Yamaha XSR700 2018 User manual

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

ELECTRICAL SPECIFICATIONS
– 4 –

CABLE ROUTING
– 5 –
EAS20021
CABLE ROUTING
Handlebar (front view)
A
B
D
C
E
F
4
8
9 10
11
12
12
13
14
14
G
1
1
1
2
2
2
3
3
5
5
6
6
7
7
12
15
16
17
18
12
13
5
5
H
I
J
K
H
I
JK
L

CABLE ROUTING
– 6 –
1. Throttle cable (decelerator cable)
2. Throttle cable (accelerator cable)
3. Clutch cable
4. Clutch switch lead
5. Handlebar switch lead (left handlebar switch)
6. Main switch lead
7. Wire harness
8. Cable guide
9. Brake hose (hydraulic unit to left front brake
caliper)
10. Front wheel sensor lead
11. Sub-wire harness coupler (headlight, turn signal
light, auxiliary light)
12. Handlebar switch lead (right handlebar switch)
13. Front brake light switch lead
14. Handlebar
15. Front brake master cylinder assembly
16. Brake hose (front brake master cylinder to
hydraulic unit)
17. Clutch lever holder
18. Sub-wire harness (headlight, turn signal light)
A. Fasten the handlebar switch lead (left handlebar
switch) and clutch cable with the holder. Align the
holder with the blue tape on the handlebar switch
lead.
B. Route the throttle cables through the guide. Be
sure to route the throttle cable (decelerator cable)
over the throttle cable (accelerator cable).
C. Route the handlebar switch lead (right handlebar
switch) to the inside of the front brake hose and
front wheel sensor lead.
D. Route the headlight lead under the wire harness.
E. Make sure that the holder contacts the holder that
is securing the handlebar switch lead (right
handlebar switch) and throttle cable (decelerator
cable).
F. Fasten the handlebar switch lead (right handlebar
switch) and throttle cable (decelerator cable) with
the holder. Align the holder with the blue tape on
the handlebar switch lead.
G. Insert the projection on the wire harness holder
into the hole in the hose bracket.
H. Upward
I. Downward
J. Forward
K. Rearward
L. Insert the projection on the headlight lead holder
into the hole in the headlight body.

CABLE ROUTING
– 7 –
ECU and clutch cable (right side view)
19
20
F
A
D
1
2
3
4
5
6
7
8
9
10
11
11
11
12
12
12
13
13
14
15
GH
B
E
C
G
H
I
J
16
18
17
K
21

CABLE ROUTING
– 8 –
1. Throttle cable (accelerator cable)
2. Throttle cable (decelerator cable)
3. Brake hose (front brake master cylinder to
hydraulic unit)
4. Wire harness (to meter assembly)
5. Front wheel sensor lead
6. Sub-wire harness coupler (headlight, turn signal
light, auxiliary light)
7. Handlebar switch lead (right handlebar switch)
8. Clutch cable
9. Fuel pump coupler
10. Sub-wire harness coupler (gear position switch,
coolant temperature sensor, fuel injector)
11. Fuel tank breather hose
12. Fuel tank overflow hose
13. Wire harness
14. Intake air temperature sensor coupler
15. Brake hose (hydraulic unit to left front brake
caliper)
16. Wire harness (to ECU)
17. Damper
18. Frame
19. Cylinder head breather hose
20. Sub-wire harness (gear position switch, coolant
temperature sensor, fuel injector)
21. Meter assembly coupler cover
A. Position the front wheel sensor lead and coupler to
the inside of the frame bracket nut.
B. Route the clutch cable through the guide as shown
in the illustration.
C. Fasten the wire harness to the frame bracket with
a plastic locking tie. Be sure to position the plastic
locking tie below the bent portion of the bracket.
D. Blue paint mark
E. Point the end of the plastic locking tie inward.
F. Cut off the excess end of the plastic locking tie to 5
mm (0.20 in) or less.
G. Inward
H. Outward
I. Forward
J. Rearward
K. After connecting the meter assembly coupler,
install the coupler cover completely until it contacts
the meter assembly.

CABLE ROUTING
– 9 –
Engine (right side view)
E
A
BC
D
1
12
3
4
56
7
12
13
B
F
G
H
I
L
Q
KJ
8
9
11
10
10
M
N
O
P
1
12
M
N
O
P
367 14

CABLE ROUTING
– 10 –
1. Wire harness
2. Clutch cable
3. Oil pressure switch lead
4. Oil pressure switch
5. O2sensor
6. O2sensor lead
7. Rear brake light switch lead
8. Rear brake light switch
9. O2sensor coupler
10. Brake fluid reservoir hose
11. Rear brake light switch coupler
12. Rear wheel sensor coupler
13. Oil pressure switch connector
14. Rear wheel sensor lead
A. Route the oil pressure switch lead through the
guide, and then secure the lead by bending the
guide around the lead.
B. Route the oil pressure switch lead to the inside of
the O2sensor lead, and then secure the leads by
bending the guides around the leads.
C. Do not pinch the O2sensor lead between the pivot
shaft protector and the engine.
D. Fasten the rear brake light switch lead and O2
sensor lead with the holder.
E. To rear brake caliper bracket
F. Connect the O2sensor coupler, and then insert the
projection on the coupler into the hole in the
bracket.
G. Route the brake fluid reservoir hose to the inside of
the frame and above of the leads.
H. Make sure that the wire harness is not pinched
between the pivot shaft protector (right) and the
frame.
I. Route the wire harness to the inside of the bracket
as shown in the illustration so that the harness
does not contact the air filter case bolt flange.
J. Pass a plastic locking tie through the hole in the
frame, and then fasten the wire harness at the
white tape with the tie.
K. Fasten the wire harness with a plastic locking tie
between the fuel tank bracket and the sub-frame.
L. Less than 10 mm (0.39 in)
M. Forward
N. Rearward
O. Inward
P. Outward
Q. Position the end of the plastic locking tie within the
range shown in the illustration.

CABLE ROUTING
– 11 –
Rectifier/regulator (left side view)
D
C
A
B
E
G
H
I
1
4
3
567
8
11
12
F9
10
T
US
V
W
10
12
X
Y
N
O
Z
22
23
24 25
26
27
14
15
P
Q
R
16 17 1819
20
21
2
2
1
J
K
L
M
13

CABLE ROUTING
– 12 –
1. Clutch cable
2. Handlebar switch lead (left handlebar switch)
3. Main switch lead
4. Intake air temperature sensor coupler
5. Throttle cable (decelerator cable)
6. Throttle cable (accelerator cable)
7. Fuel pump coupler
8. Throttle body assembly
9. Oil cooler inlet hose
10. Coolant reservoir hose
11. Horn lead
12. AC magneto lead
13. Radiator inlet hose
14. Ignition coil #2 coupler
15. Ignition coil #1 coupler
16. Injector #1 coupler
17. ISC (Idle Speed Control) unit coupler
18. Injector #2 coupler
19. Throttle position sensor coupler
20. Throttle position sensor
21. Coolant temperature sensor lead
22. Crankshaft position sensor coupler
23. Radiator fan motor coupler
24. AC magneto lead coupler
25. Rectifier/regulator coupler
26. Joint coupler
27. Auxiliary DC outlet coupler
A. Route the main switch lead between the lower
handlebar holder and the guide.
B. Fasten the main switch lead at the tape with a
plastic band. Face the buckle of the plastic band
forward with the end pointing downward.
C. Position the slack of the main switch lead between
the wire harness and the left handlebar switch
lead.
D. Make sure that the throttle cables do not cross
between the guide on the frame and the throttle
body.
E. 5–10 mm (0.20–0.39 in)
F. Fasten the AC magneto lead to the oil cooler inlet
hose with a plastic locking tie. Make sure to route
the AC magneto lead to the outside of the oil cooler
inlet hose. Align the plastic locking tie with the blue
tape on the AC magneto lead. Face the buckle of
the plastic locking tie rearward, and then cut off the
excess end of the tie to 2 mm (0.08 in) or less.
G. Fasten the AC magneto lead and coolant reservoir
hose with the holder at the location shown in the
illustration. Make sure that there is no slack in the
AC magneto lead.
H. Secure the holder by inserting the projection on
the holder into the hole in the radiator fan motor
bracket, and then fasten the AC magneto lead,
horn lead, and coolant reservoir hose with the
holder. Make sure that the coolant reservoir hose
and leads do not cross between the oil cooler inlet
hose and this holder.
I. Fasten the AC magneto lead, horn lead, and
coolant reservoir hose with the holder.
J. Fasten the AC magneto lead, horn lead, and
coolant reservoir hose with the holder at the
location shown in the illustration. Make sure that
there is no slack in the AC magneto lead, horn
lead, and coolant reservoir hose.
K. Route the rectifier/regulator lead to the inside of
the radiator inlet hose.
L. Route the AC magneto lead to the inside of the
radiator inlet hose, and then connect the AC
magneto coupler to the rectifier/regulator.
M. Route the clutch cable through the hole in the
cover.
N. Turn the handlebar all the way to the right, and
then fasten the clutch cable and left handlebar
switch lead with a plastic band at the location
shown in the illustration. Align the plastic locking tie
with the tape on the left handlebar switch lead.
Face the buckle of the plastic locking tie outward
with the end pointing downward.
O. Fasten the main switch lead and immobilizer unit
lead at the tape on the main switch lead to the
guide with a plastic band. Face the buckle of the
plastic band inward with the end pointing forward.
P. Route the coolant temperature sensor lead and
gear position switch lead between the throttle
position sensor and the cylinder head.
Q. The gear position switch lead and coolant
temperature sensor lead may be positioned and
routed in any order. Make sure that there is no
slack in the gear position switch lead.
R. Route the coolant temperature sensor lead to the
front of the gear position switch lead.
S. Face the catch of the holder inward.
T. I n w a r d
U. Outward
V. U p w a r d
W. Downward
X. Install the joint coupler completely onto the tab on
the electrical components tray 1.
Y. Connect the coupler, and then insert the projection
on the coupler into the hole in the electrical
components tray 1.
Z. Connect the coupler, and then insert the projection
on the coupler into the hole in the electrical
components tray 1.

CABLE ROUTING
– 13 –
Electrical components tray (top view)
27
27
27
27
N
26
P
Q
I
J
I
J
HF
27
28
O
1
24
5
E
G
HF
20
E
G
HF
20
IJ
H
F
K
HF
A
B
1
2
3
4
5679
10 11 12 13
16
17
18
18
18
19
19
19
20
20
20
21
24
24
25
25
26
22
23
C
8
D
27
29
L
M
20
14
15