Yamaha XSR700 2018 Manuale utente

2018

SUPPLEMENTARY

SERVICE MANUAL

XSR700

MTM690

MTM690-U

BU3-F8197-E0

EAS20236

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the

MTM690/MTM690-U 2018. For complete service information procedures 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

First edition, February 2018

Any reproduction or unauthorized use

without the written permission of

MBK Industrie

is expressly prohibited.

EAS20003

IMPORTANT

This manual was produced by MBK Industrie primarily for use by Yamaha dealers and their qualified

mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, any-

one who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic

understanding of mechanics and the techniques to repair these types of vehicles. Repair and mainte-

nance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit

for use.

Yamaha Motor Company, Ltd. and MBK Industrie are continually striving to improve all of its models.

Modifications and significant 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 are subject to change without notice.

EAS30001

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.

This is the safety alert symbol. It is used to alert you to potential person-

al injury hazards. Obey all safety messages that follow this symbol to

avoid possible injury or death.

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

result in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid

damage to the vehicle or other property.

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

WARNING

NOTICE

TIP

EAS20004

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive

explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid

out with the individual steps in sequential order.

• The manual is divided into chapters and each chapter is divided into sections. The current section title

“1” is shown at the top of each page.

• Sub-section titles “2” appear in smaller print than the section title.

• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each

removal and disassembly section.

• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-

sembly step.

• Symbols “5” indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc. This step explains removal and disassembly procedure only. For installation

and assembly procedure, reverse the steps.

• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-

tially.

EAS20005

SYMBOLS

The following symbols are used in this manual for easier understanding.

TIP

The following symbols are not relevant to every vehicle.

SYMBOL DEFINITION SYMBOL DEFINITION

Serviceable with engine mounted Gear oil

Filling fluid Molybdenum disulfide oil

Lubricant Brake fluid

Special tool Wheel bearing grease

Tightening torque Lithium-soap-based grease

Wear limit, clearance Molybdenum disulfide grease

Engine speed Silicone grease

Electrical data Apply locking agent (LOCTITE®).

Engine oil Replace the part with a new one.

Silicone fluid

New

EAS10003 TABLE OF CONTENTS

SPECIAL TOOLS ............................................................................................... 1

GENERAL SPECIFICATIONS ........................................................................... 2

ELECTRICAL SPECIFICATIONS ...................................................................... 3

CABLE ROUTING .............................................................................................. 5

PERIODIC MAINTENANCE ............................................................................. 21

INTRODUCTION ........................................................................................ 21

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL

SYSTEM.................................................................................................... 21

GENERAL MAINTENANCE 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) .............................................. 28

INSTALLING THE ECU (engine control unit) ............................................. 28

HANDLEBAR ................................................................................................... 29

FRONT FORK................................................................................................... 31

STEERING HEAD............................................................................................. 33

SWINGARM...................................................................................................... 35

FUEL TANK...................................................................................................... 38

IGNITION SYSTEM .......................................................................................... 41

CIRCUIT DIAGRAM ................................................................................... 41

TROUBLESHOOTING ............................................................................... 43

LIGHTING SYSTEM ......................................................................................... 45

CIRCUIT DIAGRAM ................................................................................... 45

TROUBLESHOOTING ............................................................................... 47

SIGNALING SYSTEM ...................................................................................... 49

CIRCUIT DIAGRAM ................................................................................... 49

TROUBLESHOOTING ............................................................................... 51

COOLING SYSTEM.......................................................................................... 57

CIRCUIT DIAGRAM ................................................................................... 57

TROUBLESHOOTING ............................................................................... 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 LOCATION CHART ......................................................... 73

[B-2] DIAGNOSIS USING THE FAULT CODES ........................................ 75

ELECTRICAL COMPONENTS......................................................................... 79

CHECKING THE FUSES ........................................................................... 81

SPECIAL TOOLS

– 1 –

EAS20012

SPECIAL TOOLS

The following special tools are necessary for complete and accurate tune-up and assembly. Use only

the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools

or improvised techniques. Special tools, part numbers or both may differ depending on the country.

When placing an order, refer to the list provided below to avoid any mistakes.

TIP

• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.

• For others, use part number starting with “90890-”.

Tool name/Tool No. Illustration Reference

pages

Yamaha diagnostic tool USB

90890-03256

Yamaha diagnostic tool (A/I)

90890-03262

Digital circuit tester (CD732)

90890-03243

Model 88 Multimeter with tachometer

YU-A1927

GENERAL SPECIFICATIONS

– 2 –

EAS20013

GENERAL SPECIFICATIONS

Model

Model BU31 (MTM690)

B9J1 (MTM690-U)

ELECTRICAL SPECIFICATIONS

– 3 –

EAS20016

ELECTRICAL SPECIFICATIONS

Fuse

Backup fuse 2 10.0 A

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