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2014 MT-07
Yamaha 2014 MT-07 Service Manual
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GENERAL CHASSIS (3)
4-10
EAS31128
INSTALLING THE HEADLIGHT ASS
EMBLY
1.
Install:
•
Headlight assembly “1”
•
Headlight assembly bolts “2”
TIP
•
Fit the projections “a” on the headlight bracket
into the holes “b” in the headlight assembly.
•
When the headlight assembly bolts are tight-
ened to specification, there may be gaps “a”
between the washers and the grommets as
shown in the illustration.
T
R
.
.
Headlight assembl
y bolt
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
b
a
1
2
a
164
166
Table of Contents
Table of Contents
7
How to Use this Manual
4
Symbols
5
General Information
9
Identification
10
Vehicle Identification Number
10
Model Label
10
Features
11
Outline of the Fi System
11
Fi System
12
Abs Layout
13
Outline of the Abs
13
Abs Component Functions
17
Abs Operation
22
Abs Warning Light and Operation
25
Multi-Function Meter Unit
27
Important Information
32
Preparation for Removal and Disassembly
32
Replacement Parts
32
Gaskets, Oil Seals and O-Rings
32
Lock Washers/Plates and Cotter Pins
32
Bearings and Oil Seals
33
Circlips
33
Rubber Parts
33
Basic Service Information
34
Quick Fasteners
34
Electrical System
35
Special Tools
39
Specifications
45
General Specifications
46
Engine Specifications
47
Chassis Specifications
53
Electrical Specifications
56
Tightening Torques
59
General Tightening Torque Specifications
59
Engine Tightening Torques
60
Chassis Tightening Torques
65
Lubrication Points and Lubricant Types
69
Engine
69
Lubrication System Chart and Diagrams
70
Engine Oil Lubrication Chart
70
Lubrication Diagrams
72
Cooling System Diagrams
84
Cable Routing
86
Periodic Checks and Adjustments
119
General Maintenance and Lubrication Chart
122
Introduction
122
Periodic Maintenance
122
Periodic Maintenance Chart for the Emission Control System
122
Checking the Fuel Line
125
Checking the Spark Plugs
125
Adjusting the Valve Clearance
126
Checking the Engine Idling Speed
129
Synchronizing the Throttle Bodies
129
Checking the Throttle Body Joints
131
Replacing the Air Filter Element and
132
Adjusting the Clutch Lever Free Play
133
Adjusting the Front Disc Brake
133
Checking the Brake Operation
133
Adjusting the Rear Disc Brake
134
Checking the Front Brake Pads
134
Bleeding the Hydraulic Brake System (Abs)
135
Checking the Brake Hoses
135
Checking the Rear Brake Pads
135
Checking the Brake Fluid Level
136
Checking the Tires
137
Checking the Wheels
137
Adjusting the Drive Chain Slack
138
Checking the Swingarm Operation
138
Checking the Wheel Bearings
138
Lubricating the Swingarm Pivot
138
Checking and Adjusting the Steering Head
140
Lubricating the Drive Chain
140
Lubricating the Steering Head
140
Adjusting the Rear Shock Absorber Assembly
141
Checking the Fasteners
141
Checking the Front Fork
141
Checking the Rear Shock Absorber Assembly
141
Checking the Sidestand
141
Checking the Sidestand Switch
141
Lubricating the Brake Lever
141
Lubricating the Clutch Lever
141
Lubricating the Pedal
141
Lubricating the Sidestand
141
Checking the Connecting Arm and Relay Arm
142
Checking the Engine Oil Level
142
Changing the Engine Oil
143
Measuring the Engine Oil Pressure
144
Changing the Coolant
145
Checking the Coolant Level
145
Checking the Cooling System
145
Adjusting the Rear Brake Light Switch
147
Checking the Front Brake Light Switch
147
Checking and Lubricating the Cables
148
Checking the Throttle Grip Operation
148
Checking and Charging the Battery
149
Checking the Fuses
149
Replacing the Headlight Bulb
149
Adjusting the Headlight Beam
150
Chassis
153
General Chassis (1)
156
Installing the Passenger Seat
157
Installing the Rider Seat
157
General Chassis (2)
158
Removing the Center Cover
160
Installing the Center Cover
160
Removing the Upper Tail Cover
160
Installing the Upper Tail Cover
160
Removing the Rear Side Covers
160
Installing the Rear Side Covers
161
Installing the Lower Tail Cover
161
Removing the Lower Fender Cover
161
Installing the Lower Fender Cover
161
General Chassis (3)
162
Installing the Headlight Assembly
165
General Chassis (4)
165
Removing the Fuel Tank Top Cover
167
Installing the Fuel Tank Top Cover
167
Removing the Fuel Tank Covers
167
Installing the Fuel Tank Covers
167
Removing the Fuel Tank Center Cover
168
Installing the Fuel Tank Center Cover
168
General Chassis (5)
169
REMOVING the ECU (Engine Control Unit)
172
INSTALLING the ECU (Engine Control Unit)
172
Installing the Electrical Components Trays
172
Front Wheel
173
Removing the Front Wheel
175
Disassembling the Front Wheel
175
Checking the Front Wheel
175
Maintenance of the Front Wheel Sensor and Sensor Rotor
176
Assembling the Front Wheel
177
Adjusting the Front Wheel Static Balance
177
Installing the Front Wheel (Disc Brake)
178
Rear Wheel
181
Removing the Rear Wheel (Disc Brake)
185
Disassembling the Rear Wheel
185
Checking the Rear Wheel
185
Checking the Rear Wheel Drive Hub
185
Checking and Replacing the Rear Wheel Sprocket
186
Maintenance of the Rear Wheel Sensor and Sensor Rotor
186
Assembling the Rear Wheel
187
Adjusting the Rear Wheel Static Balance
187
Installing the Rear Wheel (Rear Brake Disc)
187
Front Brake
190
Introduction
196
Checking the Front Brake Discs
196
Replacing the Front Brake Pads
197
Removing the Front Brake Calipers
198
Disassembling the Front Brake Calipers
199
Checking the Front Brake Calipers
199
Assembling the Front Brake Calipers
200
Installing the Front Brake Calipers
200
Removing the Front Brake Master Cylinder
201
Checking the Front Brake Master Cylinder
201
Assembling the Front Brake Master Cylinder
201
Installing the Front Brake Master Cylinder
202
Rear Brake
204
Introduction
210
Checking the Rear Brake Disc
210
Replacing the Rear Brake Pads
210
Removing the Rear Brake Caliper
212
Disassembling the Rear Brake Caliper
212
Checking the Rear Brake Caliper
212
Assembling the Rear Brake Caliper
213
Installing the Rear Brake Caliper
213
Removing the Rear Brake Master Cylinder
214
Checking the Rear Brake Master Cylinder
214
Assembling the Rear Brake Master Cylinder
215
Installing the Rear Brake Master Cylinder
215
Abs (Anti-Lock Brake System)
217
Removing the Hydraulic Unit Assembly
219
Checking the Hydraulic Unit Assembly
219
Installing the Hydraulic Unit Assembly
219
Hydraulic Unit Operation Tests
221
Checking the Abs Warning Light
224
Handlebar
225
Removing the Handlebar
227
Checking the Handlebar
227
Installing the Handlebar
227
Front Fork
230
Removing the Front Fender Side Covers and Front Fork Legs
235
Disassembling the Front Fork Legs
235
Checking the Front Fork Legs
236
Assembling the Front Fork Legs
236
Installing the Front Fork Legs and Front Fender Side Covers
239
Steering Head
244
Removing the Lower Bracket
244
Checking the Steering Head
244
Installing the Steering Head
244
Rear Shock Absorber Assembly
246
Handling the Rear Shock Absorber
248
Disposing of a Rear Shock Absorber
248
Removing the Rear Shock Absorber Assembly
248
Checking the Rear Shock Absorber Assembly
248
Checking the Relay Arm
248
Installing the Relay Arm
248
Installing the Rear Shock Absorber Assembly
249
Swingarm
250
Removing the Swingarm
253
Checking the Swingarm
253
Checking the Connecting Arm
253
Installing the Connecting Arm
254
Installing the Swingarm
254
Chain Drive
256
Removing the Drive Chain
258
Removing the Drive Sprocket
258
Checking the Drive Chain
258
Checking the Drive Sprocket
260
Checking the Rear Wheel Sprocket
260
Checking the Rear Wheel Drive Hub
260
Installing the Drive Sprocket
260
Installing the Drive Chain
260
Engine
263
Engine Inspection
266
Measure the Compression Pressure
266
Adjusting the Exhaust Gas Volume
267
Checking the Cylinder Head Breather Hose
267
Engine Removal
269
Removing the Engine
275
Installing the Engine
275
Camshafts
278
Removing the Camshafts
282
Checking the Camshafts
283
Checking the Camshaft Sprockets
284
Checking the Timing Chain Tensioner
285
Checking the Decompression System
285
Installing the Camshafts
285
Installing the Cylinder Head Cover
289
Cylinder Head
290
Removing the Cylinder Head
294
Checking the Timing Chain Guides
294
Checking the Cylinder Head
294
Installing the Cylinder Head
295
Valves and Valve Springs
297
Removing the Valves
297
Checking the Valves and Valve Guides
297
Checking the Valve Seats
299
Checking the Valve Springs
300
Checking the Valve Lifters
301
Installing the Valves
301
Generator and Starter Clutch
304
Removing the Generator
307
Removing the Starter Clutch
307
Checking the Starter Clutch
307
Checking the Torque Limiter
308
Installing the Starter Clutch
308
Installing the Generator
308
Electric Starter
310
Checking the Starter Motor
313
Assembling the Starter Motor
314
Installing the Starter Motor
314
Clutch
315
Removing the Clutch
319
Checking the Friction Plates
320
Checking the Clutch Plates
320
Checking the Clutch Springs
320
Checking the Clutch Housing
321
Checking the Clutch Boss
321
Checking the Pressure Plate
321
Checking the Primary Drive Gear
321
Checking the Primary Driven Gear
321
Checking the Pull Lever Shaft and Pull Rod
321
Installing the Clutch
322
Shift Shaft
325
Checking the Shift Shaft
327
Checking the Stopper Lever
327
Installing the Shift Shaft
327
Oil Pump
328
Checking the Sprocket and Chain
330
Checking the Oil Pump
330
Checking the Relief Valve
330
Assembling the Oil Pump
330
Installing the Oil Pump
331
Oil Pan
332
Removing the Oil Pan
333
Checking the Oil Strainer
333
Installing the Oil Pan
333
Crankcase
334
Disassembling the Crankcase
336
Checking the Crankcase
336
Assembling the Crankcase
336
Installing the Oil Pressure Switch
338
Connecting Rods and Pistons
340
Removing the Connecting Rods and Pistons
342
Checking the Cylinder and Piston
342
Checking the Piston Rings
343
Checking the Piston Pin
344
Checking the Connecting Rods
345
Installing the Connecting Rod and Piston
347
Crankshaft and Balancer Shaft
351
Removing the Balancer Shaft Journal Bearings
352
Removing the Crankshaft Journal Bearings
352
Checking the Balancer Shaft Assembly
352
Checking the Crankshaft
354
Installing the Crankshaft
356
Installing the Balancer Shaft Assembly
356
Transmission
357
Removing the Transmission
362
Checking the Shift Forks
362
Checking the Shift Drum Assembly
362
Checking the Transmission
363
Assembling the Main Axle and Drive Axle
363
Installing the Transmission
364
Cooling System
367
Radiator
368
Checking the Radiator
370
Installing the Radiator
370
Oil Cooler
371
Checking the Oil Cooler
373
Checking the Water Jacket Joint
373
Installing the Oil Cooler
373
Thermostat
374
Checking the Thermostat
375
Installing the Thermostat
375
Water Pump
376
Disassembling the Water Pump
378
Checking the Water Pump
378
Assembling the Water Pump
378
Installing the Clutch Cover
380
Fuel System
381
Fuel Tank
382
Checking the Fuel Pump Body
384
Installing the Fuel Pump
384
Removing the Fuel Pump
384
Removing the Fuel Tank
384
Installing the Fuel Tank
385
Installing the Fuel Tank Bracket
385
Air Filter Case Valve
387
Checking the Air Filter Case Valve
389
Instaling the Air Filter Case Valve
389
Throttle Bodies
390
Checking the Injectors (before Removing)
393
Removing the Injectors
393
Checking the Injectors
393
Checking the Throttle Bodies
393
Cleaning the Isc (Idle Speed Control) Valve
393
Checking the Throttle Body Joints
395
Adjusting the Throttle Position Sensor
396
Installing the Fuel Injectors
396
Checking the Injector Pressure
397
Checking the Fuel Pressure
397
Installing the Throttle Body Joints
398
Installing the Air Filter Case
398
Intake Solenoid
402
Checking the Vacuum Line
402
Electrical System
403
Default Chapter
403
General Information
403
Ignition System
406
Circuit Diagram
406
Engine Stopping Due to Sidestand Operation
408
Troubleshooting
409
Electric Starting System
412
Circuit Diagram
412
Starting Circuit Cut-Off System Operation
414
Troubleshooting
415
Charging System
418
Circuit Diagram
418
Troubleshooting
420
Lighting System
422
Circuit Diagram
422
Troubleshooting
424
Signaling System
426
Circuit Diagram
426
Troubleshooting
428
Cooling System
434
Circuit Diagram
434
Troubleshooting
436
Fuel Injection System
438
Circuit Diagram
438
Ecu Self-Diagnostic Function
440
Troubleshooting Method
440
Yamaha Diagnostic Tool
441
Troubleshooting Details
444
Fault Code 12
444
Fault Code 13
445
Fuel Pump System
478
Circuit Diagram
478
Troubleshooting
480
Immobilizer System
482
Circuit Diagram
482
General Information
484
Parts Replacement and Key Code Registration Requirements
484
Troubleshooting
488
Self-Diagnosis Fault Code Indication
488
Abs (Anti-Lock Brake System)
492
Circuit Diagram
492
Abs Coupler Location Chart
494
Maintenance of the Abs Ecu
496
Abs Troubleshooting Outline
496
Basic Instructions for Troubleshooting
497
Basic Process for Troubleshooting
498
[A] Checking the Abs Warning Light
499
[A-1] Only the Abs Warning Light Fails to Come on
499
[A-2] All Indicator Lights Fail to Come on
499
[A-3] the Abs Warning Light Comes on
499
[A-4] ONLY the ABS ECU FAILS to COMMUNICATE (the Select Unit Screen Does Not Appear.)
500
[A-5] ABS ECU and FI ECU FAIL to COMMUNICATE (Cannot Connect Due to a Tool Error.)
500
[B-1] Malfunction Are Currently Detected
500
[B-2] Diagnosis Using the Fault Codes
500
[B-3] Deleting the Fault Codes
521
[C-1] Final Check
521
Electrical Components
524
Checking the Switches
528
Checking the Bulbs and Bulb Sockets
531
Checking the Fuses
532
REPLACING the ECU (Engine Control Unit)
533
Checking and Charging the Battery
533
Checking the Relays
536
Checking the Turn Signal/Hazard Relay
537
Checking the Relay Unit (Diode)
538
Checking the Ignition Coils
539
Checking the Ignition Spark Gap
539
Checking the Crankshaft Position Sensor
540
Checking the Lean Angle Sensor
540
Checking the Starter Motor Operation
541
Checking the Stator Coil
541
Checking the Rectifier/Regulator
541
Checking the Fuel Sender
542
Checking the Fuel Meter/Fuel Level Warning Light
542
Checking the Radiator Fan Motor
543
Checking the Coolant Temperature Sensor
543
Checking the Throttle Position Sensor
544
Checking the Intake Air Pressure Sensor
544
Checking the Intake Air Temperature Sensor
545
Checking the Intake Solenoid
545
Checking the Gear Position Switch
545
Checking the Fuel Injectors
546
Troubleshooting
547
Troubleshooting
548
General Information
548
Starting Failure
548
Incorrect Engine Idling Speed
548
Poor Medium-And-High-Speed Performance
549
Faulty Gear Shifting
549
Shift Pedal Does Not Move
549
Jumps out of Gear
549
Faulty Clutch
549
Overheating
549
Overcooling
550
Poor Braking Performance
550
Faulty Front Fork Legs
550
Unstable Handling
550
Faulty Lighting or Signaling System
551
Troubleshooting at the Abs Warning Light
551
Self-Diagnostic Function and Diagnostic Code Table
552
Self-Diagnostic Function Table
552
Communication Error with the Meter
553
Diagnostic Code: Sensor Operation Table
553
Diagnostic Code: Actuator Operation Table
555
Event Code Table
558
Wiring Diagram
560
Wiring Diagrams
563
5
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Yamaha 2014 MT-07 Specifications
General
Brand
Yamaha
Model
2014 MT-07
Category
Motorcycle
Language
English
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