Yamaha MT-09 2021 User manual

2021
SERVICE MANUAL
MT-09
MT-09SP
B7N-28197-E0
MTN890
MTN890D

EAS20003
IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone 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.
Please refer to “BASIC INFORMATION” (separate volume, Y0A-28197-E0*) for basic instructions that
must be observed during servicing. Repair and maintenance work attempted by anyone without this
knowledge is likely to render the vehicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
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
• * If the contents of the manual are revised, the last digit of the manual number will be increased by
one.
• 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.
EAS20002
This is the safety alert symbol. It is used to alert you to potential personal
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.
MTN890/MTN890D
SERVICE MANUAL
©2021 by Yamaha Motor Co., Ltd.
First edition, October 2020
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
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 ex-
planations 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
G088877

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.
G
M
BF
B
T
R
.
.
LS
M
S
LT
E
New

2
3
9
1
4
5
8
6
7
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
CHASSIS
ENGINE
COOLING SYSTEM
FUEL SYSTEM
ELECTRICAL SYSTEM
SELF DIAGNOSTIC
TABLE OF CONTENTS

1
GENERAL INFORMATION
IDENTIFICATION ............................................................................................1-1
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL..........................................................................................1-1
FEATURES......................................................................................................1-2
GLOSSARY...............................................................................................1-2
DISPLAY ...................................................................................................1-2
BASIC SERVICE INFORMATION...................................................................1-9
ELECTRICAL SYSTEM.............................................................................1-9
SPECIAL TOOLS ..........................................................................................1-10

1-1
IDENTIFICATION
EAS20007
IDENTIFICATION
EAS30002
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1” is stamped
into the right side of the steering head pipe.
EAS30003
MODEL LABEL
The model label “1” is affixed to the frame under
the seat. This information will be needed to order
spare parts.
1
1

1-2
FEATURES
EAS20008
FEATURES
EAS31706
GLOSSARY
ABS - Anti-lock Brake System
ABS ECU - Anti-lock Brake System Electronic
Control Unit
BC - Brake Control
ECU - Engine Control Unit
LIF - Lift Control System
QS - Quick Shift
SCS - Slide Control System
TCS - Traction Control System
EAS31707
DISPLAY
The following items can be found on the display:
TIP
This model uses a thin-film-transistor liquid-crys-
tal display (TFT LCD) for good contrast and
readability in various lighting conditions. Howev-
er, due to the nature of this technology, it is nor-
mal for a small number of pixels to be inactive.
WARNING
EWA18210
Stop the vehicle before making any setting
changes. Changing settings while riding can
distract the operator and increase the risk of
an accident.
Speedometer
The speedometer shows the vehicle’s traveling
speed.
TIP
The display can be switched between kilometers
and miles.
Tachometer
The tachometer shows the engine speed, as
measured by the rotational velocity of the crank-
shaft, in revolutions per minute (r/min).
NOTICE
ECA19660
Do not operate the engine in the tachometer
red zone.
Vehicle information displays
The two vehicle information displays can be indi-
vidually set to show the following items:
• ODO: odometer
• F-TRIP: fuel reserve tripmeter
• TRIP1: tripmeter
• TRIP2: tripmeter
• F.AVE: average fuel economy
• F.CRNT: instantaneous fuel economy
• A.TEMP: air temperature
• C.TEMP: coolant temperature
1. Tachometer
2. Speedometer
3. Quick shift Indicator “QS”
4. Transmission gear display
5. Vehicle information displays
6. Settings menu icon “ ”
7. Grip warmer indicator (option)
8. Brake control icon “BC”
9. Clock
10. MODE display
11. Lap timer
12. Oil pressure warning “ ”
13. Coolant temperature warning “ ”
14. Auxiliary system warning “ ”
15. Error mode warning “Err” (replaces clock
when activated)
4
12
7 6
9
10
8
3
5
LAP 02
LATEST
00:12.34
00:01.23
11
14 13 1215
1. Vehicle information displays
1

1-3
FEATURES
• Fuel meter
• FUELCON: amount of fuel consumed
• TRIPTIME: running time
Operate the vehicle information display as fol-
lows:
Rotate the wheel switch to move the cursor over
a display.
Push the wheel switch inward and the selected
display will highlight gray.
Rotate the wheel switch to choose a different
display item.
Push the wheel switch inward to confirm the new
display item.
TIP
• ODO will lock at 999999 and cannot be reset.
• TRIP1 and TRIP2 will reset to 0 and begin
counting again after 9999.9 has been reached.
• When the fuel tank reserve level has been
reached, F-TRIP appears automatically and
begins recording distance traveled from that
point.
• After refueling and traveling some distance, F-
TRIP will automatically disappear.
• See “Unit” to change the fuel consumption
units.
• The air temperature is displayed from –9 °C
(16 °F) to 50 °C (122 °F) in 1 °C (1 °F) incre-
ments.
• The air temperature displayed may vary from
the actual ambient temperature.
• In LAP TIME mode, the vehicle information dis-
play is replaced by the lap information.
• TRIP1, TRIP2, F-TRIP, F.AVE, FUELCON and
TRIPTIME items can be individually reset.
• If the vehicle coolant temperature is below 40
°C (104 °F) the coolant temperature display will
read “Lo”
• If the vehicle coolant temperature is above 124
°C (255 °F) the coolant temperature display will
read “Hi”
To reset information display items
1. Rotate the wheel switch to select one of the
two vehicle information displays.
2. Press the wheel switch inward to highlight the
information display.
3. Rotate the wheel switch to select the desired
information display item.
4. Press and hold the wheel switch inward until
the highlighted display item is reset.
Transmission gear display
This shows which gear the transmission is in.
This model has 6 gears and a neutral position.
The neutral position is indicated by the neutral
indicator light “ ” and by the transmission gear
display “ ”.
MODE display
This display shows the currently selected “D-
MODE” and “TCS-MODE” settings. The mode
that is enlarged and displayed on the right can
be adjusted using the MODE up/down switches.
Use the “MODE” switch to toggle left-right be-
tween “TCS-MODE” and “D-MODE”.
TIP
• When the malfunction indicator light “ ”, the
auxiliary system warning “ ”, or the coolant
temperature warning “ ” are on, “D-MODE”
and “TCS-MODE” cannot be adjusted.
• The previously selected modes will be dis-
played when the vehicle power on.
To turn off the traction control system, select
“TCS-MODE” with the “MODE” switch, then
push and hold the MODE up switch until “OFF”
is displayed. To turn TCS back on, press the
MODE down switch (“TCS-MODE” will return to
its previous setting).
TIP
• When “TCS-MODE” has been set to “OFF”,
the TCS, SCS and LIF systems are all turned
off together.
• The “TCS-MODE OFF” and “TCSMODE M”
settings can only be selected while the vehicle
is stopped.
Clock
The clock uses a 12-hour time system.
Quick shift indicator “QS”
When able to shift, the respective QS or
turns green.
When unable to shift, QS is white.
If the QS function is turned OFF, QS itself
is not displayed.

1-4
FEATURES
The QS functions can be turned on or off in the
setting MENU.
TIP
The upshift and downshift functions are inde-
pendent and can be activated separately.
For more information on the QS system.
Setting menu icon “ ”
Choose this icon and push the wheel switch to
change the settings MENU screen.
Grip warmer indicator (Option)
The grip warmers can be used when the engine
is running. There are 10 temperature levels.
When activated, the indicator will display the
temperature level from 1 (lowest) to 10 (highest).
To activate the grip warmer, use the wheel
switch to highlight the grip warmer display with
the cursor.
Press the wheel switch inward to select the grip
warmer function.
Once selected, rotate the wheel switch up and
down to adjust the temperature level.
Press the wheel switch inward to confirm the
temperature level and exit the grip warmer func-
tion.
NOTICE
ECA17932
• Be sure to wear gloves when using the grip
warmers.
• Do not use the grip warmers in warm
weather.
• If the handlebar grip or throttle grip be-
comes worn or damaged, stop using the
grip warmers and replace the grips.
The function of the wheel switch can be locked
into grip warmer mode by pressing and holding
the wheel switch inward while the grip warmer
indicator is highlighted by the cursor.
In this mode, the temperature levels can be in-
stantly adjusted by rotating the wheel switch up/
down.
To exit this mode and return the wheel switch to
its normal functionality, press and hold the wheel
switch inward.
TIP
The current grip warmer setting is saved when
the vehicle is turned off.
Lap timer
This stopwatch function can be activated
through the setting MENU.
Once activated, the vehicle information display
is replaced with:
To start the timer, press the pass switch.
Each press of the pass switch will increase the
lap count by 1 and reset the current lap timer.
To pause the lap timer, press the wheel switch
inward.
To unpause the timer, press the pass switch and
the timer will resume without counting a new lap.
To exit the lap time mode, turn it off in the set-
tings MENU.
TIP
• The engine must be running to start the lap tim-
er.
• The headlights will flash when the pass switch
is pressed.
• Whenever the lap timer is paused, it can be re-
sumed using the pass switch.
Brake control icon “BC”
This icon is replaced by the auxiliary system
warning and coolant temperature warning indi-
cators when they are activated.
Error mode warning “Err”
When an internal error occurs (e.g., communica-
tion with a system controller has been cut off),
the error mode warning will appear as follows.
“Err” and “ ” indicator light indicates an ECU
error.
“Err” only indicates an ABS ECU error.
1. Lap count
2. Current lap time
3. Latest/Previous lap time
LAP
02
LATEST
00:12.34
00:01.23
21 3

1-5
FEATURES
TIP
Depending on the nature of the error, the display
may not function properly and TCS settings may
be impossible to change. Additionally, ABS may
not function properly. Use extra care when brak-
ing and have a Yamaha dealer check the vehicle
immediately.
Auxiliary system warning “ ”
This icon appears if a problem is detected in a
non-engine-related system.
Coolant temperature warning “ ”
This icon appears if the coolant temperature
reaches 116 °C (241 °F) or higher. Stop the ve-
hicle and turn off the engine. Allow the engine to
cool.
NOTICE
ECA10022
Do not continue to operate the engine if it is
overheating.
Oil pressure warning “ ”
This icon appears when the engine oil pressure
is low. When the vehicle is first turned on, engine
oil pressure has yet to build, so this icon will
come on and stay on until the engine has been
started.
TIP
If a malfunction is detected, the oil pressure
warning icon will flash repeatedly.
NOTICE
ECA27240
Do not continue to operate the engine if the
oil pressure is low.
Settings MENU
The settings MENU screen contains the follow-
ing settings modules. Select a module to make
related settings changes.
Settings MENU access and operation
How to use the settings MENU:
Rotate the wheel switch up or down to highlight
items or increase/decrease values and then
short push the wheel switch (briefly press the
wheel switch inward) to confirm the selection.
Press and hold the wheel switch to exit the
MENU and return to the main display any time.
TIP
• Certain settings menu screens have an up-
ward pointing triangle mark item. Select the tri-
angle mark to save settings changes and exit
the current screen.
• Should vehicle motion be detected, the screen
will automatically exit the settings MENU and
return to the main display.
• To ensure that the desired settings changes
are saved, be sure to exit each menu via the tri-
angle mark (if displayed). Exiting the settings
menu by pressing and holding the wheel
switch may not save settings changes.
Display Setting
Exit
Manual TCSSetting
Vehicle Setting
Shift Indicator
km/h
MENU
Module Description
“Exit” Exit MENU and re-
turn the main display
“Display Setting”
Switch lap time
mode on/off and ad-
just the tachometer
color
“Manual TCS Set-
ting”
Adjust TCS/SCS/LIF
settings for the
“TCS-MODE M”
“Vehicle Setting” Adjust BC/QS set-
tings
“Shift Indicator”
Turn the shift indica-
tor on/off and adjust
tachometer settings
“Maintenance” View and reset main-
tenance intervals
“Unit”
Set fuel consumption
and measurement
units
“Brightness” Adjust screen bright-
ness
“Clock” Adjust the clock
“All Reset” Return all settings to
factory default

1-6
FEATURES
“Display Setting”
This module allows you to switch the lap time
mode and tachometer color mode ON/OFF.
When the lap time mode is selected, the twin ve-
hicle information displays on the main screen
will display a lap timer and a lap counter. To exit
the lap time mode, the turn lap timer OFF in the
display setting module.
To change the tachometer to color mode, select
ON.
“Manual TCS Setting”
This module allows you to customize the “TCS-
MODE M” which is accessible on the main dis-
play using the MODE switches.
TCS
This model uses a variable traction control sys-
tem. For each setting level, the further the vehi-
cle is leaned over, the greater the amount of
traction control (system intervention) is applied.
There are 3 setting levels available for the “TCS-
MODE M”.
Setting level 1 applies the least amount of over-
all system intervention, while setting level 3 ap-
plies the greatest amount of overall traction
control.
TIP
• TCS can only be turned on or “off” via the main
screen using the MODE switches.
• SCS and LIF can be turned off independently
of TCS for “TCSMODE M”.
• When “TCS-MODE” has been set to “OFF” on
the main screen: TCS, SCS and LIF are all
turned off together.
SCS
SCS can be set to OFF, 1, 2, and 3.
OFF turns the slide control system off, setting
level 1 provides the least amount of system in-
tervention, and setting level 3 provides the
greatest amount of system intervention.
LIF
LIF can be set to OFF, 1, 2, and 3.
Setting level 1 provides the least amount of sys-
tem intervention and setting 3 most strongly re-
duces the rate of wheel lift.
OFF turns LIF off.
“Vehicle Setting”
The vehicle setting module allows you to adjust
setting for the BC and QS systems.
BC
The brake control system has two settings, BC1
and BC2. Select BC1 when only standard ABS
is desired. Select BC2 to have the brake control
system further regulate brake pressure while
cornering to suppress lateral wheel slip.
TIP
For skilled riders and when riding at the track,
due to varying conditions, the BC2 brake system
may engage sooner than expected relative to
your desired cornering speed or intended cor-
nering line.
Lap Time OFF
Tacho Color OFF
km/h
Display Setting
TCS1
SCS1
LIF 1
km/h
Manual TCSSetting
QSSetting
km/h
Vehicle Setting
BC Setting
km/h
BC Setting
BC 2

1-7
FEATURES
QS
The quick shift system indicators are divided into
QS and QS sections.
QS and QS are not linked and can be inde-
pendently turned on or off.
QS can be set to ON or OFF.
OFF turns the respective upshift or downshift
function off, and the clutch lever must then be
used when shifting in that direction.
“Shift Indicator”
This module allows a custom shift indicator to be
set. When the engine r/min (rotations per min-
ute) are in the specified range, the gear indicator
will flash.
This module has 3 options:
“IND Mode” - the shift indicator can be turned
ON/OFF
“IND Start” - the r/min at which the indicator
starts flashing can be chosen.
Once selected, rotate the wheel switch up/down
to increase or decrease the r/min value by incre-
ments of 200 r/min.
“IND Start” is settable between 6000–12800 r/
min.
“IND Stop” - the r/min at which the indicator
stops flashing can be chosen.
Once selected, rotate the wheel switch up/down
to increase or decrease the r/min value by incre-
ments of 200 r/min.
“IND Stop” is settable between 6200–13000
r/min.
“Maintenance”
This module allows you to record the distance
traveled between engine oil changes (use the
OIL item), and for two other items of your choice
(use INTERVAL 1 and INTERVAL 2).
To reset a maintenance trip meter, select it and
then long push the wheel switch.
TIP
Maintenance item names cannot be changed.
“Unit”
This module allows you to switch the display be-
tween metric and imperial measurement units.
When using kilometers, the fuel consumption
units can be changed between “km/L” or “L/
100km”. When using miles, MPG will be avail-
able.
Temperature units can be switched between
Celsius and Fahrenheit.
km/h
QSSetting
QSON
QSON
km/h
Shift Indicator
IND Mode ON
IND Start 8000 r/min
IND Stop 10000 r/min
OIL
INTERVAL 1
km/h
km
1000
km
1000 km
Maintenance
INTERVAL 2 1000
km or mile km
L/100km
°C
km/L or L/100km
°C or °F
km/h
Unit

1-8
FEATURES
“Brightness”
This module allows you to adjust the general
brightness level of the display screen.
Select the desired brightness level by rotating
the wheel switch, and then short push the wheel
switch to fix the setting and return to the top
MENU screen.
“Clock”
This module allows you to set the clock.
When the clock module is selected, the hours
will be highlighted.
Set the hours by rotating the wheel switch. Push
the switch to confirm and highlight the minutes.
After confirming the minutes, you will be re-
turned to the top MENU screen.
“All Reset”
This module resets all settings items (except the
odometer and clock) to their default or factory
presets.
Select YES to reset all items. After selecting
YES, all items will be reset and the screen will
automatically return to the top MENU screen.
km/h
Brightness
1
km/h
Clock
0010
NO
YES
km/h
All Reset

1-9
BASIC SERVICE INFORMATION
EAS20010
BASIC SERVICE INFORMATION
EAS30014
ELECTRICAL SYSTEM
Electrical parts handling
NOTICE
ECA22611
• Do not perform angle adjustment of the IMU
and battery box by pinching the washer
and related parts.
• When installing the IMU, apply a thin coat of
silicone grease onto the washer where con-
tacting the IMU grommet.
• When installing the IMU, use only a genuine
bolt and washer, and tighten the bolt to the
specified torque.
• Pay attention not to expose the IMU to
strong shocks, such as striking or drop-
ping it.
• Do not place any foreign objects in and
around the battery box.
• Do not obstruct breather opening “a” of the
IMU.
• Do not clean the breather opening and do
not blow it with compressed air.
• When replacing the collar or grommet, re-
place all four collars and grommets.
a

1-10
SPECIAL TOOLS
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
90890-03267
3-4, 3-11, 4-54,
4-55, 7-11, 9-3,
9-46, 9-47
Yamaha diagnostic tool (A/I)
90890-03264
3-4, 3-11, 4-54,
4-55, 7-11, 9-3,
9-46, 9-47
Thickness gauge
90890-03268
Feeler gauge set
YU-26900-9
3-6, 4-17, 4-24,
5-27, 5-50
Valve lapper (ø14)
90890-04101
Valve lapper (ø14)
YM-A8998
3-7
Vacuum gauge
90890-03094
Vacuummate
YU-44456
3-9
90890-04101
YM-A8998
YU-44456

1-11
SPECIAL TOOLS
Carburetor angle driver 2
90890-03173
3-9
Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472
3-20, 4-76
Oil filter wrench
90890-01426
Oil filter wrench
YU-38411
3-29
Oil pressure gauge joint 18 mm
90890-04176
YU-04176
3-30
Oil pressure gauge set
90890-03120
3-30
Fork spring compressor
90890-01441
Fork spring compressor
YM-01441
4-66, 4-71
Rod holder
90890-01434
Damper rod holder double ended
YM-01434
4-66, 4-71
Damper rod holder (ø27)
90890-01582
Damper rod holder
YM-01582
4-67, 4-68
Fork seal driver
90890-01442
Adjustable fork seal driver (36–46 mm)
YM-01442
4-69, 4-69, 4-70
Tool name/Tool No. Illustration Reference
pages
ø18