Yamaha Fascino 2021 Supplementary Service Manual Download Page 91 | Manualshive

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Yamaha Fascino 2021 Supplementary Service Manual Download Page 91

WIRING DIAGRAM

LCX125D/LCX125 2021 (For disc)

1. Battery
2. Battery positive lead
3. Battery negative lead
4. Fuse box
5. Main fuse
6. Backup fuse
7. Sub fuse
8. Sub fuse 2
9. Terminal fuse 1
10. Main switch
11. Main relay
12. Horn
13. Turn signal relay
14. Rear brake light switch
15. Front brake light switch
16. Joint connection 3
17. Injector
18. YDT (Yamaha diagnostic tool)

coupler

19. SGCU (Starter generator con-

trol unit)

20. Joint connection 2
21. Ignition coil
22. Spark plug
23. Crankshaft position sensor
24. Engine temperature sensor
25. ISC (Idle speed control) unit
26. MAQS (Modularized air quanti-

ty sensor)

27. O

2

sensor

28. Starter generator
29. Sidestand switch
30. Joint connection 1
31. Fuel pump
32. Fuel sender
33. Joint connection 4
34. Stop and start system switch
35. Start switch
36. Turn signal light switch
37. Horn switch
38. Dimmer/Pass switch
39. Headlight switch
40. Meter assembly
41. Acceleration assist indicator

light

42. ECO indicator light
43. Engine trouble warning light
44. Stop and start system indicator

light

45. Fuel meter
46. Meter light
47. Turn signal indicator light (Left)
48. Turn signal indicator light

(Right)

49. High beam indicator light
50. Accessory connector (optional)
51. Headlight assembly (Headlight/

DRL/Auxiliary light)

52. Headlight (High beam)
53. Headlight (Low beam)
54. Auxiliary light (DRL)
55. Front turn signal light assembly
56. Front turn signal light assembly

(Left)

57. Front turn signal light assembly

(Right)

58. Taillight assembly (Rear turn

signal lights, License plate
light, Tail/brake light)

59. Rear turn signal light assembly

(Left)

60. License plate light
61. Taillight
62. Brake light
63. Rear turn signal light assembly

(Right)

64. Junction (Ground)
65. Engine ground 1
66. Engine ground 2
67. Engine ground 3
68. Body ground

COLOR CODE

B

Black

Br Brown
Ch

Chocolate

Dg

Dark green

G

Green

Gy Gray
L

Blue

Or

Orange

P

Pink

R

Red

Sb

Sky blue

W

White

Y

Yellow

B/L

Black/Blue

B/Y Black/Yellow
B/W

Black/White

Br/B

Brown/Black

Br/L

Brown/Blue

Br/W

Brown/White

Br/Y

Brown/Yellow

G/L

Green/Blue

G/R

Green/Red

G/Y

Green/Yellow

Gy/R

Gray/Red

L/B

Blue/Black

L/R

Blue/Red

L/W

Blue/White

L/Y

Blue/Yellow

Lg/L

Light green/Blue

Lg/W

Light green/White

Or/B

Orange/Black

P/W

Pink/White

P/Y

Pink/Yellow

R/B

Red/Black

Y/B Yellow/Black
Y/L Yellow/Blue
Y/R

Yellow/Red

W/B

White/Black

W/L

White/Blue

W/R White/Red
W/Y

White/Yellow

B7JF8197E1.book Page 1 Tuesday, June 29, 2021 2:28 PM

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Summary of Contents for Fascino 2021

Page 1: ...2021 SUPPLEMENTARY SERVICE MANUAL LCX125D LCX125 B7J F8197 E1 B7JF8197E1 book Page 1 Tuesday June 29 2021 2 28 PM ...

Page 2: ... service manual together with the following manual FASCINO LCX125 2020 SERVICE MANUAL B7J F8197 E0 Fascino S LCX125D and Fascino LCX125 2021 SUPPLEMENTARY SERVICE MANUAL 2021 by India Yamaha Motor Pvt Ltd First edition June 2021 All rights reserved Any reproduction or unauthorized use without the written permission of India Yamaha Motor Pvt Ltd is expressly prohibited B7JF8197E1 book Page 1 Tuesda...

Page 3: ...TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 CHASSIS 3 ENGINE 4 FUEL SYSTEM 5 ELECTRICAL SYSTEM 6 B7JF8197E1 book Page 1 Tuesday June 29 2021 2 28 PM ...

Page 4: ...B7JF8197E1 book Page 2 Tuesday June 29 2021 2 28 PM ...

Page 5: ...1 GENERAL INFORMATION FEATURES 1 1 INDICATOR LIGHTS AND WARNING LIGHTS 1 1 MULTI FUNCTION METER UNIT 1 1 HANDLEBAR SWITCHES 1 2 SPECIAL TOOLS 1 4 B7JF8197E1 book Page 0 Tuesday June 29 2021 2 28 PM ...

Page 6: ...ed 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 Start Switch is set to this indicator light may not come on EAUE4...

Page 7: ...eter The odometer shows the total distance traveled by the vehicle TIP The odometer will lock at 999999 and cannot be reset EAUE4611 Tripmeter The tripmeter shows the distance traveled since it was last reset To reset a tripmeter change the display to the tripmeter and then push the SELECT button until it is reset TIP The tripmeter will reset and continue counting after 999 9 is reached EAU1234R H...

Page 8: ...position To cancel the turn signal lights push the switch in after it has returned to the center position EAU12501 Horn switch Press this switch to sound the horn EAUM1133 Start switch Push this switch while applying the front or rear brake to crank the engine with the starter EAU76391 Stop and Start System switch To turn on the Stop and Start System set the switch to To turn off the Stop and Star...

Page 9: ...dary sheave Clutch carrier nut socket ø39 mm S 1102 90890 01493 This tool is used to loosen and tighten the clutch carrier 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 loosening and tightening clutch housing nut Cam spro...

Page 10: ... compressor S 1114 90890 04108 This adapter 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 too...

Page 11: ...65A 90890 04152 This tool is necessary for separating the crank case 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 ...

Page 12: ... used to remove the bearings of primary driven gear Cup B YSST 620 B This tool is used to remove the bearings of front wheel LH RH Cup C YSST 620 C This tool is used to remove the bearing of main ax le V belt case cover drive axle LH crankcase Cup D YSST 620 D This tool is used to remove the bearing of cam shaft Bearing puller 6001 6201 YSST 623 This tool is used to remove the bearing of cam shaft...

Page 13: ...et 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 center Bush YSST 893 This tool is used as an attachment with crankshaf...

Page 14: ...rfaces e g crankcase mating surfaces Yamaha diagnostic tool INS 018 90890 03267 This tool is used to diagnose electrical fault in ad vance fuel injection system Yamaha diagnostic tool Ver 3 INS 019 90890 03264 This tool is used to diagnose electrical fault in ad vance fuel injection system Sub harness 3 90890 03266 This tool is used to connect FI YDT coupler to adapter interface BS VI models Fuel ...

Page 15: ...IFICATIONS 2 5 ELECTRICAL SPECIFICATIONS 2 7 TIGHTENING TORQUES 2 9 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 9 ENGINE TIGHTENING TORQUES 2 10 CHASSIS TIGHTENING TORQUES 2 12 LUBRICATION POINTS AND LUBRICANT TYPES 2 15 ENGINE 2 15 CHASSIS 2 16 B7JF8197E1 book Page 0 Tuesday June 29 2021 2 28 PM ...

Page 16: ...7JP Drum Dimensions Overall length 1920 mm 75 6 in Overall width 685 mm 27 0 in Overall height 1150 mm 45 3 in Wheelbase 1280 mm 50 4 in Ground clearance 145 mm 5 71 in Weight Curb weight 99 kg 218 lb Riding capacity 2 person Maximum load 156 kg 344 lb Hook maximum load 1 0 kg 2 lb B7JF8197E1 book Page 1 Tuesday June 29 2021 2 28 PM ...

Page 17: ...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 Oil filter Oil filter type Centrifugal Final transmission oil Recommended brand type YAMALUBE 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 Spark plug s Manufacture...

Page 18: ... 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 Piston to cylinder clearance 0 016 0 030 mm 0 0006 0 0012 in Piston pin...

Page 19: ...ndary 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 0 0 5 Exhaust gas s...

Page 20: ...12 Manufacturer model MAXXIS M6307 Manufacturer model TVS CONTA775F Rear tire Type Tubeless Size 110 90 10 Manufacturer model MAXXIS M6220 Manufacturer model TVS CONTA775R 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 kgf cm 29 psi 2 00 bar 2 persons Front 150 kPa 1 50 kgf cm 22 psi 1 50 bar Rear 200 kPa 2 00 kgf cm 29 psi 2 00 bar Br...

Page 21: ...drum brake Rear brake lever free play 10 0 15 0 mm 0 39 0 59 in for drum 10 0 20 0 mm 0 39 0 79 in for disc Brake drum inside diameter limit 131 0 mm 5 16 in Lining thickness limit 2 0 mm 0 08 in Front suspension Shock absorber Hydraulic damper Fork spring free length limit 248 1 mm 9 77 in Inner tube bending limit 0 2 mm 0 01 in Recommended oil Yamaha Suspension Oil G10 Quantity left 54 0 cm 1 83...

Page 22: ...ator 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 For drum LED For disc Bulb wattage Headlight HS1 35 0 W 35 0 W For drum LED For disc Brake tail light 21 0 W 5 0 W For drum LED For disc Front turn signal light 10 0 W Rear turn signal light 10 0 W Auxiliary light 3 0 W For drum Auxiliary light DRL LED For disc Meter lighti...

Page 23: ...0 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 2513 2777 at 68 F Engine temperature sensor resistance 210 221 at 100 C 210 221 at 212 F Fuse s Main fuse 15 0 A Sub fuse 7 5 A Terminal fuse 1 2 0 A Backup fuse 2 0 A Sub fuse 2 7 5 A B7JF8197E...

Page 24: ...n 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 1...

Page 25: ...3 N m 0 13 kgf m 0 95 lb ft 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 bolt 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...

Page 26: ...3 7 kgf m 27 lb ft CKP Crankshaft 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 ...

Page 27: ...2 lb 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 M6 4 11 N m 1 1 kgf m 8 1 lb ft Fuel tank cover screw M5 2 1 8 N m 0 18 kgf m 1 3 lb ft Side cover screw M5 4 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 1 lb ft Rear side reflector bracke...

Page 28: ...6 6 lb ft Leg shield screw lower M5 5 1 8 N m 0 18 kgf m 1 3 lb ft Battery cover bolt M6 1 4 N m 0 40 kgf m 3 0 lb ft Rear view mirror nut M10 2 23 N m 2 3 kgf m 17 lb ft Brake lever holder bolt front and rear drum M6 2 10 N m 1 0 kgf m 7 4 lb ft Throttle cable housing screw M5 2 1 4 N m 0 14 kgf m 1 0 lb ft Throttle cable plate and throttle cable housing screw M5 1 1 4 N m 0 14 kgf m 1 0 lb ft Th...

Page 29: ... 15 lb ft Seat lock assembly bolt M6 2 7 N m 0 7 kgf m 5 2 lb ft Front brake caliper bolt disc M12 2 35 N m 3 5 kgf m 26 lb ft Front brake disc bolt disc M8 3 23 N m 2 3 kgf m 17 lb ft Front brake master cylinder holder bolt disc M16 2 10 N m 1 0 kgf m 7 4 lb ft Front brake master cylinder cover screw disc M4 2 1 5 N m 0 15 kgf m 1 1 lb ft Front brake caliper bleed screw disc M8 1 5 N m 0 5 kgf m ...

Page 30: ...ft flange press fit part Valve stems intake and exhaust Valve stem end intake and exhaust Valve stem seals intake and exhaust Decompression cam Decompression lever Cam chain sprocket bolt Oil pump shaft outside surface Throttle body joint O ring O ring fuel injector Kickstarter pinion gear shaft Kick torsion spring Drive axle and bearing contact surface Primary shave nut and conical washer Timing ...

Page 31: ...and metal to metal moving parts Rear brake lever sliding surface and equalizer pivot Speedometer cable O ring Front wheel axle and nut thread Front wheel axle nut seat Front wheel oil seal lip Front brake cam shaft portion drum Front brake shoe plate pivot pin drum Rear brake cam shaft and O ring drum Rear brake shoe plate pivot pin drum Front brake lever pivot bolt and knocker inner surface disc ...

Page 32: ...2 17 SPEC CABLE ROUTING Change of wire harness Speedo meter routing Speedometer cable ...

Page 33: ...3 CHASSIS GENERAL CHASSIS 3 1 HANDLEBAR 3 3 FRONT FORK 3 6 B7JF8197E1 book Page 0 Tuesday June 29 2021 2 28 PM ...

Page 34: ...ght coupler 1 Disconnect 2 Rear side cover assembly 1 3 Rear shock absorber assembly 1 Refer to REAR SHOCK ABSORBER in base service manual B7J F8197 E0 on page 4 70 4 Rear fender 1 For installation reverse the removal proce dure 3 2 1 2 2 12 N m 1 2 kgf m 8 9 lb ft 12 N m 1 2 kgf m 8 9 lb ft 3 8 N m 0 38 kgf m 2 8 lb ft 1 8 N m 0 18 kgf m 1 3 lb ft 7 N m 0 7 kgf m 5 2 lb ft 1 8 N m 0 18 kgf m 1 3 ...

Page 35: ...t coupler 1 Disconnect 4 Front side cover assembly RH 1 5 Front side cover assembly LH 1 Before removing disconnected turn signal light coupler 6 Turn signal light moles LH RH 1 1 7 Turn signal light assembly LH RH 1 1 8 Front side cover LH RH 1 1 For installation reverse the removal proce dure 7 8 8 2 2 5 4 6 6 7 3 3 1 8 0 18 1 3 N m kgf m lb ft 7 0 7 5 2 N m kgf m lb ft 1 8 0 18 1 3 N m kgf m lb...

Page 36: ...11 Turn signal switch coupler 1 Disconnect 12 Dimmer pass switch coupler 1 Disconnect 13 Meter assembly 1 14 Meter assembly cover 1 15 Handlebar rear cover assembly 1 6 N m 0 6 kgf m 4 4 lb ft 2 5 N m 0 25 kgf m 1 8 lb ft 1 8 N m 0 18 kgf m 1 3 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 53 N m 5 3 kgf m 39 lb ft 2 5 N m 0 25 kgf m 1 8 lb ft 1 8 N m 0 18 kgf m 1 3 lb ft 1 8 N m 0 1...

Page 37: ...r brake cable 1 25 UBS brake cable 1 26 Rear brake lever assembly 1 6 N m 0 6 kgf m 4 4 lb ft 2 5 N m 0 25 kgf m 1 8 lb ft 1 8 N m 0 18 kgf m 1 3 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 53 N m 5 3 kgf m 39 lb ft 2 5 N m 0 25 kgf m 1 8 lb ft 1 8 N m 0 18 kgf m 1 3 lb ft 1 8 N m 0 18 kgf m 1 3 lb ft 1 4 N m 0 14 kgf m 1 0 lb ft 23 N m 2 3 kgf m 17 lb ft 7 N m 0 7 kgf m 5 2 lb ft ...

Page 38: ...kgf m 1 3 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 53 N m 5 3 kgf m 39 lb ft 2 5 N m 0 25 kgf m 1 8 lb ft 1 8 N m 0 18 kgf m 1 3 lb ft 1 8 N m 0 18 kgf m 1 3 lb ft 1 4 N m 0 14 kgf m 1 0 lb ft 23 N m 2 3 kgf m 17 lb ft 7 N m 0 7 kgf m 5 2 lb ft 6 N m 0 6 kgf m 4 4 lb ft 7 7 5 2 N m 0 kgf m lb ft 1 4 N m 0 14 kgf m 1 0 lb ft 1 5 0 15 1 1 N m kgf m lb ft 6 N m 0 6 kgf m 4 4 lb ft ...

Page 39: ...ge 4 35 Front wheel Refer to FRONT WHEEL in base service manual B7J F8197 E0 on page 4 19 1 Cable holder 1 2 Lower bracket pinch bolts 2 Loosen 3 Front fork 1 4 Front fender 1 TIP Before removing front fender remove horn lead clamp from front fender For installation reverse the removal proce dure 12 N m 1 2 kgf m 8 9 lb ft 6 N m 6 0 kgf m 4 4 lb ft 53 N m 5 3 kgf m 39 lb ft 2 1 7 N m 0 7 kgf m 5 2...

Page 40: ...FRONT FORK 3 7 CHAS B7JF8197E1 book Page 7 Tuesday June 29 2021 2 28 PM ...

Page 41: ...4 ENGINE OIL PUMP 4 1 CHECKING THE OIL STRAINER 4 2 CHECKING THE OIL PUMP 4 2 ASSEMBLING THE OIL PUMP 4 2 B7JF8197E1 book Page 0 Tuesday June 29 2021 2 28 PM ...

Page 42: ...ks Engine oil SMG starter motor generator rotor stator coil assembly Refer to STARTER GENERATOR in base service manual B7J F8197 E0 on page 5 42 1 Oil pump cover 1 2 Oil seal 1 3 O ring 1 4 Gasket 1 5 Oil pump assembly 1 For installation reverse the removal proce dure B7JF8197E1 book Page 1 Tuesday June 29 2021 2 28 PM ...

Page 43: ...r Oil pump housing Oil pump housing cover Cracks damage wear Replace the oil pump 2 Check Oil pump operation Rough movement Repeat steps 1 or re place the oil pump EAS30342 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor Oil pump shaft 2 Install Oil pump assembly O ring Oil seal Oil pump cover Recommended lubricant Engine oil New New B7JF8197E1 book Page 2 Tuesday June 29 2021 2 28 PM ...

Page 44: ...4 3 OIL PUMP ENG B7JF8197E1 book Page 3 Tuesday June 29 2021 2 28 PM ...

Page 45: ...NJECTOR 5 1 REMOVING THE FUEL HOSE 5 2 CHECKING THE FUEL INJECTOR 5 2 INSTALLING THE FUEL INJECTOR 5 2 INSTALLING THE FUEL HOSE 5 2 AIR FILTER CASE 5 4 THROTTLE BODY 5 5 B7JF8197E1 book Page 0 Tuesday June 29 2021 2 28 PM ...

Page 46: ...torage compartment Refer to GENERAL CHASSIS in base service manual B7J F8197 E0 on page 4 3 1 Fuel injector coupler 1 Disconnect 2 Fuel hose 1 Disconnect 3 Fuel injector 1 4 O ring 1 For installation reverse the removal proce dure 2 1 3 4 10 1 0 7 4 N m kgf m lb ft B7JF8197E1 book Page 1 Tuesday June 29 2021 2 28 PM ...

Page 47: ...t will be removed EAS31251 CHECKING THE FUEL INJECTOR 1 Check Injector Obstruction Replace and check the fuel pump fuel supply system Deposit Replace Damage Replace 2 Check Injector resistance Refer to CHECKING THE FUEL INJEC TOR in base service manual B7J F8197 E0 on page 7 103 EAS31617 INSTALLING THE FUEL INJECTOR 1 Install Fuel injector 1 O ring 2 TIP Lubricate the fuel injector O ring with eng...

Page 48: ...y onto the fuel in jector until a distinct click is heard To install the fuel hose onto the fuel injector slide the fuel hose connector cover 1 on the end of the hose in the direction of the arrow shown 1 B7JF8197E1 book Page 3 Tuesday June 29 2021 2 28 PM ...

Page 49: ...ment 1 3 Air filter case joint clamp screw 1 4 Cylinder head breather hose 1 5 Flap 1 Unhook from air filter case 6 Breather hose CVT case 1 Disconnect 7 Air filter case 1 8 Air filter check hose 1 For installation reverse the removal proce dure 1 3 13 0 95 N m 0 kgf m lb ft 1 3 13 0 95 N m 0 kgf m lb ft 10 1 0 7 4 N m kgf m lb ft 10 1 0 7 4 N m kgf m lb ft 2 5 0 25 1 8 N m kgf m lb ft 2 5 0 25 1 ...

Page 50: ... Cylinder head breather hose from holder Refer to AIR FILTER CASE on page 5 4 Hose Throttle body to check valve Refer to FUEL TANK in base service manual B7J F8197 E0 on page 6 3 1 ISC Idle Speed Control unit coupler 1 Disconnect 2 Throttle body sensor assembly coupler 1 Disconnect 3 Throttle cable holder 1 4 Throttle cable 1 10 1 0 7 4 N m kgf m lb ft 10 1 0 7 4 N m kgf m lb ft 5 0 5 3 7 N m kgf ...

Page 51: ... 1 9 Throttle body 1 10 O ring 1 11 ISC Idle Speed Control unit holder 1 12 ISC Idle Speed Control unit 1 For installation reverse the removal proce dure 10 1 0 7 4 N m kgf m lb ft 5 0 5 3 7 N m kgf m lb ft 10 1 0 7 4 N m kgf m lb ft 9 5 6 7 8 12 11 10 7 N m 0 7 kgf m 5 2 lb ft 10 1 0 7 4 N m kgf m lb ft LS B7JF8197E1 book Page 6 Tuesday June 29 2021 2 28 PM ...

Page 52: ...THROTTLE BODY 5 7 FI B7JF8197E1 book Page 7 Tuesday June 29 2021 2 28 PM ...

Page 53: ...M For Drum 6 11 CIRCUIT DIAGRAM 6 11 CHARGING SYSTEM For Disc 6 13 CIRCUIT DIAGRAM 6 13 CHARGING SYSTEM For Drum 6 15 CIRCUIT DIAGRAM 6 15 LIGHTING SYSTEM For Disc 6 17 CIRCUIT DIAGRAM 6 17 LIGHTING SYSTEM For Drum 6 19 CIRCUIT DIAGRAM 6 19 SIGNALING SYSTEM For Disc 6 21 CIRCUIT DIAGRAM 6 21 SIGNALING SYSTEM For Drum 6 23 CIRCUIT DIAGRAM 6 23 FUEL INJECTION SYSTEM For Disc 6 25 CIRCUIT DIAGRAM 6 2...

Page 54: ...P SYSTEM For Disc 6 29 CIRCUIT DIAGRAM 6 29 FUEL PUMP SYSTEM For Drum 6 31 CIRCUIT DIAGRAM 6 31 ELECTRICAL COMPONENTS 6 33 CHECKING THE SWITCHES For Disc 6 35 B7JF8197E1 book Page 1 Tuesday June 29 2021 2 28 PM ...

Page 55: ...B7JF8197E1 book Page 2 Tuesday June 29 2021 2 28 PM ...

Page 56: ...B Br Br Br 15A 2A 7 5A OFF ON Br Br Br R B R B B W B B B B B B L Y L Y B B B B B B W B Br Br Br Br B R B Br L Br Br R B R R B SPARE SPARE B 7 5A 2A 7 5A 2A 2A 15A 15A 7 5A R B R B R B Br R B R B B W R Or W L W R W R W R W L W L Or W L 05 06 07 10 04 01 02 03 20 21 22 23 28 29 33 34 64 66 65 67 19 L W Y Br R B B B7JF8197E1 book Page 1 Tuesday June 29 2021 2 28 PM ...

Page 57: ...witch 19 SGCU Starter generator control unit 20 Joint connection 2 21 Ignition coil 22 Spark plug 23 Crankshaft position sensor 28 Starter generator 29 Sidestand switch 33 Joint connection 4 34 Stop and start system switch 64 Junction Ground 65 Engine ground 1 66 Engine ground 2 67 Engine ground 3 B7JF8197E1 book Page 2 Tuesday June 29 2021 2 28 PM ...

Page 58: ...B R B Br L Br Br R B R R B SPARE SPARE B 7 5A 2A 7 5A 2A 2A 15A 15A 7 5A 10 W R W L W R W L L W Y Br R B 33 B7JF8197E1 book Page 3 Tuesday June 29 2021 2 28 PM 1 Battery 2 Battery 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 19 Joint connection 2 20 Ignition coil 21 Spark plug 22 Crankshaft position sens...

Page 59: ...witch 18 SGCU Starter generator control unit 19 Joint connection 2 20 Ignition coil 21 Spark plug 22 Crankshaft position sensor 27 Starter generator 28 Sidestand switch 33 Joint connection 4 34 Stop and start system switch 62 Junction Ground 63 Engine ground 1 64 Engine ground 2 65 Engine ground 3 B7JF8197E1 book Page 4 Tuesday June 29 2021 2 28 PM ...

Page 60: ... 7 5A OFF ON Br Br Br Br Br L R L R R Br L R G Y G Y R B R B Br R R B W B B B B B B B B G Y Br L Br L W B B B B B B B L Y L Y B B B B B B W B Br Br Br Br B R B Br L Br Br R B R R B SPARE SPARE B 7 5A 2A 7 5A 2A 2A 15A 15A 7 5A R B R B R B R B Br L Br Br R B R B R B Br R B B P Y P Y B Y B W R W L W R W R W L W R W L W L B L R 05 06 07 08 10 11 14 15 16 04 01 02 03 23 28 29 30 33 34 40 41 46 64 66 6...

Page 61: ...itch 16 Joint connection 3 19 SGCU Starter generator control unit 23 Crankshaft position sensor 28 Starter generator 29 Sidestand switch 30 Joint connection 1 33 Joint connection 4 34 Stop and start system switch 35 Start switch 40 Meter assembly 41 Acceleration assist indicator light 46 Meter light 64 Junction Ground 65 Engine ground 1 66 Engine ground 2 67 Engine ground 3 68 Body ground B7JF8197...

Page 62: ... B B B B B B B B B B 64 63 65 B B B 62 B B R R 01 02 03 Br G Y B Br G Y B Y B 35 R B Br Br Br Br R B Br R OFF ON B R R L R R R B L R 12 Br B R B Br R B R B L R R Br R B Y B Y B Y B L W L W L W P Y L Y B B B B W L R L R Br G Y 14 15 Y B B B Y B B B Gy P Y G L B L B G Y G Y Br L Br G Y G Y L W Br Br Br Br B R B Br L Br Br R B R R B SPARE SPARE B 7 5A 2A 7 5A 2A 2A 15A 15A 7 5A 10 66 L W Y Br R B W R...

Page 63: ...18 SGCU Starter generator control unit 22 Crankshaft position sensor 27 Starter generator 28 Sidestand switch 29 Start switch 30 Joint connection 1 33 Joint connection 4 34 Stop and start system switch 35 Rear brake light switch 39 Meter assembly 40 Acceleration assist indicator light 46 Meter light 62 Junction Ground 63 Engine ground 1 64 Engine ground 2 65 Engine ground 3 66 Body ground B7JF8197...

Page 64: ...R B Br Br Br 15A 2A 7 5A OFF ON Br L R L R R Br L R R B R B R B R R B W B B B B B B B B Br L Br B B B B B B B L Y L Y W B B B B B B B W B Br Br Br Br B R B Br L Br Br R B R R B SPARE SPARE B 7 5A 2A 7 5A 2A 2A 15A 15A 7 5A R B R B R B R B Br L Br R B R B R B Br R B B W Y R P Y P Y B L Y L P W G R W R W L B L B L Y L P W G R W R W R W L W R W L W L B L B L R 05 06 07 10 11 16 04 01 02 03 18 23 24 2...

Page 65: ...control unit 23 Crankshaft position sensor 24 Engine temperature sensor 26 MAQS Modularized air quantity sensor 28 Starter generator 29 Sidestand switch 33 Joint connection 4 34 Stop and start system switch 40 Meter assembly 41 Acceleration assist indicator light 44 Stop and start system indicator light 46 Meter light 64 Junction Ground 65 Engine ground 1 66 Engine ground 2 67 Engine ground 3 68 B...

Page 66: ... L B L B L 22 23 25 27 18 33 34 B B L Y B L L Y B 28 B W B B B B B B B B B B 64 63 65 B B B 62 B B R R 01 02 03 R B Br R B Br R OFF ON B R R L R R R B L R 12 Br B R B Br R B R B R B B Lg L Lg W L R R Br R B Y B Y B Y B Y R P Y L Y W B L B B B B W Lg L Lg W R B 17 L R L R 15 Y B B B Y B B B Gy P Y G L B L B Br L Br Br Br Br Br B R B Br L Br Br R B R R B SPARE SPARE B 7 5A 2A 7 5A 2A 2A 15A 15A 7 5A...

Page 67: ... unit 22 Crankshaft position sensor 23 Engine temperature sensor 25 MAQS Modularized air quantity sensor 27 Starter generator 28 Sidestand switch 33 Joint connection 4 34 Stop and start system switch 39 Meter assembly 40 Acceleration assist indicator light 43 Stop and start system indicator light 45 Reed switch 46 Meter light 62 Junction Ground 63 Engine ground 1 64 Engine ground 2 65 Engine groun...

Page 68: ...15A 2A 7 5A OFF ON Br L R L R R Br L R R B R B R R B W B B B B B B B B B B W Br Br Br Br B R B Br L Br Br R B R R B SPARE SPARE B 7 5A 2A 7 5A 2A 2A 15A 15A 7 5A R B R B R B Br R B R B R B W R W L W R W R W R W L W L W L B L R 05 06 07 10 11 16 04 01 02 03 23 28 66 65 68 19 L W Y Br R B B7JF8197E1 book Page 13 Tuesday June 29 2021 2 28 PM ...

Page 69: ...4 Fuse box 5 Main fuse 6 Backup fuse 7 Sub fuse 10 Main switch 11 Main relay 16 Joint connection 3 19 SGCU Starter generator control unit 23 Crankshaft position sensor 28 Starter generator 65 Engine ground 1 66 Engine ground 2 68 Body ground B7JF8197E1 book Page 14 Tuesday June 29 2021 2 28 PM ...

Page 70: ...L W L 22 27 18 B W B B B 64 63 B B R R 01 02 03 R B Br R B Br R OFF ON B R R L R R R B L R 12 Br B R B Br R B R B L R R Br R B B B B B W L R L R 15 B B Gy P Y G L B L B Br Br Br Br B R B Br L Br Br R B R R B SPARE SPARE B 7 5A 2A 7 5A 2A 2A 15A 15A 7 5A 10 66 W R W L W R W L L W Y Br R B B7JF8197E1 book Page 15 Tuesday June 29 2021 2 28 PM ...

Page 71: ...4 Fuse box 5 Main fuse 6 Backup fuse 7 Sub fuse 10 Main switch 12 Main relay 15 Joint connection 3 18 SGCU Starter generator control unit 22 Crankshaft position sensor 27 Starter generator 63 Engine ground 1 64 Engine ground 2 66 Body ground B7JF8197E1 book Page 16 Tuesday June 29 2021 2 28 PM ...

Page 72: ...B B B B W B W B W B W Y G Y Y W B Y Y G Br Y Br Y Br Y W Y Br Y Br L Y B LICENSE DRL POS LO HI Br L Br L Br L Br L Br L Br Br L W B B B B B B B B B B W B B B B B B B W DRL H L Pass Br Br Br Br B R B Br L Br Br R B R R B SPARE SPARE B 7 5A 2A 7 5A 2A 2A 15A 15A 7 5A R B R B R B R B Br L Br R B R B B Br R B B P Y W Y Br L R Br Y 05 06 07 09 10 04 01 02 03 28 39 38 40 46 49 50 52 54 58 60 61 64 66 65...

Page 73: ... 40 Meter assembly 46 Meter light 49 High beam indicator light 50 Accessory connector optional 51 Headlight assembly Headlight DRL Auxiliary light 52 Headlight High beam 53 Headlight Low beam 54 Auxiliary light DRL 58 Taillight assembly Rear turn signal lights License plate light Tail brake light 60 License plate light 61 Taillight 64 Junction ground 65 Engine ground 1 66 Engine ground 2 67 Engine...

Page 74: ... B B B B W B W B B B 64 63 65 61 B B R 01 02 03 G Y Br L G Y Br L 38 R B Br B Br B Br 50 W B B Y G W B W B W B G Br L Br L L L L Y Y Y Y 3 W 35 W 35 W 3 W 5 W R B Br R OFF ON Br B R B Br R B R B Br R B W B B B B B W B B Gy P Y G L B L B Br L Br Br L Br L Br Br Br Br B R B Br L Br Br R B R R B SPARE SPARE B 7 5A 2A 7 5A 2A 2A 15A 15A 7 5A 10 Br L G Y B Dg Ch L Y B Dg Ch B Dg Ch L B Dg Ch L Sb L 66 ...

Page 75: ...38 Dimmer switch 39 Meter assembly 46 Meter light 49 High beam indicator light 50 Accessory connector optional 51 Headlight assembly 52 Front turn signal assembly 53 Auxiliary light Left 56 Auxiliary light Right 57 Taillight assembly Rear turn signal lights Tail brake light 59 Brake light 61 Joint connection 5 63 Engine ground 1 64 Engine ground 2 65 Engine ground 3 66 Body ground B7JF8197E1 book ...

Page 76: ... B R B P Br Br B W B B B B B B B Dg Ch P Ch Dg 10W 10W 10W STOP STOP 10W B Ch Ch Ch Ch G Y G Y G Y Br B Br L Br B Br G Y Ch Dg Dg Dg Dg Dg B Ch Dg B B B B B B B B B B B B B W Br Br Br Br B R B Br L Br Br R B R R B SPARE SPARE B 7 5A 2A 7 5A 2A 2A 15A 15A 7 5A R B R B R B R B Br L Br Br R B R B B Br R B B B G Y R Y L G L P Y P Y B Y B 05 06 07 08 10 12 13 14 15 04 01 02 03 28 32 40 41 42 43 44 45 4...

Page 77: ...ight 42 ECO indicator light 43 Engine trouble warning light 44 Stop and start system indicator light 45 Fuel meter 46 Meter light 47 Turn signal indicator light Left 48 Turn signal indicator light Right 55 Front turn signal light assembly 56 Front turn signal light assembly Left 57 Front turn signal light assembly Right 58 Taillight assembly Rear turn signal lights License plate light Tail brake l...

Page 78: ...02 03 B P B Br B Ch Dg R Ch Dg Br B P B Br G Y B Br G Y B Y B 35 36 37 Br Br B R B Br Br Br Br Br Br 11 Ch Dg Dg Dg Dg Ch Ch G Y Dg Dg Ch Ch Ch 10 W 10 W 21 W 10 W 10 W R B Br R OFF ON Br B R B Br R B R B Br R B Y L G L Y R P Y W B L B B B B W Br G Y 14 Br P 13 B B Gy P Y G L B L B G Y Br L Br G Y G Y Br B Br Br Br Br Br B R B Br L Br Br R B R R B SPARE SPARE B 7 5A 2A 7 5A 2A 2A 15A 15A 7 5A B G ...

Page 79: ...or light 42 Engine trouble warning light 43 Stop and start system indicator light 44 Fuel meter 45 Reed switch 46 Meter light 47 Turn signal indicator light Left 48 Turn signal indicator light Right 52 Front turn signal light assembly 54 Front turn signal light assembly Left 55 Front turn signal light assembly Right 57 Taillight assembly Rear turn signal lights License plate light Tail brake light...

Page 80: ... R B Y B R R B Br Br Br Br 15A 2A 7 5A 7 5A OFF ON Br Br Br Or B R B R B R B B W B B B B B B Br L Br B B B B L Y L Y B B B B B B B W B Br Br Br Br B R B Br L Br Br R B R R B SPARE SPARE B 7 5A 2A 7 5A 2A 2A 15A 15A 7 5A R B R B R B R B R B Br L Br Br R B R B B Br R B B Y R Y L G L P Y P Y Gy R B L Y L P W P G Y G R W R Or W L B L Gy Sb Gy R B L Y L P W P G Y G R W R W R W L W R W L Or W L B L Gy S...

Page 81: ... sensor 24 Engine temperature sensor 25 ISC Idle speed control unit 26 MAQS Modularized air quantity sensor 27 O2 sensor 28 Starter generator 29 Sidestand switch 31 Fuel pump 33 Joint connection 4 34 Stop and start system switch 40 Meter assembly 41 Acceleration assist indicator light 42 ECO indicator light 43 Engine trouble warning light 44 Stop and start system indicator light 46 Meter light 64 ...

Page 82: ...R G R W R W R Or Or Or W L W L B L B L Gy Gy Sb Sb 19 20 21 22 23 24 25 26 27 18 31 33 34 B B L Y B L L Y B 28 B W B B B B B B B B B 64 63 65 B B B B 62 B R 01 02 03 R B Br Br R B Br R OFF ON Br B R B Br Br Or B R B R B R B B Lg L Lg W Br Or B R B Y B Y B Y B L B Y L G L Y R P Y L Y W W B B L B B B B W Lg L Lg W R B 17 16 Y B B B Y B B B Gy P Y G L B L B Br L Br Br Br Br Br B R B Br L Br Br R B R ...

Page 83: ... 23 Engine temperature sensor 24 ISC Idle speed control unit 25 MAQS Modularized air quantity sensor 26 O2 sensor 27 Starter generator 28 Sidestand switch 31 Fuel pump 33 Joint connection 4 34 Stop and start system switch 39 Meter assembly 40 Acceleration assist indicator light 41 ECO indicator light 42 Engine trouble warning light 43 Stop and start system indicator light 45 Reed switch 46 Meter l...

Page 84: ...R B Br R L B R B B R B R B L B L B R R B Br Br Br 15A 2A 7 5A OFF ON Br Br R B R B B W B B B B B B B W Br Br Br Br B R B Br L Br Br R B R R B SPARE SPARE B 7 5A 2A 7 5A 2A 2A 15A 15A 7 5A R B R B R B R B Br R B R B B 05 06 07 10 04 01 02 03 31 66 65 19 B7JF8197E1 book Page 29 Tuesday June 29 2021 2 28 PM ...

Page 85: ...attery positive lead 3 Battery negative lead 4 Fuse box 5 Main fuse 6 Backup fuse 7 Sub fuse 10 Main switch 19 SGCU Starter generator control unit 31 Fuel pump 65 Engine ground 1 66 Engine ground 2 B7JF8197E1 book Page 30 Tuesday June 29 2021 2 28 PM ...

Page 86: ...R B R B R B Br R B 05 06 07 04 31 B W B B B 64 63 R 01 02 03 R B Br R B Br R OFF ON Br B R B Br Br R B L B B B B B W B B Gy P Y G L B L B Br Br Br Br B R B Br L Br Br R B R R B SPARE SPARE B 7 5A 2A 7 5A 2A 2A 15A 15A 7 5A L B R B B R B L B 10 R B R B 18 B7JF8197E1 book Page 31 Tuesday June 29 2021 2 28 PM ...

Page 87: ...attery 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 31 Fuel pump 63 Engine ground 1 64 Engine ground 2 B7JF8197E1 book Page 32 Tuesday June 29 2021 2 28 PM ...

Page 88: ...RICAL COMPONENTS 6 33 ELEC EAS20089 ELECTRICAL COMPONENTS 1 2 3 4 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Digital Meter Analogue Meter B7JF8197E1 book Page 33 Tuesday June 29 2021 2 28 PM ...

Page 89: ...Fuel 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 B7JF8197E1 book Page 34 Tuesday June 29 2021 ...

Page 90: ... wir ing connections and if necessary replace the switch 10 8 9 7 6 1 2 3 4 5 T DRL H L W Y Br L R Br Y Br L Br Y Y Pass 1 Main switch 2 Front brake switch 3 Start switch 4 Stop and start system switch 5 Headlight switch 6 Sidestand switch 7 Turn signal switch 8 Horn switch 9 Dimmer pass switch 10 Rear brake light switch B7JF8197E1 book Page 35 Tuesday June 29 2021 2 28 PM ...

Page 91: ...urn signal indicator light Right 49 High beam indicator light 50 Accessory connector optional 51 Headlight assembly Headlight DRL Auxiliary light 52 Headlight High beam 53 Headlight Low beam 54 Auxiliary light DRL 55 Front turn signal light assembly 56 Front turn signal light assembly Left 57 Front turn signal light assembly Right 58 Taillight assembly Rear turn signal lights License plate light T...

Page 92: ... Turn signal indicator light Left 48 Turn signal indicator light Right 49 High beam indicator light 50 Accessory connector optional 51 Headlight assembly 52 Front turn signal light assembly 53 Auxiliary light Left 54 Front turn signal light assembly Left 55 Front turn signal light assembly Right 56 Auxiliary light Right 57 Taillight assembly Rear turn signal lights Tail brake light 58 Rear turn si...

Page 93: ...B7JF8197E1 book Page 1 Tuesday June 29 2021 2 28 PM ...

Page 94: ...1Y238 SSM 01 1548 6 21 E B7J F8197 E1 B7JF8197E1 book Page 2 Tuesday June 29 2021 2 28 PM ...

Page 95: ...Y B Ch Dg 10W 10W 10W STOP STOP LICENSE DRL POS LO HI TAIL 10W B Ch Ch Ch Ch Br L G Y G Y G Y G Y G Y Br L Br B Br L Br L Br B Br L Br Br L G Y L W Ch Dg Dg Dg Dg Dg B Ch Dg W B B B B B B B B B B B B B L Y L Y W W B B B B B B B B B W B DRL H L Pass Br Br Br Br B R B Br L Br Br R B R R B SPARE SPARE B 7 5A 2A 7 5A 2A 2A 15A 15A 7 5A R B R B R B R B R B Br L Br Br Br R B R B R B Br R B B W B G Y R Y...

Page 96: ... G Y B Br G Y B Y B 35 36 37 38 Br Br B R B Br B Br Br Br Br Br Br Br 11 B Br 50 W B B Y G W B W B W B G Ch Dg Dg Dg Dg Br L Br L L L L Ch Ch G Y Dg Dg Ch Ch Ch Y Y Y Y 3 W 35 W 35 W 3 W 10 W 10 W 21 W 5 W 10 W 10 W R B Br R OFF ON B R R L R R R B L R 12 Br B R B Br Br Or B R B R B R B B Lg L Lg W L R R Br Or B R B Y B Y B Y B L B L W L W L W Y L G L Y R P Y L Y W W B B L B B B B W Lg L Lg W R B 1...

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