Yamaha CYGNUS RAY ZR 2022 Supplementary Service Manual Download

Page: 77 / 163

GENERAL CHASSIS

4-2

CHAS

EAS31677

REMOVING THE BATTERY COVER

1. Remove

• Battery box cover “1”

TIP

Remove the battery box cover screws “2” then
slide the cover towards back side and remove
the battery box cover by lifting it up from front
side.

• Battery cover “3” by removing the bolt “4”

TIP

Battery cover is tied with rubber string. Remove
the battery cover and let the cover hang with rub-
ber string. Only remove the rubber string and
cover if required.

EAS31678

INSTALLING THE BATTERY COVER

1. Install:

• Battery cover “1” by installing the bolt “2”

TIP

Ensure battery cover is set properly on its origi-
nal position before tighten the battery cover bolt.

• Battery box cover “3”
• Battery box cover screws “4”

Battery cover bolt

4 N·m (0.4 kgf·m, 3.0 lb·ft)

Battery box cover screw

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

B2UF8197E1.book Page 2 Wednesday, October 6, 2021 4:38 PM

Summary of Contents for CYGNUS RAY ZR 2022

Page 1: ...SUPPLEMENTARY SERVICE MANUAL LCG125 LCG125D B2U F8197 E1 2022 B2UF8197E1 book Page 1 Wednesday October 6 2021 4 38 PM ...

Page 2: ...ry Service Manual together with the following manual FASCINO LCX125 2020 SERVICE MANUAL B7J F8197 E0 RAY ZR LCG125 LCG125D 2022 SUPPLEMENTARY SERVICE MANUAL 2022 by India Yamaha Motor Pvt Ltd First edition September 2021 All rights reserved Any reproduction or unauthorized use without the written permission of India Yamaha Motor Pvt Ltd is expressly prohibited B2UF8197E1 book Page 1 Wednesday Octo...

Page 3: ...ications 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 EAS20081 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 ...

Page 4: ...aller 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 d...

Page 5: ...e mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clearance Molybdenum disulfide grease Engine speed Silicone grease Electrical data Apply locking agent LOCTITE Engine oil Replace the part with a new one G M BF B T R LS M S LT E New B2UF8197E1 book Page 4 Wednesday October 6 2021 ...

Page 6: ...B2UF8197E1 book Page 5 Wednesday October 6 2021 4 38 PM ...

Page 7: ...TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ELECTRICAL SYSTEM 5 B2UF8197E1 book Page 1 Wednesday October 6 2021 4 38 PM ...

Page 8: ...B2UF8197E1 book Page 2 Wednesday October 6 2021 4 38 PM ...

Page 9: ...GENERAL INFORMATION FEATURES 1 1 INDICATOR LIGHTS AND WARNING LIGHTS for disc 1 1 INDICATOR LIGHTS AND WARNING LIGHTS for drum 1 2 SPECIAL TOOLS 1 3 B2UF8197E1 book Page 0 Wednesday October 6 2021 4 38 PM ...

Page 10: ... go off If the warning light does not come on initially when the vehicle is turned on or if the warning light remains on have a Yamaha dealer check the electrical circuit EAU76382 Stop and Start System indicator light This indicator light comes on when the Stop and Start System activates The indicator light will flash when the engine is automatically stopped by the Stop and Start System TIP Even i...

Page 11: ...arning light does not come on initially when the vehicle is turned on or if the warning light remains on have a Yamaha dealer check the electrical circuit EAU76382 Stop and Start System indicator light This indicator light comes on when the Stop and Start System activates The indicator light will flash when the engine is automatically stopped by the Stop and Start System TIP Even if the Stop and S...

Page 12: ...y sheave Clutch carrier nut socket ø39 mm S 1102 90890 01493 This tool is used to loosen and tighten the clutch carri er locknut of the secondary sheave Steering nut socket S 1103 90890 01403 This tool is used to loosen and tighten the steering ring nut Clutch housing holder S 1104 90890 01701 This tool is used to hold the clutch housing while loos ening and tightening clutch housing nut Cam sproc...

Page 13: ...ompressor S 1114 90890 04108 This adopter is an attachment of YSST 603 This tool is used when removing or installing the valve and the valve spring Engine stand S 1117 Bolt Bush for engine stand S 1117A This tool is used to hold the engine Funnel with long tail S 1119 This funnel is used to fill engine oil in crankcase Crankshaft installer S 1120 Crankshaft installer attachment S 1120A These tools...

Page 14: ...0890 04152 This tool is necessary for separating the crankcase Oil seal remover YSST 270 To remove oil seal TFF oil seal installation tool YSST 275 90890 01367 90890 01400 Front fork oil seal installer attachment YSST 275A 90890 01186 To install oil seal in outer tube Valve spring compressor YSST 603 90890 04019 This tool is used when removing or installing the valve valve spring and cotter Tool n...

Page 15: ...d to remove the bearings of primary driven gear Cup B YSST 620 B This tool is used to remove the bearings of front wheel left right Cup C YSST 620 C This tool is used to remove the bearing of main axle V belt case cover drive axle left crankcase Cup D YSST 620 D This tool is used to remove the bearing of camshaft Bearing puller 6001 6201 YSST 623 This tool is used to remove the bearing of camshaft...

Page 16: ...screw holder YSST 706 90890 04154 This tool is used to adjust valve clearance Tappet screw socket YSST 706 A This tool is used to adjust valve clearance Bearing puller YSST 723 This tool is used to remove the bearing 6202 of the V belt case cover and front wheel Wooden plunk YSST 892 This tool is used to stand the scooter at centre Bush YSST 893 This tool is used as an attachment with crankshaft r...

Page 17: ...90 06754 This tool is used to check efficiency of ignition at spark plug Compression gauge INS 009 90890 03081 This instrument is used to measure the engine com pression Yamaha bond No 1215 TG 1215 90890 85505 This bond is used to seal two mating surfaces e g crankcase mating surfaces Yamaha diagnostic tool INS 018 90890 03267 This tool is used to diagnose electrical fault in ad vance fuel injecti...

Page 18: ...ce fuel injection system Sub harness 3 90890 03266 This tool is used to connect FI YDT coupler to adapter interface BS VI models Fuel injector plate INS 020 This tool is used to hold the fuel injector on injector cleaning machine Tool name Tool No Illustration 16 mm 58 0 10 mm B2UF8197E1 book Page 9 Wednesday October 6 2021 4 38 PM ...

Page 19: ...AINTENANCE SPECIFICATION CHASSIS 2 5 MAINTENANCE SPECIFICATION ELECTRICAL 2 7 TIGHTENING TORQUES 2 9 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 9 ENGINE TIGHTENING TORQUES 2 10 CHASSIS TIGHTENING TORQUES 2 12 CABLE ROUTING 2 17 B2UF8197E1 book Page 0 Wednesday October 6 2021 4 38 PM ...

Page 20: ...0 in Overall width 685 mm 27 0 in Drum Disc 750 mm 29 5 in Street Rally Overall height 1190 mm 46 9 in Wheelbase 1280 mm 50 4 in Ground clearance 145 mm 5 71 in Minimum turning radius 2 1 m 6 89 ft Weight Curb weight 98 kg 216 lb Drum Disc 99 kg 218 lb Street Rally Loading Maximum load 156 kg 344 lb Riding capacity 2 persons B2UF8197E1 book Page 1 Wednesday October 6 2021 4 38 PM ...

Page 21: ...oil grade API service SL type JASO standard MB Lubrication system Wet sump Engine oil quantity Oil change 0 80 L 0 85 US qt 0 70 Imp qt Quantity disassembled 0 84 L 0 89 US qt 0 74 Imp qt Final transmission oil Type Scooter gear oil Quantity disassembled 0 11 L 0 12 US qt 0 10 Imp qt Quantity 0 10 L 0 11 US qt 0 09 Imp qt Oil filter Oil filter type Centrifugal Oil pump Oil pressure 50 0 kPa 4700 r...

Page 22: ...0032 in Valve stem to valve guide clearance limit exhaust 0 100 mm 0 0039 in Valve stem runout 0 020 mm 0 0008 in Valve spring Free length limit intake 35 30 mm 1 39 in Free length limit exhaust 35 30 mm 1 39 in Cylinder Bore 52 400 52 423 mm 2 0630 2 0639 in Wear limit 52 473 mm 2 0659 in Piston Diameter 52 377 52 400 mm 2 0621 2 0630 in Measuring point from piston skirt bottom 5 0 mm 0 20 in Pis...

Page 23: ...o 2 192 0 740 1 Secondary reduction ratio 9 559 50 17 39 12 Weight outside diameter limit 19 5 mm 0 77 in Compression spring free length limit 140 4 mm 5 53 in Air filter Air filter element Oil coated paper element V belt filter element Wet element Fuel injector Resistance 12 0 Idling condition Engine idling speed 1200 1400 r min O2 feedback control Active Engine temperature 75 85 C 167 185 F CO 0...

Page 24: ...ss Size 90 90 12 54J Manufacturer model MAXXIS M6309 Street Rally Manufacturer model MAXXIS M6307 Drum Disc TVS CONTA 775F Drum Disc Rear tire Type Tubeless Size 110 90 10 61J Manufacturer model MAXXIS M6310 Street Rally Manufacturer model MAXXIS M6220 Drum Disc TVS CONTA 775R Drum Disc Tire air pressure measured on cold tires 1 person Front 150 kPa 1 50 kgf cm 22 psi 1 50 bar Rear 200 kPa 2 00 kg...

Page 25: ...ake Rear brake lever free play 10 0 15 0 mm 0 39 0 59 in Drum 10 0 20 0 mm 0 39 0 79 in Disc Street Rally Brake drum inside diameter limit 130 0 mm 5 12 in Drum 131 0 mm 5 16 in Disc Street Rally Lining thickness limit 2 0 mm 0 08 in Disc Street Rally 4 5 mm 0 18 in Drum Steering Front suspension Shock absorber Hydraulic damper Fork spring free length limit 248 1 mm 9 77 in Inner tube bending limi...

Page 26: ...0 k Charging system Charging system Starter generator Standard output 13 0 V 33 8 A at 5000 r min Rectifier regulator Regulated voltage DC 14 3 14 7 V Battery Model YTZ6V Voltage capacity 12 V 5 0 Ah 10 HR Headlight Bulb type Halogen bulb Drum Bulb wattage Headlight HS1 35 0 W 35 0 W Drum Headlight LED Disc Street Rally Brake tail light 21 0 W 5 0 W Front turn signal light 10 0 W Rear turn signal ...

Page 27: ...unit Sender unit resistance full 4 0 10 0 Sender unit resistance empty 90 0 100 0 Fuel injection sensor Crankshaft position sensor resistance 217 325 Intake air temperature sensor resistance 5700 6300 at 0 C 5700 6300 at 32 F Atmospheric pressure sensor output voltage 3 88 4 12 V at 101 3 kPa 3 88 4 12 V at 1 01 kgf cm 3 88 4 12 V at 14 7 psi Engine temperature sensor resistance 2513 2777 at 20 C ...

Page 28: ...multi fastener assemblies in a crisscross pattern and progressive stages until the speci fied tightening torque is reached Unless otherwise specified tightening torque specifications require clean dry threads Com ponents should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques N m kgf m lb ft 10 mm 6 mm 6 0 6 4 4 12 mm 8 mm 15 1 5 11 ...

Page 29: ...Fan bolt M6 3 8 N m 0 8 kgf m 5 9 lb ft Oil pump assembly screw M5 2 4 N m 0 4 kgf m 3 0 lb ft Oil strainer bolt M30 1 20 N m 2 0 kgf m 15 lb ft Intake manifold joint M6 2 10 N m 1 0 kgf m 7 4 lb ft Injector bolt M6 1 10 N m 1 0 kgf m 7 4 lb ft Air filter case assembly bolt M6 2 10 N m 1 0 kgf m 7 4 lb ft Throttle body and intake manifold bolt M6 2 10 N m 1 0 kgf m 7 4 lb ft Air filter case joint ...

Page 30: ...nkshaft position sensor screw M6 2 11 N m 1 1 kgf m 8 1 lb ft Stator coil assembly bolt M6 3 11 N m 1 1 kgf m 8 1 lb ft Starter generator rotor nut M12 1 70 N m 7 0 kgf m 52 lb ft Engine temperature sensor M10 1 15 N m 1 5 kgf m 11 lb ft Don t use an impact wrench O2 sensor M12 1 25 N m 2 5 kgf m 18 lb ft Don t use an impact wrench Air filter case screw M5 6 1 3 N m 0 13 kgf m 0 95 lb ft Tightenin...

Page 31: ... ft Storage compartment bolt M6 4 9 N m 0 9 kgf m 6 6 lb ft Tightening pattern change now anti clock wise Grab bar bolt M8 4 11 N m 1 1 kgf m 8 1 lb ft Fuel tank cover screw M5 4 1 8 N m 0 18 kgf m 1 3 lb ft tank cover screws locked in Z pattern Side cover screw M5 2 1 8 N m 0 18 kgf m 1 3 lb ft Rear reflector nut M5 1 1 5 N m 0 15 kgf m 1 1 lb ft Rear side reflector nut M5 2 1 5 N m 0 15 kgf m 1 ...

Page 32: ... stay nut M6 2 3 8 N m 0 38 kgf m 2 8 lb ft Headlight cowling mounting bolt M6 2 7 N m 0 7 kgf m 5 2 lb ft Headlight cowling bracket bolt M6 3 7 N m 0 7 kgf m 5 2 lb ft Bring both side of bracket into contact with frame before tightening the bolts A B C sequence shall be followed for tightening bolts Leg shield assembly screw M5 2 1 8 N m 0 18 kgf m 1 3 lb ft Rear leg shield screw M5 8 1 8 N m 0 1...

Page 33: ...10 1 12 N m 1 2 kgf m 8 9 lb ft Sidestand switch bolt M6 1 7 N m 0 7 kgf m 5 2 lb ft Rear brake cable holder bolt at crankcase M6 2 7 N m 0 7 kgf m 5 2 lb ft Rear brake camshaft lever bolt M6 1 7 N m 0 7 kgf m 5 2 lb ft Rear wheel nut M16 1 150 N m 15 0 kgf m 111 lb ft Brake lever bolt drum M6 2 1 5 N m 0 15 kgf m 1 1 lb ft Brake lever nut M6 2 6 N m 0 6 kgf m 4 4 lb ft Pivot pin and crank case nu...

Page 34: ...tighten the upper steering ring nut 55 N m 5 5 kgf m 41 lb ft with the steering nut socket 5 Turn the handlebar to left or right several times and make sure the steering shaft turns smoothly Fuel pump tightening sequence Front brake light switch screw M4 1 1 2 N m 0 12 kgf m 0 88 lb ft UBS brake cable lock nut at master cylinder disc M6 1 7 N m 0 7 kgf m 5 2 lb ft Front brake lever bolt disc M6 1 ...

Page 35: ...TIGHTENING TORQUES 2 16 SPEC B2UF8197E1 book Page 16 Wednesday October 6 2021 4 38 PM ...

Page 36: ...CABLE ROUTING 2 17 SPEC CABLE ROUTING CABLE ROUTING For Drum Chassis Front left view E F B2UF8197E1 book Page 17 Wednesday October 6 2021 4 38 PM ...

Page 37: ...le B Headlight coupler È Rear brake cable shall pass through cable guide of frame É Insert the sidestand switch lead clamp into front leg shield Ê Insert the hom lead clamp into front fender Ë Horn assembly lead shall pass through the cable guide of frame Ì UBS brake cable stopper shall contact with cable holder Í Front brake cable stopper shall contact with cable holder Î Insert the wire harness ...

Page 38: ...dy 2 Check valve 3 Canister purge hose canister assembly to check valve 4 Canister 5 Fuel tank breather hose fuel tank to canister assembly 6 Cable holder 7 Rear brake cable 8 Cable guide 9 Engine bracket È Route the rear brake cable through cable guide B2UF8197E1 book Page 19 Wednesday October 6 2021 4 38 PM ...

Page 39: ...CABLE ROUTING 2 20 SPEC B2UF8197E1 book Page 20 Wednesday October 6 2021 4 38 PM ...

Page 40: ...CABLE ROUTING 2 21 SPEC CABLE ROUTING Top view Front Side G N O J I P H A B C D F K L B E M R S Q B2UF8197E1 book Page 21 Wednesday October 6 2021 4 38 PM ...

Page 41: ... breather hose fuel tank to canister assembly shall be passed above the damper as shown in figure Î Route the fuel hose fuel tank to injector through the rear fender hook Ï Insert the grommet of fuel hose fuel tank to injector into cable guide No lubricant shall apply except water Ð Insert canister purge hose canister to throttle body into the holder Ñ Route the canister purge hose canister to thr...

Page 42: ...CABLE ROUTING 2 23 SPEC CABLE ROUTING Engine Rear left view B2UF8197E1 book Page 23 Wednesday October 6 2021 4 38 PM ...

Page 43: ...direction to touch the rib of air shroud Ì Insert the clamp into air shroud assembly Í Insert the clamp into air shroud assembly after SG Starter generator lead harness bent towards center side of the vehicle Î SG Starter generator lead shall be passed through the under side to the breather pipe Ï Tighten the clamp at the center of white tape of leads and insert the clamp into rear fender Ð Clamp ...

Page 44: ...CABLE ROUTING 2 25 SPEC CABLE ROUTING For Drum Chassis Front view B2UF8197E1 book Page 25 Wednesday October 6 2021 4 38 PM ...

Page 45: ...arness Front turn signal light assem bly shall be attached with leg shield hook É Wire harness shall not be slack in this area Ê Route the seat lock cable through the out side of leg shield and inner fender Ë Route the seat lack cable through the out side of leg shield boss Ì Main switch lead shall be attached with leg shield hook Í Seat lock cable shall be attached with leg shield hook B2UF8197E1...

Page 46: ... Front handlebar cover 3 Windshield 4 Meter assembly 5 Meter cover 6 Rear handlebar cover 7 Front brake cable 8 UBS brake cable 9 Speedometer cable 0 Rear brake cable A Wire harness B Throttle cable C Handlebar assembly B2UF8197E1 book Page 27 Wednesday October 6 2021 4 38 PM ...

Page 47: ...CABLE ROUTING 2 28 SPEC B2UF8197E1 book Page 28 Wednesday October 6 2021 4 38 PM ...

Page 48: ...CABLE ROUTING 2 29 SPEC CABLE ROUTING For drum handlebar B2UF8197E1 book Page 29 Wednesday October 6 2021 4 38 PM ...

Page 49: ...wire harness Front brake light switch from back side of front brake cable and connect with front brake light switch Ó Grip end shall be properly installed till the end of throttle grip Ô Align s mark of brake lever holder with punch l mark on handlebar assembly and mismatch is allowed Õ Assemble the front brake cable until it con tacts the lever holder assembly Ö Throttle cable plate shall be asse...

Page 50: ...CABLE ROUTING 2 31 SPEC CABLE ROUTING For disc Chassis Front left view 2 9 6 5 4 8 2 A A 1 B 4 5 6 C D 7 8 G 9 5 6 E 9 6 5 4 F 4 9 6 5 B2UF8197E1 book Page 31 Wednesday October 6 2021 4 38 PM ...

Page 51: ...e É Insert the horn lead clamp into front fender Ê Insert the sidestand switch lead clamp into front leg shield Ë Insert the sidestand switch lead clamp into frame Ì Horn lead shall pass through the cable guide of frame Í Insert the wire harness clamp into frame Î Insert the throttle cable and rear brake cable clamp into frame Ï Insert the wire harness clamp headlight into headlight cowling Ð Inse...

Page 52: ...ness Horn 5 Front brake hose 6 Wire harness Main switch 7 Footrest board 8 Wire harness Battery È Route the seat lock cable through frame as sembly hole É Insert the wire harness clamp into frame hole Ê Seat lock cable shall be attached with the footrest board hook B2UF8197E1 book Page 33 Wednesday October 6 2021 4 38 PM ...

Page 53: ...CABLE ROUTING 2 34 SPEC B2UF8197E1 book Page 34 Wednesday October 6 2021 4 38 PM ...

Page 54: ...CABLE ROUTING 2 35 SPEC CABLE ROUTING For Disc Chassis Front view B2UF8197E1 book Page 35 Wednesday October 6 2021 4 38 PM ...

Page 55: ...arness Front turn signal light assem bly shall be attached with leg shield hook É Wire harness shall not be slack in this area Ê Route the seat lock cable through the out side of leg shield and inner fender Ë Route the seat lock cable through the out side of leg shield boss Ì Main switch lead shall be attached with leg shield hook Í Seat lock cable shall be attached with leg shield hook B2UF8197E1...

Page 56: ...ry light assembly 2 Front handlebar cover 3 Windshield 4 Meter assembly 5 Meter cover 6 Rear handlebar cover 7 Speedometer cable 8 Rear brake cable 9 Throttle cable 0 Wire harness A Handlebar assembly B2UF8197E1 book Page 37 Wednesday October 6 2021 4 38 PM ...

Page 57: ...CABLE ROUTING 2 38 SPEC B2UF8197E1 book Page 38 Wednesday October 6 2021 4 38 PM ...

Page 58: ...CABLE ROUTING 2 39 SPEC CABLE ROUTING For disc handlebar Q N M P O L S R T Q B2UF8197E1 book Page 39 Wednesday October 6 2021 4 38 PM ...

Page 59: ... guide of handlebar assembly Ñ Connect turn signal light left right with wire harness Ò Route the wire harness Front brake light switch from back side of handlebar assem bly and connect with front brake light switch Ó Grip end shall be properly installed till the end of throttle grip Ô Align s mark of front lever holder with punch l mark on handlebar assembly Õ Master cylinder cover shall be hooke...

Page 60: ...CABLE ROUTING 2 41 SPEC B2UF8197E1 book Page 41 Wednesday October 6 2021 4 38 PM ...

Page 61: ...DIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM 3 4 GENERAL MAINTENANCE AND LUBRICATION CHART 3 4 ENGINE 3 7 ADJUSTING THE VALVE CLEARANCE 3 7 CHECKING THE FUEL FILTER 3 8 CHECKING THE CANISTER 3 9 CHASSIS 3 10 CHECKING AND ADJUSTING THE STEERING HEAD 3 10 LUBRICATING THE STEERING HEAD 3 10 ELECTRICAL 3 11 REPLACING THE HEADLIGHT BULB 3 11 ADJUSTING THE HEADLIGHT BEAM 3 11 REPLACING LICENSE ...

Page 62: ...HECK OR MAINTENANCE JOB ODOMETER READING 1000 km 600 mi 4000 km 2400 mi 7000 km 4200 mi 10000km 6000 mi 13000km 7800 mi 16000km 9600 mi 1 Fuel line Check fuel hoses for cracks or damage Replace if necessary 2 Fuel filter Check condition Replace if necessary Every 13000 km 7800 mi 3 Spark plug Check condition Clean and regap Replace 4 Valves Check valve clearance Adjust if necessary Every 6000 km 3...

Page 63: ...Check cable free play Adjust if necessary Lubricate equalizer pivot with lithi um soap based grease 17 Sidestand center stand Check operation Lubricate with lithium soap based grease 18 Sidestand switch Check operation and replace if necessary 19 Front fork Check operation and for oil leak age Repair if necessary Replace oil Every 10000 km 6000 mi 20 Shock absorber as sembly Check operation and sh...

Page 64: ...nt needs to be replaced more frequently when riding in unusually wet or dusty areas 27 Throttle grip Check operation Check throttle grip free play and adjust if necessary Lubricate cable end and grip housing 28 Lights signals and switches Check operation Adjust headlight beam NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING 1000 km 600 mi 4000 km 2400 mi 7000 km 4200 mi 10000km 6000 mi 13000km 78...

Page 65: ...HECK OR MAINTENANCE JOB ODOMETER READING 1000 km 600 mi 4000 km 2400 mi 7000 km 4200 mi 10000km 6000 mi 13000km 7800 mi 16000km 9600 mi 1 Fuel line Check fuel hoses for cracks or damage Replace if necessary 2 Fuel filter Check condition Replace if necessary Every 13000 km 7800 mi 3 Spark plug Check condition Clean and regap Replace 4 Valves Check valve clearance Adjust if necessary Every 6000 km 3...

Page 66: ...licone grease 17 Rear brake lever pivot shaft Lubricate with lithium soap based grease 18 UBS cable and link age Check cable free play Adjust if necessary Lubricate equalizer pivot with lithi um soap based grease 19 Sidestand center stand Check operation Lubricate with lithium soap based grease 20 Sidestand switch Check operation and replace if necessary 21 Front fork Check operation and for oil l...

Page 67: ...el and fill the reservoir as required Every two years replace the internal components of the brake master cylinder and caliper and change the brake fluid Replace the brake hose every four years and if cracked or damaged 27 Front and rear brake switches Check operation 28 Moving parts and cable ends Lubricate 29 Throttle grip Check operation Check throttle grip free play and adjust if necessary Lub...

Page 68: ...easure Valve clearance Out of specification Adjust a Remove the SMG Starter generator cov er 1 TIP After removing the SMG cover screws turn the SMG cover in clockwise direction and remove carefully b Turn the crankshaft clockwise c When the piston is at the Top Dead Center TDC on the compression stroke align the mark a on the camshaft sprocket with the mark b on the cylinder head d Align the mark ...

Page 69: ... 6 EAS31178 CHECKING THE FUEL FILTER 1 Remove Seat storage compartment Center cover Fuel tank cover Grab bar Rear side covers assembly along with tail light Refer to GENERAL CHASSIS on page 4 6 Fuel pump Fuel filter Refer to FUEL TANK on base manual page no 6 1 2 Check Fuel filter 1 Damage contaminants Replace TIP Replace the fuel filter every 13000 km 7800 mi of operation 3 Install Fuel filter Fu...

Page 70: ...Check Canister 1 Fuel tank breather hose fuel tank to canister 2 Canister purge hose canister to check valve 3 Canister purge hose 4 check valve to throt tle body Cracks damage Replace Check valve 5 5 Connect Tail light coupler 6 Install Rear side cover assembly along with taillight Refer to GENERAL CHASSIS on page 4 6 Grab bar Fuel tank cover Center cover Seat storage compartment 5 B2UF8197E1 boo...

Page 71: ...ing nut c Grasp the bottom of the front fork legs and gently rock the front fork If any binding is felt remove the lower bracket and check the upper and lower bearings Refer to STEERING HEAD on base manual page no 4 66 d Hold the lower ring nut with a steering C spanner and tighten the upper steering nut with a steering nut socket 5 Install Headlight cowling assembly Front side covers Front upper ...

Page 72: ... NOTICE Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of glass the life of the bulb and the luminous flux will be adversely af fected If the headlight bulb gets soiled thor oughly clean it with a cloth moistened with alcohol or lacquer thinner 6 Install Clip lock Dust cover 7 Connect Headlight bulb coupler 8 Install Headlight cowling assem...

Page 73: ... out TIP After removing the bulb socket carefully replace the bulb 4 1 Install License plate bulb socket License plate light TIP Tighten the front license plate light to the speci fied torque Direction a Headlight beam is raised Direction b Headlight beam is lowered T R License plate light screw 1 8N m 0 18 kgf m 1 3 lb ft B2UF8197E1 book Page 12 Wednesday October 6 2021 4 38 PM ...

Page 74: ...ELECTRICAL 3 13 CHK ADJ B2UF8197E1 book Page 13 Wednesday October 6 2021 4 38 PM ...

Page 75: ...DE COVER ASSEMBLY AND HEADLIGHT COWLING 4 9 INSTALLING THE FRONT SIDE COVER ASSEMBLY AND HEADLIGHT COWLING 4 10 REMOVING THE FOOTBOARD AND LEGSHIELD ASSEMBLY 4 13 HANDLEBAR 4 15 REMOVING THE FRONT HANDLEBAR COVER ASSEMBLY 4 19 REMOVING THE HANDLEBAR 4 19 CHECKING THE HANDLEBAR 4 20 INSTALLING THE HANDLEBAR 4 20 INSTALLING THE FRONT HANDLEBAR COVER ASSEMBLY 4 22 REAR SHOCK ABSORBER ASSEMBLY 4 23 RE...

Page 76: ... cover Order Job Parts to remove Q ty Remarks 1 Battery box cover 1 2 Battery cover 1 3 Negative battery lead 1 Disconnect 4 Positive battery lead 1 Disconnect 5 Battery 1 For installation reverse the removal proce dure B2UF8197E1 book Page 1 Wednesday October 6 2021 4 38 PM ...

Page 77: ...Remove the battery cover and let the cover hang with rub ber string Only remove the rubber string and cover if required EAS31678 INSTALLING THE BATTERY COVER 1 Install Battery cover 1 by installing the bolt 2 TIP Ensure battery cover is set properly on its origi nal position before tighten the battery cover bolt Battery box cover 3 Battery box cover screws 4 T R Battery cover bolt 4 N m 0 4 kgf m ...

Page 78: ... Job Parts to remove Q ty Remarks 1 Seat storage compartment 1 2 Center cover 1 3 Fuel tank cover 1 TIP Open seat Remove the fuel tank cap before removing the fuel tank cover 4 Grab bar 1 For installation reverse the removal proce dure B2UF8197E1 book Page 3 Wednesday October 6 2021 4 38 PM ...

Page 79: ...artment Refer REMOVING THE SEAT STORAGE COMPARTMENT on page 4 4 Center cover 1 TIP Remove the center cover 1 by removing bolt 2 and screw 3 from both side then remove the latches from the slots by pulling it in forward di rection INSTALLING CENTER COVER 1 Install Center cover 1 TIP Install the center cover 1 by fix the latches 2 into the slots 3 as shown by pressing it in backward direction Tighte...

Page 80: ...el wastage INSTALLING THE FUEL TANK COVER 1 Install Fuel tank cover TIP Tighten the fuel tank cover screws as per the se quence shown in given illustrations REMOVING THE GRAB BAR 1 Remove Fuel tank cover Refer REMOVING THE FUEL TANK COV ER on page 4 5 Grab bar 1 by removing bolts 2 INSTALLING THE GRAB BAR 1 Install Grab bar Grab bar bolts Fuel tank cover Refer INSTALLING THE FUEL TANK COV ER on pa...

Page 81: ...ght coupler 1 Disconnect 2 Rear side cover assembly 1 3 Rear shock absorber assembly with cover 1 Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 23 4 Rear fender 1 Disconnect wire harness fuel hose and spark plug lead from rear fender 5 Rear fender cover 1 6 Rear turn signal light left right 2 7 License plate light 1 For installation reverse the removal proce dure 5 6 7 chapter4 fm Page 6 Wednes...

Page 82: ...assembly disconnect the tail brake light coupler first Remove the rear side cover assembly 1 by gently pulling to rearward INSTALLING THE REAR SIDE COVER ASSEMBLY 1 Install Rear cover assembly 1 by gently install to forward direction Ensure all latches set properly on its original position TIP After installing first connect the tail brake light coupler Install bolts and screws both side and tighte...

Page 83: ...1 3 Front side cover left 1 4 Headlight cowling assembly 1 Before removing headlight cowling discon nect both wire harness holding clamps as shown 5 Headlight coupler 1 Disconnect 6 Headlight unit 1 7 Side plate left right 1 1 8 Metal plate left right 1 1 For installation reverse the removal proce dure 5 6 7 8 7 8 6 For Disc For Drum 4 B2UF8197E1 book Page 8 Wednesday October 6 2021 4 38 PM ...

Page 84: ...y remov ing bolt 1 Front side cover assembly left by removing bolt 2 TIP Carefully remove side cover 1 from lugs 2 and latches 3 from its projection Headlight cowling assembly 1 by removing screws 2 from both sides Headlight cowling bracket bolts 3 TIP Before removing headlight cowling disconnect both wire harness holding clamps as shown Gently remove headlight cowling assembly with bracket in out...

Page 85: ...ection Tighten the headlight cowling bolts and screws to the specified torque 3 Install Front side covers both side TIP Carefully fix the side cover lugs and latches on its original projection Tighten the front side covers bolts to the spec ified torque 4 Install Front upper cover T R Side cover assembly screw 1 8 N m 0 18 kgf m 1 3 lb ft 1 T R Headlight cowling bracket bolt 7 N m 0 7 kgf m 5 2 lb...

Page 86: ...ling assembly Refer to GENERAL CHASSIS on page 4 8 1 Lower side moles left right 1 1 2 Footboard lower and inner cover assembly 1 TIP For removing the footboard lower and inner cover assembly removal of front cover as sembly not required 3 Inner cover 1 4 Footboard Lower 1 5 Main switch cap 1 6 Retractable hook 1 7 Turn signal relay 1 Release from its hook 8 Side stand switch lead clamp 1 Disconne...

Page 87: ...Removing the footboard and leg shield assembly Order Job Parts to remove Q ty Remarks 10 Leg shield 1 11 Foot board upper 1 For installation reverse the removal proce dure B2UF8197E1 book Page 12 Wednesday October 6 2021 4 38 PM ...

Page 88: ...moving screw 2 and bolt 3 TIP Gently slide back and remove the lower side mole 1 from its projection Footboard lower bolt 1 from both side Front inner fender screws 2 TIP Remove the footboard lower and front inner fender assembly side from its projection from leftside open the sidestand for smoothly remove the assembly Main switch cap 1 by removing the screw 2 Retractable hook 1 by removing the bo...

Page 89: ...ove Leg shield Wire harness fuse box and YDT coupler 1 Footboard assembly by removing the bolts 1 from footboard upper TIP For installation reverse the removal procedure 1 1 1 B2UF8197E1 book Page 14 Wednesday October 6 2021 4 38 PM ...

Page 90: ...connect 5 Auxiliary light with front covers windshield 1 1 1 6 Speedometer cable assy 1 Disconnect 7 Clamp Wire harness 1 Disconnect 8 Meter couplers 2 Disconnect 9 Start switch coupler 1 Disconnect 10 Stop and start switch coupler 1 Disconnect 11 Horn switch coupler 1 Disconnect 12 Turn signal switch coupler 1 Disconnect 13 Dimmer switch coupler 1 Disconnect 14 Meter assembly 1 15 Handlebar rear ...

Page 91: ...t 21 Front brake cable For drum 1 Disconnect 22 Front brake lever 1 23 Lever holder right For drum 1 24 Front brake master cylinder For disc 1 Refer to REMOVING THE FRONT BRAKE MASTER CYLINDER on base manual page no 4 40 25 Rubber cover 1 Disconnect 26 Rear brake light switch 1 Disconnect 27 Rear brake cable 1 28 UBS brake cable 1 29 Rear brake lever assembly 1 B2UF8197E1 book Page 16 Wednesday Oc...

Page 92: ...lebar Order Job Parts to remove Q ty Remarks 30 Lever holder left 1 Disconnect 31 End grip left 1 32 Handle grip left 1 33 Handlebar 1 For installation reverse the removal proce dure B2UF8197E1 book Page 17 Wednesday October 6 2021 4 38 PM ...

Page 93: ...ush gaurd for B2U8 Order Job Parts to remove Q ty Remarks 1 Rear view mirror assy 1 Disconnect 2 End grip 1 3 Brush guard assembly 1 For installation reverse the removal proce dure B2UF8197E1 book Page 18 Wednesday October 6 2021 4 38 PM ...

Page 94: ...IP Separate the auxiliary light 1 from light cover and windshield 2 by removing screws 3 from its projection as shown REMOVING THE HANDLEBAR 1 Stand the vehicle on a level surface EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over 2 Remove Front upper cover Handlebar cover front and rear Refer to HANDLEBAR on page 4 15 3 Remove Throttle cable housing 1 Thro...

Page 95: ... remove the wire har ness throttle cable rear brake cable from the guide 9 Remove Handlebar nut 1 Handlebar bolt 2 Handlebar 3 CHECKING THE HANDLEBAR 1 Check Handlebar 1 Bends cracks damage Replace WARNING Do not attempt to straighten a bent handle bar as this may dangerously weaken it INSTALLING THE HANDLEBAR For installation reverse the removal procedure 1 Place the vehicle on a centerstand WARN...

Page 96: ... of the handlebar c Wipe off any excess rubber adhesive with a clean rag Grip end WARNING Do not touch the handlebar grip until the rub ber adhesive has fully dried 8 Install Throttle cable 1 Throttle grip 2 Grip end 3 9 Install Throttle cable housing 1 TIP Lubricate the inside of the throttle grip with a thin coat of lithium soap based grease and in stall it onto the handlebar Align the projectio...

Page 97: ...ly TIP Assemble the auxiliary light 1 with light cover and windshield 2 and tighten the screws to the specified torque Auxiliary light assembly 1 and tighten the screws 2 and 3 to the specified torque 2 Connect Turn signal light connectors Head light coupler 3 Install Handlebar front cover assembly Rear view mirror assembly left right Brake lever free play lever end 10 15 mm 0 39 0 79 in drum 10 2...

Page 98: ...center cover rear side cover assembly fuel tank cover assembly Refer to GENERAL CHASSIS on page 4 1 1 Rear shock absorber lower mounting bolt 1 2 Rear shock absorber upper mounting bolt 1 3 Rear shock absorber upper mounting nut 1 4 Rear shock absorber assembly 1 5 Rubber cover 1 For installation reverse the removal proce dure B2UF8197E1 book Page 23 Wednesday October 6 2021 4 38 PM ...

Page 99: ...er bolt and nut 1 Lower rear shock absorber bolt 2 TIP Install the upper rear shock absorber bolt and nut 3 for rear side bracket hole 2 Set the centerstand to lift the rear wheel 3 Tighten Rear shock absorber lower bolt 4 Remove the rear shock absorber upper bolt and move it to front side bracket hole 5 Tighten Rear shock absorber upper bolt and nut 6 Install Rear side cover assembly Refer to GEN...

Page 100: ...at lock cable into frame Please ensure to tie seat lock cable with rope and pull the rope for proper installing the seat lock cable 2 Install Seat lock cable one end at main switch by in stalling screw and then tighten the screw to the specified torque Seat lock cable other end into the seat lock assembly Seat lock cable into the bracket Grommet at original position Main switch cap Refer REMOVING ...

Page 101: ...STEM 5 23 CIRCUIT DIAGRAM For disc 5 23 CIRCUIT DIAGRAM For drum 5 25 TROUBLESHOOTING 5 27 LIGHTING SYSTEM 5 29 CIRCUIT DIAGRAM For disc 5 29 CIRCUIT DIAGRAM For drum 5 31 TROUBLESHOOTING 5 33 SIGNALING SYSTEM 5 35 CIRCUIT DIAGRAM For disc 5 35 CIRCUIT DIAGRAM For drum 5 37 TROUBLESHOOTING 5 39 FUEL INJECTION SYSTEM 5 43 CIRCUIT DIAGRAM For disc 5 43 CIRCUIT DIAGRAM For drum 5 45 ECU SELF DIAGNOST...

Page 102: ...B2UF8197E1 book Page 1 Wednesday October 6 2021 4 38 PM ...

Page 103: ...BACKUP SUB 15A 7 5A 05 04 W R W L W R W L R B R B R R B R B Br Br Or Br Br Br Br W R L Y L Y Y B R B R B R B Br R W B L Y B L B B Br B R B R Br R B Br R Y B B 36 63 64 65 ON ACC OFF 01 02 03 10 19 20 21 22 30 31 35 03 62 B B W R B R B B B B B B B B B B B W B B B Y B Y B Y B Or Br Or Or W R L W Y B Br 18 B W L W L W L B2UF8197E1 book Page 1 Wednesday October 6 2021 4 38 PM ...

Page 104: ...18 SGCU Starter generator control unit 19 Joint connection 2 20 Ignition coil 21 Spark plug 22 Crankshaft position sensor 30 Starter generator 31 Sidestand switch 35 Joint connection 4 36 Stop and start system switch 62 Junction Ground 63 Engine ground 1 64 Engine ground 2 65 Engine ground 3 B2UF8197E1 book Page 2 Wednesday October 6 2021 4 38 PM ...

Page 105: ... W Y R B R B Br Br Br Br R B Br L Br Br B R B R R B SPARE SPARE B 7 5A 2A 7 5A 2A 7 5A 15A 15A 7 5A B B B B 01 02 03 R B B Br B R B Br R B Br R ON ACC OFF 10 Br Br 33 B B B B B L Y Y B B Y B Y B 17 B B L Y B L Y B B 37 P Y B L G L 21 22 23 Or Br Or W L W L W L 65 68 69 67 20 R B R B R B Br Br Br Br R B R R B Br Br B2UF8197E1 book Page 3 Wednesday October 6 2021 4 38 PM ...

Page 106: ...17 Joint connection 4 20 SGCU Starter generator control unit 21 Joint connection 2 22 Ignition coil 23 Spark plug 24 Crankshaft position sensor 32 Starter generator 33 Sidestand switch 37 Stop and start system switch 65 Junction Ground 67 Engine ground 2 68 Engine ground 1 69 Engine ground 3 B2UF8197E1 book Page 4 Wednesday October 6 2021 4 38 PM ...

Page 107: ...terminals Recharge or replace the battery 3 Check the spark plug Refer to CHECKING THE SPARK PLUG on base manual page no 3 10 Re gap or replace the spark plug 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on base manu al page no 7 100 Ignition system is OK 5 Check the spark plug cap Refer to CHECKING THE SPARK PLUG CAP on base manual page no 7 100 Replace the spark plug ...

Page 108: ...Replace the sidestand switch 9 Check the entire ignition system wiring Refer to CIRCUIT DIAGRAM For disc on page 5 1 Properly connect or replace the wire har ness Replace the starter generator assem bly or the SGCU Refer to REPLAC ING THE SGCU Starter generator control unit on base manual page no 7 95 B2UF8197E1 book Page 6 Wednesday October 6 2021 4 38 PM ...

Page 109: ... R L Y L Y L W L W L W Y B P Y R B R B L R L R G Y R B R W L R Br R W B G Y L W B L Y B L B B Br G Y B 43 Br B R B R Br R B Br R B R R W L R 187 187 14 15 Y B B 36 63 64 65 66 ON ACC OFF 01 02 03 10 11 18 22 30 31 32 37 35 47 48 49 03 62 B R B Br L B W R W R B R R R B B R L R B B B B B B B B B B B B B B B B B W B B B Y B G Y P Y G Y G Y Y B Y B L W G Y Br Br L Br L W R L W Y G Y B Br L W G B Y R D...

Page 110: ...3 18 SGCU Starter generator control unit 22 Crankshaft position sensor 30 Starter generator 31 Sidestand switch 32 Joint connection 1 35 Joint connection 4 36 Stop and start system switch 37 Start switch 43 Rear brake light switch 47 Meter assembly 48 Multi function display 49 Meter light 62 Junction Ground 63 Engine ground 1 64 Engine ground 2 65 Engine ground 3 66 Body ground B2UF8197E1 book Pag...

Page 111: ... 70 B B B B 01 02 03 R B B R Br B R B Br R B Br R ON ACC OFF 10 L R L R 11 R W R B L R B R R W L R 14 65 Br G Y 16 G Y L W B 38 L W 33 B B B B B G Y L W L W L Y Br L Br L P Y Br L B G Y Y B B Y B Y B G Y G Y G Y 17 B B L Y B L Br G Y B B Y B Y B B 1 7 W 1 7 W ILLUMI 1 7 W ASS Y Br L W B B Dg Ch P Y G L Y R W G B L Y L 36 37 15 47 48 53 ILLUMI 54 Y Br Ch W B B Dg B B B B B B B P Y B L G L 68 69 67 ...

Page 112: ...light switch 17 Joint connection 4 20 SGCU Starter generator control unit 24 Crankshaft position sensor 32 Starter generator 33 Sidestand switch 36 Joint connection 1 37 Stop and start system switch 38 Start switch 47 Meter assembly 48 Acceleration assist indicator light 53 Meter light 1 54 Meter light 2 65 Junction Ground 67 Engine ground 2 68 Engine ground 1 69 Engine ground 3 70 Body ground B2U...

Page 113: ...t switch is closed and the sides tand is up the sidestand switch is closed The rear brake lever is pulled to the handlebar the rear brake light switch is closed and the sidestand is up the sidestand switch is closed 1 Battery 2 Main relay 3 Main fuse 4 Main switch 5 Backup fuse 6 Rear brake light switch 7 Front brake light switch 8 Start switch 9 Sidestand switch 10 SGCU starter generator control ...

Page 114: ...harge or replace the battery 3 Check the starter generator Refer to CHECKING THE START ER GENERATOR on base manual page no 7 102 Replace the starter generator assembly 4 Check the main relay Refer to CHECKING THE RE LAYS on base manual page no 7 99 Replace the main relay 5 Check the main switch Refer to CHECKING THE SWITCHES on base manual page no 7 92 Replace the main switch 6 Check the sidestand...

Page 115: ...place the brake light switch es 9 Check the entire starting system wiring Refer to CIRCUIT DIAGRAM For disc on page 5 7 Properly connect or replace the wire har ness Replace the starter generator assem bly or SGCU Refer to REPLACING THE SGCU Starter generator control unit on base manual page no 7 95 B2UF8197E1 book Page 13 Wednesday October 6 2021 4 38 PM ...

Page 116: ...ELECTRIC STARTING SYSTEM 5 14 ELEC B2UF8197E1 book Page 14 Wednesday October 6 2021 4 38 PM ...

Page 117: ... Y B Y R P Y R B R B L R L R R B R B R B R W L R Br R W B L Y B L B B Br B R B R Br R B Br R B R R W L R Y B L L P W Br W B 15 Y B B 36 63 64 65 66 B Y G R ON ACC OFF 01 02 03 10 11 17 18 22 23 28 30 31 35 47 48 49 03 62 B R B W B Y Br L Br W Lg W Lg L B W R W R B R R R B B R B L R L B B B B B B B B B B B B B B B B B W W B B B Y B P Y Y R Y B Y B W R W L G R B Y 25 26 27 P W B L Y Br W L L W Y Lg ...

Page 118: ...sition sensor 23 Engine temperature sensor 25 MAQS Modularized air quantity sensor assembly 26 Intake air pressure sensor 27 Intake air temperature sensor 28 Throttle position sensor 30 Starter generator 31 Sidestand switch 35 Joint connection 4 36 Stop and start system switch 47 Meter assembly 48 Multi function display 49 Meter light 62 Junction Ground 63 Engine ground 1 64 Engine ground 2 65 Eng...

Page 119: ...Br Br Br Br R B Br L Br Br B R B R R B SPARE SPARE B 7 5A 2A 7 5A 2A 7 5A 15A 15A 7 5A 70 B B B B B 01 02 03 R B B R Br B R B Br R B Br R ON ACC OFF 10 L R L R 11 R W R B L R B R R W L R 14 65 33 B R B B B B B L Y Br L Br L B L W Y R P Y Br L B Y B B Y B Y B 17 B B L Y B L Y B B REED_SW 1 7 W 1 7 W ILLUMI 1 7 W 1 7 W ASS IDLE_STOP Y Br L W B B Dg Ch P Y G L Y R W G B L Y L 37 47 48 51 53 ILLUMI 54...

Page 120: ...ngine temperature sensor 27 MAQS Modularized air quantity sensor 28 Intake air pressure sensor 29 Intake air temperature sensor 30 Throttle position sensor 32 Starter generator 33 Sidestand switch 37 Stop and start system switch 47 Meter assembly 48 Acceleration assist indicator light 51 Stop and start system indicator light 53 Meter light 1 54 Meter light 2 57 Reed switch 65 Junction Ground 67 En...

Page 121: ...raveled at a speed of more than 10 km h after the engine was started TIP The engine stop function may not operate when the vehicle is traveling at a speed of 10 km h or less such as when traveling in heavy traffic This however does not indicate a malfunction Engine start function When all of the following conditions are met this function restarts the engine Sidestand UP Throttle valve opened 1 Bat...

Page 122: ...heck the battery Refer to CHECKING AND CHARGING THE BATTERY on base manual page no 7 96 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on base manual page no 7 92 Replace the main switch 4 Check the Stop and Start System switch Refer to CHECKING THE SWITCHES on base manual page no 7 92 The Stop and Start System switch is faulty Re...

Page 123: ...ck the meter assembly reed switch Replace the front wheel speed sensor 4 Check the entire wiring Properly connect or replace the wiring harness Replace the SGCU Refer to RE PLACING THE SGCU Starter genera tor control unit on base manual page no 7 95 1 Check the sidestand switch Refer to CHECKING THE SWITCHES on base manual page no 7 92 Replace the sidestand switch 2 Check the starter generator Ref...

Page 124: ...assembly 5 Check the entire Stop and Start System wiring Refer to CIRCUIT DIAGRAM For disc on page 5 15 Properly connect or replace the wiring harness Replace the starter generator assem bly or the SGCU Refer to REPLAC ING THE SGCU Starter generator control unit on base manual page no 7 95 1 Check the entire wiring Refer to TIP Properly connect or replace the wiring harness Replace the SGCU or met...

Page 125: ...5A 7 5A 07 06 7 5A MAIN BACKUP SUB 15A 7 5A 05 04 W R W L W R W L R B R B R R B R B Br Br Br Br Br Br W R R B R B L R L R R B R W L R Br R W B Br B R B R Br R B Br R B R R W L R 15 63 64 66 ON ACC OFF 01 02 03 10 11 22 30 03 B W R W R B R R B B R B L R B B B B B B B W B B B W R W L L W Y 18 W L B2UF8197E1 book Page 23 Wednesday October 6 2021 4 38 PM ...

Page 126: ... box 5 Main fuse 6 Backup fuse 7 Sub fuse 10 Main switch 11 Main relay 15 Joint connection 3 18 SGCU Starter generator control unit 22 Crankshaft position sensor 30 Starter generator 63 Engine ground 1 64 Engine ground 2 66 Body ground B2UF8197E1 book Page 24 Wednesday October 6 2021 4 38 PM ...

Page 127: ... R W L W R W L W L 24 32 W R W L L W Y R B R B Br Br Br Br R B Br L Br Br B R B R R B SPARE SPARE B 7 5A 2A 7 5A 2A 7 5A 15A 15A 7 5A 70 01 02 03 R B B R Br B R B Br R B Br R ON ACC OFF 10 L R L R 11 R W R B L R B R R W L R 14 B B B B P Y B L G L 68 67 R B R B R B Br Br Br Br R B R R B Br B2UF8197E1 book Page 25 Wednesday October 6 2021 4 38 PM ...

Page 128: ... box 5 Main fuse 6 Backup fuse 7 Sub fuse 10 Main switch 11 Main relay 14 Joint connection 3 20 SGCU Starter generator control unit 24 Crankshaft position sensor 32 Starter generator 67 Engine ground 2 68 Engine ground 1 70 Body ground B2UF8197E1 book Page 26 Wednesday October 6 2021 4 38 PM ...

Page 129: ...e the battery 3 Check the starter generator Refer to CHECKING THE START ER GENERATOR on base manual page no 7 102 Replace the starter generator assembly 4 Check the main relay Refer to CHECKING THE RE LAYS on base manual page no 7 99 Replace the main relay 5 Check the main switch Refer to CHECKING THE SWITCHES on base manual page no 7 92 Replace the main switch 6 Check the entire charging system w...

Page 130: ...CHARGING SYSTEM 5 28 ELEC B2UF8197E1 book Page 28 Wednesday October 6 2021 4 38 PM ...

Page 131: ... B Br R W B Br L Br L Y G Y Br L B G Y L B B L B Br L 38 39 46 1 7 W 5 W 5 W B L Pass Br B R B R Br R B Br R 63 64 66 Y W B G G W B Y DIMMER ON ACC OFF 01 02 03 10 18 30 47 48 49 52 03 54 56 53 B R B Y Br Br L B W Br B R B R R B B B B B B B B B Y Y Y G Y G B B B B B B B B B B B B W B B W B B B Br L Br L Br L Br L Br L Br L Br L Br L Br L Br B 2A TERMINAL L W Y B Br L Br L Br L 40 42 55 Br L W G B ...

Page 132: ...rter generator 38 Auxiliary light 39 License plate light 40 Taillight assembly 42 Taillight 46 Dimmer Pass switch 47 Meter assembly 48 Multi function display 49 Meter light 52 High beam indicator light 53 Accessory connector optional 54 Headlight assembly 55 Headlight High beam 56 Headlight Low beam 63 Engine ground 1 64 Engine ground 2 66 Body ground B2UF8197E1 book Page 30 Wednesday October 6 20...

Page 133: ...10 Br B Br 58 B Br 46 DIMMER 5 W B Br L 41 43 B L 40 5 W B 39 1 7 W B 35 W 35 W B W B W B B B B B B W B W B W B W B Br L Br L Br L Br L Br L Br L Br L Br L W B B Y G W B Y Br L B Br L G Y G Y Y G Y Br L G Y Br L B B G Y Br L B B Br L B L 1 7 W HI BEAM 1 7 W 1 7 W ILLUMI Y Br L W B B Dg Ch P Y G L Y R W G B L Y L 47 TERMINAL 53 ILLUMI 54 55 L Y Br Ch W B B Dg B B B B B B P Y B L G L 68 69 67 59 66 ...

Page 134: ...t 32 Starter generator 39 Auxiliary light 40 License plate light 41 Taillight assembly 43 Taillight 46 Dimmer switch 47 Meter assembly 53 Meter light 1 54 Meter light 2 55 High beam indicator light 58 Accessory connector optional 59 Headlight assembly 66 Joint connection 6 67 Engine ground 2 68 Engine ground 1 69 Engine ground 3 70 Body ground B2UF8197E1 book Page 32 Wednesday October 6 2021 4 38 ...

Page 135: ... the bulb s and bulb socket s 2 Check the fuses Main backup fuse Refer to CHECKING THE FUSES on base manual page no 7 95 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on base manual page no 7 96 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on base manual page no 7 92 Replace the main switch 5 ...

Page 136: ...IAGRAM For disc on page 5 29 Properly connect or replace the wire har ness Replace the SGCU meter assembly tail brake light assembly or headlight unit Refer to REPLACING THE SGCU Starter generator control unit on base manual page no 7 95 B2UF8197E1 book Page 34 Wednesday October 6 2021 4 38 PM ...

Page 137: ... Dg R G Y Br L B G Y L B Br G Y B 43 44 45 21 W Br B R B R Br R B Br R B Br B 13 187 187 14 63 64 65 66 ON ACC OFF 01 02 03 10 12 18 30 34 47 48 49 50 51 03 57 58 60 61 G B R B Ch Ch Ch Ch Ch Ch Dg Dg Dg Dg Dg Dg Dg B G Br L B W Br B R B R R B B B B B B B B B B B B P B B B B B B B B B B B B B W B B B G Y P Y Y L Y L Y R G Y G Y P G Y Br B Br Br L Br L L W Y 40 41 G Y Ch Ch B 10 W 10 W 10 W 10 W B ...

Page 138: ... light 43 Rear brake light switch 44 Turn signal light switch 45 Horn switch 47 Meter assembly 48 Multi function display 49 Meter light 50 Turn signal indicator light Left 51 Turn signal indicator light Right 57 Front turn signal light assembly Left 58 Front turn signal light assembly Right 59 Rear turn signal assembly 60 Rear turn signal light assembly Left 61 Rear turn signal light assembly Righ...

Page 139: ...h Dg B 10 W 10 W Ch Dg B 65 12 Br G Y 16 B G Gy 35 G B B B B B P B B B B Br L Br L B Dg B L W Dg Ch G Y R Y L G L P Y Br L B Ch Dg Ch Ch Ch Dg Dg Dg Dg G Y G Y G Y B P B Br B Ch Dg R Br G Y B B Y B REED_SW TURN 1 7 W 1 7 W 1 7 W ILLUMI FUEL 1 7 W 1 7 W 1 7 W 1 7 W ASS ECO IDLE_STOP Y Br L W B B Dg Ch P Y G L Y R W G B L Y L Ch 15 47 48 49 50 51 52 53 ILLUMI 54 56 57 Y Br Ch W B B Dg B B B B B B P ...

Page 140: ...mbly 48 Acceleration assist indicator light 49 ECO indicator light 50 Engine trouble warning light 51 Stop and start system indicator light 52 Fuel meter 53 Meter light 1 54 Meter light 2 56 Turn signal indicator light 57 Reed switch 60 Turn signal indicator light Left 61 Turn signal indicator light Right 62 Rear turn signal indicator light assembly 63 Rear turn signal indicator light Left 64 Rear...

Page 141: ...ses Refer to CHECKING THE FUSES on base manual page no 7 95 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on base manual page no 7 96 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on base manual page no 7 92 Replace the main switch 4 Check the main relay Refer to CHECKING THE RE LAYS on base ma...

Page 142: ...ECKING THE SWITCHES on base manual page no 7 92 Replace the front brake light switch 2 Check the rear brake light switch Refer to CHECKING THE SWITCHES on base manual page no 7 92 Replace the rear brake light switch 3 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM For disc on page 5 35 Properly connect or replace the wire har ness Replace the tail brake light assembly 1 Check th...

Page 143: ...URN SIGNAL RELAY on base manual page no 7 99 Replace the turn signal relay 4 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM For disc on page 5 35 Properly connect or replace the wire har ness Replace the meter assembly B2UF8197E1 book Page 41 Wednesday October 6 2021 4 38 PM ...

Page 144: ...SIGNALING SYSTEM 5 42 ELEC B2UF8197E1 book Page 42 Wednesday October 6 2021 4 38 PM ...

Page 145: ...R B R B Pu B Br Gy R B Or B B W L B Or B Br B Br R W B L Y B L B B L B R B B Br B R B R Br R B Br R G Y P Sb Gy B Y B L L P W Br W B Y B B 36 63 64 65 66 B Y G R ON ACC OFF 01 02 03 10 16 17 18 19 20 21 22 23 24 28 29 30 31 33 35 47 48 49 03 62 P B R B B Y Sb Gy Br L Br W Lg W Lg L Gy R B Or B W Or B R B R R B B Or B L B B B B B B B B B B B B B B B B B W B B B Y B P Y Y L Y L Y R Y B Y B G Y P Sb ...

Page 146: ...n sensor 23 Engine temperature sensor 24 ISC Idle speed control unit 25 MAQS Modularized air quantity sensor assembly 26 Intake air pressure sensor 27 Intake air temperature sensor 28 Throttle position sensor 29 O2 sensor 30 Starter generator 31 Sidestand switch 33 Fuel pump 35 Joint connection 4 36 Stop and start system switch 47 Meter assembly 48 Multi function display 49 Meter light 62 Junction...

Page 147: ...R B R B R B B Lg W Lg L Lg L B Lg W R B R Br Or B Br B 18 Or B Br Br Br Br R B Br L Br Br B R B R R B SPARE SPARE B 7 5A 2A 7 5A 2A 7 5A 15A 15A 7 5A 70 B B B B B 01 02 03 R B B Br B R B Br R B Br R ON ACC OFF 10 65 R B L B R B B 34 33 B R B B B B B L Y L B B L W Y R Y L G L P Y Br L B Y B B Y B Y B 17 B B L Y B L Y B B REED_SW 1 7 W 1 7 W ILLUMI 1 7 W 1 7 W 1 7 W 1 7 W ASS ECO IDLE_STOP Y Br L W ...

Page 148: ...Idle speed control unit 27 MAQS Modularized air quantity sensor 28 Intake air pressure sensor 29 Intake air temperature sensor 30 Throttle position sensor 31 O2 sensor 32 Starter generator 33 Sidestand switch 34 Fuel pump 37 Stop and start system switch 47 Meter assembly 48 Acceleration assist indicator light 49 ECO indicator light 50 Engine trouble warning light 51 Stop and start system indicator...

Page 149: ...ng instructions that enable the engine to continue operating or stop operating depending on the conditions EAS30506 TROUBLESHOOTING METHOD The engine operation is not normal and the engine trouble warning light comes on 1 Check Fault code number a Check the fault code number displayed on the computer b Identify the faulty system with the fault code number c Identify the probable cause of the malfu...

Page 150: ...FUEL INJECTION SYSTEM 5 48 ELEC B2UF8197E1 book Page 48 Wednesday October 6 2021 4 38 PM ...

Page 151: ...RE SPARE B 7 5A 2A 7 5A 2A 7 5A 15A 15A 7 5A 07 06 7 5A MAIN BACKUP SUB 15A 7 5A 05 04 R B R B R R B R B R B Br Br Br Br Br Br L B R B L B R B R B R B Br R W B L B R B B Br B R B R Br R B Br R 63 64 ON ACC OFF 01 02 03 10 18 33 03 B W R B R B B B B B B W B B B B2UF8197E1 book Page 49 Wednesday October 6 2021 4 38 PM ...

Page 152: ... positive lead 3 Battery negative lead 4 Fuse box 5 Main fuse 6 Backup fuse 7 Sub fuse 10 Main switch 18 SGCU Starter generator control unit 33 Fuel pump 63 Engine ground 1 64 Engine ground 2 B2UF8197E1 book Page 50 Wednesday October 6 2021 4 38 PM ...

Page 153: ... B Br R W B B W B B B R B R B Br Br Br Br R B Br L Br Br B R B R R B SPARE SPARE B 7 5A 2A 7 5A 2A 7 5A 15A 15A 7 5A 01 02 03 R B B Br B R B Br R B Br R ON ACC OFF 10 R B L B R B B 34 B B L B P Y B L G L 68 67 20 R B R B R B R B Br Br Br Br R B R R B Br B2UF8197E1 book Page 51 Wednesday October 6 2021 4 38 PM ...

Page 154: ... positive lead 3 Battery negative lead 4 Fuse box 5 Main fuse 6 Backup fuse 7 Sub fuse 10 Main switch 20 SGCU Starter generator control unit 34 Fuel pump 67 Engine ground 2 68 Engine ground 1 B2UF8197E1 book Page 52 Wednesday October 6 2021 4 38 PM ...

Page 155: ... CHARGING THE BATTERY on base manual page no 7 96 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on base manual page no 7 92 Replace the main switch 4 Check the fuel pump Refer to CHECKING THE FUEL PRESSURE on base manual page no 6 6 Replace the fuel pump 5 Check the entire fuel pump system wiring Refer to CIRCUIT DIAGRAM For disc...

Page 156: ...ELECTRICAL COMPONENTS 5 54 ELEC EAS20089 ELECTRICAL COMPONENTS 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 B2UF8197E1 book Page 54 Wednesday October 6 2021 4 38 PM ...

Page 157: ...el pump 10 Intake air pressure sensor 11 Intake air temperature sensor 12 Throttle position sensor 13 ISC idle speed control unit 14 Throttle body sensor assembly 15 Fuel injector 16 Starter generator 17 Crankshaft position sensor 18 Engine temperature sensor 19 O2 sensor 20 Spark plug 21 Sidestand switch 22 YDT coupler 23 Fuse box 24 Battery 25 Horn B2UF8197E1 book Page 55 Wednesday October 6 202...

Page 158: ...immer Pass switch 47 Meter assembly 48 Multi function display 49 Meter light 50 Turn signal indicator light Left 51 Turn signal indicator light Right 52 High beam indicator light 53 Accessory connector optional 54 Headlight assembly 55 Headlight High beam 56 Headlight Low beam 57 Front turn signal light assembly Left 58 Front turn signal light assembly Right 59 Rear turn signal assembly 60 Rear tu...

Page 159: ...ator light 49 ECO indicator light 50 Engine trouble warning light 51 Stop and start system indicator light 52 Fuel meter 53 Meter light 1 54 Meter light 2 55 High beam indicator light 56 Turn signal indicator light 57 Reed switch 58 Accessory connector optional 59 Headlight assembly 60 Turn signal indicator light Left 61 Turn signal indicator light Right 62 Rear turn signal indicator light assembl...

Page 160: ...B2UF8197E1 book Page 1 Wednesday October 6 2021 4 38 PM ...

Page 161: ...1Y242 SSM 01 1573 09 21 E B2U F8197 E1 B2UF8197E1 book Page 2 Wednesday October 6 2021 4 38 PM ...

Page 162: ... 64 65 66 B Y G R Y W B G G W B Y DIMMER ON ACC OFF 01 02 03 10 11 16 17 18 19 20 21 22 24 28 29 30 31 32 33 37 34 35 47 48 49 50 51 52 03 54 56 57 58 60 61 62 53 P B G B B R B W Y Ch Ch Ch Ch Ch Ch Dg Dg Dg Dg Dg Dg Dg B G B Y Br Sb Gy Br L Br W Lg W Lg L Gy R B Or B W Or B Br B Br B R W R B R R R B B R B L R Or B L B B B B B B B B B B B B B B B B B Y Y Y G Y G P B B B B B B B B B B B B B B B B B...

Page 163: ...R R W L R 14 Ch B 10 W Ch B 10 W Dg B 35 W 35 W B Ch Dg B 10 W 10 W Ch Dg B W B 12 Br G Y 16 G Y L W B 38 L W R B B G Gy L B R B B 34 35 G 33 B R B W B B B B B G Y L W L W L Y L B B Br Br Br Br R B P B B B B B W B W B W B W B Br L Br L Br L G Y Br L Br L Br L Br L Br L W B B Y G B Dg B L W B W Dg Ch G Y R Y L G L P Y Br L B Ch Dg Ch Ch Ch Dg Dg Dg Dg G Y P Br Br L G Y G Y Y Y B B Y B Y B Br G Y G ...

Search results

Summary of Contents for CYGNUS RAY ZR 2022

Reviews:

Related manuals for CYGNUS RAY ZR 2022

Brands by name

Popular brands

Yamaha CYGNUS RAY ZR 2022, Supplementary Service Manual

Search results

Summary of Contents for CYGNUS RAY ZR 2022

Reviews:

Related manuals for CYGNUS RAY ZR 2022

Brands by name

Popular brands