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Yamaha 2006 FJR1300AS, Service Manual

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Yamaha 2006 FJR1300AS Service Manual Download Page 13

SPECIAL TOOLS

– 4 –

EAS20260

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.

NOTE:

• 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

Vacuum/pressure pump gauge set
90890-06756
Mityvac brake bleeding tool
YS-42423

32

Magnet base B
90890-06844
Magnetic base stand
YU-A8438

33

Dial gauge & stand set
90890-01252

33

Fork seal driver weight
90890-01184

46

Fork seal driver attachment
90890-01186
Replacement 27 mm
YM-A9409-1

46

Oil seal installing tool
90890-01512

46

Pivot shaft wrench
90890-01471
Frame spanner socket
YM-01471

49

Summary of Contents for 2006 FJR1300AS

Page 1: ...2006 SUPPLEMENTARY SERVICE MANUAL FJR1300AS V 3P6 28197 E1 ...

Page 2: ...is necessary to use this Supplementary Service Manual together with the following manual FJR1300A V SERVICE MANUAL 3P6 28197 E0 EAS20040 FJR1300AS V 2006 SUPPLEMENTARY SERVICE MANUAL 2006 by Yamaha Motor Co Ltd First edition February 2006 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 3: ... 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 NOTE Designs and specifications are subject to change without notice EAS20080 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following The Safety A...

Page 4: ...ub 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 ch...

Page 5: ... 14 15 16 LT New T R 1 2 3 4 5 6 7 8 1 Serviceable with engine mounted 2 Filling fluid 3 Lubricant 4 Special tool 5 Tightening torque 6 Wear limit clearance 7 Engine speed 8 Electrical data 9 Engine oil 10 Gear oil 11 Molybdenum disulfide oil 12 Wheel bearing grease 13 Lithium soap based grease 14 Molybdenum disulfide grease 15 Apply locking agent LOCTITE 16 Replace the part ...

Page 6: ...TIGHTENING TORQUES 11 CABLE ROUTING 13 PERIODIC MAINTENANCE 29 INTRODUCTION 29 PERIODIC MAINTENANCE AND LUBRICATION CHART 29 ENGINE 31 CHECKING THE CLUTCH FLUID LEVEL 31 BLEEDING THE HYDRAULIC CLUTCH SYSTEM 31 CHECKING THE VEHICLE AFTER BLEEDING THE HYDRAULIC CLUTCH SYSTEM 33 CLEANING THE AIR FILTER ELEMENT 34 CHASSIS 35 ADJUSTING THE SHIFT PEDAL 35 ELECTRICAL SYSTEM 36 REPLACING THE HEADLIGHT BUL...

Page 7: ...ATOR 56 SHIFT ACTUATOR AND SHIFT ROD 57 REMOVING THE SHIFT ACTUATOR 59 CHECKING THE SHIFT ROD 59 INSTALLING THE FOOT SHIFT SWITCH 59 ADJUSTING THE FOOT SHIFT SWITCH 60 INSTALLING THE LEFT FOOTREST ASSEMBLY 61 INSTALLING THE SHIFT ACTUATOR 61 SHIFT SHAFT 63 INSTALLING THE SHIFT SHAFT 63 MIDDLE GEAR 64 CRANKCASE 66 TRANSMISSION 68 ELECTRIC STARTING SYSTEM 71 CIRCUIT DIAGRAM 1 2 71 CIRCUIT DIAGRAM 2 ...

Page 8: ... FUNCTION TABLE 91 TROUBLESHOOTING METHOD 94 DIAGNOSTIC MODE 95 TROUBLESHOOTING DETAILS 99 ELECTRICAL COMPONENTS 123 CHECKING THE SWITCHES 127 CHECKING THE RELAYS 130 CHECKING THE YCC S SPEED SENSOR 132 CHECKING THE GEAR POSITION SENSOR 132 CHECKING THE FOOT SHIFT SWITCH 133 CHECKING THE GRIP WARMERS 133 CHECKING THE GRIP WARMER CONTROL UNIT 134 CHECKING THE DIODE 2 134 FJR1300AS V 2006 WIRING DIA...

Page 9: ......

Page 10: ...A signal is sent to the MCU when the trans mission is shifted from neutral to 1st gear by hand or foot When the throttle is opened the MCU then engages the clutch according to engine r min Clutch engagement is controlled optimally by the MCU Clutch engagement is not constant in order to provide smooth shifting according to engine require ments and conditions The YCC S system will not shift up if t...

Page 11: ...led by pressing the hand shift select button 3 prior to being used The gear positions are shown in the illustration 1 2 3 4 5 6 7 9 11 12 8 10 1 YCC S test coupler 2 YCC S control relay 3 YCC S indicator and warning light 4 YCC S motor control fuse 5 Hand shift switch 6 Gear position sensor 7 Neutral switch 8 MCU motor control unit 9 Shift actuator 10 Clutch actuator 11 Foot shift switch 12 YCC S ...

Page 12: ...ain switch to LOCK when parking the vehicle YCC S indicator and warning light The YCC S system is constantly performing a self diagnosis The YCC S system also performs a self diagnosis when the main switch is turned to ON The YCC S indicator and warning light 1 come on during this self diagnosis After the self diagnosis is com pleted if there were no problems found the YCC S indicator and warning ...

Page 13: ...ed below to avoid any mistakes NOTE 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 Vacuum pressure pump gauge set 90890 06756 Mityvac brake bleeding tool YS 42423 32 Magnet base B 90890 06844 Magnetic base stand YU A8438 33 Dial gauge stand set 90890 01252 33 Fork seal driver weight 90890...

Page 14: ...476 49 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 50 60 Test coupler adapter 90890 03149 95 Pocket tester 90890 03112 Analog pocket tester YU 03112 C 129 130 132 133 134 Tool name Tool No Illustration Reference pages ...

Page 15: ...GENERAL SPECIFICATIONS 6 EAS20280 GENERAL SPECIFICATIONS Model Model 2D21 Europe except B and F ZA 2D22 B F 2D23 AUS Weight With oil and fuel 295 0 kg 650 lb Maximum load 208 kg 459 lb ...

Page 16: ...ing height 6 78 mm 0 27 in Minimum height 6 4 mm 0 25 in Spring quantity 1 pc Push rod bending limit 0 370 mm 0 0146 in Clutch pressure plate stroke 2 8 mm 0 11 in or more Transmission Transmission type Constant mesh 5 speed Primary reduction system Spur gear Primary reduction ratio 75 48 1 563 Secondary reduction system Shaft drive Secondary reduction ratio 35 37 21 27 33 9 2 698 Operation Left f...

Page 17: ... tires Loading condition 0 90 kg 0 198 lb Front 270 kPa 39 psi 2 70 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm Loading condition 90 208 kg 198 459 lb Front 270 kPa 39 psi 2 70 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm High speed riding Front 270 kPa 39 psi 2 70 kgf cm Rear 290 kPa 42 psi 2 90 kgf cm ...

Page 18: ...stance 1 21 1 48 Ω at 20 C 68 F Fuses Main fuse 50 0 A Headlight fuse 25 0 A Signaling system fuse 15 0 A Ignition fuse 10 0 A Radiator fan fuse 15 0 A 2 Auxiliary DC jack fuse 3 0 A Hazard fuse 10 0 A Fuel injection system fuse 15 0 A ABS motor fuse 30 0 A ABS control unit fuse 10 0 A YCC S motor control fuse 30 0 A Backup fuse 10 0 A Reserve fuse 30 0 A Reserve fuse 25 0 A Reserve fuse 15 0 A Re...

Page 19: ...0 4 m kg 2 9 ft lb Gear position sensor bracket M5 2 9 Nm 0 9 m kg 6 5 ft lb Shift actuator front bolt M8 1 20 Nm 2 0 m kg 14 ft lb Shift actuator rear bolt M8 1 20 Nm 2 0 m kg 14 ft lb Shift rod bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Shift rod bolt M8 1 10 Nm 1 0 m kg 7 2 ft lb Shift rod front locknut M6 1 7 Nm 0 7 m kg 5 1 ft lb Shift rod rear locknut M8 1 10 Nm 1 0 m kg 7 2 ft lb Foot shift switch ...

Page 20: ...S TIGHTENING TORQUES Item Thread size Q ty Tightening torque Remarks Shift pedal bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Shift pedal pivot bolt M8 1 16 Nm 1 6 m kg 11 ft lb Pivot shaft locknut retainer bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb LT LT LT ...

Page 21: ...TIGHTENING TORQUES 12 ...

Page 22: ...CABLE ROUTING 13 EAS20430 CABLE ROUTING B B A A B B A B C D E F F G G H I J K L 1 1 1 2 2 2 2 3 3 3 7 7 6 7 4 8 5 9 6 13 13 14 14 10 13 12 11 14 15 17 16 18 19 20 22 21 23 23 23 24 24 24 1 2 3 M ...

Page 23: ...warmer lead main switch lead and immobilizer unit lead with a plastic locking tie E Temporarily tighten the brake hose joint bolt union bolt and brake hose holder bolt in the proper tightening sequence as shown Then tighten the bolts to the specified torque making sure to tighten the brake hose joint bolt 1 last F To front cowling wire harness G Install the horn L shaped connectors so that the lea...

Page 24: ... A A B B F F A A CB D E D E A B C E I J K L 1 1 2 3 3 4 4 5 5 5 5 5 5 6 7 8 9 10 11 12 13 13 14 15 16 17 18 18 18 18 19 20 21 23 24 25 26 27 27 29 28 30 30 31 32 33 34 35 36 37 38 39 D F G M N S 27 30 30 18 Q R H 22 40 41 42 41 O P 11 ...

Page 25: ...cking tie rearward Do not cut off the excess end of the plastic locking tie F Route the positive battery lead between the battery stay and the battery box G To front cowling wire harness H Align the rear end of the right radiator fan motor coupler with the tape on the wire harness as shown in the illustration I Fasten the wire harness right horn high leads and right radiator fan motor lead with a ...

Page 26: ...CABLE ROUTING 17 B C 1 A D E G 1 2 3 4 5 6 7 8 9 14 13 10 11 12 15 F ...

Page 27: ... hose proportioning valve to rear brake caliper A Route the rear wheel sensor lead to the inside of the swingarm making sure that the lead does not protrude above the swingarm B 45 55 mm 1 77 2 17 in C 10 20 mm 0 39 0 79 in D Route the rear brake light switch lead under the rear wheel sensor lead E Fasten the clutch actuator motor lead and clutch actuator sensor lead to the brake hose hydraulic un...

Page 28: ...CABLE ROUTING 19 A B C D E 1 2 3 4 6 5 8 7 9 11 10 12 13 ...

Page 29: ...g tie Face the end of the plastic locking tie rearward along the side of the accessory box Do not cut off the excess end of the plastic locking tie B Fasten the wire harness and left radiator fan motor lead with the holder C Route the grip warmer control unit leads to the outside of the thermostat assembly breather hose D Fasten the front cowling wire harness to the radiator inlet hose with a plas...

Page 30: ...CABLE ROUTING 21 UP A A B D C C B D A A A B D C F G H I J K L M N O P Q T R S 1 3 2 19 19 11 12 13 11 15 14 17 18 20 21 22 23 10 24 25 26 16 27 28 29 30 31 32 33 E 7 9 8 4 6 5 30 34 35 U 16 ...

Page 31: ...ch and crankshaft position sensor that branch off from the wire harness to the guide on the holder with a plastic locking tie making sure that the end of the tie faces upward Do not cut off the excess end of the plastic locking tie E Fasten the sidestand switch lead stator coil lead and oil level switch lead with a plastic locking tie making sure to bundle and fasten the sidestand switch lead so t...

Page 32: ...CABLE ROUTING 23 A A B B C C B B A A A B E D C G F H I J L K M 2 2 1 1 5 5 5 6 6 6 7 8 9 16 11 12 13 15 10 17 18 19 12 3 3 4 3 20 21 11 22 11 22 23 24 25 26 27 14 ...

Page 33: ...n the harness to the outside of the other leads Face the end of the plastic locking tie inward without cutting off the excess end D Fasten the ABS wire harness with the holder E Route the stator coil lead and rectifier regulator lead to the outside of the rear shock absorber spring preload adjusting cable and under the hydraulic unit breather hose and clutch fluid reservoir hose F Pass the stator ...

Page 34: ...CABLE ROUTING 25 H A D E B C F G I I J K L M N O P 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 31 30 ...

Page 35: ... the plastic locking tie 0 20 mm 0 0 79 in from the end of the protective sleeve of the front wheel sensor lead C Position the plastic locking tie 10 30 mm 0 39 1 18 in from the end of the protective sleeve of the immobilizer unit lead D Route the throttle cables and brake hoses through the right opening in the frame E Install the immobilizer unit coupler holder so that the end with the bolt is fa...

Page 36: ...CABLE ROUTING 27 D B C A E E F I 3 4 5 2 1 6 H G ...

Page 37: ...uator motor lead and clutch actuator sensor lead with the band that is used to secure the MCU motor control unit C Make sure that the projection on the storage compartment fits into the indentation in the MCU motor control unit The MCU should not be resting on top of the projection D Route the tail brake light assembly lead and license plate light lead between the rib and the U lock holder on the ...

Page 38: ...hoses for cracks or damage 2 Spark plugs Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust Every 40000 km 4 Air filter element Clean Replace 5 YCC S clutch Check operation fluid level and vehicle for fluid leakage 6 Front brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 7 Rear brake Check operation fluid level...

Page 39: ...ng points Check operation Lubricate with lithium soap based grease 20 Fuel injection Adjust engine idling speed and synchronization 21 Engine oil Change Check oil level and vehicle for oil leakage 22 Engine oil filter car tridge Replace 23 Cooling system Check coolant level and vehicle for coolant leakage Change Every 3 years 24 Final gear oil Check oil level and vehicle for oil leakage Change 25 ...

Page 40: ...to GENERAL CHASSIS in chapter 4 Manual No 3P6 28197 E0 ET2D21001 BLEEDING THE HYDRAULIC CLUTCH SYSTEM WARNING EWA13000 Bleed the hydraulic clutch system whenever the system was disassembled a clutch hose was loosened or removed the clutch fluid level is very low clutch operation is faulty NOTE Before bleeding the hydraulic clutch system shift the transmission into neutral to engage the clutch Be c...

Page 41: ...ith the swingarm removed l Repeat steps i to k until all of the air bub bles have disappeared from the clutch fluid in the plastic hose of the vacuum pressure pump gauge set m Tighten the bleed screw to specification n Manually engage and disengage the clutch 30 times using the manual clutch operation bolt o Add the recommended clutch fluid to the proper level Refer to CHECKING THE CLUTCH FLUID LE...

Page 42: ...ate drag torque does not progressively increase in the following or der neutral 1st gear and when rear wheel starts to rotate in 1st gear Check the pres sure plate stroke Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM on page 31 a Place the vehicle on the centerstand b Turn the main switch to ON c Shift the transmission into neutral and then rotate the rear wheel by hand d Shift the transmission in...

Page 43: ...l and then raise the centerstand f Shift the transmission into 1st gear and then slowly turn the throttle grip and check the starting off performance of the vehicle EAS20920 CLEANING THE AIR FILTER ELEMENT 1 Remove Rider seat Left side cover Refer to GENERAL CHASSIS on page 37 Shift actuator Refer to SHIFT ACTUATOR AND SHIFT ROD on page 57 Air filter case cover Air filter element Refer to GENERAL ...

Page 44: ...s to suit the rider s preference as shown 2 Adjust Shift pedal position a Remove the shift pedal 1 by removing the shift pedal bolt 2 b Move the shift pedal to the desired position c Install the shift pedal bolt and then tighten it to specification a High position b Standard position c Low position T R Shift pedal bolt 7 Nm 0 7 m kg 5 1 ft lb LOCTITE ...

Page 45: ...d your hands away from the bulb until it has cooled down 6 Install Headlight bulb Secure the new headlight bulb with the head light bulb holder CAUTION ECA13690 Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean ...

Page 46: ...signal light coupler 1 Disconnect 7 Bottom cowling 1 8 Front cowling right inner panel 1 1 9 Headlight beam adjusting knob 2 10 Front cowling right inner panel 2 1 11 Adjusting knob shaft 2 12 Headlight beam adjusting cable 2 Disconnect 13 Front cowling left inner panel 1 1 14 Grip warmer control unit coupler 2 Disconnect 15 Grip warmer control unit 1 T R 32 Nm 3 2 m kg 23 ft Ib T R 10 Nm 1 0 m kg...

Page 47: ...cowling wire harness coupler 6 Disconnect 22 Horn connector 4 Disconnect 23 Grip warmer coupler 2 Disconnect 24 Front cowling assembly 1 For installation reverse the removal proce dure Removing the front cowling assembly Order Job Parts to remove Q ty Remarks T R 32 Nm 3 2 m kg 23 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LT LT LT 10 9 4 8 24 1 3 6 7 2 12 11 5 12 18 11 16 13 15 23 23 14 14 9 21 22 19 22 ...

Page 48: ...IFT ACTUATOR AND SHIFT ROD on page 57 1 Air shroud 1 2 Air duct 1 3 Air filter case cover 1 4 Air filter element 1 5 Tool kit 1 6 ECU coupler 1 Disconnect 7 MCU coupler 2 Disconnect 8 MCU 1 9 Storage compartment 1 10 ECU engine control unit 1 11 Rear lower fuel tank bracket 1 12 Intake air temperature sensor 1 T R 8 Nm 0 8 m kg 5 8 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib New T R 4 Nm 0 4 m kg 2 9 ft Ib ...

Page 49: ...w 4 Loosen 17 Air filter case joint assembly 1 18 Air filter case 1 19 Air filter case breather hose 2 20 Filter assembly 1 For installation reverse the removal proce dure Removing the air filter case Order Job Parts to remove Q ty Remarks T R 8 Nm 0 8 m kg 5 8 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib New T R 4 Nm 0 4 m kg 2 9 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 5 6 9 1 2 4 11 4 4 10 11 12 16 18 3 4 16 19 ...

Page 50: ...move Q ty Remarks 1 Left handlebar 1 2 Left grip warmer lead 1 3 Hand shift switch lead 1 4 Left handlebar switch lead 1 5 Lead holder 1 1 6 Hand shift switch 1 7 Lead holder 2 1 8 Left handlebar switch 1 9 Grip end 1 10 Handlebar grip 1 For installation reverse the removal proce dure ...

Page 51: ...ront brake master cylinder holder 1 3 Front brake master cylinder assembly 1 4 Grip end 1 5 Throttle cable housing 2 6 Throttle cable 2 Disconnect 7 Throttle grip 1 8 Right handlebar 1 9 Right grip warmer lead 1 10 Right handlebar switch lead 1 11 Lead holder 1 12 Right handlebar switch 1 For installation reverse the removal proce dure ...

Page 52: ...switch 1 NOTE Align the projection a on the right handlebar switch with the hole b on the right handlebar 4 Install Left handlebar switch 1 NOTE Align the projection a on the left handlebar switch with the hole b on the left handlebar 5 Install Hand shift switch 1 Lead holder 2 2 NOTE Align the projection a on the hand shift switch with hole b on the left handlebar When installing the hand shift s...

Page 53: ...rough the throttle cable housing When installing the throttle cable housing align the projection a on the housing with the hole b in the right handlebar and be sure not to pinch the right grip warmer lead There should be 1 3 mm 0 04 0 12 in of clearance c between the throttle grip and the grip end 10 Install Front brake master cylinder assembly Front brake master cylinder holder 1 NOTE Install the...

Page 54: ...t tighten the upper bolt then the lower bolt 11 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CA BLE FREE PLAY in chapter 3 Manual No 3P6 28197 E0 Throttle cable free play 3 0 5 0 mm 0 12 0 20 in b a 1 ...

Page 55: ...splines with the driven yoke of the universal joint 7 Tighten Final drive assembly nuts 8 Install Sidestand Left footrest assembly Refer to SHIFT ACTUATOR AND SHIFT ROD on page 57 9 Install Rear wheel Refer to REAR WHEEL in chapter 4 Man ual No 3P6 28197 E0 10 Fill Final gear case Refer to CHECKING THE FINAL GEAR OIL LEVEL in chapter 3 Manual No 3P6 28197 E0 Recommended lubricant Molybdenum disulf...

Page 56: ...o 3P6 28197 E0 Thermostat Thermostat inlet pipe 1 Refer to THERMOSTAT in chapter 6 Manual No 3P6 28197 E0 Engine oil Oil filter cartridge Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Manual No 3P6 28197 E0 Oil cooler Refer to OIL COOLER in chapter 6 Manu al No 3P6 28197 E0 Water pump Refer to WATER PUMP in chapter 6 Man ual No 3P6 28197 E0 Starter motor Refer to ELECTRIC STARTER in chapter ...

Page 57: ...oupler 1 Disconnect 7 Oil level switch coupler 1 Disconnect 8 Crankshaft position sensor coupler 1 Disconnect 9 Neutral switch coupler 1 Disconnect 10 YCC S speed sensor coupler 1 Disconnect 11 Ground lead 1 Disconnect 12 Spark plug cap 4 For installation reverse the removal proce dure Disconnecting the leads and hoses Order Job Parts to remove Q ty Remarks R 10 Nm 1 0 m kg 7 2 ft Ib LT LT T R 4 N...

Page 58: ...oving it ET2D21004 INSTALLING THE GEAR POSITION SENSOR 1 Connect MCU coupler ECU coupler Refer to GENERAL CHASSIS on page 37 2 Install Gear position sensor 1 CAUTION EC2D21002 Shift the transmission into neutral before in stalling the gear position sensor otherwise the sensor may be damaged NOTE Fit the end a of the shift drum assembly into the opening b in the gear position sensor 1 and then rota...

Page 59: ...ition sensor voltage e Adjust the gear position sensor angle so that the voltage is within the specified range f After adjusting the gear position sensor an gle tighten the gear position sensor screws 3 to specification 3 Check Gear position setting Refer to Diagnostic code table Diagnostic code No Sh_ _65 Positive tester probe yellow 1 Negative tester probe black blue 2 Digital circuit tester 908...

Page 60: ...r coupler 1 Disconnect 3 Clutch actuator sensor coupler 1 Disconnect 4 Clutch actuator bracket 1 5 Clutch fluid reservoir cap 1 6 Clutch fluid reservoir diaphragm holder 1 7 Clutch fluid reservoir diaphragm 1 8 Clutch fluid reservoir 1 9 Clutch fluid reservoir hose 1 10 Clutch hose union bolt 1 11 Copper washer 2 12 Clutch hose 1 Disconnect T R 19 Nm 1 9 m kg 13 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 61: ... For installation reverse the removal proce dure Removing the clutch actuator and clutch master cylinder Order Job Parts to remove Q ty Remarks T R 19 Nm 1 9 m kg 13 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib New New LS T R 7 Nm 0 7 m kg 5 1 ft Ib 1 2 4 5 7 6 8 9 10 11 12 13 14 3 16 15 ...

Page 62: ...y silicon grease Disassembling the clutch master cylinder Order Job Parts to remove Q ty Remarks 1 Clutch master cylinder kit 1 2 Clutch master cylinder body 1 For assembly reverse the disassembly pro cedure 1 2 New ...

Page 63: ...remove Q ty Remarks Clutch fluid Drain Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM on page 31 1 Clutch hose union bolt 1 2 Copper washer 2 3 Clutch hose 1 Disconnect 4 Clutch release cylinder 1 5 Dowel pin 2 6 Plate 1 For installation reverse the removal proce dure ...

Page 64: ...stalls re start the engine let it idle for at least 90 seconds and then repeat steps b to d ET2D21038 REPLACING THE CLUTCH MASTER CYLINDER 1 Check Pressure plate stroke Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM on page 31 2 Measure Shim clutch master cylinder kit 1 thickness 3 Replace Clutch master cylinder kit NOTE The thickness of the new shim 1 is 1 5 mm 0 06 in 4 Bleed Hydraulic clutch sys...

Page 65: ...maximum setting is reached b Operate the hand shift lever switch shift down ten times and check that the hand shift select indicator light comes on 5 Check Rear wheel drag torque Refer to CHECKING THE VEHICLE AFTER BLEEDING THE HYDRAULIC CLUTCH SYSTEM on page 33 6 Check Shift operation Refer to CHECKING THE VEHICLE AFTER BLEEDING THE HYDRAULIC CLUTCH SYSTEM on page 33 7 Check Starting off performa...

Page 66: ...isconnect 4 Shift actuator motor coupler 1 Disconnect 5 Shift actuator 1 6 Sidestand switch coupler 1 Disconnect 7 Left footrest assembly 1 8 Sidestand 1 9 Foot shift switch coupler 1 Disconnect 10 Foot shift switch 1 11 Holder 1 12 Shift pedal pivot bolt 1 13 Shift pedal pivot 1 LT LT T R 65 Nm 6 5 m kg 47 ft Ib T R 28 Nm 2 8 m kg 20 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 67: ...uator shift rod and foot shift switch Order Job Parts to remove Q ty Remarks LT LT T R 65 Nm 6 5 m kg 47 ft Ib T R 28 Nm 2 8 m kg 20 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib LS LS T R 49 Nm 4 9 m kg 35 ft Ib LT LT LT LT LT LT LS 2 1 6 8 17 18 16 19 7 12 15 14 13 5 4 3 10 11 9 ...

Page 68: ...ensor coupler and shift actuator motor coupler e Remove the shift actuator front bolt 4 and then remove the rear bolt 5 f Remove the shift actuator ET2D21008 CHECKING THE SHIFT ROD 1 Check Shift rod operation Rough movement Replace 2 Check Shift rod groove Groove and end of rod cover are not aligned Replace 3 Check Shift rod Bends Replace ET2D21009 INSTALLING THE FOOT SHIFT SWITCH 1 Lubricate Wash...

Page 69: ... 60 ET2D21010 ADJUSTING THE FOOT SHIFT SWITCH 1 Check Foot shift switch Refer to CHECKING THE FOOT SHIFT SWITCH on page 133 2 Adjust Foot shift switch angle a Connect the foot shift switch coupler to the foot shift switch b Connect the digital circuit tester to the foot shift switch coupler c Turn the main switch to ON d Measure the foot shift switch voltage e Adjust the foot shift switch angle so...

Page 70: ...the rear shift arm and shift actuator to secure the shift rod e Install the shift rod 4 NOTE Check that the hole a in the shift rod is aligned with the hole b in the front shift arm If the holes are not aligned loosen the shift rod rear locknut 5 and front locknut 6 and then turn the shift rod to adjust its length f Tighten the shift rod bolts to specification g If the shift rod front locknut and ...

Page 71: ...SHIFT ACTUATOR AND SHIFT ROD 62 h Pull out the rod from the holes T R Shift rod front locknut 7 Nm 0 7 m kg 5 1 ft lb Shift rod rear locknut 10 Nm 1 0 m kg 7 2 ft lb ...

Page 72: ...r lever and the crankcase boss 3 Mesh the stopper lever with the shift drum seg ment assembly 2 Install Shift shaft 1 NOTE Hook the end of the shift shaft spring onto the shift shaft spring stopper 2 3 Install Front shift arm 1 NOTE Align the punch mark a on the front shift arm with the punch mark b on the shift shaft T R Front shift arm bolt 10 Nm 1 0 m kg 7 2 ft lb 1 2 3 2 1 b a 1 ...

Page 73: ...fer to OIL PUMP in chapter 5 Manual No 3P6 28197 E0 1 Middle gear case cover 1 2 Middle gear case cover gasket 1 3 Dowel pin 2 4 Damper cover 1 5 Damper 1 6 Middle drive shaft bearing housing 1 7 Bearing 1 8 Middle driven shaft end cover 1 9 Middle driven shaft assembly 1 10 Middle driven pinion gear shim 11 Middle drive pinion gear nut 1 12 Lock washer 1 13 Middle drive pinion gear 1 ...

Page 74: ...assembly 1 15 Spacer 1 16 Middle driven gear 1 17 Bearing retainer 1 18 Bearing 1 19 Middle drive pinion gear shim 20 Bearing 1 For installation reverse the removal proce dure Removing the middle gear Order Job Parts to remove Q ty Remarks ...

Page 75: ...ual No 3P6 28197 E0 Middle drive shaft assembly Refer to MIDDLE GEAR in chapter 5 Manual No 3P6 28197 E0 Clutch housing Refer to CLUTCH in chapter 5 Manual No 3P6 28197 E0 1 Timing chain 1 2 Oil pump drive chain guide 1 3 Oil pump drive chain 1 4 Oil pump drive sprocket 1 T R 24 Nm 2 4 m kg 17 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 1st 20 Nm 2 0 m kg 14 ft Ib 2nd 20 Nm...

Page 76: ...Order Job Parts to remove Q ty Remarks T R 24 Nm 2 4 m kg 17 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 1st 20 Nm 2 0 m kg 14 ft Ib 2nd 20 Nm 2 0 m kg 14 ft Ib Final Specified angle 115 125 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib E E E E E E E E LT LT LT 11 11 7 6 5 4 1 2 3 11 10 4 10 10 2 2 8 9 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib New...

Page 77: ...er to CRANKCASE in chapter 5 Man ual No 3P6 28197 E0 Stopper lever Refer to SHIFT SHAFT in chapter 5 Man ual No 3P6 28197 E0 1 Gear position sensor bracket 1 2 Oil seal 1 3 Drive axle assembly 1 4 Bearing 1 5 Washer 1 6 Bearing 1 7 Shift drum retainer 1 8 Long shift fork guide bar 1 9 Shift fork L 1 10 Shift fork R 1 11 Short shift fork guide bar 1 12 Spring 4 ...

Page 78: ... 13 Shift drum assembly 1 14 Shift fork C 1 15 Main axle assembly 1 For installation reverse the removal proce dure Removing the transmission shift drum assembly and shift forks Order Job Parts to remove Q ty Remarks ...

Page 79: ...TRANSMISSION 70 ...

Page 80: ...B W BB B Y L Lg R W R G B2 L Y L Y W B Y G W W L Y G L W P B R G B G R GRAY B Y Y W Y L L L W Y G W L G W P GRAY G R G B B R DARK GREEN R W W G W L W Y R W R W GRAY GRAY GRAY GRAY R R G R G W W B W R B B R L R B R W W B L Y B L BLACK L O B BLACK W L Y B L L W Y B L P R B B L B B R B B R Br B Y R W B W L W Y W B R BLACK Lg W R B W Lg W R B W B2 B1 B1 BB B B B B BB2 BB1 BB4 BB3 B L Br W B L G W B B ...

Page 81: ... wire harness front cowling wire harness 18 Neutral switch 25 Rear brake light switch 27 Brake light relay 33 Coupler 3 wire harness front cowling wire harness 34 Sidestand switch 56 MCU motor control unit 64 YCC S control relay 65 Coupler 6 wire harness front cowling wire harness 68 Signaling system fuse 70 Ignition fuse ...

Page 82: ...L Y G L W P B R G B G R B Y Y W Y L L L W G R Y G W L G W P G B B R B W Ch Dg L G B L B Ch B W L G B L B Dg Ch Dg R G B W G R Sb B L Lg W W G B B R L W Y W P B Y R W G W Y L Sb W Y Br B BLACK L Y R B B R R L R G G Y Sb R L W R B W L R L L W L Y R W L G B R Sb B R Sb W Sb B Lg Br R R Br R G Sb Lg B Sb W Br B L Y G L G L R W Br Br B L R R Y R B L Y Br R Br B B BLACK B B B B R B B R B R R B B B B B B...

Page 83: ...wling wire harness wire harness 33 Coupler 3 front cowling wire harness wire harness 65 Coupler 6 front cowling wire harness wire harness 82 Front brake light switch 83 Engine stop switch 84 Start switch 92 Relay unit 93 Starting circuit cut off relay ...

Page 84: ...tor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay stays open so current cannot reach the starter motor When at least one of the above conditions has been met the starting circuit cut off relay is closed and the engine can be started by pushing the start switch 19 1 18 4 6 7 12 a b 9 14 10 8 15 2 3 11 8 8 13 16 17 5 a WHEN THE TRAN...

Page 85: ...P6 28197 E0 Clean the battery terminals Recharge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION in chap ter 8 Manual No 3P6 28197 E0 Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 4 Check the starter motor Refer to CHECKING THE START ER MOTOR in chapter 5 Manual No 3P6 28197 E0 Repair or repla...

Page 86: ...in switch immobilizer unit 11 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 127 Replace the right handlebar switch 12 Check the neutral switch Refer to CHECKING THE SWITCHES on page 127 Replace the neutral switch 13 Check the sidestand switch Refer to CHECKING THE SWITCHES on page 127 Replace the sidestand switch 14 Check the front brake light switch Refer to CHECKING THE SWI...

Page 87: ...G SYSTEM 78 NG OK 17 Check the entire starting system wiring Refer to CIRCUIT DIAGRAM 1 2 on page 71 and CIRCUIT DIA GRAM 2 2 on page 73 Properly connect or repair the starting sys tem wiring Replace the MCU or diode 1 ...

Page 88: ... G B2 L Y L Y W B Y G W W L Y G L W P B R G B G R GRAY B Y Y W Y L L L W Y G W L G W P GRAY G R G B B R DARK GREEN R W W G W L W Y R W R W GRAY GRAY GRAY GRAY R R G R G W W B W R B B R L R B R W W B L Y B L BLACK L O B BLACK W L Y B L L W Y B L P R B B L B B R B B R Br B Y R W B W L W Y W B R BLACK B Br L O W G R O B G B B L Br L O W O B G R G B Lg W R B W Lg W R B W B2 B1 B1 BB B B B B BB2 BB1 BB...

Page 89: ...1 Main switch 7 Main fuse 8 Battery 43 ECU engine control unit 65 Coupler 6 wire harness front cowling wire harness 66 Headlight on off grip warmer relay 68 Signaling system fuse 69 Headlight fuse 72 Grip warmer control unit ...

Page 90: ...Y R B L R Br B G L Y L B G BLACK B L R B L R B R L W R L W L Y R W L G B R S Sb B Lg Br R R Br R G Sb Lg B Sb W Br G L R W Br Br B L R R Y R B L Y Br R Br B B BLACK B B R B B R B R R B B B B B B B B Dg Br Y B BLACK G Y Dg W L R W Ch Br Br G B R B Dg Dg Ch Sb Ch Lg Lg L B L B R W L W Dg R B B Br Br W Ch G Y B B Y Y P P Sb W Br G Br W R Y R Y L R Br G BLACK R B Br L BLACK B B B B GRAY Br Br L GRAY G...

Page 91: ...GRIP WARMER SYSTEM 82 65 Coupler 6 front cowling wire harness wire harness 122 Right grip warmer 123 Left grip warmer ...

Page 92: ...m and head light Refer to CHECKING THE FUS ES in chapter 8 Manual No 3P6 28197 E0 Replace the fuse s 2 Check that the engine is started Start the engine 3 Check that the headlight is on Replace the headlight on off grip warmer relay 4 Check the grip warmers Refer to CHECKING THE GRIP WARMERS on page 133 Replace the grip warmer s 5 Check the entire grip warmer sys tem wiring Refer to CIRCUIT DIAGRA...

Page 93: ...ck for continuity between the light green white terminal of the ECU coupler and the light green white terminal of the grip warmer control unit coupler The wiring system from ECU coupler to the grip warmer control unit coupler black and light green white is faulty and must be repaired 2 Check that the grip warmer adjust ing knob is set to the HI position Adjust the grip warmer temperature using the...

Page 94: ... R W G B Y L B W BB B Y L Lg R W R G B2 L Y L Y W B Y G W W L Y G L W P B R G B G R GRAY B Y Y W Y L L L W Y G W L G W P GRAY G R G B B R DARK GREEN R W W G W L W Y R W R W GRAY GRAY GRAY GRAY R R G R G W W B W R B B R L R B R W W B L Y B L BLACK L O B BLACK W L Y B L L W Y B L P R B B L B B R B B R Br B Y R W B W L W Y W B R BLACK Lg W R B W Lg W R B W B2 B1 B1 BB B B B B BB2 BB1 BB4 BB3 B L Br W...

Page 95: ...rness 34 Sidestand switch 43 ECU engine control unit 52 Shift actuator motor 53 Shift actuator sensor 54 Clutch actuator sensor 55 Clutch actuator motor 56 MCU motor control unit 57 YCC S test coupler 58 Coupler 4 wire harness front cowling wire harness 60 Coupler 5 wire harness front cowling wire harness 61 Foot shift switch 62 YCC S speed sensor 63 Gear position sensor 64 YCC S control relay 65 ...

Page 96: ... Y G W W L Y G L W P B R G B G R B Y Y W Y L L L W G R Y G W L G W P G B B R B W Ch Dg L G B L B Ch B W L G B L B Dg Ch Dg R G B W G R Sb B L Lg W W G B B R L W Y W P B Y R W G W Y L Sb W Y Br B BLACK L Y R B B R R L R G G Y Sb R L W R B W L R L L W L Y R W L G B R Sb B R Sb W Sb B Lg Br R R Br R G Sb Lg B Sb W Br B L Y G L G L R W Br Br B L R R Y R B L Y Br R Br B B BLACK B B B B R B B R B R R B ...

Page 97: ...harness 60 Coupler 5 front cowling wire harness wire harness 65 Coupler 6 front cowling wire harness wire harness 82 Front brake light switch 83 Engine stop switch 84 Start switch 92 Relay unit 93 Starting circuit cut off relay 100 Multi function meter 102 Engine trouble warning light 109 Hand shift switch 110 Hand shift lever switch shift up 111 Hand shift lever switch shift down 112 Hand shift s...

Page 98: ... 28197 E0 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 8 Manual No 3P6 28197 E0 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES in chapter 8 Manual No 3P6 28197 E0 Replace the main switch immobilizer unit 4 Check the entire YCC S system wiring Refer to CIRCUIT DIAGRAM 1 2 on page 85 a...

Page 99: ...ntrol unit After the engine has been stopped the lowest fault code number appears on the odometer tripmeter fuel reserve trip meter LCD Once a fault code has been displayed it remains stored in the memory of the MCU motor control unit until it is deleted NOTE If the engine trouble indicator 1 YCC S indicator 2 and engine trouble warning light 3 all come on malfunctions have been detected in both t...

Page 100: ...n abnormal signal is received from a sensor the MCU motor control unit processes the spec ified values that are programmed for each sensor in order to provide the YCC S system with alternate operating instructions that enable the system to continue operating or stop operating depending on the conditions Self Diagnostic Function table SHIFT 3 1 2 a b c c d a Main switch OFF b Main switch ON c YCC S...

Page 101: ... of shift actuator sensor is ab normal Output signal of shift actuator sen sor is below 0 5 V or above 4 5 V Unable Unable Sh_ _21 Output signal of gear position sensor is ab normal Output signal of gear position sen sor is below 0 3 V or above 4 7 V Unable Unable Sh_ _22 Output signal of foot shift switch is abnor mal Output signal of foot shift switch is below 0 9 V or above 4 1 V Able Able Sh_ ...

Page 102: ...hift down are closed at the same time Able Able Sh_ _39 Ignition timing retard output signal is abnor mal Detected ignition retard signal from MCU motor control unit to ECU is abnormal Able Able Sh_ _41 Coolant temperature sensor signal is ab normal Coolant temperature sensor signal is too high or too low Able Able Sh_ _42 Communication be tween ECU and multi function meter is ab normal Error dete...

Page 103: ...e fault code number displayed on the meter and diagnostic code Sh_ _61 Refer to Diagnostic code table Diagnostic code No Sh_ _61 b Identify the faulty system with the fault code Refer to Self Diagnostic Function table 2 Check and repair the probable cause of the malfunction Refer to TROUBLESHOOTING DETAILS on page 99 3 Perform the reinstatement action for the YCC system Refer to Reinstatement meth...

Page 104: ... coupler 4 Connect the test coupler adapter 2 to the YCC S test coupler 5 Push and hold the hand shift select button 1 turn the main switch 2 to ON and continue to push the button for 8 seconds or more NOTE All displays on the meter disappear except the odometer tripmeter fuel reserve tripmeter displays Sh_ _61 appears on the odometer tripmeter fuel reserve tripmeter LCD 6 Select the diagnostic co...

Page 105: ...een shown the display re peats the same process If fault codes are stored in the malfunction history the hand shift select indicator light will come on Sh_ _62 Malfunction history code erasure No history Sh_ _62 History exists 01 09 First displays Sh_ _62 for 6 seconds and then displays the total number of malfunctions including the cur rent malfunction that have oc curred since the history was la...

Page 106: ...Sh_ 16 Sh_ _18 Sh_ _19 Sh_ _25 Sh_ _37 and Sh_ _51 Sh_ _64 The shift actuator can be operated in this mode 1 Make sure that the transmission is in neutral 2 Set the engine stop switch to and operate the hand shift lever switch shift up simultaneously The MCU motor control unit operates the shift actuator once The shift actuator is operated once each time two switches are operated 3 The MCU motor c...

Page 107: ...ed 6 Shift the transmission into 4th gear us ing the hand shift lever switch shift down and then rotate the rear wheel at least 1 2 turn by hand to ensure that the dog completely engages the 4th gear 7 Push the start switch If the gear position sensor output signal is correct for the 4th gear position the hand shift select indicator light will come on for 0 5 second 8 Repeat steps 6 and 7 for each...

Page 108: ...nt point manually The clutch engagement point while the ve hicle is starting off can be adjusted manu ally to 21 engine speed settings in this mode The initial setting of the clutch en gagement point varies according to the ve hicle Hand shift lever switch operation shift up To increase the clutch engagement point by approximately 100 150 r min oper ate the hand shift lever switch shift up four ti...

Page 109: ...G THE BATTERY in chapter 8 Manual No 3P6 28197 E0 3 Malfunction in rectifier regulator Replace if detective Refer to CHARGING SYS TEM in chapter 8 Manual No 3P6 28197 E0 4 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between battery and main switch coupler red red Between main switch coupler and signaling system fuse brown blue brown blue Between sig...

Page 110: ...ble cause Check or maintenance job Reinstatement method 1 Connections Wire harness MCU motor control unit coupler Clutch actuator motor coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Turning the main switch to OFF See NOTE 2 Open or short circuit in wire harness Repair or...

Page 111: ...nd probable cause Check or maintenance job Reinstatement method 1 Connections Wire harness MCU motor control unit coupler Shift actuator motor coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Turning the main switch to OFF See NOTE 2 Open or short circuit in wire harness Re...

Page 112: ...ft actuator motor coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Turning the main switch to OFF See NOTE 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between clutch actuator motor coupler and MCU motor con trol unit couple...

Page 113: ...Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Wire harness MCU motor control unit coupler Clutch actuator motor coupler Shift actuator motor coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Turning the main switch to OFF See ...

Page 114: ...ause Check or maintenance job Reinstatement method 1 Connections Wire harness MCU motor control unit coupler Clutch actuator motor coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Turning the main switch to OFF See NOTE 2 Open or short circuit in wire harness Repair or repl...

Page 115: ...obable cause Check or maintenance job Reinstatement method 1 Connections Wire harness MCU motor control unit coupler Shift actuator motor coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Turning the main switch to OFF See NOTE 2 Open or short circuit in wire harness Repair ...

Page 116: ...al of shift actuator sensor is abnor mal Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Wire harness MCU motor control unit coupler Shift actuator sensor coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Turning the main ...

Page 117: ...THE GEAR POSITION SENSOR on page 50 and CHECKING THE GEAR POSITION SENSOR on page 132 4 Gear position setting Execute the diagnostic mode Code No Sh_ _65 Fault code No Sh_ _22 Symptom Output signal of foot shift switch is abnormal Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Wire harness MCU motor control unit coupler Foot shift switch couple...

Page 118: ...f the malfunction 2 Open circuit in wire harness Repair or replace if there is an open circuit Between sidestand switch cou pler and MCU motor control unit coupler blue green blue green 3 Defective sidestand switch Check and replace if defective Refer to CHECKING THE SWITCHES in chapter 8 Manual No 3P6 28197 E0 Fault code No Sh_ _25 Symptom Error has occurred in the actuator drive circuit in MCU m...

Page 119: ...numbers can be confirmed in the mal function history Fault code No Sh_ _26 Symptom Abnormal clutch movement is detected during check when main switch is turned to ON Order Item components and probable cause Check or maintenance job Reinstatement method 1 Clutch fluid Check for clutch fluid leakage Check the clutch fluid level Refer to CHECKING THE CLUTCH FLUID LEVEL on page 31 Turning the main swi...

Page 120: ...r it and connect the coupler se curely Repairing the cause of the malfunction 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between ECU coupler and MCU motor control unit cou pler yellow black yellow black Fault code No Sh_ _32 Symptom YCC S speed sensor signal is abnormal Order Item components and probable cause Check or maintenance job Reinstateme...

Page 121: ... Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Wire harness MCU motor control unit coupler Relay unit coupler Right handlebar switch coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Repairing the cause of the malfunction 2 Op...

Page 122: ... coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Repairing the cause of the malfunction 2 Open or short circuit in wire harness and or sub lead 1 Repair or replace if there is an open or short circuit Between clutch actuator sen sor coupler and MCU motor control unit coupler orange orange o...

Page 123: ...bable cause Check or maintenance job Reinstatement method 1 Connections Wire harness MCU motor control unit coupler Clutch actuator motor coupler Shift actuator motor coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Turning the main switch to OFF See NOTE 2 Open or short ci...

Page 124: ... unit coupler orange white orange white orange black orange black green red green red green black green black 3 Defective hand shift lever switch shift up or shift down Replace hand shift switch Refer to CHECKING THE SWITCHES on page 127 Fault code No Sh_ _39 Symptom Ignition timing retard output signal is abnormal Order Item components and probable cause Check or maintenance job Reinstatement met...

Page 125: ...s an open or short circuit Between ECU coupler and MCU motor control unit cou pler yellow blue yellow blue Fault code No Sh_ _42 Symptom Communication between ECU and multi func tion meter is abnormal Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Wire harness MCU motor control unit coupler YCC S speed sensor coupler Check the coupler for any p...

Page 126: ...Connections Wire harness MCU motor control unit coupler ABS ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Repairing the cause of the malfunction 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between ABS ECU coupler and...

Page 127: ...ostic code No Sh_ _61 The fault code numbers can be confirmed in the mal function history Fault code No Sh_ _45 Symptom Shift operation and gear position do not match Order Item components and probable cause Check or maintenance job Reinstatement method 1 Shift rod Check the shift rod pin hole lo cation Check the shift rod groove loca tion Adjust or replace if defective Refer to CHECKING THE SHIFT...

Page 128: ...pair it and connect the coupler se curely Repairing the cause of the malfunction 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between battery and main switch coupler red red Between main switch coupler and signaling system fuse brown blue brown blue Between signaling system fuse and brake light relay coupler brown brown Between brake light relay co...

Page 129: ...ke Refer to BLEEDING THE HY DRAULIC CLUTCH SYSTEM on page 31 Turning the main switch to OFF See NOTE 2 Clutch slippage Check the friction plate thick ness and replace the friction plates if necessary Refer to CHECKING THE FRICTION PLATES in chapter 5 Manual No 3P6 28197 E0 Fault code No Sh_ _51 Symptom Shift actuator sensor signal is abnormal Order Item components and probable cause Check or maint...

Page 130: ...52 Symptom Main switch signal is abnormal Order Item components and probable cause Check or maintenance job Reinstatement method 1 Connections Wire harness MCU motor control unit coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Turning the main switch to OFF See NOTE 2 Open...

Page 131: ...YCC S Yamaha Chip Controlled Shift SYSTEM 122 ...

Page 132: ...ELECTRICAL COMPONENTS 123 EAS27970 ELECTRICAL COMPONENTS 1 2 3 4 5 6 7 8 9 10 11 12 13 15 14 16 18 19 20 17 ...

Page 133: ...ront brake light switch 6 Fuse box 2 7 Fuse box 1 8 Right radiator fan motor 9 Left radiator fan motor 10 Neutral switch 11 Sidestand switch 12 YCC S speed sensor 13 Oil level switch 14 Rear brake light switch 15 Left horn low 16 Right horn high 17 Ignition coil 18 Main fuse 19 Diode 1 20 Diode 2 ...

Page 134: ...ELECTRICAL COMPONENTS 125 1 19 18 17 20 21 3 2 4 5 6 8 7 9 10 11 12 13 14 15 16 ...

Page 135: ...lic unit 7 MCU motor control unit 8 ECU engine control unit 9 ABS ECU 10 Cylinder identification sensor 11 O2 sensor 12 Crankshaft position sensor 13 Accessory box solenoid 14 Headlight relay dimmer 15 Radiator fan motor relay 16 Headlight on off grip warmer relay 17 Brake light relay 18 YCC S control relay 19 Turn signal hazard relay 20 Relay unit 21 Lean angle sensor ...

Page 136: ... R 2 BROWN B B 3 Lg B Sb UP DOWN 15 DgBr W Ch 16 B P 12 14 R Y Y R Y L B 13 B Br W Ch Dg R B R W G Y L W Br 7 L W B R W R B 8 Ch Dg Br W 6 BLUE B B 5 4 G Y Br Sb 10 Shift up Shift down G R G B B L 11 O W O B B L Br L B L 9 PUSH B R B G R B L G B O W Br L O B Dg Sb Ch Lg L B B Y P Br W R Y ...

Page 137: ...tch 4 Neutral switch 5 Sidestand switch 6 Hazard switch 7 Start switch 8 Engine stop switch 9 Hand shift select button 10 Hand shift lever switch shift up 11 Hand shift lever switch shift down 12 Horn switch 13 Dimmer switch 14 Pass switch 15 Windshield position switch 16 Turn signal switch ...

Page 138: ...range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals at a given switch positi...

Page 139: ... warmer relay Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe R B L W R W R L 1 2 4 3 Result Continuity between 3 and 4 1 Positive battery terminal ...

Page 140: ...ery terminal 3 Positive tester probe 4 Negative tester probe 5 Negative tester probe Result No continuity between 3 and 4 Continuity between 3 and 5 G L Y L B B 1 3 2 G G L Y L B B 1 2 3 5 4 G 1 Positive tester probe 2 Negative tester probe Result Continuity between 1 and 2 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result No continuity ...

Page 141: ...sor NOTE Remove only the screws 1 when removing the gear position sensor Do not remove the screws 2 2 Check Gear position sensor maximum resistance Out of specification Replace the gear posi tion sensor Result No continuity between 1 and 2 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery ter...

Page 142: ...SWITCH on page 59 ET2D21024 CHECKING THE GRIP WARMERS The following procedure applies to both of the grip warmers 1 Check Grip warmer resistance Out of specification Replace the grip warmer a Disconnect the grip warmer coupler from the front cowling wire harness b Connect the pocket tester Ω 1 to the grip warmer coupler as shown Resistance 4 0 6 0 kΩ Pocket tester 90890 03112 Analog pocket tester ...

Page 143: ...and the analog pocket tester readings are shown in the following table a Remove the diode 2 from the wire harness b Connect the pocket tester Ω 1 to the diode 2 terminals as shown c Check the diode 2 for continuity d Check the diode 2 for no continuity Grip warmer control unit continu ity On Continuity Off No continuity Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester prob...

Page 144: ...ELECTRICAL COMPONENTS 135 ...

Page 145: ... 69 Headlight fuse 70 Ignition fuse 71 Auxiliary DC jack fuse 72 Grip warmer control unit 73 Radiator fan motor relay 74 Left radiator fan motor fuse 75 Left radiator fan motor 76 Right radiator fan motor fuse 77 Right radiator fan motor 78 YCC S motor control fuse 79 Auxiliary DC jack 80 Turn signal hazard relay 81 Right handlebar switch 82 Front brake light switch 83 Engine stop switch 84 Start ...

Page 146: ...B Red Black R G Red Green R L Red Blue R W Red White R Y Red Yellow Sb W Sky blue White W B White Black W G White Green W L White Blue W Y White Yellow Y B Yellow Black Y G Yellow Green Y L Yellow Blue Y W Yellow White ...

Page 147: ......

Page 148: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 149: ... WIRE HARNESS WIRE HARNESS O G O G B L B L O O L L WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS GRAY GRAY L W W L Y Br W B Br B B W G Y L L B L B O R O Br B Br B E B G F A C D R R R Br L R Br L Br R Br R W W W GRAY B R BLACK R Br B R W G Y B L BLACK B BLACK L B BLACK B BLACK L R Y G L R Y Y W B B G B B W R R L W R L R W BLUE B ...

Page 150: ...R B R B B R R Br R W G L L W R Y R B L R Br B G L Y L B G BLACK B L R B L R B GRAY GRAY B B GRAY B L B W GRAY L Y L Y W B Y G W W L Y G L W P B R G B G R B Y Y W Y L L L W G R Y G W L G W P G B B R B W Ch Dg L G B L B Ch B W L G B L B Dg Ch Dg R G B W G R Sb B L Lg W W G B B R L W Y W P B Y R W G W Y L Sb W Y Br B BLACK L Y R B B R R L R G G Y Sb R L W R B W L R L L W L Y R W L G B R Sb B R Sb W S...

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