Yamaha MTN1000 2016 User manual

2016
SERVICE MANUAL
MTN1000
MTN1000G
B67-28197-E0

EAS20002
MTN1000
MTN1000G
SERVICE MANUAL
©2016 by Yamaha Motor Co., Ltd.
First edition, March 2016
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.

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.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-
cle 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
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 per-
sonal 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
G
M
BF
B
T
R
.
.
LS
M
S
LT
E
New
S

GENERAL INFORMATION 1
SPECIFICATIONS 2
PERIODIC CHECKS AND ADJUSTMENTS 3
CHASSIS 4
ENGINE 5
COOLING SYSTEM 6
FUEL SYSTEM 7
ELECTRICAL SYSTEM 8
TROUBLESHOOTING 9
EAS10003
TABLE OF CONTENTS

1
2
3
4
5
6
7
8
9
GENERAL INFORMATION
IDENTIFICATION..............................................................................................1-1
VEHICLE IDENTIFICATION NUMBER ......................................................1-1
MODEL LABEL...........................................................................................1-1
FEATURES .......................................................................................................1-2
YCC-T (Yamaha Chip Controlled Throttle).................................................1-2
OUTLINE OF THE CRUISE CONTROL SYSTEM.....................................1-4
OUTLINE OF THE TCS (Traction Control System)..................................1-11
MULTI-FUNCTION DISPLAY...................................................................1-14
IMPORTANT INFORMATION .........................................................................1-21
PREPARATION FOR REMOVAL AND DISASSEMBLY..........................1-21
REPLACEMENT PARTS..........................................................................1-21
GASKETS, OIL SEALS AND O-RINGS ...................................................1-21
LOCK WASHERS/PLATES AND COTTER PINS ....................................1-21
BEARINGS AND OIL SEALS ...................................................................1-21
CIRCLIPS .................................................................................................1-22
RUBBER PARTS......................................................................................1-22
BASIC SERVICE INFORMATION ..................................................................1-23
QUICK FASTENERS................................................................................1-23
ELECTRICAL SYSTEM............................................................................1-24
SPECIAL TOOLS ...........................................................................................1-28

IDENTIFICATION
1-1
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 passenger seat. This information will be
needed to order spare parts.
1
1