Yamaha TRACER MT09 TRA User manual

2015
SERVICE MANUAL
MT09TRA
MT09TRAF
2PP-28197-E0

EAS20002
MT09TRA/MT09TRAF
SERVICE MANUAL
©2014 by Yamaha Motor Co., Ltd.
First edition, June 2014
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.
CLUTCH
5-39
EAS20055
CLUTCH
Removing the clutch cover
Order Job/Parts to remove Q’ty Remarks
Engine oil
Drain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-25.
.tcennocsiD1elbachctulC1
1revoC2
3O2sensor coupler bracket 1
1revochctulC4
1teksagrevochctulC5
2niplewoD6
1pacrellifliO7
1
2
3
4
5
6
7
12 Nm (1.2 m • kgf, 8.7 ft • Ibf)
12 Nm (1.2 m • kgf, 8.7 ft • Ibf)
12 Nm (1.2 m • kgf, 8.7 ft • Ibf)
1.5 Nm (0.15 m • kgf, 1.1 ft • Ibf)
6
(7)
CLUTCH
5-43
8. Remove:
•Clutch boss nut
•Conical spring washer
•Washer
•Clutch boss
•Thrust plate
•Clutch housing
•Oil pump drive chain
EAS30348
CHECKING THE FRICTION PLATES
The following procedure applies to all of the fric-
tion plates.
1. Check:
•Friction plate 1, 2
Damage/wear →Replace the friction plates
as a set.
2. Measure:
•Friction plate 1, 2 thickness
Out of specification →Replace the friction
plates as a set.
TIP
Measure the friction plate at four places.
EAS30349
CHECKING THE CLUTCH PLATES
The following procedure applies to all of the
clutch plates.
1. Check:
•Clutch plate
Damage →Replace the clutch plates as a
set.
2. Measure:
•Clutch plate warpage
(with a surface plate and thickness gauge “1”)
Out of specification →Replace the clutch
plates as a set.
EAS30351
CHECKING THE CLUTCH SPRINGS
The following procedure applies to all of the
clutch springs.
1. Check:
•Clutch spring
Damage →Replace the clutch springs as a
Friction plate 1 thickness
2.92–3.08 mm (0.115–0.121 in)
Wear limit
2.82 mm (0.111 in)
Friction plate 2 thickness
2.92–3.08 mm (0.115–0.121 in)
Wear limit
2.82 mm (0.111 in)
2
1
3
A. Friction plate 1
B. Friction plate 2
Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9
Clutch plate thickness
1.90–2.10 mm (0.075–0.083 in)
Warpage limit
0.10 mm (0.004 in)

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
OUTLINE OF THE FI SYSTEM..................................................................1-2
FI SYSTEM.................................................................................................1-3
YCC-T (Yamaha Chip Controlled Throttle).................................................1-4
OUTLINE OF THE ABS..............................................................................1-5
ABS COMPONENT FUNCTIONS ............................................................1-10
ABS OPERATION ....................................................................................1-15
ABS WARNING LIGHT AND OPERATION..............................................1-18
OUTLINE OF THE TCS (Traction Control System)..................................1-19
MULTI-FUNCTION METER UNIT ............................................................1-23
D-mode (drive mode)................................................................................1-31
IMPORTANT INFORMATION .........................................................................1-33
PREPARATION FOR REMOVAL AND DISASSEMBLY..........................1-33
REPLACEMENT PARTS..........................................................................1-33
GASKETS, OIL SEALS AND O-RINGS ...................................................1-33
LOCK WASHERS/PLATES AND COTTER PINS ....................................1-33
BEARINGS AND OIL SEALS ...................................................................1-33
CIRCLIPS .................................................................................................1-34
RUBBER PARTS......................................................................................1-34
BASIC SERVICE INFORMATION ..................................................................1-35
QUICK FASTENERS................................................................................1-35
ELECTRICAL SYSTEM............................................................................1-36
SPECIAL TOOLS ...........................................................................................1-40

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 battery box
under the passenger seat. This information will
be needed to order spare parts.
1
1

FEATURES
1-2
EAS20008
FEATURES
EAS30005
OUTLINE OF THE FI SYSTEM
The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum
air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In
the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion
chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the
respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating con-
ditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that meter the
fuel through the use of jets have been provided with various auxiliary devices, so that an optimum air-
fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the en-
gine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases increase,
it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accom-
modate this need, this model has adopted an electronically controlled fuel injection (FI) system, in place
of the conventional carburetor system. This system can achieve an optimum air-fuel ratio required by
the engine at all times by using a microprocessor that regulates the fuel injection volume according to
the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine response,
better fuel economy, and reduced exhaust emissions.
1 2 3, 4, 5, 6 7 8 9
10
111213
1415, 16
17
1. Engine trouble warning light
2. ECU (engine control unit)
3. Throttle position sensor
4. Accelerator position sensor
5. Intake air pressure sensor
6. Throttle servo motor
7. Fuel pump
8. Lean angle sensor
9. Battery
10.Rear wheel sensor
11.O2sensor
12.Crankshaft position sensor
13.Coolant temperature sensor
14.Injector
15.Ignition coil
16.Spark plug
17.Intake air temperature sensor

FEATURES
1-3
EAS30617
FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the
fuel pressure that is applied to the fuel injector at a certain level. Accordingly, when the energizing signal
from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into
the intake manifold only during the time the passage remain open.
Therefore, the longer the length of time the fuel injector is energized (injection duration), the greater the
volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is energized
(injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from the
throttle position sensor, accelerator position sensor, coolant temperature sensor, lean angle sensor,
crankshaft position sensor, intake air pressure sensor, intake air temperature sensor, rear wheel sensor
and O2sensor enable the ECU to determine the injection duration. The injection timing is determined
through the signals from the crankshaft position sensor. As a result, the volume of fuel that is required
by the engine can be supplied at all times in accordance with the driving conditions.
Illustration is for reference only.
1
15
B
14
13
12
11
16 9
A
2
3
C6
54
7
8
#2#1 #3
10
1. Fuel pump
2. Injector
3. ECU (engine control unit)
4. Throttle position sensor
5. Accelerator position sensor
6. Rear wheel sensor
7. Lean angle sensor
8. Intake air temperature sensor
9. O2sensor
10.Catalytic converter
11.Coolant temperature sensor
12.Crankshaft position sensor
13.Intake air pressure sensor
14.Throttle body
15.Air filter case
16.Throttle servo motor
A. Fuel system
B. Air system
C. Control system

FEATURES
1-4
EAS30852
YCC-T (Yamaha Chip Controlled Throttle)
Mechanism characteristics
Yamaha developed the YCC-T system employing the most advanced electronic control technologies.
Electronic control throttle systems have been used on automobiles, but Yamaha has developed a fast-
er, more compact system specifically for the needs of a sports motorcycle. The Yamaha-developed
system has a high-speed calculating capacity that produces computations of running conditions every
1/1000th of a second.
The YCC-T system is designed to respond to the throttle action of the rider by having the ECU instan-
taneously calculate the ideal throttle valve opening and generate signals to operate the motor-driven
throttle valves and thus actively control the intake air volume.
The ECU contains two CPUs with a capacity about five times that of conventional units, making it pos-
sible for the system to respond extremely quickly to the slightest adjustments made by the rider. In par-
ticular, optimized control of the throttle valve opening provides the optimum volume of intake air for
easy-to-use torque, even in a high-revving engine.
Aims and advantages of using YCC-T
•Increased engine power
By shortening the air intake path, higher engine speed is possible Increased engine power.
•Improved driveability
Air intake volume is controlled according to the operating conditions Improved throttle response to
meet engine requirement.
Driving force is controlled at the optimal level according to the transmission gear position and engine
speed Improved throttle control.
•Engine braking control
Due to the throttle control, optimal engine braking is made possible.
•Simplified idle speed control (ISC) mechanism
The bypass mechanism and ISC actuator are eliminated A simple mechanism is used to maintain
a steady idle speed.
•Reduced weight
Compared to using a sub-throttle mechanism, weight is reduced.
12
3
4
1. Accelerator position sensor
2. Throttle servo motor
3. Throttle position sensor
4. Throttle valves

FEATURES
1-5
YCC-T system outline
EAS30683
OUTLINE OF THE ABS
1. The Yamaha ABS (anti-lock brake system) features an electronic control system, which acts on the
front and rear brakes independently.
2. The ABS features a compact and lightweight design to help maintain the basic maneuverability of
the vehicle.
3. The hydraulic unit assembly, which is the main component of the ABS, is centrally located on the
vehicle to increase mass centralization.
5
6
7
8
9
32
1
4
1. Throttle position sensor
2. Throttle servo motor
3. Accelerator position sensor
4. ECU (engine control unit)
5. Sensor input
6. Gear position switch
7. Crankshaft position sensor
8. Rear wheel sensor
9. Coolant temperature sensor

FEATURES
1-6
ABS layout
ABS
The operation of the Yamaha ABS brakes is the same as conventional brakes on other vehicles, with
a brake lever for operating the front brake and a brake pedal for operating the rear brake.
When wheel lock is detected during emergency braking, hydraulic control is performed by the hydraulic
system on the front and rear brakes independently.
Useful terms
•Wheel speed:
The rotation speed of the front and rear wheels.
•Chassis speed:
The speed of the chassis.
When the brakes are applied, wheel speed and chassis speed are reduced. However, the chassis
travels forward by its inertia even though the wheel speed is reduced.
•Brake force:
The force applied by braking to reduce the wheel speed.
•Wheel lock:
A condition that occurs when the rotation of one or both of the wheels has stopped, but the vehicle
1
23
4
5
6
7
89
1
1. Hydraulic unit assembly
2. Fuse box 3
3. ABS test coupler
4. Rear wheel sensor
5. Rear wheel sensor rotor
6. Front wheel sensor
7. Front wheel sensor rotor
8. ABS warning light
9. Fuse box 2

FEATURES
1-7
continues to travel.
•Side force:
The force on the tires which supports the vehicle when cornering.
•Slip ratio:
When the brakes are applied, slipping occurs between the tires and the road surface. This causes a
difference between the wheel speed and the chassis speed.
Slip ratio is the value that shows the rate of wheel slippage and is defined by the following formula.
0 %: There is no slipping between the wheel and the road surface. The chassis speed is equal to the
wheel speed.
100 %: The wheel speed is “0”, but the chassis is moving (i.e., wheel lock).
Brake force and vehicle stability
When the brake pressure is increased, wheel speed is reduced. Slipping occurs between the tire and
the road surface and brake force is generated. The limit of this brake force is determined by the friction
force between the tire and the road surface and is closely related to wheel slippage. Wheel slippage is
represented by the slip ratio.
Side force is also closely related to wheel slippage. See figure “A”. If the brakes are applied while keep-
ing the proper slip ratio, it is possible to obtain the maximum brake force without losing much side force.
ABS allows full use of the tires’ capabilities even on slippery road surfaces or less slippery road surfac-
es. See figure “B”.
Slip ratio =
Chassis speed –
Wheel speed 100 (%)
Chassis speed
b
c
a
A
d
a
e
f
g
d
B
a. Friction force between the tire and road sur-
face
b. Brake force
c. Side force
d. Slip ratio (%)
e. Less slippery road surface
f. Controlling zone
g. Slippery road surface

FEATURES
1-8
Wheel slip and hydraulic control
The ABS ECU calculates the wheel speed of each wheel according to the rotation signal received from
the front and rear wheel sensors. In addition, the ABS ECU calculates the vehicle chassis speed and
the rate of speed reduction based on the wheel speed values.
The difference between the chassis speed and the wheel speed calculated in the slip ratio formula is
equal to the wheel slip. When the wheel speed is suddenly reduced, the wheel has a tendency to lock.
When the wheel slip and the wheel speed reduction rate exceed the preset values, the ABS ECU de-
termines that the wheel has a tendency to lock.
If the slip is large and the wheel has a tendency to lock (point A in the following figure), the ABS ECU
reduces the brake fluid pressure in the brake caliper. Once the ABS ECU determines that the tendency
of the wheel to lock has diminished after the brake fluid pressure is reduced, it increases the hydraulic
pressure (point B in the following figure). The hydraulic pressure is initially increased quickly, and then
it is increased gradually.
ABS operation and vehicle control
If the ABS starts operating, there is a tendency of the wheel to lock, and the vehicle is approaching the
limit of control. To make the rider aware of this condition, the ABS has been designed to generate a
reaction-force pulsating action in the brake lever and brake pedal independently.
TIP
When the ABS is activated, a pulsating action may be felt at the brake lever or brake pedal, but this
does not indicate a malfunction.
The higher the side force on a tire, the less traction there is available for braking. This is true whether
the vehicle is equipped with ABS or not. Therefore, sudden braking while cornering is not recommend-
ed. Excessive side force, which ABS cannot prevent, could cause the tire to slip sideways.
ddede
A
A
B
BA
A
B
B
A
A
B
B
b
c
a
e
a. Chassis speed
b. Wheel speed
c. Brake force
d. Depressurizing phase
e. Pressurizing phase

FEATURES
1-9
WARNING
EWA16510
The braking of the vehicle, even in the worst case, is principally executed when the vehicle is
advancing straight ahead. During a turn, sudden braking is liable to cause a loss of traction of
the tires. Even in vehicles equipped with ABS, overturning of the vehicle cannot be prevented
if it is braked suddenly.
The ABS functions to prevent the tendency of the wheel to lock by controlling the brake fluid pressure.
However, if there is a tendency of the wheel to lock on a slippery road surface, due to engine braking,
the ABS may not be able to prevent the wheel from locking.
WARNING
EWA13870
The ABS controls only the tendency of the wheel to lock caused by applying the brakes. The
ABS cannot prevent wheel lock on slippery surfaces, such as ice, when it is caused by engine
braking, even if the ABS is operating.
Electronic ABS features
The Yamaha ABS (anti-lock brake system) has been developed with the most advanced electronic
technology.
The ABS control is processed with good response under various vehicle travel conditions.
The ABS also includes a highly developed self-diagnosis function. The ABS detects any problem con-
dition and allows normal braking even if the ABS is not operating properly.
When this occurs, the ABS warning light on the meter assembly comes on.
The ABS stores the fault codes in the memory of the ABS ECU for easy problem identification and trou-
bleshooting.
a. Friction force between the tire and road sur-
face
b. Brake force
c. Side force
d. Slip ratio (%)

FEATURES
1-10
ABS block diagram
EAS30684
ABS COMPONENT FUNCTIONS
Wheel sensors and wheel sensor rotors
Wheel sensors “1” detect the wheel speed and transmit the rotation signal to the ABS ECU.
Each wheel sensor is composed of a permanent magnet and a hall IC. The sensor rotors “2” rotate with
the wheels. The sensor rotors “2” have 40 slots and are installed close to the wheel sensors. As the
sensor rotor rotates, the hall element in the hall IC installed in the wheel sensor generates pulses. The
pulse frequency, which is proportional to the magnetic flux density, is converted into a wave in the hall
IC so that it can be output.
The ABS ECU calculates the wheel rotation speed by detecting the pulse frequency.
1
2
3
44
77
566
8
99
10
11
12
13
14
1. Rear brake master cylinder
2. Hydraulic unit assembly
3. Front brake master cylinder
4. Inlet solenoid valve
5. ABS motor
6. Hydraulic pump
7. Outlet solenoid valve
8. ABS ECU
9. Buffer chamber
10.Rear brake caliper
11.Rear wheel sensor
12.ABS warning light
13.Front brake caliper
14.Front wheel sensor

FEATURES
1-11
ABS warning light
The ABS warning light “1” comes on to warn the rider if a malfunction in the ABS occurs.
When the main switch is turned to “ON”, the ABS warning light comes on to check the electrical circuit
and the system function (ABS self-diagnosis), and goes off when the vehicle is operated (the function
check is properly completed at a speed of about 6 to 10 km/h [3.8 to 6.3 mi/h]).
TIP
After all checks and servicing are completed, the ABS warning light will go off when the vehicle is ridden
or pushed at a speed of 7 km/h (4 mi/h) or faster.
NOTICE
ECA20350
If the rear wheel is raced with the vehicle on the centerstand, the ABS warning light may flash
or come on. If this occurs, turn the main switch to “OFF”, then back to “ON”. The ABS operation
is normal if the ABS warning light goes off after the vehicle starts off. If the fault codes are not
deleted, the ABS warning light goes off after the vehicle is ridden at a speed of approximately
30 km/h (19 mph).
1
2
2
1
3. At low speed
4. At high speed
5. Wheel sensor
6. Wheel sensor rotor
7. Voltage
8. Time