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MT-09 2021
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Yamaha MT-09 2021 - Page 383
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Manual
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8-28
LIGHTING SYSTEM
Replace the ECU, meter assemb
ly,
headlight assembly, tail/brake light, li-
cense plate light or au
xiliary light.
Refer to “REPLACING THE ECU
(En-
gine Control Unit)” on page
8-56.
382
384
Table of Contents
Main Page
Table of Contents
7
General Information
9
Identification
10
Vehicle Identification Number
10
Model Label
10
Glossary
11
Display
11
Basic Service Information
18
Electrical System
18
Special Tools
19
Specifications
27
General Specifications
28
Engine Specifications
29
Chassis Specifications
33
Electrical Specifications
37
Chassis Tightening Torques
39
Engine Tightening Torques
39
Tightening Torques
39
Cable Routing
42
Periodic Checks and Adjustments
95
General Maintenance and Lubrication Chart
97
Introduction
97
Periodic Maintenance
97
Periodic Maintenance Chart for the Emission Control System
97
Checking the Fuel Line
100
Checking the Vehicle Using the Yamaha Diagnostic Tool
100
Adjusting the Valve Clearance
101
Checking the Spark Plugs
101
Checking the Engine Idling Speed
104
Synchronizing the Throttle Bodies
104
Checking the Cylinder Head Breather Hose
106
Checking the Exhaust System
106
Checking the Throttle Body Joints
106
Adjusting the Exhaust Gas Volume
107
Checking the Canister
107
Checking the Purge Cut Valve Solenoid
107
Replacing the Air Filter Element
107
Adjusting the Clutch Lever Free Play
108
Adjusting the Front Disc Brake
109
Checking the Brake Fluid Level
109
Checking the Brake Operation
109
Adjusting the Rear Disc Brake
110
Checking the Front Brake Pads
110
Bleeding the Hydraulic Brake System (Abs)
111
Checking the Front Brake Hoses
111
Checking the Rear Brake Hose
111
Checking the Rear Brake Pads
111
Checking the Tires
112
Checking the Wheels
112
Checking the Swingarm Operation
114
Checking the Wheel Bearings
114
Drive Chain Slack
114
Lubricating the Swingarm Pivot
114
Checking and Adjusting the Steering Head
115
Lubricating the Drive Chain
115
Checking the Chassis Fasteners
116
Lubricating the Brake Lever
116
Lubricating the Steering Head
116
ADJUSTING the FRONT FORK LEGS (for MTN890)
117
Adjusting the Shift Pedal
117
Checking the Front Fork
117
Checking the Sidestand
117
Checking the Sidestand Switch
117
Lubricating the Clutch Lever
117
Lubricating the Pedal
117
Lubricating the Sidestand
117
ADJUSTING the FRONT FORK LEGS (for MTN890D)
119
ADJUSTING the REAR SHOCK ABSORBER ASSEMBLY (for MTN890)
121
Checking the Rear Shock Absorber Assembly
121
ADJUSTING the REAR SHOCK ABSORBER ASSEMBLY (for MTN890D)
122
Changing the Engine Oil
124
Checking the Connecting Arm and Relay Arm
124
Checking the Engine Oil Level
124
Measuring the Engine Oil Pressure
125
Changing the Coolant
127
Checking the Coolant Level
127
Checking the Cooling System
127
Adjusting the Rear Brake Light Switch
129
Checking and Lubricating the Cables
129
Checking the Front Brake Light Switch
129
Adjusting the Headlight Beam
130
Checking and Charging the Battery
130
Checking the Fuses
130
Checking the Throttle Grip
130
Chassis
131
General Chassis (1)
135
Installing the Fuel Tank Side Cover
140
Removing the Fuel Tank Side Cover
140
Removing the Headlight
140
Removing the Seat
140
Installing the Headlight
141
Installing the Imu
141
General Chassis (2)
142
Installing the Seat
142
Front Wheel
144
Checking the Front Wheel
146
Disassembling the Front Wheel
146
Removing the Front Wheel
146
Assembling the Front Wheel
147
Adjusting the Front Wheel Static Balance
148
Maintenance of the Front Wheel Sensor and Sensor Rotor
148
Installing the Front Wheel (Front Brake Discs)
149
Rear Wheel
151
Checking and Replacing the Rear Wheel Sprocket
154
Checking the Rear Wheel
154
Checking the Rear Wheel Drive Hub
154
Disassembling the Rear Wheel
154
Removing the Rear Wheel
154
Adjusting the Rear Wheel Static Balance
155
Assembling the Rear Wheel
155
Maintenance of the Rear Wheel Sensor and Sensor Rotor
155
Installing the Rear Wheel (Rear Brake Disc)
156
Front Brake
158
Checking the Front Brake Discs
164
Introduction
164
Replacing the Front Brake Pads
164
Checking the Front Brake Calipers
166
Disassembling the Front Brake Calipers
166
Removing the Front Brake Calipers
166
Assembling the Front Brake Calipers
167
Installing the Front Brake Calipers
167
Assembling the Front Brake Master Cylinder
168
Checking the Front Brake Master Cylinder
168
Installing the Front Brake Master Cylinder
168
Removing the Front Brake Master Cylinder
168
Rear Brake
170
Adjusting the Footrest Position
176
Checking the Rear Brake Disc
176
Introduction
176
Replacing the Rear Brake Pads
177
Checking the Rear Brake Caliper
178
Disassembling the Rear Brake Caliper
178
Removing the Rear Brake Caliper
178
Assembling the Rear Brake Caliper
179
Installing the Rear Brake Caliper
179
Assembling the Rear Brake Master Cylinder
180
Checking the Rear Brake Master Cylinder
180
Installing the Rear Brake Master Cylinder
180
Removing the Rear Brake Master Cylinder
180
Abs (Anti-Lock Brake System)
182
Checking the Hydraulic Unit Assembly
184
Removing the Hydraulic Unit Assembly
184
Checking the Brake Pipes
185
Installing the Hydraulic Unit Assembly
185
Hydraulic Unit Operation Tests
186
Checking the Abs Warning Light
189
Handlebar
190
Adjusting the Handlebar Position
192
Removing the Handlebar
192
Checking the Handlebar
193
Installing the Handlebar
193
Front Fork
196
Disassembling the Front Fork Legs
199
Removing the Front Fork Legs
199
Checking the Front Fork Legs
200
Assembling the Front Fork Legs
201
Installing the Front Fork Legs
205
Steering Head
207
Checking the Steering Head
209
Removing the Lower Bracket
209
Installing the Steering Head
210
Checking the Rear Shock Absorber Assembly
213
DISPOSING of a REAR SHOCK ABSORBER (for MTN890)
213
DISPOSING of a REAR SHOCK ABSORBER (for MTN890D)
213
Handling the Rear Shock Absorber
213
Rear Shock Absorber Assembly
213
Removing the Rear Shock Absorber Assembly
213
Checking the Connecting Arm and Relay Arm
214
Installing the Rear Shock Absorber Assembly
214
Installing the Relay Arm
214
Swingarm
216
Checking the Swingarm
217
Installing the Swingarm
217
Removing the Swingarm
217
Chain Drive
219
Checking the Drive Chain
220
Removing the Drive Chain
220
Checking the Drive Sprocket
221
Checking the Rear Wheel Drive Hub
221
Checking the Rear Wheel Sprocket
221
Installing the Drive Chain
222
Adjusting the Shift Pedal
223
Engine
225
Engine Oil Lubrication Chart
228
Lubrication System Chart and Diagrams
228
Lubrication Diagrams
229
Engine Inspection
234
Measure the Compression Pressure
234
Engine Removal
236
Installing the Engine
241
Removing the Engine
241
Camshafts
243
Removing the Camshafts
246
Checking the Camshafts
247
Checking the Timing Chain and Camshaft Sprocket
248
Checking the Timing Chain Guides
248
Checking the Timing Chain Tensioner
248
Installing the Camshafts
249
Cylinder Head
253
Checking the Cylinder Head
254
Checking the Timing Chain Guide (Exhaust Side)
254
Removing the Cylinder Head
254
Installing the Cylinder Head
255
Valves and Valve Springs
257
Checking the Valves and Valve Guides
258
Removing the Valves
258
Checking the Valve Seats
260
Checking the Valve Lifters
261
Checking the Valve Springs
261
Installing the Valves
261
Generator and Starter Clutch
263
Checking the Starter Clutch
265
Removing the Generator
265
Removing the Starter Clutch
265
Installing the Generator
266
Installing the Starter Clutch
266
Electric Starter
268
Assembling the Starter Motor
270
Checking the Starter Motor
270
Installing the Starter Motor
271
Clutch
272
Removing the Clutch
276
Checking the Clutch Plates
277
Checking the Friction Plates
277
Checking the Clutch Housing
278
Checking the Clutch Springs
278
Checking the Clutch Boss
279
Checking the Pressure Plate
279
Checking the Primary Drive Gear
279
Checking the Primary Driven Gear
279
Checking the Pull Lever Shaft and Pull Rod
279
Installing the Clutch
279
Shift Shaft
282
Checking the Shift Shaft
283
Checking the Stopper Lever
283
Installing the Shift Shaft
283
Oil Pump
284
Assembling the Oil Pump
286
Checking the Oil Pump
286
Checking the Relief Valve
286
Checking the Sprocket and Chain
286
Installing the Oil Pump
287
Oil Pan
288
Checking the Oil Strainer
289
Installing the Oil Pan
289
Removing the Oil Pan
289
Crankcase
290
Assembling the Crankcase
292
Checking the Crankcase
292
Disassembling the Crankcase
292
Installing the Gear Position Sensor
294
Installing the Oil Pressure Switch
294
Checking the Cylinder and Piston
297
Connecting Rods and Pistons
297
Removing the Connecting Rods and Pistons
297
Checking the Piston Rings
298
Checking the Connecting Rods
299
Checking the Piston Pin
299
Installing the Connecting Rod and Piston
302
Checking the Crankshaft
308
Checking the Oil Nozzles
308
Crankshaft and Balancer Shaft
308
Removing the Crankshaft and Balancer Shaft
308
Checking the Balancer Shaft
310
Installing the Balancer Assembly
312
Installing the Crankshaft
312
Transmission
313
Checking the Shift Forks
318
Removing the Transmission
318
Checking the Shift Drum Assembly
319
Checking the Transmission
319
Assembling the Main Axle and Drive Axle
320
Installing the Transmission
320
Cooling System
323
Cooling System Diagrams
324
Radiator
327
Checking the Radiator
328
Installing the Radiator
328
Oil Cooler
330
Checking the Oil Cooler
331
Installing the Oil Cooler
331
Thermostat
332
Checking the Thermostat
333
Installing the Thermostat Assembly
333
Water Pump
334
Assembling the Water Pump
336
Checking the Water Pump
336
Disassembling the Water Pump
336
Fuel System
339
Fuel Tank
340
Checking the Fuel Pump Body
342
Checking the Fuel Pump Operation
342
Removing the Fuel Pump
342
Removing the Fuel Tank
342
Checking the Purge Cut Valve Solenoid
343
Installing the Fuel Pump
343
Installing the Fuel Tank
343
Checking and Cleaning the Throttle Bodies
346
Checking the Injectors
346
Checking the Injectors (before Removing)
346
Removing the Fuel Hose (Fuel Rail Side)
346
Removing the Injectors
346
Installing the Injectors
348
Replacing the Throttle Bodies
348
Checking the Fuel Pressure
349
Checking the Injector Pressure
349
Adjusting the Throttle Position Sensor
350
Installing the Fuel Hose (Fuel Rail Side)
350
Electrical System
353
Circuit Diagram
356
Ignition System
356
Engine Stopping Due to Sidestand Operation
360
Troubleshooting
361
Circuit Diagram
364
Electric Starting System
364
Starting Circuit Cut-Off System Operation
368
Troubleshooting
370
Charging System
372
Circuit Diagram
372
Troubleshooting
376
Circuit Diagram
378
Lighting System
378
Troubleshooting
382
Circuit Diagram
384
Signaling System
384
Troubleshooting
388
Circuit Diagram
394
Cooling System
394
Troubleshooting
398
Circuit Diagram
400
Fuel Pump System
400
Troubleshooting
404
Electrical Components
406
Checking the Switches
408
Checking and Charging the Battery
411
Checking the Relays
411
REPLACING the ECU (Engine Control Unit)
411
Checking the Relay Unit (Diode)
413
Checking the Ignition Coils
414
Checking the Ignition Spark Gap
414
Checking the Crankshaft Position Sensor
415
Checking the Starter Motor Operation
415
Checking the Rectifier/Regulator
416
Checking the Stator Coil
416
Checking the Fuel Level Warning Light
417
Checking the Fuel Sender
417
Checking the Horn
417
Checking the Coolant Temperature Sensor
418
Checking the Radiator Fan Motor
418
Checking the Throttle Servo Motor
418
Checking the Fuel Injectors
419
Checking the Intake Air Temperature Sensor
419
Checking the Purge Cut Valve Solenoid
420
Checking the Wheel Switch
420
Self Diagnostic
423
Glossary
431
Outline
431
Self-Diagnostic Function
431
Checking the Warning Light
432
Ydt
433
Cope with the Mil Flashing
434
Parts Connected to the Abs Ecu
434
Parts Connected to the Ecu
434
Precautions for Road Test
434
Ecu Circuit Diagram
435
System Diagram
435
Ecu Coupler Layout
438
Circuit Diagram
442
Fuel Injection System
442
Basic Process for Troubleshooting
446
[A] the Mil Comes On/Flashes and Engine Operation Is Not Normal
447
[B] the Mil Does Not Come On, but the Engine Operation Is Not Normal
447
Circuit Diagram
448
Immobilizer System
448
System Outline
452
Part Replacement and Key Code Registration Requirements
453
Troubleshooting
456
How to Check Dtc
457
Circuit Diagram
458
CRUISE CONTROL SYSTEM (for MTN890D)
458
Cruise Control Circuit Operation
460
Basic Instructions for Troubleshooting
461
Basic Process for Troubleshooting
462
[A] Checking the Cruise Control System Indicator Light
463
[B-1] Diagnosis Using the Dtc
463
[B-2] Diagnosis Using the Malfunction History Codes
463
[B-3] Malfunction History Is Not Displayed
463
[C-1] Erasing the Dtc
464
[C-2] Final Check
464
ABS (Anti-Lock Brake System)
466
Circuit Diagram
466
Abs Components Chart
470
Abs Coupler Location Chart
471
Abs Troubleshooting Outline
472
Maintenance of the Abs Ecu
472
Basic Instructions for Troubleshooting
473
[A-1] Only the Abs Warning Light Fails to Come on
475
[A-2] All Indicator Lights Fail to Come on
475
[A-3] the Abs Warning Light Comes on
475
[A-4] Only the Abs Ecu Fails to Communicate
475
[A] Checking the Abs Warning Light
475
[A-5] Abs Ecu and Fi Ecu Fail to Communicate
476
[B-1] Malfunction Are Currently Detected
476
[B-2] Diagnosis Using the Dtc
476
[B-3] Deleting the Dtc
477
[C-1] Final Check
477
Dtc Table
478
Self-Diagnostic Function and Diagnostic Code Table
478
Self-Diagnostic Function Table (for Fuel Injection System)
483
SELF-DIAGNOSTIC FUNCTION TABLE (for ABS (Anti-Lock Brake System))
501
Self-Diagnostic Function Table (for Immobilizer System)
501
Communication Error with the Meter
506
Diagnostic Code: Sensor Operation Table
506
Diagnostic Code: Actuator Operation Table
510
Event Code Table
512
30_Event
515
Troubleshooting
515
70_Event
517
Troubleshooting
517
C0520
518
Troubleshooting
518
P0030
522
Troubleshooting
522
P00D1, P2195
526
Troubleshooting
526
P0105
530
Troubleshooting
530
P0106
532
Troubleshooting
532
P0107, P0108
534
Troubleshooting
534
P0110
538
Troubleshooting
538
P0111
540
Troubleshooting
540
P0112, P0113
543
Troubleshooting
543
P0115
547
Troubleshooting
547
P0116
548
Troubleshooting
548
P0117, P0118
551
Troubleshooting
551
P0122, P0123, P0222, P0223, P2135
555
Troubleshooting
555
P0132
560
Troubleshooting
560
Fail-Safe System
564
Outline
564
P0133
564
Troubleshooting
565
P0134
566
Troubleshooting
566
P0201
568
Troubleshooting
568
P0202
571
Troubleshooting
571
P0203
574
Troubleshooting
574
Outline
577
Fail-Safe System
578
Troubleshooting
578
P0335
581
Troubleshooting
581
P0351
585
Troubleshooting
585
P0352
589
Troubleshooting
589
P0353
593
Troubleshooting
593
P0458
597
Troubleshooting
597
P0480
601
Troubleshooting
601
P0500, P1500
604
Troubleshooting
604
P0560, P0563
617
Troubleshooting
617
P0564
618
Troubleshooting
618
P056C
624
Troubleshooting
624
P0601
631
Troubleshooting
631
P0606
632
Troubleshooting
632
P062F
633
Troubleshooting
633
P0638
635
Troubleshooting
635
P0657
639
Troubleshooting
639
P0914
643
Troubleshooting
643
P0915
645
Troubleshooting
645
P0916, P0917
647
Troubleshooting
647
P1004
651
Troubleshooting
651
P1600
653
Troubleshooting
653
P1601
657
Troubleshooting
657
P1602
661
Troubleshooting
661
P1606, P1607
665
Troubleshooting
665
P1608
669
Troubleshooting
669
P1609
671
Troubleshooting
671
P1806, P1807
673
Troubleshooting
673
P2122, P2123, P2127, P2128, P2138
677
Troubleshooting
677
P2158
681
Troubleshooting
681
Troubleshooting
686
U0125
686
Troubleshooting
690
U0155 or Err
690
51_Immobilizer
694
Troubleshooting
694
52_Immobilizer
695
Troubleshooting
695
53_Immobilizer
696
Troubleshooting
696
54_Immobilizer
699
Troubleshooting
699
55_Immobilizer
701
Troubleshooting
701
56_Immobilizer
702
Troubleshooting
702
11_Abs
705
Troubleshooting
705
12_Abs
706
Troubleshooting
706
13, 26_Abs
707
Troubleshooting
707
14, 27_Abs
708
Troubleshooting
708
15_Abs
709
Troubleshooting
709
16_Abs
711
Troubleshooting
711
21_Abs
713
Troubleshooting
713
31_Abs
714
Troubleshooting
714
33_Abs
716
Troubleshooting
716
34_Abs
718
Troubleshooting
718
41_Abs
719
Troubleshooting
719
42_Abs
720
Troubleshooting
720
43, 45_Abs
721
Troubleshooting
721
44, 46_Abs
722
Troubleshooting
722
51_Abs
723
Troubleshooting
723
53_Abs
724
Troubleshooting
724
55_Abs
726
Troubleshooting
726
56_Abs
727
Troubleshooting
727
57_Abs
728
Troubleshooting
728
62_Abs
732
Troubleshooting
732
68_Abs
733
Troubleshooting
733
89_Abs
734
Troubleshooting
734
90_Abs
737
Troubleshooting
737
91_Abs
740
Troubleshooting
740
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