Yamaha YZ 2019 Series, Owner'S Service Manual

Page: 73 / 398

CABLE ROUTING DIAGRAM
2-32
1. Clutch cable
2. Throttle cable (return)
3. Throttle cable (pull)
4. Engine stop switch lead
5. Warning light lead
6. Coupler for connecting optional part
7. Engine stop switch coupler
8. Rectifier/regulator coupler
9. Warning light coupler
10.AC magneto lead
11.Starter knob/idle screw
12.Starter motor lead
13.Radiator fan motor fuse
14.Starting circuit cut-off relay (no identification tape)
15.Diode
16.Holder plate
17.Left of the vehicle: radiator fan motor relay
(blue tape)
Right of the vehicle: main relay (red tape)
18.Neutral switch lead
19.Engine bracket
20.Front engine bracket
21.Plastic locking tie
22.Radiator hose
23.Neutral switch coupler
24.Crankshaft position sensor coupler
25.Tension arm
26.Wire harness
27.Tank rail
28.Rectifier/regulator
29.Rectifier/regulator bracket
30.Rear frame
31.Side cover 5
32.Crankcase cover
33.Crankcase
34.Lead holder
35.Frame
A. Pass the engine stop switch lead between the
frame and the cable holder.
B. Pass the warning light lead between the
frame and the cable holder.
C. Insert the coupler for connecting optional part
into the connector, and fix it to the bracket.
D. Insert and fix the engine stop switch coupler
to the bracket.
E. Insert and fix the rectifier/regulator coupler to
the bracket.
F. Insert and fix the warning light coupler to the
bracket.
G. Pass the AC magneto lead to the front of the
vehicle beyond the starter knob/idle screw
and to the rear of the vehicle beyond the radi-
ator. No pinch is allowed between the radiator
and the tension arm.
H. Pass the starter motor lead so that the lead
does not contact with the end of the bolt.
I. Place the rear grommet of the starter motor
lead matching the rear end of the side cover 5.
J. Insert the radiator fan motor fuse into the pro-
trusion of the holder plate.
K. Place the diode on top of the rear fender on
the inner side of the rear frame.
L. Bring the neutral switch lead into line with the
crankcase cover with no sag allowed.
M. Route the AC magneto lead under the starter
clutch cover.
N. Pass the neutral switch lead to the inside of
the front engine bracket (the side of the vehi-
cle).
O. Insert the plastic locking tie into the bracket
hole and clamp the clutch cable. Clamp it so
that the lock of the plastic locking tie faces
downward, and then cut off the end of the
plastic locking tie.
P. Pass the clutch cable with no downward sag
allowed.
Q. Place the grommet of the clutch cable so that
it contacts the radiator hose. Route the clutch
cable outside the neutral switch lead, AC
magneto lead and starter motor lead.
R. Route each lead so that the leads are not
pinched between the radiator hose and the
frame.
S. 40 mm (1.57 in)
T. Clamp the clutch cable, AC magneto lead,
neutral switch lead and starter motor lead by
the plastic locking tie. Make sure that they are
clamped at the positioning tapes in the clutch
cable and the starter motor lead. Make the
lock on the plastic locking tie face the front of
the vehicle, and cut the end.
U. Clamp the starter motor lead to the inside of
the tension arm with a plastic locking tie.
Clamp it so that the lock of the plastic locking
tie faces upward and outward, and do not cut
off the end of the plastic locking tie. Route the
lead so that there is no slack at the bottom
from the clamp position onwards.
V. After connecting the neutral switch coupler,
attach the coupler cover.
W. After connecting the crankshaft position sen-
sor coupler, attach the coupler cover.
X. Pass the rectifier/regulator lead and the warn-
ing light lead to the inside of the tension arm
(the side of the vehicle).
Y. Pass the main harness to the front of the radiator
hose (the front of the vehicle), and to the inside
of the clutch cable (the side of the vehicle).
Z. Pass the engine stop switch lead between the
coupler for connecting optional part and the
tank rail, with the lead on the main harness
side facing the top of the vehicle.
AA. Insert the starter motor lead completely into
the end of the side cover 5.
AB. Clamp the clutch cable at the front of the
lead (the front of the vehicle).
AC. Insert the clip of the plastic locking tie into
the frame. Face the lock of the plastic locking
tie forward, and then cut off the end.