Yamaha XSR700 2018, Supplement Service Manual

Page 1: ...2018 SUPPLEMENTARY SERVICE MANUAL XSR700 MTM690 MTM690 U BU3 F8197 E0...

Page 2: ...s it is necessary to use this Supplementary Service Manual together with the following manual MTM690 MTM690 U 2018 SERVICE MANUAL B34 F8197 E2 EAS20002 MTM690 MTM690 U SUPPLEMENTARY SERVICE MANUAL 201...

Page 3: ...nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable TIP Designs and specifications ar...

Page 4: ...n title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in the explod...

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

Page 6: ...ENANCE AND LUBRICATION CHART 21 CHECKING THE VEHICLE USING THE YAMAHA DIAGNOSTIC TOOL 24 CHECKING THE EXHAUST SYSTEM 24 GENERAL CHASSIS 3 25 GENERAL CHASSIS 5 26 REMOVING THE ECU engine control unit 2...

Page 7: ...BLESHOOTING 59 FUEL INJECTION SYSTEM 61 CIRCUIT DIAGRAM 61 TROUBLESHOOTING DETAILS FAULT CODE 63 TROUBLESHOOTING DETAILS EVENT CODE 69 ABS ANTI LOCK BRAKE SYSTEM 71 CIRCUIT DIAGRAM 71 ABS COUPLER LOCA...

Page 8: ...tools part numbers or both may differ depending on the country When placing an order refer to the list provided below to avoid any mistakes TIP For U S A and Canada use part number starting with YM YU...

Page 9: ...GENERAL SPECIFICATIONS 2 EAS20013 GENERAL SPECIFICATIONS Model Model BU31 MTM690 B9J1 MTM690 U...

Page 10: ...ELECTRICAL SPECIFICATIONS 3 EAS20016 ELECTRICAL SPECIFICATIONS Fuse Backup fuse 2 10 0 A...

Page 11: ...ELECTRICAL SPECIFICATIONS 4...

Page 12: ...CABLE ROUTING 5 EAS20021 CABLE ROUTING Handlebar front view A B D C E F 4 8 9 10 11 12 12 13 14 14 G 1 1 1 2 2 2 3 3 5 5 6 6 7 7 12 15 16 17 18 12 1 3 5 5 H I J K H I J K L...

Page 13: ...r Align the holder with the blue tape on the handlebar switch lead B Route the throttle cables through the guide Be sure to route the throttle cable decelerator cable over the throttle cable accelerat...

Page 14: ...CABLE ROUTING 7 ECU and clutch cable right side view 19 20 F A D 1 2 3 4 5 6 7 8 9 10 11 11 11 12 12 12 13 13 14 15 G H B E C G H I J 16 18 17 K 21...

Page 15: ...er 16 Wire harness to ECU 17 Damper 18 Frame 19 Cylinder head breather hose 20 Sub wire harness gear position switch coolant temperature sensor fuel injector 21 Meter assembly coupler cover A Position...

Page 16: ...CABLE ROUTING 9 Engine right side view E A B C D 1 1 2 3 4 5 6 7 12 13 B F G H I L Q K J 8 9 11 10 10 M N O P 1 12 M N O P 3 6 7 14...

Page 17: ...light switch lead and O2 sensor lead with the holder E To rear brake caliper bracket F Connect the O2 sensor coupler and then insert the projection on the coupler into the hole in the bracket G Route...

Page 18: ...CABLE ROUTING 11 Rectifier regulator left side view D C A B E G H I 1 4 3 5 6 7 8 11 12 F 9 10 T U S V W 10 12 X Y N O Z 22 23 24 25 26 27 14 15 P Q R 16 17 18 19 20 21 2 2 1 J K L M 13...

Page 19: ...gneto lead horn lead and coolant reservoir hose with the holder Make sure that the coolant reservoir hose and leads do not cross between the oil cooler inlet hose and this holder I Fasten the AC magne...

Page 20: ...l components tray top view 27 27 27 27 N 26 P Q I J I J H F 27 28 O 1 2 4 5 E G H F 20 E G H F 20 I J H F K H F A B 1 2 3 4 5 6 7 9 10 11 12 13 16 17 18 18 18 19 19 19 20 20 20 21 24 24 25 25 26 22 23...

Page 21: ...in switch lead 29 Electrical components tray 1 A Insert the projection on the bracket into the hole in the sub wire harness coupler B White paint mark C Insert the projection on the wire harness holde...

Page 22: ...CABLE ROUTING 15 Battery and rear fender top view 8 9 10 15 16 16 17 17 A B C D 1 2 2 3 3 4 5 6 7 8 9 10 11 11 11 12 12 13 14 14 14 15 18 18 19 20 21 21 22 23 F G H I J K L 14 21 G H G H E...

Page 23: ...gnostic tool lead and coupler above fuse boxes 1 and 2 as shown in the illustration C Connect all of the couplers near fuse box 2 and then install fuse box 2 to the battery box D Fasten the license pl...

Page 24: ...CABLE ROUTING 17 Rear brake hose right side view I N 1 E J K L G M 1 1 5 5 5 4 5 2 2 2 2 2 2 6 7 E H 5 2 A B C F D D D 1 2 3 8 8 5 4 4 4 2 6 7...

Page 25: ...inward with the end pointing downward G Position the end of the plastic locking tie to the inside of the brake hoses H Route the brake hoses on top of the frame I Point the end of the plastic locking...

Page 26: ...CABLE ROUTING 19 Front brake hose left and right side view A B C D E D F G G H 1 1 2 2 2 3 2 3 4 1...

Page 27: ...e the lead over the hose C Face the catch of the holder forward and then close the holder until three clicks or more are heard D Make sure that the holder contacts the end of the hose protector on the...

Page 28: ...formed by your Yamaha dealer because these items re quire special tools data and technical skills From 50000 km 30000 mi repeat the maintenance intervals starting from 10000 km 6000 mi The annual chec...

Page 29: ...and after washing the motorcycle riding in the rain or riding in wet areas 14 Steering bearings Check bearing assemblies for looseness Moderately repack with lithi um soap based grease 15 Chassis fas...

Page 30: ...our years and if cracked or damaged 25 Engine oil Change warm engine before draining Check oil level and vehicle for oil leakage 26 Engine oil filter cartridge Replace 27 Cooling system Check coolant...

Page 31: ...FAULT CODE on page 63 and B 2 DI AGNOSIS USING THE FAULT CODES on page 75 4 Perform Dynamic inspection TIP Use the Dynamic inspection function of the Yamaha diagnostic tool version 3 0 and after to p...

Page 32: ...center cover 1 5 Air scoop left 1 6 Air scoop right 1 7 Outer side cover left 1 8 Inner side cover left 1 9 Outer side cover right 1 10 Inner side cover right 1 4 3 3 4 4 6 1 2 3 4 5 6 8 10 9 7 8 1 5...

Page 33: ...age 25 Fuel tank Refer to FUEL TANK on page 38 Hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYS TEM in chapter 4 Manual No B34 F8197 E2 1 Stator coil coupler 1 Disconnect 2 Rectifier regulator...

Page 34: ...motor coupler 1 12 Crankshaft position sensor coupler 1 13 Electrical components tray 1 1 14 ECU coupler 1 Disconnect 15 ECU Engine Control Unit 1 16 Band 1 17 Sub wire harness coupler 1 18 Electrica...

Page 35: ...the portion a of the ECU cou pler move the lock lever b in the direction of the arrow shown to disconnect the coupler EAS31109 INSTALLING THE ECU engine control unit 1 Connect ECU coupler 1 TIP Conne...

Page 36: ...1 9 Throttle cable housing 1 10 Throttle cable 2 Disconnect LT LS LS LS LS 1 5 7 3 2 4 9 9 10 10 1 8 6 8 10 N m 1 0 kgf m 7 4 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T...

Page 37: ...ower handlebar holder 1 LT LS LS LS LS 18 21 20 20 11 12 11 16 13 19 22 14 15 14 17 10 N m 1 0 kgf m 7 4 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 1 8 N m 0 18 kgf m 1 3 lb ft T R 2 0 N m 0 20 kgf m...

Page 38: ...Fuel tank Refer to FUEL TANK on page 38 Front wheel Refer to FRONT WHEEL in chapter 4 Manual No B34 F8197 E2 1 Front brake hose lead holder 2 2 Front fender 1 3 Front fender bracket 1 4 Front fork cap...

Page 39: ...ler 2 Disconnect 8 Immobilizer unit coupler 1 Disconnect 9 Upper bracket 1 10 Lower bracket pinch bolt 2 Loosen 11 Front fork leg 1 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0...

Page 40: ...AL CHASSIS 2 in chap ter 4 Manual No B34 F8197 E2 Handlebar Refer to HANDLEBAR on page 29 Front fork legs Refer to FRONT FORK on page 31 1 Front brake hose lower holder 1 2 Front brake hose upper hold...

Page 41: ...b Parts to remove Q ty Remarks 5 Cap nut 1 6 Lower bracket 1 7 Lower bracket cap 1 8 Bearing cover 1 9 Lower bearing dust seal 1 10 Upper bearing 1 11 Lower bearing 1 5 8 10 6 7 9 11 LS LS LS 1st 52 N...

Page 42: ...n chapter 4 Manual No B34 F8197 E2 Drive sprocket cover Refer to CHAIN DRIVE in chapter 4 Man ual No B34 F8197 E2 1 Pivot shaft protector left 1 2 Pivot shaft protector right 1 3 Sidestand switch coup...

Page 43: ...e 1 12 Dust cover 2 13 Oil seal 2 14 Collar 2 15 Oil seal 2 16 Bearing 3 16 15 14 14 10 13 12 13 9 11 16 12 8 5 7 6 LT LT LT LT LS LS LS LS LS New New New New LS New 10 N m 1 0 kgf m 7 4 lb ft T R 7 N...

Page 44: ...Oil seal 2 21 Bearing 2 22 Washer 1 17 19 18 20 20 21 17 22 LT LT LT LT LS LS LS LS LS New New New New LS New 10 N m 1 0 kgf m 7 4 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R...

Page 45: ...AL CHASSIS 3 on page 25 1 Intake air temperature sensor coupler 1 Disconnect 2 Fuel tank overflow hose 1 Disconnect 3 Fuel tank breather hose 1 Disconnect 4 Fuel pump coupler 1 Disconnect 5 Fuel hose...

Page 46: ...ir temperature sensor 1 10 Fuel pump 1 11 Front fuel tank bracket 1 12 Rear fuel tank bracket 1 8 4 New 7 6 8 12 9 10 11 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0 kgf m 7 4 lb ft T R 3 8 N m 0 38 kgf...

Page 47: ...FUEL TANK 40...

Page 48: ...Dg B B Y Y G G L R L R Ch Ch B Dg B Ch L R G Y B B B B B B B B L R L L L R L R L B L B L R L R L B L B R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W L W R...

Page 49: ...nt coupler 26 Sidestand switch 27 Crankshaft position sensor 30 Ignition coil 1 31 Ignition coil 2 32 Spark plug 36 ECU Engine Control Unit 40 Lean angle sensor 62 Gear position switch 63 Handlebar sw...

Page 50: ...G THE BATTERY in chapter 8 Manual No B34 F8197 E2 Clean the battery terminals Recharge or replace the battery 3 Check the spark plugs Refer to CHECKING THE SPARK PLUGS in chapter 3 Manual No B34 F8197...

Page 51: ...No B34 F8197 E2 Replace the gear position switch 10 Check the sidestand switch Refer to CHECKING THE SWITCHES in chapter 8 Manual No B34 F8197 E2 Replace the sidestand switch 11 Check the relay unit d...

Page 52: ...Dg B B Y Y G G L R L R Ch Ch B Dg B Ch L R G Y B B B B B B B B L R L L L R L R L B L B L R L R L B L B R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W L W R...

Page 53: ...25 Joint coupler 36 ECU Engine Control Unit 48 Meter assembly 51 Meter light 57 High beam indicator light 68 Handlebar switch left 70 Dimmer switch 71 Pass switch 77 Headlight assembly 78 Auxiliary li...

Page 54: ...fuses Ignition signaling system head light backup 2 and main Refer to CHECKING THE FUS ES on page 81 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 8 Manu...

Page 55: ...al No B34 F8197 E2 Replace the headlight relay 8 Check the entire lighting system wiring Refer to CIRCUIT DIAGRAM on page 45 Properly connect or replace the wiring har ness Replace the ECU meter assem...

Page 56: ...g Dg B B Y Y G G L R L R Ch Ch B Dg B Ch L R G Y B B B B B B B B L R L L L R L R L B L B L R L R L B L B R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W L W...

Page 57: ...light 52 Tachometer 53 Multi function meter 54 Oil pressure warning light 56 Coolant temperature warning light 58 Turn signal indicator light left 59 Turn signal indicator light right 61 Horn 62 Gear...

Page 58: ...trol unit ignition signaling system backup 2 backup and main Refer to CHECKING THE FUS ES on page 81 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 8 Manu...

Page 59: ...switch Refer to CHECKING THE SWITCHES in chapter 8 Manual No B34 F8197 E2 Replace the front brake light switch 2 Check the rear brake light switch Refer to CHECKING THE SWITCHES in chapter 8 Manual N...

Page 60: ...entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 49 Properly connect or replace the wiring har ness Replace the meter assembly 1 Check the gear position switch Refer to CHECKING THE GE...

Page 61: ...IRCUIT DIAGRAM on page 49 Properly connect or replace the wiring har ness 2 Measure the engine oil pressure Refer to MEASURING THE EN GINE OIL PRESSURE in chapter 3 Manual No B34 F8197 E2 Check the en...

Page 62: ...RAM on page 49 Properly connect or replace the wiring har ness Replace the ECU or meter assembly Refer to REPLACING THE ECU en gine control unit in chapter 8 Manu al No B34 F8197 E2 1 Check the rear w...

Page 63: ...SIGNALING SYSTEM 56...

Page 64: ...Dg B B Y Y G G L R L R Ch Ch B Dg B Ch L R G Y B B B B B B B B L R L L L R L R L B L B L R L R L B L B R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W L W R...

Page 65: ...ator fan motor fuse 15 Battery 16 Engine ground 18 Main fuse 25 Joint coupler 36 ECU Engine Control Unit 38 Coolant temperature sensor 83 Radiator fan motor 84 Radiator fan motor relay A Wire harness...

Page 66: ...4 F8197 E2 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES in chapter 8 Manual No B34 F8197 E2 Replace the main switch immobilizer un...

Page 67: ...7 Check the entire cooling system wiring Refer to CIRCUIT DIAGRAM on page 57 Properly connect or replace the wiring har ness Replace the ECU Refer to REPLAC ING THE ECU engine control unit in chapter...

Page 68: ...Y L Dg Dg B B Y Y G G L R L R Ch Ch B Dg B Ch L R G Y B B B B B B B B L R L L L R L R L B L B L R L R L B L B R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L R R W...

Page 69: ...ector 2 35 ISC Idle Speed Control unit 36 ECU Engine Control Unit 37 Intake air temperature sensor 38 Coolant temperature sensor 39 Intake air pressure sensor 40 Lean angle sensor 42 Rear wheel sensor...

Page 70: ...oupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler securel...

Page 71: ...the malfunction mode of the Yamaha diagnostic tool Condition is Recover Go to item 7 and finish the ser vice Condition is Malfunction Go to item 6 6 Malfunction in ECU Replace the ECU Refer to REPLACI...

Page 72: ...and ECU coupler gray gray black blue black blue Crank the engine and then check the condition of the fault code using the malfunc tion mode of the Yamaha di agnostic tool Condition is Recover Go to i...

Page 73: ...mal signals are received from the crankshaft position sensor Fault code No P2195 Item O2 sensor Open circuit detected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No Too...

Page 74: ...eplace the wire harness Start the engine and let it idle for approximately 10 sec onds Check the condition of the fault code using the malfunc tion mode of the Yamaha di agnostic tool Condition is Rec...

Page 75: ...Manual No B34 F8197 E2 Start the engine and let it idle for approximately 10 sec onds Check the condition of the fault code using the malfunc tion mode of the Yamaha di agnostic tool Condition is Rec...

Page 76: ...Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect...

Page 77: ...ervice is finished 6 Delete the fault code and check that the engine trouble warning light goes off Confirm that the fault code has a condition of Recover using the Yamaha diagnostic tool and then del...

Page 78: ...R G Y L Dg Dg B B Y Y G G L R L R Ch Ch B Dg B Ch L R G Y B B B B B B B B L R L L L R L R L B L B L R L R L B L B R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R L W R W B Br Y B B Y L...

Page 79: ...em 15 Battery 16 Engine ground 18 Main fuse 21 Rear brake light switch 25 Joint coupler 36 ECU Engine Control Unit 41 Front wheel sensor 42 Rear wheel sensor 43 ABS ECU electronic control unit 44 Yama...

Page 80: ...KE SYSTEM 73 EAS30990 ABS COUPLER LOCATION CHART 2 5 3 1 4 W B Gy W Gy W W B L R L B R W B G R G W L R L B Sb W Y Dg Ch G R Gy O W R Y W P W R W R G G B B W Gy B W B W Y W G G R Y G G B L Br W B L R L...

Page 81: ...ABS ANTI LOCK BRAKE SYSTEM 74 1 ABS ECU coupler 2 Rear wheel sensor coupler 3 Yamaha diagnostic tool coupler 4 Meter assembly coupler 5 Front wheel sensor coupler...

Page 82: ...ar ness between the front wheel sensor and the hydraulic unit assembly Check for continuity between the black terminal 1 and the black terminal 4 and between the white terminal 2 and the white termina...

Page 83: ...use Check or maintenance job Fault code No 63 Item Front wheel sensor power supply voltage of power supply is low Symptom Power voltage supplied from the ABS ECU to the front wheel sensor is too low O...

Page 84: ...eel sensor 3 Defective hydraulic unit assembly Replace the hydraulic unit assembly Refer to ABS ANTI LOCK BRAKE SYSTEM in chapter 4 Manual No B34 F8197 E2 Fault code No 63 Item Front wheel sensor powe...

Page 85: ...ABS ANTI LOCK BRAKE SYSTEM 78...

Page 86: ...ELECTRICAL COMPONENTS 79 EAS20089 ELECTRICAL COMPONENTS 1 2 3 4 5 5 6 7 8 9 11 12 13 14 10 15 16 17 18...

Page 87: ...switch 4 Rectifier regulator 5 Ignition coil 6 Battery 7 Fuse box 1 8 Fuse box 2 9 Main fuse 10 Starter relay 11 Rear brake light switch 12 Sidestand switch 13 O2 sensor 14 Gear position switch 15 Oi...

Page 88: ...eck the electrical circuit WARNING EWA13310 Never use a fuse with an amperage rating other than that specified Improvising or us ing a fuse with the wrong amperage rating may cause extensive damage to...

Page 89: ...ELECTRICAL COMPONENTS 82...

Page 90: ...cator light right 60 ABS warning light 61 Horn 62 Gear position switch 63 Handlebar switch right 64 Front brake light switch 65 Hazard switch 66 Start engine stop switch 67 Turn signal hazard relay 68...

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Page 93: ...R R R R R R Lg R W G B R G Y L Dg Dg B B Y Y G G L R L R Ch Ch B Dg B Ch L R G Y B B B B B B B B L R L L L R L R L B L B L R L R L B L B R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R B R R...

Page 94: ...D D D D D D A E B B B B B B L B B B B B B B B Gy Gy B B B B B B B B B Gy Gy B B B O B B Gy B B B B B B Gy Gy Gy Gy B B B Y Y B B B 1 2 3 6 5 4 7 8 9 17 13 14 15 16 18 19 20 21 22 23 24 25 25 26 25 27...

Page 95: ...L W L R R R R R R R Lg R W G B R G Y L Dg Dg B B Y Y G G L R L R Ch Ch B Dg B Ch L R G Y B B B B B B B B L R L L L R L R L B L B L R L R L B L B R Br L R W Br L Br R Br R B W R G Y L G B R W W W W B R...

Page 96: ...A A B A D D D D D D A E B B B B B B L B B B B B B B B Gy Gy B B B B B B B B B Gy Gy B B B O B B Gy B B B B B B Gy Gy Gy Gy B B B Y Y B B B 1 2 3 6 5 4 7 8 9 17 13 14 15 16 18 19 20 21 22 23 24 25 25...