi Rear 250 kPa 2 50 k...

Page 37: ...2 mm 0 01 in Recommended oil Yamaha Suspension Oil 01 Quantity left 444 0 cm 15 01 US oz Quantity right 434 0 cm 14 67 US oz Level left 114 mm 4 5 in Level right 118 mm 4 6 in Rear suspension Type Swi...

Page 38: ...ge up to operating angle 0 4 1 4 V Output voltage over operating angle 3 7 4 4 V Charging system Charging system AC magneto Standard output 14 0 V 25 0 A at 5000 r min Stator coil resistance 0 224 0 3...

Page 39: ...air temperature sensor resistance 5400 6600 at 0 C 5400 6600 at 32 F Intake air temperature sensor resistance 290 390 at 80 C 290 390 at 176 F Atmospheric pressure sensor output voltage 3 59 3 67 V a...

Page 40: ...kgf m 30 lb ft Coolant drain bolt M12 1 1 6 N m 0 16 kgf m 1 2 lb ft Engine oil drain bolt M14 1 43 N m 4 3 kgf m 32 lb ft Item Thread size Q ty Tightening torque Remarks Front wheel axle M14 1 91 N m...

Page 41: ...h a soft hammer until its end is flush with the front fork However if the surface of the front axle end is not parallel to the surface of the front fork align a point on the outer edge of the axle wit...

Page 42: ...2 13 CABLE ROUTING EAS20021 CABLE ROUTING Headlight bracket front view...

Page 43: ...te handle bar switch coupler 3 left white rear brake light switch coupler white for XP560D front brake light switch cou pler black for XP560D handlebar switch coupler 3 right black for XP560E han dleb...

Page 44: ...2 15 CABLE ROUTING Front cowling assembly rear view...

Page 45: ...lamp does not matter D Route the headlight sub wire harness going to the right turn signal light in front of the headlight assembly lead E Fully push in the blue tape section of the headlight sub wire...

Page 46: ...2 17 CABLE ROUTING Frame right side view front...

Page 47: ...cooling sys tem air bleed hose G Insert the injector couplers separately into 1 and 2 H Route the radiator fan motor lead on the inside of the radiator inlet hose I Fasten the radiator fan motor lead...

Page 48: ...2 19 CABLE ROUTING Frame right side view rear...

Page 49: ...ck cylinder E To seat heater for XP560D F Fasten the storage box light switch lead with the clamp G It does not matter whether the storage box light leads are installed on the left or right of the sto...

Page 50: ...2 21 CABLE ROUTING Frame left side view front Q...

Page 51: ...ead cou pler D Pass it outside the starter motor lead E Make sure the spark plug leads after this clamp are not twisted F Make sure there is no slack in the spark plug lead when installed within this...

Page 52: ...2 23 CABLE ROUTING Rear frame left side view center...

Page 53: ...he illustration Point the end of the plastic locking tie rearward and place it inside of the footboard I Assemble the wire harness clamp to the round area of the rib J Install the plastic locking tie...

Page 54: ...2 25 CABLE ROUTING Frame left side view rear...

Page 55: ...P560D B The order of arrangement of the lead does not matter as long as it is installed within this range C Install the plastic locking tie within this range D Fasten the tape portion of each lead wit...

Page 56: ...2 27 CABLE ROUTING Frame top view front...

Page 57: ...ront brake hose hydraulic unit to front brake caliper 16 Windshield drive unit cable for XP560D A After connecting the coupler to the meter insert it until the coupler cover contacts the bottom of the...

Page 58: ...2 29 CABLE ROUTING Frame top view rear...

Page 59: ...relay control for XP560D 11 Seat heater relay power for XP560D 12 Radiator fan motor relay 13 Turn signal hazard relay 14 Wire harness 15 Storage box light switch lead A Route the lead along the edge...

Page 60: ...2 31 CABLE ROUTING Handlebar top and left side view for XP560E...

Page 61: ...e hose holder A Route the rear brake lock cable through the hole in the handlebar cover B Route through the cable guide in the order of the throttle cable decelerator cable fol lowed by throttle cable...

Page 62: ...2 33 CABLE ROUTING Handlebar front view for XP560E...

Page 63: ...ront brake hose with the white paint mark on the metal part facing the front L Route the metal part of the rear brake hose between the guides of the rear brake mas ter cylinder M Attach the rear brake...

Page 64: ...2 35 CABLE ROUTING Handlebar top and left side view for XP560D...

Page 65: ...y throttle cable accelerator cable C Install the grip warmer lead left into the slot in the handlebar switch left D Turn the rear brake lock lever up to the position shown in the illustration before i...

Page 66: ...2 37 CABLE ROUTING Handlebar front view for XP560D...

Page 67: ...right to assemble it N The metal part of the front brake hose should come into contact with the guide section of the front brake master cylinder O Install the front brake hose with the white paint mar...

Page 68: ...2 39 CABLE ROUTING Front brake front left side and right side view Q...

Page 69: ...tic locking tie The plastic locking tie should face downward with the end cut to 5 mm 0 2 in or less J Install the bracket with the identification mark facing the front K Install the front brake hose...

Page 70: ...2 41 CABLE ROUTING Frame right side view front...

Page 71: ...ke lock cable in front of the section where the electrical compo nents tray and frame are fastened D Route the rear brake hose along the guide of the electrical components tray E Make sure there is no...

Page 72: ...2 43 CABLE ROUTING Rear brake right side view rear...

Page 73: ...ation stopper against the rear frame C Install the clamp with the clamp in contact with the protector end of the rear wheel sensor lead D Install the rear brake hose with the rear brake hose in contac...

Page 74: ...2 45 CABLE ROUTING Fuel tank right side view...

Page 75: ...nd fuel tank breather hose with the clamp Install the clamp with the longer side of the fixed sec tion facing downward and adjust the posi tion so that the intersection of the rear brake hose and fuel...

Page 76: ...2 47 CABLE ROUTING Fuel tank left side view...

Page 77: ...all the fuel tank overflow hose with the mark facing the outside B Route the fuel tank overflow hose between the sidestand bracket and the frame C Align the mark on the fuel tank with the mark on the...

Page 78: ...2 49 CABLE ROUTING Fuel tank top view...

Page 79: ...he hose mounting area G Insert the canister purge hose until it butts against the throttle body assembly H Do not allow the bolt head of the clamp that is holding the throttle body joint to touch the...

Page 80: ...2 51 CABLE ROUTING Air filter case and throttle body left side view...

Page 81: ...ntil it butts against the throttle body assembly E Do not allow the intake air pressure sensor hose to be twisted F Pass the intake air pressure sensor hose under the brim of the air filter case duct...

Page 82: ...2 53 CABLE ROUTING Radiator right side view...

Page 83: ...lant reservoir hose to the bottom of the radiator filler hose O 2 mm 0 08 in or more P Insert the oil cooler inlet hose all the way to the paint mark on the end Q Make sure the clamp does not ride on...

Page 84: ...2 55 CABLE ROUTING Radiator left side view...

Page 85: ...contact with it 0 10 mm 0 0 39 in J Align the clamp with the paint mark on the coolant reservoir hose K Make sure the clamp does not ride on top of the bulge in the hose installing area L Make sure t...

Page 86: ...2 57 CABLE ROUTING Radiator top view...

Page 87: ...e clamp does not ride on top of the bulge in the hose mounting area C Install the clip with its end facing the down D Insert the coolant reservoir hose until it comes into contact with the rib of the...

Page 88: ...2 59 CABLE ROUTING Hydraulic unit assembly top and front view...

Page 89: ...front brake hose 3 with the L shaped pin in contact with the side of the hydraulic unit The installation order of rear brake hose 1 and front brake hose 3 does not matter 2 Install the front brake ho...

Page 90: ...2 61 CABLE ROUTING...

Page 91: ...NT AND CLEANING THE CHECK HOSE 3 12 CLEANING THE V BELT CASE AIR FILTER ELEMENT 3 13 CHECKING THE BRAKE OPERATION 3 14 CHECKING THE BRAKE FLUID LEVEL 3 14 ADJUSTING THE FRONT DISC BRAKE 3 14 CHECKING...

Page 92: ...SHOCK ABSORBER ASSEMBLY for XP560D 3 25 CHECKING THE CONNECTING ARM AND RELAY ARM 3 26 CHECKING THE ENGINE OIL LEVEL 3 27 CHANGING THE ENGINE OIL 3 27 MEASURING THE ENGINE OIL PRESSURE 3 29 CHECKING T...

Page 93: ...ISSION CONTROL SYSTEM EAS30615 GENERAL MAINTENANCE AND LUBRICATION CHART No ITEM CHECK OR MAINTENANCE JOB ODOMETER READINGS ANNUAL CHECK 1000 km 600 mi 10000 km 6000 mi 20000 km 12000 mi 30000 km 1800...

Page 94: ...es for looseness Moderately repack with lithi um soap based grease 17 Chassis fasteners Make sure that all nuts bolts and screws are properly tight ened 18 Front and rear brake lever pivot shaft Lubri...

Page 95: ...ternal components of the brake master cylinders and calipers and change the brake fluid every 2 years Replace the brake hoses every 4 years or sooner if cracked or damaged 28 Front and rear brake swit...

Page 96: ...AND DIAGNOSTIC CODE TABLE on page 9 38 4 Perform 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 u...

Page 97: ...plug Insulator 2 Abnormal color Replace the spark plug Normal color is medium to light tan 6 Clean Spark plug with a spark plug cleaner or wire brush 7 Measure Spark plug gap a with a wire thickness...

Page 98: ...e generator rotor with the mark b on the generator cover TIP TDC on the compression stroke can be found when the cylinder 1 camshaft lobes are turned away from each other In order to be sure that the...

Page 99: ...valve clearance Example Specified valve clearance 0 15 0 22 mm 0 0059 0 0087 in Measured valve clearance 0 25 mm 0 0098 in 0 25 mm 0 0098 in 0 22 mm 0 0087 in 0 03 mm 0 001 in c Check the thickness o...

Page 100: ...e specified clearance is obtained 8 Install All removed part TIP For installation reverse the removal procedure 9 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP on page 3 33 EAS310...

Page 101: ...Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Fuel tank Refer to FUEL TANK on page 7 1 3 Remove Intake air pressure sensor hose 1 Cap 2 4 Install Hose 1 Parts No 5JW 24311 00 3 way joint 2 Parts N...

Page 102: ...ace the throttle bodies The difference in vacuum pressure between the throttle bodies should not exceed 1 33 kPa 10 mmHg 2 Stop the engine and remove the measuring equipment 3 Install Intake air press...

Page 103: ...r 5 4 Install Footboard right Rear side cowling assembly right Side cover right Fuel tank cover assembly Center cover Refer to GENERAL CHASSIS 2 on page 4 11 Bottom center cowling Side panel Bottom si...

Page 104: ...olume use the CO adjustment mode of the YDT For more infor mation refer to the operation manual of the YDT 1 Remove the protective cap and then connect the YDT to coupler Refer to YDT on page 9 3 TIP...

Page 105: ...HE V BELT CASE AIR FILTER ELEMENT 1 Remove Bottom side cowling Side panel Bottom center cowling Refer to GENERAL CHASSIS 1 on page 4 1 Center cover Fuel tank cover assembly Side cover Rear side cowlin...

Page 106: ...e 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...

Page 107: ...the brake pads as a set Refer to FRONT BRAKE on page 4 38 EAS30631 ADJUSTING THE REAR DISC BRAKE 1 Adjust Rear brake lever position distance a from the left side grip to the brake lever a Push the bra...

Page 108: ...AR BRAKE on page 4 50 EAS30893 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING EWA14000 Always bleed the brake system when the brake related parts are removed NOTICE ECA18050 Bleed the brake system in the...

Page 109: ...ir to the proper level with the speci fied brake fluid l Tighten the bleed screw to specification m Fill the brake master cylinder reservoir to the proper level with the specified brake flu id Refer t...

Page 110: ...1 Check Rear brake lock operation Apply the rear brake lock and then pushing the vehicle for properly locks the rear brake lock Rear brake lock not working properly Check the rear brake lock cable an...

Page 111: ...ires 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 c...

Page 112: ...on page 4 94 2 Clean Drive belt a Wipe the drive belt with a clean cloth b Put the drive belt in a mixture of mild deter gent and water Then remove any dirt from the drive belt c Remove the drive bel...

Page 113: ...t room temperature and when the drive belt is dry 1 Stand the vehicle on a level surface TIP Place the vehicle on the centerstand 2 Remove the drive belt upper guard Refer to REAR WHEEL on page 4 30 3...

Page 114: ...tween the left and right sides is within 0 8 mm 0 03 in 7 Use the tension meter and measure the drive belt tension again 8 Measure and adjust until proper drive belt tension within specification value...

Page 115: ...ou put in too much grease the grease will come out of the holder which could cause grease to get on the drive belt TIP Use a scale to weigh the grease and inject 38 g into the drive pulley assembly in...

Page 116: ...turning the front fork all the way in both directions If any binding is felt re move the lower bracket and check the up per and lower bearings Refer to STEERING HEAD on page 4 90 e Install the rubber...

Page 117: ...ace WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Check Inner tube Damage scratches Replace Front fork leg Oil leaks between inner tube and outer tube R...

Page 118: ...is ad justment range may not exactly match the spec ifications listed due to small differences in production EAS30809 CHECKING THE CONNECTING ARM AND RELAY ARM 1 Check Rear shock absorber assembly ope...

Page 119: ...ankcase TIP Before checking the engine oil level wait a few minutes until the oil has settled 4 Start the engine warm it up for several min utes and then turn it off 5 Check the engine oil level again...

Page 120: ...g and bot tom center cowling Refer to GENERAL CHASSIS 1 on page 4 1 b Slightly loosen the engine oil check bolt 1 c Start the engine and keep it idling until en gine oil starts to seep from the oil ch...

Page 121: ...point plug TIP Lubricate the O ring of the engine oil pressure check point plug with a thin coat of lithium soap based grease EAS30811 CHECKING THE COOLANT LEVEL 1 Stand the vehicle on a level surface...

Page 122: ...CKING THE COOLING SYSTEM 1 Remove Bottom side cowling Side panel Radiator cover Bottom center cowling Refer to GENERAL CHASSIS 1 on page 4 1 Center cover Fuel tank cover assembly Side cover Rear side...

Page 123: ...team may be blown out which could cause serious in 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...

Page 124: ...lant to the maxi mum level mark a 12 Install Coolant reservoir cap 13 Start the engine warm it up for one minute and then stop it TIP Place the vehicle on the centerstand 14 Check Coolant level Refer...

Page 125: ...all of the in ner and outer cables WARNING EWA13270 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 possibl...

Page 126: ...CHARGING THE BATTERY Refer to CHECKING AND CHARGING THE BATTERY on page 8 94 EAS30662 CHECKING THE FUSES Refer to CHECKING THE FUSES on page 8 93 EAS30664 ADJUSTING THE HEADLIGHT BEAMS 1 Adjust Headli...

Page 127: ...EL 4 22 REMOVING THE FRONT WHEEL 4 24 DISASSEMBLING THE FRONT WHEEL 4 24 CHECKING THE FRONT WHEEL 4 24 ASSEMBLING THE FRONT WHEEL 4 25 MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR 4 26 ADJUS...

Page 128: ...ALIPER 4 60 ASSEMBLING THE REAR BRAKE CALIPER 4 60 INSTALLING THE REAR BRAKE CALIPER 4 60 REMOVING THE REAR BRAKE MASTER CYLINDER 4 61 CHECKING THE REAR BRAKE MASTER CYLINDER 4 61 ASSEMBLING THE REAR...

Page 129: ...THE DRIVE BELT 4 95 INSTALLING THE DRIVE BELT AND DRIVE PULLEY 4 95 REAR SHOCK ABSORBER ASSEMBLY 4 96 HANDLING THE REAR SHOCK ABSORBER 4 97 DISPOSING OF A REAR SHOCK ABSORBER 4 97 REMOVING THE REAR S...

Page 130: ...r 1 6 Rearview mirror 2 7 Windshield inner panel 1 8 Meter assembly coupler 1 Disconnect 9 Meter assembly 1 10 Meter panel assembly 1 3 1 1 3 4 5 7 8 10 9 6 6 2 2 1 6 N m 0 16 kgf m 1 2 lb ft 1 5 N m...

Page 131: ...6 Windshield inner panel 1 7 Meter assembly coupler 1 Disconnect 8 Meter assembly 1 9 Meter panel assembly 1 3 1 1 3 4 6 7 9 8 5 5 2 2 1 6 N m 0 16 kgf m 1 2 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N...

Page 132: ...ct 2 Front turn signal light 2 3 Headlight assembly coupler 2 Disconnect 4 Front cowling assembly 1 5 Side cowling 2 6 Front turn signal light bracket 2 7 Headlight under panel 1 8 Headlight sub wire...

Page 133: ...rts to remove Q ty Remarks 1 Footboard mat 4 2 Bottom side cowling 2 3 Side panel 2 4 Radiator cover 1 5 Bottom center cowling 1 3 1 1 1 2 3 2 3 4 5 1 5 N m 0 15 kgf m 1 1 lb ft 1 5 N m 0 15 kgf m 1 1...

Page 134: ...SIS 2 on page 4 11 1 Battery cover 1 2 Negative battery lead 1 Disconnect 3 Positive battery lead 1 Disconnect 4 Battery band 1 5 Battery 1 6 Storage compartment lid lock solenoid coupler 1 Disconnect...

Page 135: ...13 Auxiliary DC jack 1 14 Storage box 1 15 Protector 1 16 Storage compartment lid lock solenoid 1 17 Cover 1 FWD FWD 13 14 15 16 17 1 5 N m 0 15 kgf m 1 1 lb ft 4 0 N m 0 40 kgf m 3 0 lb ft 1 5 N m 0...

Page 136: ...shield by removing the screws 3 d Install the windshield to the desired position by installing the screws 3 e Tighten the screws to the specified torque f Install the caps 1 g Place the windshield cov...

Page 137: ...ts b EAS30821 REMOVING THE SIDE PANEL The following procedure applies to both of the side panels 1 Remove Bottom side cowling 2 Remove Side panel 1 a Remove the side panel screws 2 b Remove the quick...

Page 138: ...ners 3 c Install the side panel screws 4 2 Install Bottom side cowling EAS30819 REMOVING THE INNER PANEL The following procedure applies to both of the in ner panels 1 Remove Inner panel 1 a Remove th...

Page 139: ...by moving it in the arrow direction EAS31677 REMOVING THE BATTERY COVER 1 Remove Battery cover 1 a Remove the battery cover screw 2 b Remove the part a of the battery cover c Remove the battery cover...

Page 140: ...1 2 Fuel tank cover assembly 1 3 Seat fuel lid lock solenoid coupler 1 Disconnect 4 Seat lock cable 1 Disconnect 5 Side cover 2 6 Footboard 4 7 Seat fuel button cover 1 8 Cover 2 9 Seat fuel lid lock...

Page 141: ...sembly Side cover Refer to GENERAL CHASSIS 2 on page 4 11 1 Grab bar 2 2 Rubber cover 1 3 Rear side cowling assembly 2 4 Rear side cowling 2 5 Inner panel 2 6 Rear turn signal light coupler 2 Disconne...

Page 142: ...n page 4 11 1 Rear cover 1 2 Tail brake light coupler 1 Disconnect 3 Seat lock cable 1 Disconnect 4 Rear cowling assembly 1 5 Lid 1 6 Tail brake light 1 7 Seat lock key cylinder 1 8 Tail brake light c...

Page 143: ...Refer to GENERAL CHASSIS 2 on page 4 11 1 Storage box inner mat 1 2 Storage box light switch connector 2 Disconnect 3 Wire harness 1 Disconnect 4 Storage box 1 5 Rear panel 2 6 Storage box light 1 7...

Page 144: ...Remove Side cover Rear cover Grab bar Refer to GENERAL CHASSIS 2 on page 4 11 2 Remove Rear side cowling assembly 1 a Remove the rear side cowling assembly screw bolt and quick fastener EAS31523 REMOV...

Page 145: ...liding it to the upper side EAS31193 REMOVING THE REAR COVER 1 Remove Rubber cover 1 2 Remove Grab bar Rear side cowling assembly GENERAL CHASSIS 2 on page 4 11 3 Remove Tail brake light cover 1 a Rem...

Page 146: ...el tank cover assembly Side cover Rear side cowling assembly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 1 Ignition coil connector 2 Disconnect 2 Ignition coil 1 3 Buzzer coupler 1 Disconnect 4...

Page 147: ...r cover Fuel tank cover assembly Side cover Rear side cowling assembly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 1 Handlebar switch coupler 2 2 Rectifier regulator coupler 1 Disconnect 3 Recti...

Page 148: ...ssembly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Brake hose holder Refer to HANDLEBAR on page 4 74 1 Handlebar switch coupler 2 2 Rectifier regulator coupler 1 Disconnect 3 Rectifier regulato...

Page 149: ...ly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Battery box Electrical components tray Meter bracket Windshield bracket XP560E Wind shield drive unit XP560D Refer to GENERAL CHASSIS 3 on page 4 1...

Page 150: ...drive unit coupler to the wire harness b Adjust the distances at the top a and bot tom b of the rails so they are the same TIP Refer to the illustration below for the positions to measure c c After i...

Page 151: ...heel axle bolt 1 8 Front wheel axle 1 9 Front wheel 1 10 Collar 1 Length 22 mm 0 87 in 11 Collar 1 Length 18 mm 0 71 in 12 Front brake disc 2 LT LT 1 2 3 3 3 3 4 5 5 6 6 7 8 9 10 11 12 12 1 2 2 5 N m...

Page 152: ...ng the front wheel Order Job Parts to remove Q ty Remarks 1 Front wheel sensor rotor 1 2 Oil seal 2 3 Wheel bearing 2 4 Collar 1 LT 8 N m 0 8 kgf m 5 9 lb ft 2 0 N m 0 20 kgf m 1 5 lb ft 3 0 N m 0 30...

Page 153: ...ousing 3 Elevate Front wheel TIP Place the vehicle on the centerstand so that the front wheel is elevated 4 Loosen Wheel axle pinch bolt 5 Remove Front wheel axle bolt Front wheel axle Front wheel EAS...

Page 154: ...4 that matches the diameter of the wheel bearing outer race b Install the spacer c Install the new wheel bearing left side TIP Place a suitable washer 1 between the socket 2 and the bearing so that bo...

Page 155: ...e 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...

Page 156: ...NT WHEEL STATIC BALANCE TIP After replacing the tire wheel or both the front wheel static balance should be adjusted Adjust the front wheel static balance with the brake disc installed Refer to ADJUST...

Page 157: ...sensor rotor and front wheel sensor TIP When installing the front wheel sensor check the front wheel sensor lead for twists To route the front wheel sensor lead refer to CABLE ROUTING on page 2 13 7...

Page 158: ...holder WARNING EWA13500 Make sure the brake hose is routed properly Front brake caliper bolt 35 N m 3 5 kgf m 26 lb ft Front brake hose holder bolt left 9 N m 0 9 kgf m 6 6 lb ft Front brake hose hol...

Page 159: ...Loosen 6 Adjusting bolt 2 Loosen 7 Rear wheel axle nut 1 8 Washer 1 9 Rear wheel axle 1 10 Adjusting block left 1 11 Adjusting block right 1 12 Rear wheel 1 13 Rear wheel sensor housing 1 14 Brake ca...

Page 160: ...der Job Parts to remove Q ty Remarks 1 Rear brake disc 1 2 Rear wheel sensor rotor 1 3 Drive belt guide 1 4 Rear wheel pulley 1 5 Rear wheel 1 1 2 3 4 5 LT LT LT LT 8 N m 0 8 kgf m 5 9 lb ft 10 N m 1...

Page 161: ...4 32 REAR WHEEL Disassembling the rear wheel assembly Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Wheel bearing left 1 3 Collar 1 4 Wheel bearing right 1 1 4 3 2 1...

Page 162: ...wheel axle Rear wheel Rear brake caliper bracket Rear wheel sensor housing Collar NOTICE ECA21400 Be sure to remove the rear wheel sensor be fore removing the brake caliper bracket oth erwise the sens...

Page 163: ...h care since they have been accurately adjusted Keep them away from dirt and do not sub ject them to shocks The rear wheel sensor cannot be disassem bled Do not attempt to disassemble it If faulty rep...

Page 164: ...ousing Rear brake caliper bracket Rear wheel Adjusting block Rear wheel axle Washer Wheel axle nut TIP Do not install the brake caliper and brake lock caliper Fit the brake torque stop pin a on the sw...

Page 165: ...1 and adjusting bolt 2 9 Install Rear wheel sensor 1 NOTICE ECA21080 Make sure there are no foreign materials in the rear wheel sensor rotor and rear wheel sensor Foreign materials cause damage to the...

Page 166: ...ct during ser vice and caught foreign materials If there is any defective part repair or replace the de fective part TIP Measure the distance between the rear wheel sensor rotor and rear wheel sensor...

Page 167: ...rake pad 2 5 Front brake hose holder bolt 1 The tightening torque of the front brake hose holder bolt on the right side is 7 N m 0 7 kgf m 5 2 lb ft 6 Front brake hose holder 1 7 Front reflector 1 8 F...

Page 168: ...servoir diaphragm holder 1 3 Brake master cylinder reservoir diaphragm 1 4 Front brake lever 1 5 Front brake light switch connector 2 Disconnect For XP560E 6 Brake hose union bolt 1 7 Brake hose gaske...

Page 169: ...4 40 FRONT BRAKE Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 1 2...

Page 170: ...brake hose holder bolt 1 The tightening torque of the front brake hose holder bolt on the right side is 7 N m 0 7 kgf m 5 2 lb ft 2 Front brake hose holder 1 3 Front reflector 1 4 Brake hose union bol...

Page 171: ...lipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Front 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 Left brak...

Page 172: ...ace the brake disc a Place the vehicle on the centerstand so that the front wheel is elevated b Remove the brake caliper c Hold the dial gauge at a right angle against the brake disc surface d Measure...

Page 173: ...the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw d Install the brake pads and brake pad spring TIP The arrow mark a on the brake pa...

Page 174: ...the brake caliper WARNING EWA17060 Never try to pry out the brake caliper pis tons Do not loosen the bolts 4 c Remove the brake caliper piston dust seals and brake caliper piston seals d Repeat the pr...

Page 175: ...Brake hose gasket Brake hose 2 Brake hose union bolt 3 WARNING EWA13531 Proper brake hose routing is essential to in sure safe vehicle operation NOTICE ECA21410 When installing the brake hose onto the...

Page 176: ...master cylinder drain the brake fluid from the entire brake sys tem 1 Disconnect Brake light switch connector from the front brake light switch 2 Remove Brake hose union bolt Brake hose gasket Brake h...

Page 177: ...ter cylinder reservoir with the specified amount of the specified brake fluid WARNING EWA13540 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing...

Page 178: ...nimum level mark Add the specified brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 14 6 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Ref...

Page 179: ...the rear brake pads Order Job Parts to remove Q ty Remarks 1 Rear brake caliper bolt 2 2 Rear brake caliper 1 3 Rear brake pad 2 4 Brake pad support 2 5 Bleed screw 1 S 3 4 3 4 2 5 1 1 FWD FWD 27 N m...

Page 180: ...der reservoir diaphragm holder 1 3 Brake master cylinder reservoir diaphragm 1 4 Rear brake lever 1 5 Rear brake light switch connector 2 Disconnect For XP560E 6 Brake hose union bolt 1 7 Brake hose g...

Page 181: ...4 52 REAR BRAKE Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 S BF 1 2...

Page 182: ...EEDING THE HYDRAULIC BRAKE SYSTEM on page 3 16 1 Brake hose union bolt 1 2 Brake hose gasket 2 3 Rear brake hose 1 4 Rear brake caliper bolt 2 5 Rear brake caliper 1 6 Rear brake pad 2 7 Brake pad sup...

Page 183: ...ear brake caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston 1 2 Brake caliper piston dust seal 1 3 Brake caliper piston seal 1 4 Bleed screw 1 5 Brake caliper body 1 6 N m 0 6 kgf...

Page 184: ...ear brake lock pads Order Job Parts to remove Q ty Remarks 1 Rear brake lock cable adjusting nut 1 2 Pin 1 3 Rear brake lock spring 1 4 Rear brake lock caliper 1 5 Rear brake lock pad 2 5 3 2 1 4 FWD...

Page 185: ...moving the rear brake lock caliper Order Job Parts to remove Q ty Remarks 1 Rear brake lock cable adjusting nut 1 2 Pin 1 3 Rear brake lock spring 1 4 Rear brake lock caliper 1 3 2 1 4 FWD FWD 23 N m...

Page 186: ...r brake lock pad 2 6 Caliper piston assembly 1 Locknut Left hand thread 7 Rear brake lock caliper bracket bolt 1 8 Rear brake lock caliper bracket 1 9 Sleeve 1 10 Boot 2 11 Boot 1 12 Slide pin bolt 1...

Page 187: ...ng Replace 3 Measure Brake disc runout Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 43 4 Measure Brake disc thickn...

Page 188: ...EM on page 3 16 EAS30186 REMOVING THE REAR BRAKE CALIPER TIP Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Brake hose union bolt Brake hose gasket Rear...

Page 189: ...ake caliper is disassembled replace the brake caliper piston dust seal and brake caliper piston seal EAS30190 INSTALLING THE REAR BRAKE CALIPER 1 Install Rear brake caliper 1 temporarily Brake hose ga...

Page 190: ...AKE SYSTEM on page 3 16 EAS30193 REMOVING THE REAR BRAKE MASTER CYLINDER TIP Before removing the rear brake master cylinder drain the brake fluid from the entire brake sys tem 1 Remove Brake hose unio...

Page 191: ...brake hose does not touch other parts e g wire harness cables leads Correct if necessary 3 Fill Brake master cylinder reservoir with the specified amount of the specified brake fluid WARNING EWA13540...

Page 192: ...RAKE LOCK PADS 1 Remove Rear brake lock cable adjusting nut Pin Rear brake lock spring 2 Remove Rear brake lock caliper bolt Rear brake lock caliper 3 Remove Rear brake lock pad left side 1 TIP Push o...

Page 193: ...able 3 Install Rear brake lock cable WARNING EWA13490 Make sure the brake cable is routed properly 4 Adjust Rear brake lock cable length a Adjust the clearance for the rear brake lock pad Refer to ADJ...

Page 194: ...es the locknut b With shaft L fastened turn and adjust the piston adjusting bolt so that the length a between the end of shaft L and the end of the piston adjusting bolt is changed to 19 mm 0 75 in Re...

Page 195: ...ter installing the rear brake lock pad to the caliper check that the pad rotates smoothly EAS31422 INSTALLING THE REAR BRAKE LOCK CALIPER 1 Install Rear brake lock caliper Rear brake lock caliper bolt...

Page 196: ...YSTEM on page 3 16 1 ABS ECU coupler 1 Disconnect 2 Brake hose union bolt 4 3 Brake hose gasket 8 4 Rear brake hose rear brake master cylinder to hydraulic unit 1 Disconnect 5 Front brake hose hydraul...

Page 197: ...cou plers and cause bad contacts If the union bolts for the hydraulic unit as sembly have been removed be sure to tighten them to the specified torque and bleed the brake system 1 Disconnect ABS ECU c...

Page 198: ...draulic unit 4 Gasket Brake hose union bolt NOTICE ECA21121 If the brake hose union bolt does not turn easily replace the hydraulic unit assembly brake hoses and related parts as a set TIP To route th...

Page 199: ...ine routing confirmation use the diagnosis of function of the YDT Before performing the brake line routing confir mation make sure that no malfunctions have been detected in the ABS ECU and that the w...

Page 200: ...o danger of it falling over 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...

Page 201: ...IP The reaction force pulsating action consists of quick pulses Be sure to continue operating the front brake lever and rear brake lever even after the pul sating action has stopped ON and OFF on the...

Page 202: ...it brake pipes and related parts as a set 17 If the operation of the hydraulic unit is normal delete all of the DTC EAS30202 CHECKING THE ABS WARNING LIGHT After all checks and servicing are completed...

Page 203: ...er front 1 3 Parking Unlock switch coupler 1 Disconnect 4 OFF LOCK switch coupler 1 Disconnect 5 Lower handlebar cover 1 6 Accelerator position sensor coupler 1 Disconnect 7 Handlebar cover rear 1 8 P...

Page 204: ...r Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Handlebar cover Refer to HANDLEBAR on page 4 74 1 Front brake light switch connector 2 Disconnect for XP560E 2 Front brake master cylinder holder 1...

Page 205: ...ver 1 13 Rear brake lock cable 1 Disconnect 14 Rear brake master cylinder assembly 1 15 Handlebar switch left 1 16 Handlebar switch holder 2 17 Handlebar grip 1 FWD FWD 10 9 11 12 13 14 15 17 16 16 3...

Page 206: ...board Refer to GENERAL CHASSIS 2 on page 4 11 Handlebar cover Brake master cylinder Handle bar switch Refer to HANDLEBAR on page 4 74 1 Clamp 2 2 Bracket 1 3 Upper handlebar holder 2 4 Handlebar 1 5 L...

Page 207: ...ehicle so that there is no danger of it falling over 2 Install Brake hose bracket Lower handlebar holder Handlebar 1 Upper handlebar holder 2 Bracket 3 NOTICE ECA18300 First tighten the bolts on the f...

Page 208: ...efer to INSTALLING THE REAR BRAKE MASTER CYLINDER on page 4 62 9 Install Handlebar grip Grip end 1 a Apply a thin coat of rubber adhesive onto the end of the left handlebar b Slide the handlebar grip...

Page 209: ...Diagnostic code No 14 is selected g Turn the throttle grip to the fully closed po sition h Adjust the position of the accelerator posi tion sensor angle so that 11 20 can appear in the YDT screen i A...

Page 210: ...nel Meter assembly Bottom side cowling Side panel Front cowling assembly Refer to GENERAL CHASSIS 1 on page 4 1 Front wheel Refer to FRONT WHEEL on page 4 22 1 Front fender 1 2 Upper bracket pinch bol...

Page 211: ...Damper rod locknut 1 4 Spacer 1 5 Fork spring 1 6 Damper rod assembly bolt 1 7 Copper washer 1 8 Damper rod assembly 1 9 Dust seal 1 10 Oil seal clip 1 11 Outer tube 1 12 Oil seal 1 13 Washer 1 14 Out...

Page 212: ...e front fork legs NOTICE ECA22020 Because the left and right damper rod as semblies are different be sure to install them in the correct positions 1 Remove Cap bolt 1 Spacer 2 Damper rod locknut 3 a P...

Page 213: ...ld the front fork leg horizontally b Securely clamp the brake caliper bracket in a vise with soft jaws c Separate the outer tube from the inner tube by pulling the outer tube forcefully but care fully...

Page 214: ...he following parts Inner tube bushing Outer tube bushing Oil seal Dust seal Oil seal clip O ring Copper washer Before assembling the front fork leg make sure all of the components are clean 1 Lubricat...

Page 215: ...t side is used for the rebound operation and left side for the compression Pay attention not to mistake the right and left TIP The left side for the compression damper rod assembly has the holes a of...

Page 216: ...allow any foreign ma terial to enter the front fork 12 After filling the front fork leg slowly stroke the damper rod assembly 1 up and down at least ten times to distribute the fork oil TIP Be sure t...

Page 217: ...rod puller and install the rod holder 2 between the damper rod locknut 3 and the spacer 4 TIP Use the side of the rod holder that is marked B f Remove the rod puller and the rod puller at tachment g...

Page 218: ...y tighten the upper and lower bracket pinch bolts TIP Make sure the outer tube is flush with the top of the upper bracket 2 Tighten Lower bracket pinch bolt 1 Cap bolt 2 Upper bracket pinch bolt 3 Low...

Page 219: ...ENERAL CHASSIS 1 on page 4 1 Center cover Fuel tank cover assembly Rear side cowling assembly Side cover Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Handlebar cover Handlebar Lower handlebar hol...

Page 220: ...remove Q ty Remarks 8 Lower bracket 1 9 Upper bearing cover 1 10 Upper bearing 1 11 Lower bearing 1 12 Dust seal 1 13 Steering lock unit coupler 1 Disconnect 14 Steering lock unit 1 15 Stay 1 FWD LT L...

Page 221: ...ve the bearing races from the steer ing head pipe 1 with a long rod 2 and hammer b Remove the bearing race from the lower bracket 3 with a floor chisel 4 and ham mer c Install a new rubber seal and ne...

Page 222: ...STEERING HEAD on page 3 23 3 Install Upper bracket Washer Steering stem nut TIP Temporarily tighten the steering stem nut 4 Install Front fork leg Refer to FRONT FORK on page 4 81 TIP Temporarily tig...

Page 223: ...per Rear brake lock caliper Refer to REAR BRAKE on page 4 50 Rear wheel Refer to REAR WHEEL on page 4 30 1 Drive pulley cover 1 2 Dust cover 1 3 Holder 1 4 Collar 2 5 Circlip 1 6 Drive pulley 1 7 O ri...

Page 224: ...VE BELT AND DRIVE PULLEY 1 Install Drive belt NOTICE ECA22720 Align the mark of the drive belt with the prog ress direction A Do not twist the drive belt when installing it 2 Lubricate Drive pulley as...

Page 225: ...nut Rear shock absorber assembly lower bolt 1 1 3 Washer 1 4 Collar 1 5 Collar 1 6 Rear shock absorber assembly upper nut Washer Rear shock absorber assembly upper bolt 1 2 1 7 Rear shock absorber as...

Page 226: ...ORBER 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 rear shock absorber as shown WARNING EWA13760...

Page 227: ...Lubricate Collar Oil seal 2 Install Bearing 1 Oil seal 2 TIP When installing the oil seals 2 to the connect ing arms 3 face the character stamp of the oil seals outside Install the bearing to the conn...

Page 228: ...the rear shock absorber assembly so that the label is facing downward Install the rear shock absorber assembly so that the rebound damping adjusting screw b is facing downward for XP560D EAS30225 INST...

Page 229: ...R ASSEMBLY on page 4 96 Drive belt Refer to BELT DRIVE on page 4 94 1 Holder 1 2 Holder 1 3 Drive belt inner guard 1 4 Swingarm left 1 5 Swingarm right 1 6 Dowel pin 2 7 Pivot shaft 1 8 Oil seal 1 9 O...

Page 230: ...housing 1 13 O ring 1 14 Collar 1 15 Oil seal 1 16 Bearing 1 FWD FWD LT 11 12 13 14 15 16 7 N m 0 7 kgf m 5 2 lb ft 6 N m 0 6 kgf m 4 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 30 N...

Page 231: ...Refer to BELT DRIVE on page 4 94 4 Remove Drive pulley assembly bolt Swingarm bolt Pivot shaft nut EAS30227 CHECKING THE SWINGARM 1 Check Swingarm left Swingarm right Bends cracks damage Replace 2 Che...

Page 232: ...uches the collar and then tighten the pivot shaft to the specified torque b Tighten the pivot shaft nut to the specified torque Swingarm bolt 40 N m 4 0 kgf m 30 lb ft Drive pulley assembly bolt 48 N...

Page 233: ...HEAD 5 20 REMOVING THE CYLINDER HEAD 5 21 CHECKING THE CYLINDER HEAD 5 21 INSTALLING THE CYLINDER HEAD 5 21 VALVES AND VALVE SPRINGS 5 23 REMOVING THE VALVES 5 24 CHECKING THE VALVES AND VALVE GUIDES...

Page 234: ...STARTER CLUTCH 5 52 CHECKING THE STARTER CLUTCH 5 53 CHECKING THE OIL STRAINER 5 53 ASSEMBLING THE OIL TANK 5 53 INSTALLING THE STARTER CLUTCH 5 53 INSTALLING THE GENERATOR 5 53 CLUTCH 5 55 REMOVING T...

Page 235: ...MBLING THE CRANKCASE 5 71 CRANKSHAFT 5 73 REMOVING THE CONNECTING RODS 5 75 REMOVING THE CRANKSHAFT JOURNAL BEARINGS 5 75 CHECKING THE CRANKSHAFT AND CONNECTING RODS 5 75 INSTALLING THE CRANKSHAFT JOU...

Page 236: ...camshaft 2 Exhaust camshaft 3 Timing chain tensioner 4 Connecting rod 5 To piston 6 Starter clutch gear 7 Crankshaft 8 Balancer connecting rod 9 To balancer piston 10 Oil pipe 11 Check valve 12 Relie...

Page 237: ...LUBRICATION DIAGRAMS 2 8 9 1 3 7 7 6 5 4 7 11 10 12 4 1 Exhaust camshaft 2 Intake camshaft 3 Oil delivery pipe 4 Oil pump assembly 5 Scavenge pump 6 Feed pump 7 Oil pipe 8 Oil cooler 9 Oil filter 10 E...

Page 238: ...5 3 LUBRICATION SYSTEM CHART AND DIAGRAMS 1 2 3 4 5 1 Crankshaft 2 Secondary shaft 3 Drive axle 4 Clutch 5 Generator cover...

Page 239: ...5 4 LUBRICATION SYSTEM CHART AND DIAGRAMS 1 3 2 1 Oil strainer 2 Intake camshaft 3 Exhaust camshaft...

Page 240: ...5 5 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 4 3 A A 1 1 Generator cover 2 Oil strainer 3 Main gallery 4 Crankcase right A Forward...

Page 241: ...nk the en gine until the reading on the compression gauge stabilizes TIP The difference in compression pressure be tween cylinders should not exceed 100 kPa 1 kgf cm 14 psi c If the compression pressu...

Page 242: ...ly right Footboard right Refer to GENERAL CHASSIS 2 on page 4 11 1 O2 sensor coupler 1 Disconnect 2 O2 sensor 1 3 Exhaust assembly 1 4 Gasket 2 5 Front muffler protector 1 6 Muffler protector 1 7 Muff...

Page 243: ...sembly Seat assembly Storage box Refer to GENERAL CHASSIS 2 on page 4 11 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 27 Coolant Drain Refer to CHANGING THE COOLANT on page 3 31 Exhaust...

Page 244: ...SION on page 5 39 Radiator inlet hose Cooling system air bleed hose Radiator outlet hose Refer to RADIATOR on page 6 3 1 Spark plug cap 2 Disconnect 2 Sidestand switch coupler 1 Disconnect 3 Centerst...

Page 245: ...Rear frame 2 6 Engine mounting bolt front left lower side 2 7 Sidestand 1 8 Engine mounting bolt front right lower side 1 9 Engine mounting bolt front upper side 2 10 Engine 1 LT LT LT LT LT LT 78 N m...

Page 246: ...nut rear side 4 Rear frame bolts 5 TIP When tightening the engine mounting nuts and engine mounting bolts do not apply an upward load to the frame such as supporting the area around steering head of t...

Page 247: ...AL CHASSIS 1 on page 4 1 Center cover Fuel tank cover assembly Side cover Rear side cowling assembly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Radiator bracket Refer to RADIATOR on page 6 3 1...

Page 248: ...n page 5 12 1 Timing mark accessing plug 1 2 Timing chain tensioner 1 3 Timing chain tensioner gasket 1 4 Intake camshaft cap 1 5 Exhaust camshaft cap 1 6 Dowel pin 4 TIP During removal the dowel pins...

Page 249: ...nt marks d on the exhaust camshaft sprocket must align with the cylinder head mating surface as shown in the illustration 2 Remove Timing chain tensioner 1 Timing chain tensioner gasket 3 Remove Intak...

Page 250: ...he specified torque To prevent the camshaft cap from cracking tighten the camshaft cap carefully by tapping the camshaft using a soft face hammer both for temporary and final tightening Do not turn th...

Page 251: ...CHAIN TENSIONER 1 Check Timing chain tensioner Cracks damage rough movement Replace a Using the valve spring compressor 1 push and insert timing chain tensioner rod 2 into the timing chain tensioner h...

Page 252: ...pointer b on the generator cover c Install the timing chain onto both camshaft sprockets and then install the camshafts onto the cylinder head TIP Lubricate the camshaft journal with the molyb denum...

Page 253: ...vent the camshaft cap from cracking tighten the camshaft cap carefully by tapping the camshaft using a soft face hammer both for temporary and final tightening 4 Install Timing chain tensioner gasket...

Page 254: ...g surface Out of alignment Correct Refer to the installation steps above 8 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 5 9 Install Timing chai...

Page 255: ...on page 5 12 Thermostat Refer to THERMOSTAT on page 6 9 1 Coolant temperature sensor coupler 1 Disconnect 2 Coolant temperature sensor 1 3 Gasket 1 4 Cylinder head 1 5 Cylinder head gasket 1 6 Dowel p...

Page 256: ...head a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylin der head as follows d Place a 400 600 grit wet sand...

Page 257: ...when the cylinder head and cylinder are cold Use four steps to tighten the cylinder head nuts 4 Install Exhaust camshaft Intake camshaft Refer to INSTALLING THE CAMSHAFTS on page 5 17 Cylinder head n...

Page 258: ...remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD on page 5 20 1 Valve lifter 8 2 Valve pad 8 3 Valve cotter 16 4 Valve spring retainer 8 5 Valve spring 8 6 Intake valve 4 7 Exhaust valve 4 8 V...

Page 259: ...re should be no leakage at the valve seat 1 3 Remove Valve cotter TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attach...

Page 260: ...de clearance TIP After replacing the valve guide reface the valve seat Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0032 in Valve stem to valve guide cl...

Page 261: ...seat Pitting wear Replace the cylinder head 3 Measure Valve seat width a Out of specification Replace the cylinder head a Apply blue layout fluid b onto the valve face b Install the valve into the cy...

Page 262: ...d 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 h Install t...

Page 263: ...r head TIP Make sure each valve is installed in its original place Install the valve springs with the larger pitch a facing up 4 Install Valve cotter TIP Install the valve cotters by compressing the v...

Page 264: ...OTICE ECA22150 After making sure that the valve pads are ful ly inserted install the valve lifter taking care so that the pads do not fall TIP The valve lifter must move smoothly when ro tated with a...

Page 265: ...rks Cylinder head Refer to CYLINDER HEAD on page 5 20 1 Coolant hose 1 Disconnect 2 Timing chain guide exhaust side 1 3 Cylinder 1 4 Cylinder gasket 1 5 Dowel pin 2 6 Piston pin clip 4 7 Piston pin 2...

Page 266: ...ring 2nd ring Oil ring TIP When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS30291 CHECKING THE CYLINDERS AND PISTONS The fol...

Page 267: ...of the cylinder where the cylinder wear is lowest 3 Measure Piston ring end gap Out of specification Replace the piston ring set TIP The oil ring expander spacer s end gap cannot be measured If the o...

Page 268: ...following procedure applies to all of the pis tons and cylinders 1 Install Oil ring expander 1 Lower oil ring rail 2 Upper oil ring rail 3 2nd ring 4 Top ring 5 into the piston TIP Be sure to install...

Page 269: ...e cutout c in the piston as shown in the illustration 3 Install Dowel pin Cylinder gasket 4 Lubricate Piston Piston ring Cylinder with the recommended lubricant 5 Offset Piston ring end gap 6 Install...

Page 270: ...r cowling Refer to GENERAL CHASSIS 1 on page 4 1 Center cover Fuel tank cover assembly Side cover Rear side cowling assembly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Fuel tank Refer to FUEL T...

Page 271: ...lator and starter motor rear cover replace the starter motor assembly Order Job Parts to remove Q ty Remarks 1 Starter motor front cover 1 2 Armature assembly 1 3 Starter motor yoke 1 4 O ring 2 5 Bru...

Page 272: ...it tester and check the continuity b If there is no continuity replace the starter motor 4 Measure Brush length a Out of specification Replace the brush holder set 5 Measure Brush spring force Out of...

Page 273: ...otor front cover 3 TIP Align the match mark a on the starter motor rear cover with the match mark b on the start er motor yoke Align the match mark c on the starter motor yoke with the match mark d on...

Page 274: ...NERAL CHASSIS 2 on page 4 11 1 Crankshaft end access cover 1 2 Damper 1 3 V belt case air filter case cover 1 4 O2 sensor lead 1 5 V belt case air filter case 1 6 V belt case air filter element right...

Page 275: ...e nut 1 6 Secondary sheave assembly 1 7 V belt 1 8 Primary fixed sheave 1 9 V belt case air duct joint clamp 1 Loosen 10 V belt case air duct 1 11 Inner V belt case plate 1 12 Inner V belt case 1 13 D...

Page 276: ...pply YAMAHA GREASE F 2 When replacing the primary sliding sheave or collar replace them as a set Order Job Parts to remove Q ty Remarks 1 Cam 1 2 Slider 8 3 Primary sheave weight 8 4 Primary sliding s...

Page 277: ...Job Parts to remove Q ty Remarks 1 Secondary sheave spring seat nut 1 2 Upper spring seat 1 3 Secondary sheave compression spring 1 4 Spring seat 1 5 Guide pin 6 6 Secondary sliding sheave 1 7 O ring...

Page 278: ...with the sheave holder 3 loosen the second ary sheave spring seat nut with the locknut wrench 4 Do not loosen the secondary sheave spring seat nut 1 more than 1 4 turn 2 Remove Secondary sheave spring...

Page 279: ...e applies to all of the pri mary sheave weights 1 Check Primary sheave weight Cracks damage wear Replace 2 Measure Primary sheave weight outside diameter Out of specification Replace EAS30318 CHECKING...

Page 280: ...DARY SHEAVE 1 Lubricate Secondary fixed sheave inner surface 1 Secondary sliding sheave inner surface 2 Oil seals with the recommended lubricant 2 Install Guide pin TIP Before installing the guide pin...

Page 281: ...arily tighten the secondary sheave spring seat nut 5 Tighten Secondary sheave spring seat nut 1 TIP While holding the secondary fixed sheave 2 with the sheave holder 3 tighten the second ary sheave sp...

Page 282: ...A22160 Do not allow grease to contact the V belt pri mary and secondary sheave TIP When installing the belt screw M6 more than 45 mm 1 77 in bolts 4 to spread apart the secondary sheave and then insta...

Page 283: ...t EAS31235 INSTALLING THE V BELT CASE 1 Install Oil seal 1 into outer V belt case 2 Fill the space b shown in the illustration with 10 g 0 35 oz or more of lithium soap based grease 3 Install Bearing...

Page 284: ...assembly Side cover left Rear side cowling assembly left Footboard left Refer to GENERAL CHASSIS 2 on page 4 11 V belt case air filter element left Generator cover protector Water pump inlet pipe Wat...

Page 285: ...ch idle gear shaft 1 8 Starter clutch idle gear 1 9 Generator rotor nut 1 10 Spacer 1 11 Generator rotor 1 12 Woodruff key 1 13 Washer 1 14 Starter clutch gear 1 15 Starter clutch 1 13 15 5 6 7 8 6 11...

Page 286: ...15 Three bond No 1215 Order Job Parts to remove Q ty Remarks 1 Oil tank 1 2 Oil tank gasket 1 3 Dowel pin 2 4 Oil strainer 1 5 Crankshaft position sensor 1 6 Stator coil 1 7 Bearing cover 1 8 Oil seal...

Page 287: ...ion on the generator rotor 3 Remove Generator rotor 1 with the flywheel puller 2 Woodruff key TIP Make sure the flywheel puller is centered over the generator rotor EAS30868 REMOVING THE STARTER CLUTC...

Page 288: ...n turning the starter clutch gear clock wise B it should turn freely otherwise the starter clutch is faulty and must be re placed EAS31439 CHECKING THE OIL STRAINER 1 Check Oil strainer Damage Replace...

Page 289: ...t Do not allow the sheave holder to touch the projection on the generator rotor TIP Tighten the nut until it is at the specified angle 3 Apply Sealant onto the crankshaft position sensor stator lead g...

Page 290: ...Refer to GENERAL CHASSIS 2 on page 4 11 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 27 Coolant Drain Refer to CHANGING THE COOLANT on page 3 31 V belt case air filter element left Gen...

Page 291: ...e 1 4 Pressure plate 1 5 Clutch plate 2 2 6 Clutch damper spring 7 7 Friction plate 6 8 Clutch plate 1 5 9 Clutch spring 6 10 Thrust plate 1 11 Clutch boss nut 1 12 Primary drive gear 1 13 Bearing 2 1...

Page 292: ...5 57 CLUTCH Disassembling the clutch Order Job Parts to remove Q ty Remarks 16 Washer 1 17 Clutch weight 12 18 Clutch housing 1 16 17 12 18 E 130 N m 13 kgf m 96 lb ft T R...

Page 293: ...plate 1 TIP To ensure proper balance of the clutch assem bly one to three holes a or no hole at all may have been drilled in the spring stopper plate Be fore removing the spring stopper plate make al...

Page 294: ...plates as a set Clutch plate thickness Out of specification Replace the clutch plates and friction plates as a set TIP Measure the clutch plate 2 at four places EAS31442 CHECKING THE CLUTCH DAMPER SP...

Page 295: ...housing dogs will cause er ratic clutch operation EAS30353 CHECKING THE CLUTCH BOSS 1 Check Clutch boss spline Damage pitting wear Replace the clutch boss TIP Pitting on the clutch boss splines will...

Page 296: ...t plate 1 can be identified by punch mark b on the pressure plate 4 Install Clip 1 TIP While compressing the clutch springs with the clutch spring compressor 2 install the clip EAS30363 INSTALLING THE...

Page 297: ...5 62 CLUTCH 1 3 2...

Page 298: ...HASSIS 2 on page 4 11 V belt case air filter element left Generator cover protector Water pump inlet pipe Water pump outlet pipe Water pump assembly Refer to WATER PUMP on page 6 11 Generator cover Ge...

Page 299: ...Oil pump housing 1 1 2 Dowel pin 2 3 Oil pump outer rotor 1 1 4 Oil pump inner rotor 1 1 5 Pin 1 6 Washer 1 7 Oil pump housing center 1 8 Oil pump outer rotor 2 1 9 Oil pump inner rotor 2 1 10 Pin 1...

Page 300: ...KING THE OIL PUMP DRIVE CHAIN 1 Check Oil pump drive chain Cracks stiffness Replace the oil pump chain and oil pump assembly as a set EAS30342 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rot...

Page 301: ...page 6 11 Generator cover Generator rotor Starter clutch gear Refer to GENERATOR AND STARTER CLUTCH on page 5 49 Clutch assembly Refer to CLUTCH on page 5 55 Oil pump assembly Refer to OIL PUMP on pa...

Page 302: ...1 4 Crankcase left 1 5 Dowel pin 2 6 Oil strainer 1 7 Crankcase right 1 8 Centerstand lock solenoid cover 1 9 Centerstand lock solenoid 1 3 3 6 6 8 5 2 New New 1 2 3 4 5 6 7 8 9 5 LT LT LT LS LS 10 N...

Page 303: ...RANKCASE Disassembling the Centerstand assembly Order Job Parts to remove Q ty Remarks 1 Spring 1 2 Spring tube 1 3 Centerstand bracket 2 4 Centerstand 1 68 N m 6 8 kgf m 50 lb ft T R 3 1 2 4 3 LS LS...

Page 304: ...Order Job Parts to remove Q ty Remarks Crankshaft assembly Refer to CRANKSHAFT on page 5 73 Transmission Refer to TRANSMISSION on page 5 83 1 Bearing retainer 2 2 Oil seal 2 3 Bearing 5 1 2 2 3 3 3 3...

Page 305: ...t 4 Tighten Centerstand nut 5 Lubricate Centerstand 1 Centerstand bracket 2 TIP Apply grease to the sliding surfaces of the cen terstand and centerstand bracket After applying grease while the centers...

Page 306: ...a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passage Obstruction Blow out with compressed air EAS31445 C...

Page 307: ...t a time in stag es and in a crisscross pattern M8 120 mm 4 72 in bolts 1 M8 110 mm 4 33 in bolts 2 M6 50 mm 1 97 in bolts 3 M6 35 mm 1 38 in bolts 4 6 Check Crankshaft and transmission operation Roug...

Page 308: ...Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 66 1 Dowel pin 2 2 Balancer cylinder 1 3 Crankshaft assembly 1 4 Oil seal 1 5 Crankshaft journal bearing 2 3 5 4 2 1 4 5 N...

Page 309: ...piston pin 1 7 Balancer piston 1 8 Balancer connecting rod cap 1 9 Balancer big end lower bearing 1 10 Balancer connecting rod 1 11 Balancer big end upper bearing 1 1 1 2 2 3 3 4 4 5 5 6 7 8 9 10 11 N...

Page 310: ...kshaft journal bearings 1 Remove Crankshaft assembly Crankshaft journal bearing 1 TIP Remove the crankshaft journal bearing using the plane bearing installer 2 TIP Identify the position of each cranks...

Page 311: ...a piece of Plastigauge 1 on the crankshaft pin d Assemble the connecting rod halves TIP Do not move the connecting rod or crankshaft until the clearance measurement has been completed Lubricate the b...

Page 312: ...the smaller value is used The following procedure applies to all of the crankshaft journal bearings NOTICE ECA13920 Do not interchange the crankshaft journal bearings To obtain the correct crankshaft...

Page 313: ...arance is If the oil clearance is out of specification select replacement bearings 6 Select Crankshaft journal bearing J1 J2 TIP The numbers A is stamped onto the crank shaft web the number B on the l...

Page 314: ...e an iron plate 3 beneath the crankcase and press fit until the end of the plain bearing installer touches the iron plate EAS30426 INSTALLING THE CONNECTING RODS 1 Lubricate Bolt thread Nut seat with...

Page 315: ...rench b Put a mark 1 on the corner of the connect ing rod nut 2 and the connecting rod cap 3 c Tighten the connecting rod nuts further to reach the specified angle 120 WARNING EWA13400 If the connecti...

Page 316: ...nterrupted between 30 N m 3 0 kgf m 22 lb ft and 60 N m 6 0 kgf m 44 lb ft loosen the nut to less than 30 N m 3 0 kgf m 22 lb ft and start again 7 Install Balancer piston 1 Balancer piston pin Piston...

Page 317: ...5 82 CRANKSHAFT 2 1 2 1 2 4 3...

Page 318: ...rease R0 Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 66 1 Secondary shaft 1 2 Collar 1 3 O ring 1 4 Primary driven gear 1 5 Main axle 1 6 1st pinion gear 1 7...

Page 319: ...e part s 3 Check Main axle Cracks damage wear Replace the main axle 4 Measure Drive axle runout with a centering device and dial gauge Out of specification Replace the drive axle 5 Measure Secondary s...

Page 320: ...5 85 TRANSMISSION...

Page 321: ...OR 6 5 OIL COOLER 6 7 CHECKING THE OIL COOLER 6 8 INSTALLING THE OIL COOLER 6 8 THERMOSTAT 6 9 CHECKING THE THERMOSTAT 6 10 INSTALLING THE THERMOSTAT ASSEMBLY 6 10 WATER PUMP 6 11 DISASSEMBLING THE WA...

Page 322: ...ller hose 3 Cooling system air bleed hose 4 Coolant reservoir hose 5 Radiator inlet hose 6 Thermostat 7 Oil cooler inlet hose 8 Oil cooler 9 Oil cooler outlet hose 10 Coolant hose 11 Water pump outlet...

Page 323: ...AMS 1 2 3 4 5 3 6 10 9 8 7 1 Thermostat 2 Cooling system air bleed hose 3 Coolant reservoir hose 4 Radiator cap 5 Radiator filler hose 6 Radiator 7 Radiator bracket 8 Radiator inlet hose 9 Oil cooler...

Page 324: ...otboard Refer to GENERAL CHASSIS 2 on page 4 11 Coolant Drain Refer to CHANGING THE COOLANT on page 3 31 1 Coolant reservoir hose 1 2 Coolant reservoir 1 3 Coolant reservoir cap 1 4 Coolant reservoir...

Page 325: ...hose 1 10 Radiator inlet hose 1 11 Radiator fan motor coupler 1 Disconnect 12 Radiator 1 13 Radiator fan 1 14 Radiator bracket 1 FWD LT 7 8 9 10 11 12 13 14 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5...

Page 326: ...age Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 39 EAS30440 INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHAN...

Page 327: ...6 6 RADIATOR b Apply 137 3 kPa 1 37 kgf cm2 19 9 psi of pressure c Measure the indicated pressure with the gauge...

Page 328: ...sembly Side cover Rear side cowling assembly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 27 Coolant Drain Refer to CHANGING THE COOLAN...

Page 329: ...the slot b in the crankcase 3 Install Oil filter cartridge Refer to CHANGING THE ENGINE OIL on page 3 27 4 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING T...

Page 330: ...de panel Bottom center cowling Refer to GENERAL CHASSIS 1 on page 4 1 Center cover Fuel tank cover assembly Side cover Rear side cowling assembly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Cool...

Page 331: ...ooling 2 Check Thermostat cover Cracks damage Replace EAS30445 INSTALLING THE THERMOSTAT ASSEMBLY 1 Install Thermostat TIP Install the thermostat with its jiggle valve a facing upward 2 Fill Cooling s...

Page 332: ...lant Drain Refer to CHANGING THE COOLANT on page 3 31 1 V belt case air filter element joint clamp 1 Loosen 2 V belt case air filter element left 1 3 Oil filler cap 1 4 Generator cover protector 1 5 O...

Page 333: ...ump Order Job Parts to remove Q ty Remarks 1 Water pump housing cover 1 2 Circlip 1 3 Impeller shaft 1 4 Mechanical seal 1 5 Bearing 1 6 Oil seal 1 7 Water pump housing 1 M E New New New New New 1 2 2...

Page 334: ...k Water pump inlet pipe Water pump outlet pipe Cracks damage wear Replace EAS30448 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 Bearing 2 into the water pump housing TIP Before installing the oil se...

Page 335: ...e specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 31 3 Check Cooling system Leaks Repair or replace any faulty part Refer to INSTALLING THE RADIATOR on page 6 5 4...

Page 336: ...6 15 WATER PUMP...

Page 337: ...ANK 7 4 THROTTLE BODY 7 5 CHECKING THE INJECTORS BEFORE REMOVING 7 9 REMOVING THE FUEL HOSE FUEL RAIL SIDE 7 9 REMOVING THE INJECTORS 7 9 CHECKING THE INJECTORS 7 9 CHECKING AND CLEANING THE THROTTLE...

Page 338: ...ing assembly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 1 Fuel tank overflow hose 1 2 Fuel tank breather hose 1 Disconnect 3 Fuel pump coupler 1 Disconnect 4 Fuel hose connector 1 Disconnect 5...

Page 339: ...cover Rear side cowling assembly Footboard Refer to GENERAL CHASSIS 2 on page 4 11 Fuel tank Refer to FUEL TANK on page 7 1 1 Canister breather hose 1 2 Canister purge hose hose joint to canister 1 3...

Page 340: ...el pump slide the fuel hose connector cover 1 on the end of the hose in the direction of the arrow shown press the two buttons 2 on the sides of the connector and then remove the hose Before removing...

Page 341: ...tight ening sequence as shown EAS30457 INSTALLING THE FUEL TANK 1 Connect Fuel hose fuel tank side NOTICE ECA17500 When installing the fuel hose make sure that it is securely connected and that the fu...

Page 342: ...ootboard Refer to GENERAL CHASSIS 2 on page 4 11 Fuel tank Refer to FUEL TANK on page 7 1 Throttle body assembly Refer to THROTTLE BODY on page 7 5 Cylinder head cover Refer to CAMSHAFTS on page 5 12...

Page 343: ...on page 7 1 Air filter case Disconnect Refer to THROTTLE BODY on page 7 5 Canister purge hose hose joint to canister Disconnect Refer to FUEL TANK on page 7 1 1 Throttle servo motor coupler 1 Disconn...

Page 344: ...le body Order Job Parts to remove Q ty Remarks 9 Throttle body joint 1 10 Fuel hose 1 11 Fuel rail 1 12 Injector 2 New New New New New New 9 10 12 12 11 10 N m 1 0 kgf m 7 4 lb ft 3 8 N m 0 38 kgf m 2...

Page 345: ...8 THROTTLE BODY Disassembling the throttle body assembly Order Job Parts to remove Q ty Remarks 1 Throttle position sensor 1 2 Canister purge hose 2 3 Hose joint 1 3 2 2 1 3 5 N m 0 35 kgf m 2 6 lb f...

Page 346: ...be removed It is prohibited to wear the cotton work gloves or equivalent coverings EAS30476 REMOVING THE INJECTORS WARNING EWA20210 Check the injectors in a well ventilated area free of combustible ma...

Page 347: ...tion Do not apply cleaning solvent directly to any plastic parts sensors or seals Be careful not to remove the white paint mark that identifies the standard throttle body Do not turn the bypass air sc...

Page 348: ...e bodies synchronizing Out of specification Replace the throttle bodies Refer to SYNCHRONIZING THE THROT TLE BODIES on page 3 9 EAS31160 REPLACING THE THROTTLE BODIES 1 Remove the throttle bodies from...

Page 349: ...ure drops Check the pressure gauge and adapter Check the seals and O rings and then rein stall Out of specification Replace the fuel in jectors EAS30482 CHECKING THE FUEL PRESSURE 1 Check Fuel pressur...

Page 350: ...E POSITION SENSOR NOTICE ECA17540 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 i...

Page 351: ...ired For information about using the YDT refer to the operation manual that is included with the tool e Diagnostic code number 01 is selected f Adjust the position of the throttle position sensor angl...

Page 352: ...7 15 THROTTLE BODY...

Page 353: ...M 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 CIR...

Page 354: ...T POSITION SENSOR 8 104 CHECKING THE LEAN ANGLE SENSOR 8 104 CHECKING THE STARTER MOTOR OPERATION 8 105 CHECKING THE STATOR COIL 8 105 CHECKING THE RECTIFIER REGULATOR 8 105 CHECKING THE FUEL SENDER 8...

Page 355: ......

Page 356: ...L Y Y W R R W Y R L Lg L W W R B L B Lg B L B B B B B W B B B W B B B W B W B W B W B B B B B B W B B B Lg B B B B B G B B G B L Y L Y R B R B R B R B R B R W R W B L L L R R L Y L Y B B Br L Br B Br...

Page 357: ...ion fuse 22 Battery 23 Engine ground 24 Main fuse 27 Diode 1 28 Sidestand relay 29 Diode 2 31 Starting circuit cut off relay 32 Sidestand switch 34 Handlebar switch right 35 Engine stop switch 57 ECU...

Page 358: ...Lg L W W R B L B Lg B L B Y L Y G P Lg L O W W G Y L Lg W B L Br W Gy G G L R G Lg L W G W Y G R Lg B L W Lg B B B B B W B B B W B B B W B W B W B W B B B B B B W B B B Br Y R W Br W R B R W Br Y R B...

Page 359: ...ion fuse 22 Battery 23 Engine ground 24 Main fuse 27 Diode 1 28 Sidestand relay 29 Diode 2 31 Starting circuit cut off relay 32 Sidestand switch 34 Handlebar switch right 35 Engine stop switch 70 ECU...

Page 360: ...on page 8 94 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS on page 3 5 NG Re gap or replace the spark plugs OK 4 Check th...

Page 361: ...on page 8 91 NG Replace the sidestand switch OK 12 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 91 NG The engine stop switch is faulty Replace the handlebar switch right OK 13...

Page 362: ...B W B B B W B B B W B W B W B W B B B B B B W B B B Y W Y Br Y BL B Sb G Y Lg B B B B B G B B G B L Y L Y R B R B R B R W R W B R R L Y L Y B B B Br L Br B Br B Br L Br L Br L B Br Br Br B B Br L W L...

Page 363: ...4 Main fuse 25 Starter relay 26 Starter motor 28 Sidestand relay 29 Diode 2 31 Starting circuit cut off relay 32 Sidestand switch 33 Diode 4 34 Handlebar switch right 35 Engine stop switch 36 ON start...

Page 364: ...B B W B B B W B W B W B W B B B B B B W B B B Y W Y Br Y BL B Br Lg B G Y B Br Y R W Br W R B L W B W G B W L W W G B W R W Br Y R B Br W B Sb G Y Lg B B B B B G B B G B L Y L Y R B R B R B R W R W B...

Page 365: ...use 25 Starter relay 26 Starter motor 28 Sidestand relay 29 Diode 2 31 Starting circuit cut off relay 32 Sidestand switch 33 Diode 4 34 Handlebar switch right 35 Engine stop switch 36 ON start switch...

Page 366: ...ed The rear brake lever is pulled to the handlebar the rear brake light switch is closed and the sidestand is up the sidestand switch is closed The starting circuit cut off relay prevents the starter...

Page 367: ...brake light switch 8 Rear brake light switch 9 Diode 4 10 Starting circuit cut off relay 11 ON start switch 12 ECU Engine Control Unit 13 Fuel injection system relay 14 Engine stop switch 15 Fuel inj...

Page 368: ...ace the battery OK 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 105 OK Starter motor is OK Perform the electric starting system troubleshooting starting...

Page 369: ...tand switch Refer to CHECKING THE SWITCHES on page 8 91 NG Replace the sidestand switch OK 13 Check the front brake light switch Refer to CHECKING THE SWITCHES on page 8 91 NG Replace the front brake...

Page 370: ...8 15 ELECTRIC STARTING SYSTEM OK Replace the remote control unit Refer to SMART KEY SYSTEM on page 8 67...

Page 371: ...8 16 ELECTRIC STARTING SYSTEM...

Page 372: ...8 17 CHARGING SYSTEM EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM XP560E 22 23 24 10 12 13 B B A A A W W W W W W R B W W W R R R R R R R Br G R B B G B B G W W W B B R R R B B B B Gy R R R R R...

Page 373: ...8 18 CHARGING SYSTEM 10 Joint coupler 12 AC magneto 13 Rectifier regulator 22 Battery 23 Engine ground 24 Main fuse A Wire harness B Negative battery sub wire harness...

Page 374: ...8 19 CHARGING SYSTEM XP560D 22 23 24 10 12 13 B B A A A W W W W W W R B W W W R R R R R R R Br G R B B G B B G W W W B B R R R B B B B Gy R R R R R...

Page 375: ...8 20 CHARGING SYSTEM 10 Joint coupler 12 AC magneto 13 Rectifier regulator 22 Battery 23 Engine ground 24 Main fuse A Wire harness B Negative battery sub wire harness...

Page 376: ...y Refer to CHECKING AND CHARGING THE BATTERY on page 8 94 NG Clean the battery terminals Recharge or replace the battery OK 3 Check the stator coil Refer to CHECKING THE STA TOR COIL on page 8 105 NG...

Page 377: ...8 22 CHARGING SYSTEM...

Page 378: ...B Lg L B W R G Lg W B W B W B W B W B B B B B B W B B B R W B W Y W Y Br Y BL B B B G B B G B R W R W R W L L B Y Y B B R R L Y L Y L B L B Y L L Lg W Lg W Lg L Lg L Lg W Lg W L G L G R G R G B W B W...

Page 379: ...mmer 41 Smart key system relay unlock 44 Meter assembly 46 Meter light 55 High beam indicator light 56 Multi function display 57 ECU Engine Control Unit 78 YDT coupler 82 Handlebar switch left 84 Dimm...

Page 380: ...B W B B Lg L B W R G Lg W B W B W B W B W B B B B B B W B B B R W B W Y W Y Br Y BL B B B G B B G R Y V Y L Gy Y B R Y Ch Y L B B Dg Y B B R W R W R W L L B Y Y Y B Y B B B R R Y B Y B L Y L Y L B L...

Page 381: ...r 45 Smart key system relay unlock 55 Meter assembly 57 Meter light 68 High beam indicator light 69 Multi function display 70 ECU Engine Control Unit 91 YDT coupler 95 Handlebar switch left 98 Dimmer...

Page 382: ...ion signaling system and taillight Refer to CHECKING THE FUS ES on page 8 93 NG Replace the fuse s OK 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 94 NG Clean the battery t...

Page 383: ...K 9 Check the storage box light switch Refer to CHECKING THE SWITCHES on page 8 91 NG Replace the storage box light switch OK 10 Check the entire lighting system s wiring Refer to CIRCUIT DIAGRAM on p...

Page 384: ...g L Lg L Lg W Lg W R G B B B B B B B B B B B B Br L Br L Br L Br L Br L Br L B W B W Ch Ch Ch Gy W Gy W V V Gy Gy R G R G R G R G R G R G R G R G Br Br Br B B Br Br Br P R B R B R G Br Br R G R G R G...

Page 385: ...Turn signal indicator light left 52 Turn signal indicator light right 56 Multi function display 57 ECU Engine Control Unit 63 Coolant temperature sensor 64 Intake air temperature sensor 73 Fuel sender...

Page 386: ...B W R G Lg W B W B W B W B W B B B B B B W B B B P B G Y G Y G Y Y W Y Br Y BL B Br Lg B G Y B Br Y R W Br W R B R W Br Y R B Br W Lg B B B B B G B B G R Y V Y L Gy Y B R Y Ch Y L B B Dg Y B B Dg Dg...

Page 387: ...dicator light 61 Traction control system indicator light 62 Turn signal indicator light left 63 Turn signal indicator light right 69 Multi function display 70 ECU Engine Control Unit 76 Coolant temper...

Page 388: ...t s 1 Front cowling assembly 2 Storage box 3 Fuel tank 4 Footboards 5 Rear side cowling assembly right 1 Check the fuses Main signaling system ABS mo tor ABS solenoid ABS ECU brake light and backup Re...

Page 389: ...ace the front brake light switch OK 2 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 91 NG Replace the rear brake light switch OK 3 Check the entire signaling sys tem s wir...

Page 390: ...CKING THE FUEL SENDER on page 8 106 NG Replace the fuel pump assembly OK 2 Check the entire signaling sys tem s wiring Refer to CIRCUIT DIAGRAM on page 8 29 NG Properly connect or replace the wire har...

Page 391: ...sensor OK 2 Check the entire wheel sensor wir ing Refer to TIP NG Properly connect or replace the wire har ness OK Replace the hydraulic unit assembly ECU and or meter assembly The tachometer fails t...

Page 392: ...r replace the wire har ness OK Replace the meter assembly The oil change indicator fails to come on 1 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 29 NG Properly connect...

Page 393: ...8 38 SIGNALING SYSTEM...

Page 394: ...W W R B L B Lg B L Lg L B W R G Lg W B W B W B W B W B B B B B B W B B B B L B L Br B L R W Y R B B G B B G B R W R W R W R W B R R L Y L Y Y R Y R Lg W Lg W Lg L Lg L Lg W Lg W B Br L Br B Br B Br L...

Page 395: ...18 Radiator fan motor fuse 20 Backup fuse 22 Battery 23 Engine ground 24 Main fuse 44 Meter assembly 56 Multi function display 57 ECU Engine Control Unit 63 Coolant temperature sensor 78 YDT coupler...

Page 396: ...W G W Y G R Lg B L W Lg Lg L B W R G Lg W B W B W B W B W B B B B B B W B B B B L B L Br B L R W Y R B B G B B G B R W R W R W R W B R R L Y L Y Y R Y R Lg W Lg W Lg L Lg L Lg W Lg W B Br L Br B Br B...

Page 397: ...18 Radiator fan motor fuse 20 Backup fuse 22 Battery 23 Engine ground 24 Main fuse 55 Meter assembly 69 Multi function display 70 ECU Engine Control Unit 76 Coolant temperature sensor 91 YDT coupler...

Page 398: ...battery OK 3 Check the ignition system relay Refer to CHECKING THE RE LAYS on page 8 94 NG Replace the ignition system relay OK 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTO...

Page 399: ...8 44 COOLING SYSTEM Replace the ECU and or meter as sembly...

Page 400: ...B W B W B W B W B B B B B B W B B B B B G B B G B R B R B R B R B R W R W B R R R R L Y L Y Lg W Lg W Lg L Lg L Lg W Lg W B B B Br L Br L Br L Br L L Y L Y R G R G R G R G R G R G R G R L R L B B R G...

Page 401: ...6 Ignition fuse 19 Fuel injection system fuse 20 Backup fuse 22 Battery 23 Engine ground 24 Main fuse 30 Fuel injection system relay 34 Handlebar switch right 35 Engine stop switch 57 ECU Engine Contr...

Page 402: ...B B B B W B B B Br Y R W Br W R B R W Br Y R B Br W B B G B B G B R B R B R B R B R W R W B R R R R L Y L Y Lg W Lg W Lg L Lg L Lg W Lg W B B B Br L Br B Br B Br L Br L Br L L Y L Y R G R G R G R G R...

Page 403: ...6 Ignition fuse 19 Fuel injection system fuse 20 Backup fuse 22 Battery 23 Engine ground 24 Main fuse 30 Fuel injection system relay 34 Handlebar switch right 35 Engine stop switch 70 ECU Engine Contr...

Page 404: ...engine stop switch Refer to CHECKING THE SWITCHES on page 8 91 NG The engine stop switch is faulty Replace the handlebar switch right OK 4 Check the ignition system relay Refer to CHECKING THE RE LAY...

Page 405: ...8 50 FUEL PUMP SYSTEM...

Page 406: ...W R W B R R L Y L Y W L W L R W R W R W G W G P B P B Br B Br L Br B Br B Br L Br L Br L B W P W P W R G R G R G R G R G R G R G R G R G R G Br L R B R B R B R B R B R B R B R B B R G R W R W B W B W...

Page 407: ...ay 16 Ignition fuse 20 Backup fuse 22 Battery 23 Engine ground 24 Main fuse 49 Windshield drive unit relay down 50 Windshield drive unit 51 Windshield drive unit relay up 55 Meter assembly 69 Multi fu...

Page 408: ...to CHECKING THE FUS ES on page 8 93 NG Replace the fuse s OK 4 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 94 NG Clean the battery terminals Recharge or replace the battery...

Page 409: ...e unit relay down OK 10 Check the windshield drive motor Refer to CHECKING THE WIND SHIELD DRIVE UNIT for XP560D on page 8 109 NG Replace the windshield drive unit OK 11 Check the entire windshield dr...

Page 410: ...W G Lg W Lg W Lg L Lg L Lg W Lg W B Br L Br B Br B Br L Br L Br L R G R G R G R G R G R G R G R G R G R G R G R G Br L B B B B B B B Y R Y R R G R W R W B W B W B W B W B W B W Lg L Lg L R G Y R R G R...

Page 411: ...0 Backup fuse 22 Battery 23 Engine ground 24 Main fuse 55 Meter assembly 69 Multi function display 70 ECU Engine Control Unit 73 Grip warmer connector 74 Grip warmer left 75 Grip warmer right 91 YDT c...

Page 412: ...grip warmer settings OK 3 Check the fuses Main ignition and backup Refer to CHECKING THE FUS ES on page 8 93 NG Replace the fuse s OK 4 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on...

Page 413: ...ture level of the high grip warmer setting is set to highest temperature NG Adjust the temperature levels of the grip warmer settings OK 2 Check that the MIL is on and that DTC No P0500 is displayed i...

Page 414: ...8 59 GRIP WARMER SYSTEM for XP560D OK Replace the meter assembly...

Page 415: ...8 60 GRIP WARMER SYSTEM for XP560D...

Page 416: ...L W Lg B W B W B W B W B B B B B B W B B B B B G B B G B B R R L Y L Y W L W L W R W R W G W G G B G B Br Y Br Y B W B W B B B Br L Br B Br B Br L Br L Br L R G R G R G R G R G R G R G R G R G R G Br...

Page 417: ...em fuse 20 Backup fuse 22 Battery 23 Engine ground 24 Main fuse 52 Seat heater relay control 53 Seat heater relay power 54 Seat heater 55 Meter assembly 69 Multi function display 70 ECU Engine Control...

Page 418: ...that the engine is started NG Start the engine OK 4 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 94 NG Clean the battery terminals Recharge or replace the battery OK 5 Check...

Page 419: ...to CHECKING THE RE LAYS on page 8 94 NG Replace the seat heater relay power OK 3 Check the seat heater Refer to CHECKING THE SEAT HEATER for XP560D on page 8 110 NG Replace the seat assembly OK Repla...

Page 420: ...anged 1 Check the menu switch Refer to CHECKING THE SWITCHES on page 8 91 NG The menu switch is faulty Replace the handlebar switch left OK 2 Check the select switch Refer to CHECKING THE SWITCHES on...

Page 421: ...8 66 SEAT HEATER SYSTEM for XP560D...

Page 422: ...Y W Y L L L G Y G Y L Y L Y L R L R V W V W Br Y Br Y R L R L O L O L Lg L Lg L Lg W Lg W Lg L Lg L Lg L Lg L Lg W Lg W Lg W Lg W L G L G L G L G R G R G R G B B B B B B B B B R L R R R B Br L Br B B...

Page 423: ...relay unlock 42 Seat fuel lid lock solenoid 43 Smart key system relay lock 44 Meter assembly 45 Smart key system indicator light 51 Turn signal indicator light left 52 Turn signal indicator light rig...

Page 424: ...B G Y B Br Y R W Br W R B L W B W G B W L W W G B W R W Br Y R B Br W B B B G B B G R Y V Y L Gy Y B R Y Ch Y L Dg Y B B R W R W Dg Dg Br G Dg B R R W Y W Y L L L G Y G Y L Y L Y L R L R V W Br Y Br...

Page 425: ...lock 46 Storage compartment lid lock solenoid 47 Seat fuel lid lock solenoid 48 Smart key system relay lock 55 Meter assembly 56 Smart key system indicator light 62 Turn signal indicator light left 63...

Page 426: ...RT KEY BATTERY on page 8 112 NG Replace the button cell battery of the smart key Standard battery CR2025 OK 2 Check the fuses Main backup ignition and signal ing system Refer to CHECKING THE FUS ES on...

Page 427: ...8 72 SMART KEY SYSTEM Replace the remote control unit...

Page 428: ...Replace the smart key or remote control unit The vehicle cannot be turned on in the emergency mode but the storage box light comes on when the seat is opened Replace the remote control unit The storag...

Page 429: ...not flash There are sources of strong electro magnetic waves in the vicinity Move the vehicle Smart key malfunction Register and use a different smart key Remote control unit malfunction Replace the r...

Page 430: ...ssible Check the wire harness Light green White Light green White and or replace the remote control unit and or meter NO The seat fuel lid cannot be opened Check the mechanical components of the lock...

Page 431: ...rage compartment lid solenoid for XP560D Refer to CHECKING THE STOR AGE COMPARTMENT LID LOCK SOLENOID for XP560D on page 8 112 Replace the remote control unit and or meter assembly 1 Check the turn si...

Page 432: ...between the remote con trol unit and centerstand lock unit is not possible Check the wire harness Light green White Light green White and or replace the remote control unit and or cen terstand lock u...

Page 433: ...67 Vehicle power off ver ification error a LED on b LED off 10 seconds The smart key cannot be recognized Check that there are no sources of strong electromagnetic waves in the vicinity the smart key...

Page 434: ...g lock unit ECU communica tion error Data error ECU malfunction a LED on b LED off Flashes continuously until the error is re solved flashes 4 times in a repeating cycle Check the wire har ness Check...

Page 435: ...serting the mechanical key into the lock located right side of body and turn it counter clockwise 3 Open the seat and check that the trunk light comes on 4 Push the ON start switch once 5 Without comp...

Page 436: ...system indicator light flashes twice The second digit has been set as 2 Repeat the above procedure until all digits of the identification number have been set The smart key system indicator light wil...

Page 437: ...mote control unit Be sure to register the smart keys one at a time Do not register multiple smart keys at the same time 1 Place the smart key 1 that will be registered within 80 cm 31 5 in a of the re...

Page 438: ...system indicator light will come on for 3 seconds and then the smart key system will turn off If the smart key was not registered successfully the smart key system indicator light will flash for 3 se...

Page 439: ...e mode is activat ed 5 Turn on unlocked setting the smart keys that you want to enable and place them within 80 cm 31 5 in of the remote control unit 6 Push the OFF LOCK switch 1 time to start the com...

Page 440: ...ication number on the smart key with the new number EAS31556 REPLACING THE STEERING LOCK UNIT 1 Replace the steering lock unit and then place the previously used smart key within 80 cm 31 5 in of the...

Page 441: ...umber in the emergency mode Remote control unit When the vehicle system is turned on the smart key identifi cation number is automatically registered to the remote control unit Steering lock unit When...

Page 442: ...d ECU as a set Smart key Remote control unit Steer ing lock unit Replace the smart key remote control unit steering lock unit and ECU as a set Smart key Remote control unit ECU Replace the smart key r...

Page 443: ...ery 8 Steering lock unit 9 Diode 3 10 Diode 1 11 Injector 12 Coolant temperature sensor 13 Spark plug 14 Spark plug cap 15 Radiator fan motor 16 Throttle position sensor 17 Throttle servo motor 18 Fro...

Page 444: ...nd relay Turn signal hazard relay Radiator fan motor relay Seat heater relay power for XP560D Seat heater relay control for XP560D Windshield drive unit relay down for XP560D Windshield drive unit rel...

Page 445: ...rake light switch for XP560E 7 Rear brake light switch for XP560D 8 Starter relay 9 Fuse box 4 Brake light fuse for XP560D Fuse box 5 Cruise control fuse for XP560D 10 Fuse box 1 11 Fuse box 2 12 Fuse...

Page 446: ...N DOWN B L B B PASS HI LO Br W R W G L B B P Br G Y Dg Ch Br W W L B W L B L B L B L B Br Y R W Br W R B Br G Y L G R R L G L W W G B W B Br P PUSH FREE B R B R W RUN OFF L W B OFF ON Br WBr Y OFF ON...

Page 447: ...W W G UP N DOWN B B B B B L B B PASS HI LO Br P PUSH FREE B R B R W RUN OFF L W B OFF ON Br WBr Y OFF ON 1 2 3 4 5 6 7 8 9 10 11 12 15 16 18 13 14 17 1 Cruise control power switch 2 Cruise control set...

Page 448: ...d ignition systems to malfunction and could possibly cause a fire 4 Install Front cover Refer to GENERAL CHASSIS 1 on page 4 1 EAS31006 REPLACING THE ECU Engine Control Unit 1 Push the ON start switch...

Page 449: ...ery terminal Dirt Clean with a wire brush Loose connection Connect properly 8 Lubricate Battery terminal 9 Install Battery band Battery cover Refer to GENERAL CHASSIS 1 on page 4 1 EAS30553 CHECKING T...

Page 450: ...Negative tester probe Result Continuity between 1 and 2 No continuity between 1 and 3 1 2 G R Br Y W Y Y B Br L B 2 1 3 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe...

Page 451: ...ve battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 R R L R B L Y G R G Y L Y Lg 1 Positive battery terminal 2 Negative ba...

Page 452: ...Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result No continuity between 3 and 4 R Br L R L Y Br G Y Lg B B 1 Positive tester probe 2 Negative tester probe 3 Negative tes...

Page 453: ...en 1 and 3 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe 5 Negative tester probe Result No continuity between 3 and 4 Continuity between 3 and...

Page 454: ...egative tester probe 3 Negative tester probe A XP560E B XP560D 1 2 3 4 G Y Y Br R B Br R R G O L A 1 2 3 R B R B R G O L 1 2 3 B Result Continuity between 1 and 2 No continuity between 1 and 3 1 Posit...

Page 455: ...Continuity between 1 and 2 No continuity between 1 and 3 Br B Br R R L R G 1 2 3 A Br B R B R L R G 1 2 3 B 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative t...

Page 456: ...r probe Brown 2 Negative tester probe Green Red Blue White 1 Diode 2 Continuity Positive tester probe Red Black 3 Negative tester probe Blue Yellow 4 No continuity Positive tester probe Blue Yellow 4...

Page 457: ...specification Replace a Remove the spark plug cap from the spark plug lead b Connect the digital circuit tester to the spark plug cap as shown c Measure the spark plug cap resistance EAS30558 CHECKIN...

Page 458: ...sconnect the spark plug cap from the spark plug b Connect the ignition checker 1 as shown c Push the ON start switch and the engine stop switch to d Measure the ignition spark gap a e Crank the engine...

Page 459: ...ngle sensor and wire harness as shown b Connect the digital circuit tester DC V to the test harness lean angle sensor 6P c Push the ON start switch d When turn the lean angle sensor to 65 e Measure th...

Page 460: ...Connect the digital circuit tester to the stator coil coupler as shown b Measure the stator coil resistance EAS30680 CHECKING THE RECTIFIER REGULATOR 1 Check Battery charging voltage Out of specifica...

Page 461: ...detection circuit 1 Check Fuel meter fuel level warning indicator 1 Push the ON start switch Fuel meter fuel level warning indicator comes on for a few seconds then goes off Fuel meter fuel level war...

Page 462: ...ied temperature e Measure the coolant temperature sensor resistance 3 Install Coolant temperature sensor EAS30581 CHECKING THE THROTTLE POSITION SENSOR 1 Remove Throttle position sensor from the throt...

Page 463: ...position sensor terminals as shown b Measure the accelerator position sensor maximum resistance 3 Install Accelerator position sensor EAS30592 CHECKING THE THROTTLE SERVO MOTOR 1 Remove Air filter ca...

Page 464: ...1 Check Grip warmer resistance Out of specification Replace the grip warmer a Disconnect the grip warmer coupler from the wire harness b Connect the digital circuit tester to the grip warmer coupler a...

Page 465: ...e test harness S pressure sensor 3P coupler a b Connect the digital circuit tester to the test harness S pressure sensor 3P c Push the ON start switch d Measure the intake air pressure sensor out put...

Page 466: ...l down to the specified temperatures e Measure the intake air temperature sensor resistance 3 Install Intake air temperature sensor EAS30681 CHECKING THE FUEL INJECTOR 1 Check Fuel injector resistance...

Page 467: ...ce a Disconnect the seat fuel lid lock solenoid from the wire harness b Connect the battery DC 12 V as shown c Check the seat fuel lid lock solenoid move ment EAS32450 CHECKING THE STORAGE COMPARTMENT...

Page 468: ...8 113 ELECTRICAL COMPONENTS c Check the storage compartment lid lock so lenoid movement B Br 1 2...

Page 469: ...OPERATION 9 20 BASIC INSTRUCTIONS FOR TROUBLESHOOTING 9 21 BASIC PROCESS FOR TROUBLESHOOTING 9 22 A CHECKING THE CRUISE CONTROL SYSTEM INDICATOR LIGHT 9 23 B 1 DIAGNOSIS USING THE DTC 9 23 B 2 DIAGNOS...

Page 470: ...BLE FOR ABS Anti lock Brake System 9 53 COMMUNICATION ERROR WITH THE METER 9 58 DIAGNOSTIC CODE SENSOR OPERATION TABLE 9 58 DIAGNOSTIC CODE ACTUATOR OPERATION TABLE 9 62 EVENT CODE TABLE 9 63 30_EVENT...

Page 471: ...9 112 TROUBLESHOOTING 9 112 P0500 9 115 TROUBLESHOOTING 9 115 P0507 9 119 TROUBLESHOOTING 9 119 P0560 P0563 9 121 TROUBLESHOOTING 9 121 P0564 9 122 TROUBLESHOOTING 9 122 P056C 9 128 TROUBLESHOOTING 9...

Page 472: ...P2138 9 158 TROUBLESHOOTING 9 158 P2158 9 162 TROUBLESHOOTING 9 162 U0155 or Err 9 166 TROUBLESHOOTING 9 166 11 25_ABS 9 169 TROUBLESHOOTING 9 169 12_ABS 9 170 TROUBLESHOOTING 9 170 13 26_ABS 9 171 TR...

Page 473: ...9 186 TROUBLESHOOTING 9 186 33_ABS 9 187 TROUBLESHOOTING 9 187 34_ABS 9 189 TROUBLESHOOTING 9 189 41_ABS 9 190 TROUBLESHOOTING 9 190 42 47_ABS 9 191 TROUBLESHOOTING 9 191 43_ABS 9 192 TROUBLESHOOTING...

Page 474: ...55_ABS 9 199 TROUBLESHOOTING 9 199 56_ABS 9 200 TROUBLESHOOTING 9 200 63_ABS 9 201 TROUBLESHOOTING 9 201 64_ABS 9 203 TROUBLESHOOTING 9 203...

Page 475: ...TC is a code that is saved within a control unit s memory when the control unit detects an abnormal condition If the abnormal condition continues a malfunction may be determined Driving cycle Driving...

Page 476: ...cause the occurrence of the warning light coming on without malfunction Reprogramming of the ECU software Using the electrical accessory which may affect the ECU Using the incorrect specification of s...

Page 477: ...protective cap 1 and then connect the YDT to the coupler EAS32864 PARTS CONNECTED TO THE ECU The following parts are connected to the ECU When checking for a power short circuit the couplers must be...

Page 478: ...ng for a power short circuit the couplers must be disconnected from all of the following parts beforehand EAS33137 PRECAUTIONS FOR ROAD TEST WARNING EWA20860 When test riding the vehicle always comply...

Page 479: ...se control power switch 29 Cruise control setting switch RES 28 Cruise control setting switch SET 25 Front brake light switch 26 Rear brake light switch 31 Crankshaft position sensor 32 Intake air pre...

Page 480: ...celerator position sensor 38 Accelerator position sensor 37 Throttle position sensor 37 Throttle position sensor 50 Headlight control unit 47 Radiator fan motor relay 45 Grip warmer left 1 ECU Engine...

Page 481: ...24 Brake light fuse 25 Front brake light switch 26 Rear brake light switch 27 Cruise control power switch 28 Cruise control setting switch SET 29 Cruise control setting switch RES 30 Grip cancel switc...

Page 482: ...16 Injector 1 R B 17 Joint coupler B 18 Electronic throttle valve fuse R L 19 Radiator fan motor relay Y R 20 21 22 23 24 25 Joint coupler B 26 Battery charger ter minal seat heater relay power wind...

Page 483: ...70 Lean angle sensor Y G 71 72 Joint coupler L 73 74 75 No Connected parts Wireharness color 76 Crankshaft position sensor B Y 77 Joint coupler Lg L 78 79 80 81 82 Handlebar switch left R G 83 Handleb...

Page 484: ...9 10 SYSTEM DIAGRAM 107 ABS ECU Electron ic Control Unit W G 108 No Connected parts Wireharness color...

Page 485: ...9 11 SYSTEM DIAGRAM...

Page 486: ...B B B B L B L Br B L R W Y R Y W Y Br Y BL B Lg B B B B B G B B G B R B R B R B R B R B R B R W B R R B B L L L L Y Y Y B Y B B B W W R R R R Y B Y B L Y L Y R R B L B L W W Gy G Gy G Y R Y R Y Y Lg W...

Page 487: ...57 ECU Engine Control Unit 58 Ignition coil 59 Spark plug 60 Grip warmer connector 61 Grip warmer left OPTION 62 Grip warmer right OPTION 63 Coolant temperature sensor 64 Intake air temperature sensor...

Page 488: ...W R G Lg W B W B W B W B W B B B B B B W B B B B L B L Br B L R W Y R Y W Y Br Y BL B Br Lg B G Y B Br Y R W Br W R B R W Br Y R B Br W Lg B B B B B G B B G R Y V Y L Gy Y B R Y Ch Y L B B Dg Y B B R...

Page 489: ...8 High beam indicator light 69 Multi function display 70 ECU Engine Control Unit 71 Ignition coil 72 Spark plug 73 Grip warmer connector 74 Grip warmer left 75 Grip warmer right 76 Coolant temperature...

Page 490: ...ck and repair it according to applicable troubleshooting When pushing the ON start switch does the MIL come on Does the MIL LED work properly B Perform the checking with the diagnostic mode Check the...

Page 491: ...MIL DOES NOT COME ON BUT THE ENGINE OPERATION IS NOT NORMAL 1 Monitor the operation of these sensors and actuators by using the YDT in the diagnostic mode Refer to DIAGNOSTIC CODE SENSOR OPERATION TAB...

Page 492: ...Gy G G L R G Lg L W G W Y G R Lg B L W Lg Lg L B W R G Lg W B W B W B W B W B B B B B B W B B B B B G B B G B R W R W B R R L Y L Y W L W L W R W R W G W G Lg W Lg W Lg L Lg L Lg W Lg W B Br L Br B B...

Page 493: ...ke light switch 43 Rear brake light switch 44 Grip cancel switch 55 Meter assembly 64 Cruise control system indicator light 65 Cruise control setting indicator light 69 Multi function display 70 ECU E...

Page 494: ...n meter 14 Grip cancel switch 17 ECU Engine Control Unit 19 Cruise control system indicator light 20 Cruise control setting indicator light 1 Battery 2 Main fuse 3 Ignition system relay 4 Backup fuse...

Page 495: ...art switch and then check the DTC of mal function is not displayed TIP If another DTC is displayed repeat steps 1 to 3 until no DTC is displayed Push the OFF LOCK switch will not erase the malfunction...

Page 496: ...control system to the customer Finished Is there automatic deactivation history for the cruise control system Check the malfunction history using the malfunction mode of the YDT Is there any malfuncti...

Page 497: ...nction mode of the YDT Malfunction history is displayed on the YDT B 1 Malfunction history is not displayed on the YDT B 3 EAS32882 B 3 MALFUNCTION HISTORY IS NOT DISPLAYED Use the YDT to check whethe...

Page 498: ...may not be able to maintain the set cruising speed When going uphill the actual traveling speed may become lower than the set cruising speed If this occurs accelerate to the desired traveling speed u...

Page 499: ...e rear brake light switches Refer to CHECKING THE SWITCHES on page 8 91 3 Execute the diagnostic mode DTC No 82 and 83 to check the operation of the front brake light switch rear brake light switch an...

Page 500: ...B B B B B W B B B Y W Y Br Y BL B B B G B B G B R W R W B W W W B B B B B G W W R R R R L Y L Y Lg W Lg W Lg W Lg W Lg L Lg L Lg W Lg W B B B Br L Br B Br B Br L Br L Br L Br L Br L B W R G R G R G R...

Page 501: ...39 Front brake light switch 40 Headlight relay dimmer 44 Meter assembly 54 ABS warning light 56 Multi function display 57 ECU Engine Control Unit 75 Front wheel sensor 76 Rear wheel sensor 77 ABS ECU...

Page 502: ...W B W B W B W B B B B B B W B B B Y W Y Br Y BL B Br Lg B G Y B B B G B B G B R W R W B W W W B B B B B G W W R R R R L Y L Y Lg W Lg W Lg W Lg W Lg L Lg L Lg W Lg W B B B Br L Br B Br B Br L Br L Br...

Page 503: ...mmer 40 Brake light relay 41 Brake light fuse 42 Front brake light switch 43 Rear brake light switch 55 Meter assembly 67 ABS warning light 69 Multi function display 70 ECU Engine Control Unit 88 Fron...

Page 504: ...6 7 2 8 10 9 1 4 4 3 1 YDT coupler 2 ABS warning light 3 Fuse box ABS motor fuse ABS solenoid fuse and ABS ECU fuse 4 ABS ECU 5 Front wheel sensor rotor 6 Front wheel sensor 7 Front brake caliper 8 Re...

Page 505: ...B WR GR G W B B W G W W Y G R Lg Lg B L B Lg LLg W B B G W B W B Gy W Gy W 5 6 1 2 3 4 R W R L G Y Br W R Lg LB W R GLg W Gy O L R L Br Y Ch Dg R GR W Gy V Gy WV W G RG L G W GW R W L Y B WLg WLg L B...

Page 506: ...inal check before delivering the vehicle to the customer TIP To final check refer to C 1 FINAL CHECK on page 9 37 ABS operation when the ABS warning light comes on 1 The ABS warning light remains on A...

Page 507: ...to damage components by subjecting them to shocks or pulling on them with too much force since the ABS components are precisely adjusted The ABS ECU and hydraulic unit are united assemblies and canno...

Page 508: ...ere all of the final checks completed normally The reaction force generated during brake line routing confirmation is incorrect Refer to C 1 FINAL CHECK The brake hoses and brake pipes are not connect...

Page 509: ...start switch for continuity Refer to CHECKING THE SWITCHES on page 8 91 If there is no continuity replace the handlebar switch right 2 Battery Check the condition of the battery Refer to CHECKING AND...

Page 510: ...y EAS32902 A 5 ABS ECU AND FI ECU FAIL TO COMMUNICATE 1 YDT Check that the YDT is properly connected 2 Wire harness Open circuit in the wire harness between the ABS ECU coupler and the YDT coupler Che...

Page 511: ...rake master cylinder reservoir Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 14 2 Check the wheel sensors for proper installation Refer to INSTALLING THE FRONT WHEEL DISC BRAKE on page 4 27 and IN...

Page 512: ...sembly defective sole noid drive circuit 24_ABS Brake light switch or tail brake light 30_EVENT Latch up detected Unable Unable D08 31_ABS Hydraulic unit assembly abnormal ABS solenoid power supply 32...

Page 513: ...ssure sensor ground short circuit detected P0108 Intake air pressure sensor open or power short circuit detected Able Able P0112 P0113 P0112 Intake air temperature sensor ground short circuit detected...

Page 514: ...voltage is abnormal P0563 Vehicle system power voltage out of range Able Able P0564 Cruise control setting switch RES open or short circuit is detected Cruise control setting switch SET open or short...

Page 515: ...or position sensor open or ground short circuit detected P2123 Accelerator position sensor power short circuit detected P2127 Accelerator position sensor ground short circuit detected P2128 Accelerato...

Page 516: ...ected Open or short cir cuit in wire har ness Disconnected cou pler Defective O2 sen sor heater control ler Malfunction in ECU Broken or discon nected lead in O2 sensor heater When the O2 sen sor does...

Page 517: ...learning is not carried out Cruise control sys tem cannot be oper ated P0112 P0113 P0112 Intake air temperaturesensor ground short circuit detected P0113 Intake air temperaturesensor open or power sh...

Page 518: ...short cir cuit in wire har ness between coolant tempera ture sensor and ECU Improperly in stalled coolant temperature sen sor Defective coolant temperature sen sor Malfunction in ECU Engine is diffic...

Page 519: ...speed is high Engine idling speed is unstable Engine response is poor Loss of engine pow er Deceleration is poor Increased exhaust emissions Vehicle cannot be driven Change in the throt tle opening is...

Page 520: ...ankshaftposition sensor and ECU Improperly in stalled crankshaft position sensor Malfunction in generator rotor Defective crank shaft position sen sor Malfunction in ECU Engine cannot be started Does...

Page 521: ...ot displayed on the meter Engine idling speed is unstable Traction control does not work Vehicle speed dis played on the meter 0 km h O2 feedback is not carried out Fuel cut off control when the rear...

Page 522: ...ss Defective cruise control setting switch Malfunction in ECU Cruise control sys tem cannot be oper ated Cruise control sys tem cannot be oper ated P056C Front brake light switch open or short circuit...

Page 523: ...t is restricted Cruise control sys tem cannot be oper ated P062F EEPROM DTC an error is detected while reading or writing on EE PROM CO adjustment value is not prop erly written ISC learning value is...

Page 524: ...it in wire har ness between fuel injection system relay and ECU Open circuit in wire harness between battery and ECU Defective fuel in jection system re lay Malfunction in ECU Engine is difficult to s...

Page 525: ...s not carried out O2 feedback learn ing value is not writ ten Cruise control sys tem cannot be oper ated P1604 P1605 P1604 Lean angle sensor ground short circuit detect ed P1605 Lean angle sensor open...

Page 526: ...U Engine response is poor Loss of engine pow er Engine idling speed is unstable No change in accel erator opening transient control is not carried out Accelerator open ing is fixed to 0 O2 feedback is...

Page 527: ...while the vehicle is traveling Foreign material ad hered around the rear wheel sensor Incorrect installation of the rear wheel Defective sensor rotor or incorrect installation of the rotor Defective...

Page 528: ...or miss ing pulses Front wheel sensor signal is not received properly Missing pulses are de tected in the signal while the vehicle is traveling Foreign material ad hered around the front wheel sensor...

Page 529: ...oupler be tween the battery and the hydraulic unit assembly Open or short circuit in the wire harness be tween the battery and the hydraulic unit assembly Defective hydraulic unit assembly 32 Hydrauli...

Page 530: ...ront wheel sensor miss ing pulses Front wheel sensor signal is not received properly Missing pulses are de tected in the signal while the vehicle is traveling Foreign material ad hered around the fron...

Page 531: ...ulic unit assembly Defective charging sys tem Defective hydraulic unit assembly 55 Hydraulic unit assembly defective ABS ECU Abnormal data is detected in the hydraulic unit as sembly Defective hydraul...

Page 532: ...ol sys tem cannot be oper ated Diagnostic code No Item Tool display Procedure D01 Throttle position sensor signal 1 Fully closed position 11 20 Check with throttle valves fully closed Fully open posit...

Page 533: ...position 93 109 Check with throttle valves fully open D14 Accelerator position sen sor signal 1 Fully closed position 11 20 Check with throttle grip fully closed position Fully open position 95 106 Ch...

Page 534: ...on display ISC Idle Speed Control learning data erasure 00 ISC Idle Speed Control learning data has been erased 01 It is not necessary to erase the ISC Idle Speed Con trol learning data 02 It is neces...

Page 535: ...irec tion ON Throttle grip is released OFF D83 Front brake light switch and rear brake light switch Operate the front brake lever and rear brake lever Front brake lever is squeezed ON Front brake leve...

Page 536: ...el pump coupler before doing this procedure Check that injector 2 is actuated five times by lis tening for the operating sound D50 Fuel injection system relay Actuates the fuel injection system relay...

Page 537: ...P0118 Perform the inspection items listed for DTC No P0117 and P0118 197 Intake air tem perature sensor Brief abnormality detected in the in takeairtemperature sensor Same as for DTC No P0112 and P01...

Page 538: ...he sys tem is functioning properly 243 ISC Stuck at the lower limit for adjustment During idling the adjustment is main tained at the lower limit Idling engine speed is fast Poorly adjusted throt tle...

Page 539: ...n off under the fol lowing conditions Unable to maintain the set cruising speed when traveling up a steep slope Wheel slip detected Engine stalls Sidestand is extend ed Engine stop switch is set to th...

Page 540: ...of the sensor 3 Defective lean angle sensor Execute the diagnostic mode Code D08 Check the lean angle sensor output voltage Is the MIL on YES Go to step 2 NO Service is completed Is check result OK YE...

Page 541: ...9 67 30_EVENT 4 Malfunction in ECU Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 93 Is the MIL on YES Go to step 4 NO Service is completed...

Page 542: ...s displayed at the same time check the other error code first and repair it 1 Allow to idle for a long period Push the OFF LOCK switch Check whether it is possible to start the engine 2 Malfunction in...

Page 543: ...tion of the pins TIP For this check also set the engine stop switch to ON 2 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broke...

Page 544: ...d condition YES Go to step 6 and complete the service NO Start the engine and then check the condition of the DTC Is it in the Recovered condition YES Go to step 6 and complete the service NO Go to st...

Page 545: ...ep 6 and complete the service NO Go to Short circuit check Between O2 sensor coupler 1 and ground red blue ground black green ground O2 sensor coupler 1 red blue any other coupler terminal black green...

Page 546: ...ntrol Unit on page 8 93 6 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go...

Page 547: ...bent or broken terminals and locking condition of the pins Is check result OK YES Go to step 2 NO a Reinstall or replace the O2 sensor Refer to ENGINE REMOVAL on page 5 7 b Start the engine and let i...

Page 548: ...DT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 4 Between O2 sensor coupler 1 and ECU cou pler 2 black green black green gray green gray green black blue bl...

Page 549: ...coupler terminal black blue any other coupler terminal ECU coupler 2 black green any other coupler terminal gray green any other coupler terminal black blue any other coupler terminal Fuel injection...

Page 550: ...service NO Go to step 5 Is check result OK YES Go to step 6 NO a Replace the fuel pump Refer to REMOVING THE FUEL PUMP on page 7 3 b Start the engine and let it idle for approximately 1 minute c Chec...

Page 551: ...nt or broken terminals and locking condition of the pins 3 Wire harness continuity Disconnect the intake air pressure sensor coupler and ECU coupler Open circuit check Is the coupler condition normal...

Page 552: ...resistance 0 YES Go to Short circuit check NO a Replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovere...

Page 553: ...Go to step 4 NO a Replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 a...

Page 554: ...tion of Recovered using the YDT and then delete the DTC At sea level Approx 101 kPa 757 6 mmHg 29 8 inHg approx 3 64 V 1000 m 3300 ft above sea level Approx 90 kPa 675 1 mmHg 26 6 inHg approx 3 30 V 2...

Page 555: ...ing condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coup...

Page 556: ...L Y G P W G Y L Lg W B L Br W Gy G Lg L W G W Y G R L W Lg B L Br W 1 2 2 XP560D XP560E Is resistance 0 YES Go to Short circuit check NO a Replace the wire harness b Push the ON start switch and then...

Page 557: ...O W W G Y L Lg W B L Br W Gy G G L R G Lg L W G W Y G R Lg B L W Lg B Y L Y G P W G Y L Lg W B L Br W Gy G Lg L W G W Y G R L W Lg B L Br W B L Br W A B 1 1 2 2 XP560D XP560E Is resistance YES Go to...

Page 558: ...hat the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Go to step 6 NO a Replace the intake air temperature sensor Refer to GENERAL CHASSIS 3 on page 4 1...

Page 559: ...the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect...

Page 560: ...Y G P W G Y L Lg W B L Br W Gy G Lg L W G W Y G R L W Lg B L G R 2 2 1 XP560D XP560E Is resistance 0 YES Go to step Short circuit check NO a Replace the wire harness b Push the ON start switch and the...

Page 561: ...G Y L Lg W B L Br W Gy G G L R G Lg L W G W Y G R Lg B L W Lg B Y L Y G P W G Y L Lg W B L Br W Gy G Lg L W G W Y G R L W Lg B L G R B L G R A B 1 1 2 2 XP560D XP560E Is resistance YES Go to step 4 NO...

Page 562: ...m that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Go to step 6 NO a Replace the coolant temperature sensor Refer to CYLINDER HEAD on page 5 20 b...

Page 563: ...oupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins 2 Connection of ECU coupler Check the locking con...

Page 564: ...222 blue blue P0122 P0123 P0222 P0223 P2135 white white P0123 P0223 black blue black blue P0122 P0123 P0222 P0223 P2135 black black Is resistance 0 YES Go to Short circuit check NO a Replace the wire...

Page 565: ...2 P0222 blue any other coupler terminal P0122 P0123 P0222 P0223 P2135 white any other coupler terminal P0123 P0223 black blue any other coupler terminal P0122 P0123 P0222 P0223 P2135 black any other c...

Page 566: ...the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 9 and complete the service NO Go to step 5 Is check result OK YES Go to step 6 NO a Repla...

Page 567: ...covered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 9 and complete the service NO Go to step 7 When the throttle valves are fully closed 9 23 When throttle va...

Page 568: ...rminals and locking condition of the pins Is check result OK YES Go to step 2 NO a Reinstall or replace the sensor b Push the ON start switch and then check the condition of the DTC using the malfunct...

Page 569: ...hen check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 4 Between O2 sensor coupler 1 and ECU...

Page 570: ...t circuit check Between O2 sensor coupler 1 and ground gray green ground black blue ground O2 sensor coupler 1 black blue any other coupler terminal gray green any other coupler terminal ECU coupler 2...

Page 571: ...resistance YES Go to step 5 NO a Replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES...

Page 572: ...bent or broken terminals and locking condition of the pins 2 Defective injector 1 Measure the injector resistance Refer to CHECKING THE FUEL INJECTOR on page 8 111 Is the coupler condition normal YES...

Page 573: ...ct the coupler securely or replace the wire harness b Execute the diagnostic mode Code D36 Is it hear operating sound YES Go to step 6 NO Go to step 4 Between injector 1 coupler 1 and ECU cou pler 2 r...

Page 574: ...he DTC has a condition of Recovered using the malfunction mode of the YDT and then delete the DTC Between injector 1 coupler 1 and ground red black ground red blue ground Injector 1 coupler 1 red blac...

Page 575: ...bent or broken terminals and locking condition of the pins 2 Defective injector 2 Measure the injector resistance Refer to CHECKING THE FUEL INJECTOR on page 8 111 Is the coupler condition normal YES...

Page 576: ...the coupler securely or replace the wire harness b Execute the diagnostic mode Code D37 Is it hear operating sound YES Go to step 6 NO Go to step 4 Between injector 2 coupler 1 and ECU cou pler 2 gree...

Page 577: ...DTC has a condition of Recovered using the malfunction mode of the YDT and then delete the DTC Between injector 2 coupler 1 and ground green black ground red blue ground Injector 2 coupler 1 green bla...

Page 578: ...harness continuity Disconnect the crankshaft position sensor coupler and ECU coupler Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace th...

Page 579: ...resistance 0 YES Go to Short circuit check NO a Replace the wire harness b Crank the engine and then check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered conditi...

Page 580: ...B Y B L 2 2 1 1 A B XP560D XP560E Is resistance YES Go to step 4 NO a Replace the wire harness b Crank the engine and then check the condition of the DTC using the malfunction mode of the YDT Is it i...

Page 581: ...Engine Control Unit on page 8 93 7 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Go to...

Page 582: ...nect the ignition coil coupler and ECU coupler Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Start the engine and...

Page 583: ...et it idle for approximately 5 seconds c Check the condition of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to Short...

Page 584: ...lete the service NO Go to step 4 Is check result OK YES Go to step 5 NO a Reinstall or replace the ignition coil b Start the engine and let it idle for approximately 5 seconds c Check the condition of...

Page 585: ...rm that spark plug does not sparking Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 93 7 Delete the DTC and check that the MIL goes off Confirm that...

Page 586: ...he pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Push the ON start sw...

Page 587: ...and ECU coupler 2 yellow red yellow red Is resistance 0 YES Go to Short circuit check NO a Replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfun...

Page 588: ...he MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is resistance YES Go to step 4 NO a Replace the wire harness b Push the ON start switch and then...

Page 589: ...of the pins 3 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler...

Page 590: ...sensor coupler 1 and ABS ECU coupler 2 black black white white Between ABS ECU coupler 2 and ECU cou pler 3 white green white green B Y L Y G P Lg L O W W G Y L Lg W B L Br W Gy G G L R G Lg L W G W...

Page 591: ...hite any other coupler terminal ABS ECU coupler 2 black any other coupler terminal white any other coupler terminal white green any other coupler terminal ECU coupler 3 white green any other coupler t...

Page 592: ...tate the rear wheel by hand Start the engine and input the vehicle speed signals by operating the vehicle at 20 to 30 km h 12 to 19 mph Confirm that the DTC has a condition of Recovered using the malf...

Page 593: ...DIES on page 7 10 Is check result OK YES Go to step 2 NO a Replace the throttle bodies b Start the engine and let it idle for approximately 5 minutes c Push the ON start switch and then check the cond...

Page 594: ...P0507 3 Malfunction in ECU Replace the ECU and complete the service 4 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete th...

Page 595: ...fer to CHARGING SYSTEM on page 8 17 2 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Repe...

Page 596: ...e from step 3 to step 5 and from step 9 to step 10 b Execute the diagnostic mode Code 81 c Confirm that it is defective d Go to step 6 Is the coupler condition normal YES Go to step 2 NO a Connect the...

Page 597: ...ise control setting switch and then check the condi tion of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 10 and complete the service NO Go to step 4 Be...

Page 598: ...ed condition YES Go to step 10 and complete the service NO Go to Short circuit check Between ignition system relay coupler 1 and ground brown blue ground Between handlebar switch coupler left 3 and gr...

Page 599: ...ES side of the cruise control setting switch and then check the condi tion of the DTC using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 10 and complete the service...

Page 600: ...andlebar switch coupler left 3 and ECU coupler 4 green blue green blue Is resistance 0 YES Go to Short circuit check NO a Replace the wire harness b Push the ON start switch c Push and SET side of the...

Page 601: ...any other coupler terminal Handlebar switch coupler left 3 green blue any other coupler terminal yellow black any other coupler terminal ECU coupler 4 green blue any other coupler terminal Is resistan...

Page 602: ...11 2 Connection of ECU coupler front brake light switch coupler brake light relay coupler and handlebar switch coupler right Check the locking condition of the coupler Disconnect the coupler and chec...

Page 603: ...ng the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 11 and complete the service NO Go to step 4 Between ignition system relay coupler 1 and signaling system fuse holder...

Page 604: ...to step 11 and complete the service NO Go to Short circuit check Between ignition system relay coupler 1 and ground brown blue ground Between front brake light switch 3 and ground green white ground...

Page 605: ...ler and check the pins bent or broken terminals and locking condition of the pins Is resistance YES Go to step 5 NO a Replace the wire harness b Push the ON start switch c Operate the front brake leve...

Page 606: ...YES Go to step 11 and complete the service NO Go to step 7 Is check result OK YES Go to step 8 NO a Replace the fuse b Push the ON start switch c Operate the rear brake lever and then check the condit...

Page 607: ...check Between ignition system relay coupler 1 and ground brown blue ground Between rear brake light switch coupler 3 and ground green yellow ground light green black ground Between brake light relay...

Page 608: ...ered condition YES Go to step 11 and complete the service NO Go to step 9 Is check result OK YES Go to step 10 NO a Push the ON start switch b Operate the rear brake lever and then check the condition...

Page 609: ...place the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 93 11 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered u...

Page 610: ...ion is detected in the ECU the DTC might not appear on the tool display Fail safe system Unable to start engine Unable to drive vehicle Procedure 1 Malfunction in ECU Replace the ECU Refer to REPLACIN...

Page 611: ...are detected at the same time correct the P0122 P0123 P0222 P0223 and P2135 first Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT 2 Malfunction...

Page 612: ...de push the OFF LOCK switch Push the ON start switch and then check the condition of the DTC using the malfunction mode of the YDT 3 02 is indicated in diagnostic mode code D60 EEPROM data error for a...

Page 613: ...malfunction mode of the YDT 5 Malfunction in ECU Replace the ECU and complete the service Refer to REPLACING THE ECU Engine Control Unit on page 8 93 6 Delete the DTC and check that the MIL goes off C...

Page 614: ...pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Push the ON start switc...

Page 615: ...using the malfunction mode of the YDT Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 4 Between throttle servo motor coupler 1 and ECU coupler 2 yellow red yel...

Page 616: ...r coupler terminal red blue any other coupler terminal Is resistance YES Go to step 5 NO a Replace the wire harness b Push the ON start switch and then check the condition of the DTC using the malfunc...

Page 617: ...onfirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 8 and complete the service NO Go to step 6 Is check result OK YES...

Page 618: ...ler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace t...

Page 619: ...fuel injection system relay coupler 2 red black red black Between fuel injection system relay coupler 2 and ECU coupler 5 red blue red blue blue yellow blue yellow Is resistance 0 YES Go to Short cir...

Page 620: ...ler terminal blue yellow any other coupler terminal Is resistance YES Go to step 4 NO a Replace the wire harness b Start the engine and let it idle for approximately 5 seconds c Check the condition of...

Page 621: ...s a condition of Recovered using the YDT and then delete the DTC Is it in the Recovered condition YES Go to step 7 and complete the service NO Go to step 5 Is the fuel system voltage less than 3V YES...

Page 622: ...he locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect t...

Page 623: ...4 Between sidestand relay coupler 1 and ECU coupler 2 light green light green Between sidestand relay coupler 1 and side stand switch coupler 3 light green light green B Y L Y G P Lg L O W W G Y L Lg...

Page 624: ...green any other coupler terminal Sidestand switch coupler 3 light green any other coupler terminal B Y L Y G P Lg L O W W G Y L Lg W B L Br W Gy G G L R G Lg L W G W Y G R Lg B L W Lg B Y L Y G P W G...

Page 625: ...es off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Sidestand retracted ON Sidestand extended OFF Is check result OK YES Go to step 6 NO a Replace the sidest...

Page 626: ...e pins bent or broken terminals and locking condition of the pins Is check result OK YES Go to step 2 NO a Reinstall or replace the battery leads b Push the ON start switch and then check the conditio...

Page 627: ...condition YES Go to step 6 and complete the service NO Go to step 4 Between battery 1 and starter relay terminal 2 red red Between starter relay coupler 3 and ECU cou pler 4 red red Is resistance 0 YE...

Page 628: ...TC has a condition of Recovered using the YDT and then delete the DTC Between starter relay coupler 3 and ground red ground Starter relay coupler 3 red any other coupler terminal ECU coupler 4 red any...

Page 629: ...ondition of the pins 3 Wire harness continuity Disconnect the lean angle sensor coupler and ECU coupler Open circuit check Is the coupler condition normal YES Go to step 2 NO a Connect the coupler sec...

Page 630: ...Lg W B L Br W Gy G Lg L W G W Y G R L W Lg B L Y G L 2 2 1 XP560D XP560E Is resistance 0 YES Go to Short circuit check NO a Replace the wire harness b Push the ON start switch then to OFF and then ba...

Page 631: ...g B Y L Y G P W G Y L Lg W B L Br W Gy G Lg L W G W Y G R L W Lg B L Y G L B A 2 2 1 XP560D XP560E Is resistance YES Go to step 4 NO a Replace the wire harness b Push the ON start switch then to OFF a...

Page 632: ...pler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins 2 Connection of ECU coupler Check the locking condi...

Page 633: ...122 P2123 P2127 P2128 P2138 white white P2123 P2128 black blue black blue P2122 P2127 blue blue P2122 P2123 P2127 P2128 P2138 red red Is resistance 0 YES Go to Short circuit check NO a Replace the wir...

Page 634: ...122 P2123 P2127 P2128 P2138 white any other coupler terminal P2123 P2128 black blue any other coupler terminal P2122 P2127 blue any other coupler terminal P2122 P2123 P2127 P2128 P2138 red any other c...

Page 635: ...page 8 93 6 Delete the DTC and check that the MIL goes off Confirm that the DTC has a condition of Recovered using the YDT and then delete the DTC Is check result OK YES Go to step 5 NO Replace the ac...

Page 636: ...check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect the coupler securely or replace the wire harness b Execute the d...

Page 637: ...at the indicated value increases Is that value increased YES Go to step 8 and complete the service NO Go to step 4 Between front wheel sensor coupler 1 and ABS ECU coupler 2 black black white white Be...

Page 638: ...ground white yellow ground Front wheel sensor coupler 1 black any other coupler terminal white any other coupler terminal ABS ECU coupler 2 black any other coupler terminal white any other coupler ter...

Page 639: ...irm that the DTC has a condition of Recovered using the malfunction mode of the YDT and then delete the DTC Delete this DTC even if it has a condition of Detected Is resistance YES Go to step 5 NO a R...

Page 640: ...the locking condition of the coupler Disconnect the coupler and check the pins bent or broken terminals and locking condition of the pins Is the coupler condition normal YES Go to step 2 NO a Connect...

Page 641: ...y G Lg L W G W Y G R L W Lg G B P WP B O L R LB W Br Y L R Br YChDgR GR W Gy V Gy WV WG RG L G W GW RW L Y B WLg WLg LB WR GR G 2 2 1 XP560D XP560E Is resistance 0 YES Go to Short circuit check NO a R...

Page 642: ...Y L Lg W B L Br W Gy G G L R G Lg L W G W Y G R Lg B L W Lg B Y L Y G P W G Y L Lg W B L Br W Gy G Lg L W G W Y G R L W Lg G B P WP B O L R LB W Br Y L R Br YChDgR GR W Gy V Gy WV WG RG L G W GW RW L...

Page 643: ...4 24 3 Defective sensor rotor or incorrect installation of the rotor Check the surface of the sensor rotor for damage Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 26 4 Def...

Page 644: ...e surface of the sensor rotor for damage Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 34 4 Defective rear wheel sensor or incorrect installation of the sensor Check the whe...

Page 645: ...r to CHECKING THE FRONT WHEEL on page 4 24 3 Defective sensor rotor or incorrect installation of the rotor Check the surface of the sensor rotor for damage Refer to MAINTENANCE OF THE FRONT WHEEL SENS...

Page 646: ...r to CHECKING THE REAR WHEEL on page 4 33 3 Defective sensor rotor or incorrect installation of the rotor Check the surface of the sensor rotor for damage Refer to MAINTENANCE OF THE REAR WHEEL SENSOR...

Page 647: ...pler and front wheel sensor coupler Open circuit check Short circuit check TIP Disconnect the ABS ECU related connectors before checking Refer to PARTS CONNECTED TO THE ABS ECU on page 9 4 Ground shor...

Page 648: ...nit assembly Refer to FRONT WHEEL on page 4 22 and ABS Anti lock Brake System on page 4 67 ABS ECU coupler 1 white any other coupler terminal black any other coupler terminal Front wheel sensor 2 whit...

Page 649: ...pler and rear wheel sensor coupler Open circuit check Short circuit check TIP Disconnect the ABS ECU related connectors before checking Refer to PARTS CONNECTED TO THE ABS ECU on page 9 4 Ground short...

Page 650: ...nit assembly Refer to REAR WHEEL on page 4 30 and ABS Anti lock Brake System on page 4 67 ABS ECU coupler 1 white any other coupler terminal black any other coupler terminal Rear wheel sensor 2 white...

Page 651: ...ortion and bends Refer to CHECKING THE FRONT WHEEL on page 4 24 3 Defective sensor rotor or incorrect installation of the rotor Check the surface of the sensor rotor for damage Refer to MAINTENANCE OF...

Page 652: ...tortion and bends Refer to CHECKING THE REAR WHEEL on page 4 33 3 Defective sensor rotor or incorrect installation of the rotor Check the surface of the sensor rotor for damage Refer to MAINTENANCE OF...

Page 653: ...1_ABS EAS33320 TROUBLESHOOTING Item Hydraulic unit assembly defective solenoid drive circuit Procedure 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS Anti lock Br...

Page 654: ...OFF LOCK switch before disconnecting or connecting a coupler 3 Wire harness continuity XP560E Disconnect the handlebar switch coupler right handlebar switch coupler left and ABS ECU cou pler Open circ...

Page 655: ...1 green yellow any other coupler terminal Handlebar switch coupler left 2 green yellow any other coupler terminal ABS ECU coupler 3 green yellow any other coupler terminal Is resistance YES Go to step...

Page 656: ...coupler 2 green yellow any other coupler terminal Rear brake light switch coupler 3 green yellow any other coupler terminal light green black any other coupler terminal Brake light relay coupler 4 bro...

Page 657: ...9 183 24_ABS 5 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to CHECKING THE FUEL PRESSURE on page 7 12 Is resistance YES Go to step 5 NO Replace the wire harness...

Page 658: ...sh the OFF LOCK switch before disconnecting or connecting a coupler 3 Wire harness continuity Disconnect the ABS solenoid fuse and ABS ECU coupler Open circuit check Short circuit check Is check resul...

Page 659: ...ic unit assembly Replace the hydraulic unit assembly Refer to ABS Anti lock Brake System on page 4 67 Between ABS ECU coupler 2 and ground red white ground ABS ECU coupler 2 red white any other couple...

Page 660: ...33376 TROUBLESHOOTING Item Hydraulic unit assembly short circuit in ABS solenoid power supply circuit Procedure 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS Ant...

Page 661: ...pler TIP Push the OFF LOCK switch before disconnecting or connecting a coupler 3 Wire harness continuity Disconnect the ABS motor fuse and ABS ECU coupler Open circuit check Is check result OK YES Go...

Page 662: ...ssembly Replace the hydraulic unit assembly Refer to ABS Anti lock Brake System on page 4 67 Between ABS ECU coupler 2 and ground red blue ground ABS ECU coupler 2 red blue any other coupler terminal...

Page 663: ...S33323 TROUBLESHOOTING Item Hydraulic unit assembly short circuit in ABS motor power supply circuit Procedure 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS Anti...

Page 664: ...G THE FRONT WHEEL on page 4 24 and CHECKING THE FRONT BRAKE DISCS on page 4 43 3 Front brake dragging Check that the brake fluid pressure is correctly transmitted to the brake caliper when the brake l...

Page 665: ...o CHECKING THE REAR WHEEL on page 4 33 and CHECKING THE REAR BRAKE DISC on page 4 58 3 Rear brake dragging Check that the brake fluid pressure is correctly transmitted to the brake caliper when the br...

Page 666: ...of the sensor rotor for damage Refer to MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR on page 4 26 4 Defective front wheel sensor or incorrect installation of the sensor Check the wheel sens...

Page 667: ...of the sensor rotor for damage Refer to MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR on page 4 34 4 Defective rear wheel sensor or incorrect installation of the sensor Check the wheel sensor...

Page 668: ...Recharge or replace the battery and check again Refer to CHECKING AND CHARGING THE BATTERY on page 8 94 2 Disconnected battery terminal Check the connection 3 Defective charging system Check the char...

Page 669: ...disconnecting or connecting a coupler 3 Wire harness continuity Disconnect the ABS ECU fuse and ABS ECU coupler Open circuit check Short circuit check TIP Disconnect the ABS ECU related connectors be...

Page 670: ...hite any other coupler terminal Is resistance YES Go to step 4 NO Replace the wire harness Is check result OK YES Replace the hydraulic unit assembly ABS ECU NO Confirm the cause of the problem and re...

Page 671: ...before disconnecting or connecting a coupler 3 Wire harness continuity Disconnect the ABS ECU fuse ABS motor fuse and ABS ECU coupler Open circuit check Short circuit check TIP Disconnect the ABS ECU...

Page 672: ...n page 9 26 Between ABS ECU coupler 3 and ground brown white ground red blue ground ABS ECU coupler 3 brown white any other coupler terminal red blue any other coupler terminal Is resistance YES Go to...

Page 673: ...20700 55_ABS EAS33328 TROUBLESHOOTING Item Hydraulic unit assembly defective ABS ECU Procedure 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS Anti lock Brake Syst...

Page 674: ...56_ABS EAS33329 TROUBLESHOOTING Item Hydraulic unit assembly abnormal internal power supply Procedure 1 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS Anti lock Bra...

Page 675: ...check A Lines short circuit check B Between front wheel sensor coupler 1 and ground white ground black ground Front wheel sensor coupler 1 white any other coupler terminal black any other coupler ter...

Page 676: ...63_ABS 3 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS Anti lock Brake System on page 9 26 Is resistance YES Go to step 3 NO Replace the wire harness W Gy W Gy A A...

Page 677: ...A Lines short circuit check B Between rear wheel sensor coupler 1 and ground white ground black ground Rear wheel sensor coupler 1 white any other coupler terminal black any other coupler terminal ABS...

Page 678: ...64_ABS 3 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS Anti lock Brake System on page 9 26 Is resistance YES Go to step 3 NO Replace the wire harness W Gy W Gy A A...

Page 679: ...mper and suspen sion warning light 54 ABS warning light 55 High beam indicator light 56 Multi function display 57 ECU Engine Control Unit 58 Ignition coil 59 Spark plug 60 Grip warmer connector 61 Gri...

Page 680: ...cator light left 63 Turn signal indicator light right 64 Cruise control system indicator light 65 Cruise control setting indicator light 66 Steering damper and suspen sion warning light 67 ABS warning...

Page 681: ...L Green Blue G R Green Red G W Green White G Y Green Yellow Gy G Gray Green Gy W Gray White L B Blue Black L G Blue Green L R Blue Red L W Blue White L Y Blue Yellow Lg B Light green Black Lg L Light...

Page 682: ......

Page 683: ......

Page 684: ......

Page 685: ...B L B L R L R V W V W W L W G W R W L Br Y Br Y Y B R Y W R W G R L R L O L O L L L P Lg L Lg L Lg W Lg W Lg W Lg W Lg W Lg W Lg L Lg L Lg W Lg W Lg L Lg L Lg L Lg L Lg W Lg W Lg W Lg W L G L G L G L...

Page 686: ...0 14 22 25 31 33 32 27 28 29 30 41 42 43 58 10 59 60 61 62 63 57 45 44 46 48 47 49 50 51 52 53 54 68 10 10 71 72 73 74 75 10 77 10 80 79 78 76 69 70 64 65 66 10 67 23 26 24 11 10 12 13 9 N HI FREE PAS...

Page 687: ...Y V Y L Gy Y B R Y Ch Y L B B Dg Y B W W W B L Y L Y R B R B R B R B R B R B R B R W R W R W R W Dg Br G Dg L L Br B Br B Br Y B R R W W W B B B B L L L L B G Y Y Y B Y B B B W W R R R R Y B Y B W Y...

Page 688: ...41 43 42 44 45 46 47 48 49 51 50 53 52 71 10 72 73 74 75 76 70 56 55 57 59 58 60 61 62 63 64 65 66 67 81 10 10 84 85 86 87 88 10 90 10 93 92 91 89 82 83 77 78 79 10 80 54 23 26 24 11 10 12 13 9 RES N...

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