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
©2018 by MBK Industrie
First edition, February 2018
All rights reserved.
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.
1
7
3
5
4
6
2
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
G
M
BF
B
T
R
.
.
LS
M
S
LT
E
New
S
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
24
Yamaha diagnostic tool (A/I)
90890-03262
24
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with tachometer
YU-A1927
81
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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