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EAS20070 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
EAS20100 1. Serviceable with engine mounted SYMBOLS 2. Filling fluid The following symbols are used in this manual 3. Lubricant for easier understanding. 4. Special tool NOTE: 5. Tightening torque The following symbols are not relevant to every 6. Wear limit, clearance vehicle.
EAS20110 CONTENTS FEATURES......................1 OUTLINE OF THE YCC-S (Yamaha Chip Controlled-Shift) SYSTEM ..1 SPECIAL TOOLS ....................4 GENERAL SPECIFICATIONS ................6 ENGINE SPECIFICATIONS ................7 CHASSIS SPECIFICATIONS ................8 ELECTRICAL SPECIFICATIONS ..............9 TIGHTENING TORQUES ................. 10 ENGINE TIGHTENING TORQUES............10 CHASSIS TIGHTENING TORQUES............
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SHAFT DRIVE ....................46 INSTALLING THE DRIVE SHAFT AND FINAL DRIVE ASSEMBLY ..46 ENGINE REMOVAL ..................47 REMOVING THE GEAR POSITION SENSOR .......... 49 REMOVING THE ENGINE ................. 49 INSTALLING THE GEAR POSITION SENSOR......... 49 ADJUSTING THE GEAR POSITION SENSOR ......... 50 CLUTCH ......................
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YCC-S (Yamaha Chip Controlled-Shift) SYSTEM......... 85 CIRCUIT DIAGRAM (1/2)................85 CIRCUIT DIAGRAM (2/2)................87 TROUBLESHOOTING ................89 MAINTENANCE OF THE MCU ..............90 MCU (motor control unit) SELF-DIAGNOSTIC FUNCTION ....... 90 SELF-DIAGNOSTIC FUNCTION TABLE ........... 91 TROUBLESHOOTING METHOD............... 94 DIAGNOSTIC MODE ................. 95 TROUBLESHOOTING DETAILS ...............
FEATURES EAS20170 FEATURES ET2D21013 OUTLINE OF THE YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Concept YCC-S offers more enjoyable and easy riding by eliminating the need for the user to operate the clutch, which also reduces fatigue during long touring. YCC-S is not an automatic transmission, although it allows the user to shift gears by foot or hand ac- cording to preference.
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FEATURES 1. YCC-S test coupler 8. MCU (motor control unit) 2. YCC-S control relay 9. Shift actuator 3. YCC-S indicator and warning light 10. Clutch actuator 4. YCC-S motor control fuse 11. Foot shift switch 5. Hand shift switch 12. YCC-S speed sensor 6.
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• If the YCC-S indicator and warning light come on while riding, stop the vehicle, park it in a safe place, and then contact a Yamaha dealer. Because the YCC-S system stops automatically when the YCC-S indicator and warning light come on, it is impossible to shift since clutch operation is stopped.
SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 2D21(Europe except (B)and(F))(ZA) 2D22(B)(F) 2D23(AUS) Weight With oil and fuel 295.0 kg (650 lb) Maximum load 208 kg (459 lb) – 6 –...
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CABLE ROUTING 1. Brake hose (front brake master cylinder to M. Fasten the right handlebar switch lead, right grip hydraulic unit) warmer lead, and main switch lead with a plastic locking tie at the location shown in the illustration. 2. Right handlebar switch lead Position the buckle of the plastic locking tie under 3.
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CABLE ROUTING 1. O sensor lead F. Route the positive battery lead between the battery stay and the battery box. 2. Engine idling speed adjusting cable G. To front cowling wire harness 3. Starter motor lead H. Align the rear end of the right radiator fan motor 4.
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CABLE ROUTING 1. Auxiliary DC jack 2. Left radiator fan motor lead 3. Accessory box solenoid 4. Wire harness 5. Front cowling wire harness 6. Radiator inlet hose 7. Grip warmer control unit leads 8. Left radiator fan 9. Coolant reservoir breather hose 10.
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CABLE ROUTING 1. Grip warmer couplers E. Fasten the sidestand switch lead, stator coil lead, and oil level switch lead with a plastic locking tie, 2. Hand shift switch coupler making sure to bundle and fasten the sidestand 3. Handlebar switch couplers switch lead so that the coupler is positioned to the 4.
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CABLE ROUTING 1. Wire harness L. Route the leads between the left tail/brake light bulb socket and the rear left turn signal light bulb 2. ECU (engine control unit) socket. 3. ABS ECU (electronic control unit) M. Route the tail/brake light assembly lead between 4.
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CABLE ROUTING 1. Spark plug lead #1 L. Route the stator coil lead to the inside of the engine bracket (top) and under the crankcase 2. Spark plug lead #2 breather hose. 3. Front wheel sensor lead M. Route the wire harness (to sub-wire harness) 4.
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CABLE ROUTING 1. Clutch actuator motor lead 2. Clutch actuator sensor lead 3. License plate light lead 4. Tail/brake light assembly lead 5. Seat lock cable 6. Intake air temperature sensor A. Connect the clutch actuator motor lead and clutch actuator sensor lead, install the rubber cover around the leads, and then place the cover between the hydraulic unit and the frame.
• From 50000 km, repeat the maintenance intervals starting from 10000 km. • Items marked with an asterisk should be performed by a -Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (× 1000 km)
ENGINE EAS20470 NOTE: ENGINE In order to ensure a correct reading of the clutch fluid level, make sure the top of the reservoir is EAS20890 CHECKING THE CLUTCH FLUID LEVEL horizontal. 1. Stand the vehicle on a level surface. 4. Install: NOTE: •...
ENGINE b. Turn the main switch to “ON” and check that l. Repeat steps (i) to (k) until all of the air bub- the transmission is in neutral. bles have disappeared from the clutch fluid in c. Add the recommended clutch fluid to the the plastic hose of the vacuum/pressure proper level.
ENGINE g. If the pressure plate stroke is out of specifica- tion, repeat steps (j) to (l) in the procedure for step “2. Bleed” until clutch pressure plate stroke is within specification. L LLL L LLL L LLL L LLL L LLL 4.
ENGINE b. Start the engine. • Left side cover c. Shift the transmission from neutral to 1st gear Refer to “GENERAL CHASSIS” on page 37. and back to neutral ten times. • Shift actuator d. Shift the transmission into 1st gear, and then Refer to “SHIFT ACTUATOR AND SHIFT apply the rear brake.
CHASSIS EAS21140 CHASSIS ET2D21002 ADJUSTING THE SHIFT PEDAL 1. Check: • Shift pedal position NOTE: The shift pedal “1” can be adjusted to three po- sitions to suit the rider’s preference as shown. 2. Adjust: • Shift pedal position M MMM M MMM M MMM M MMM...
ELECTRICAL SYSTEM EAS21750 ECA13690 ELECTRICAL SYSTEM CAUTION: Avoid touching the glass part of the head- EAS21790 light bulb to keep it free from oil, otherwise REPLACING THE HEADLIGHT BULBS the transparency of the glass, the life of the The following procedure applies to both of the bulb and the luminous flux will be adversely headlight bulbs.
GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the front cowling assembly 10 Nm (1.0 m kg, 7.2 ft • • 32 Nm (3.2 m kg, 23 ft • • Order Job/Parts to remove Q’ty Remarks Open the accessory box lid. Left side panel Left side cowling Front left turn signal light coupler Disconnect.
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GENERAL CHASSIS Removing the front cowling assembly 10 Nm (1.0 m kg, 7.2 ft • • 32 Nm (3.2 m kg, 23 ft • • Order Job/Parts to remove Q’ty Remarks Front cowling left inner panel 2 Plastic band Disconnect. Plastic holder Disconnect.
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GENERAL CHASSIS Removing the air filter case 18 Nm (1.8 m kg, 13 ft • • 7 Nm (0.7 m kg, 5.1 ft • • (11) 8 Nm (0.8 m kg, 5.8 ft • • 4 Nm (0.4 m kg, 2.9 ft •...
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GENERAL CHASSIS Removing the air filter case 18 Nm (1.8 m kg, 13 ft • • 7 Nm (0.7 m kg, 5.1 ft • • (11) 8 Nm (0.8 m kg, 5.8 ft • • 4 Nm (0.4 m kg, 2.9 ft •...
HANDLEBARS EAS22850 HANDLEBARS Removing the left handlebar Order Job/Parts to remove Q’ty Remarks Left handlebar Left grip warmer lead Hand shift switch lead Left handlebar switch lead Lead holder 1 Hand shift switch Lead holder 2 Left handlebar switch Grip end Handlebar grip For installation, reverse the removal proce- dure.
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HANDLEBARS Removing the right handlebar Order Job/Parts to remove Q’ty Remarks Front brake light switch connector Disconnect. Front brake master cylinder holder Front brake master cylinder assembly Grip end Throttle cable housing Throttle cable Disconnect. Throttle grip Right handlebar Right grip warmer lead Right handlebar switch lead Lead holder Right handlebar switch...
HANDLEBARS EAS22900 INSTALLING THE HANDLEBARS 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. Install: • Handlebar grip • Grip end “1” 4. Install: M MMM M MMM M MMM...
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HANDLEBARS es to the rear of the other section of the lead, NOTE: and route the lead through the throttle cable Fit the projections on each handlebar into the housing. holes in the upper bracket, making sure that the • When installing the throttle cable housing, handlebars are installed in the same position.
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HANDLEBARS • First, tighten the upper bolt, then the lower bolt. 11.Adjust: • Throttle cable free play Refer to “ADJUSTING THE THROTTLE CA- BLE FREE PLAY” in chapter 3. (Manual No.: 3P6-28197-E0) Throttle cable free play 3.0–5.0 mm (0.12–0.20 in) –...
ENGINE REMOVAL EAS23710 ENGINE REMOVAL Disconnecting the leads and hoses 10 Nm (1.0 m kg, 7.2 ft • • 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “FRONT WHEEL” in chapter 4. Front fender (Manual No.: 3P6-28197-E0) Air filter case...
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ENGINE REMOVAL Disconnecting the leads and hoses 10 Nm (1.0 m kg, 7.2 ft • • 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “SHIFT ACTUATOR AND SHIFT Gear position sensor cover ROD”...
ENGINE REMOVAL ET2D21003 REMOVING THE GEAR POSITION SENSOR 1. Disconnect: • Gear position sensor coupler 2. Remove: • Gear position sensor NOTE: Remove only the screws “1” when removing the gear position sensor. Do not remove the screws “2”. ET2D21004 INSTALLING THE GEAR POSITION SENSOR 1.
ENGINE REMOVAL 3. Check: ET2D21005 ADJUSTING THE GEAR POSITION SENSOR • Gear position setting 1. Check: Refer to “Diagnostic code table (Diagnostic • Gear position sensor code No. Sh_ _65)”. Refer to “CHECKING THE GEAR POSITION SENSOR” on page 132. 2.
CLUTCH EAS25060 CLUTCH Removing the clutch actuator and clutch master cylinder 7 Nm (0.7 m kg, 5.1 ft • • 19 Nm (1.9 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft •...
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CLUTCH Removing the clutch actuator and clutch master cylinder 7 Nm (0.7 m kg, 5.1 ft • • 19 Nm (1.9 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft •...
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CLUTCH Disassembling the clutch master cylinder ∗ Order Job/Parts to remove Q’ty Remarks Clutch master cylinder kit Clutch master cylinder body For assembly, reverse the disassembly pro- cedure. * Apply silicon grease – 53 –...
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CLUTCH Removing the clutch release cylinder Order Job/Parts to remove Q’ty Remarks Drain. Clutch fluid Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” on page 31. Clutch hose union bolt Copper washer Clutch hose Disconnect. Clutch release cylinder Dowel pin Plate For installation, reverse the removal proce- dure.
CLUTCH ET2D21037 BREAKING IN THE FRICTION PLATES AFTER REPLACEMENT 1. If the friction plates are replaced, perform the following procedure to break them in. M MMM M MMM M MMM M MMM M MMM a. Start the engine and warm it up until at least three segments appear on the coolant tem- perature meter “1”...
SHIFT ACTUATOR AND SHIFT ROD ET2D21006 SHIFT ACTUATOR AND SHIFT ROD Removing the shift actuator, shift rod and foot shift switch 4 Nm (0.4 m kg, 2.9 ft • • 20 Nm (2.0 m kg, 14 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
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SHIFT ACTUATOR AND SHIFT ROD Removing the shift actuator, shift rod and foot shift switch 4 Nm (0.4 m kg, 2.9 ft • • 20 Nm (2.0 m kg, 14 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
SHIFT ACTUATOR AND SHIFT ROD ET2D21007 REMOVING THE SHIFT ACTUATOR 1. Remove: • Shift actuator M MMM M MMM M MMM M MMM M MMM a. Pass a suitable 5 mm diameter rod “1” through the holes in the rear shift arm and shift actuator to secure the shift rod.
SHIFT ACTUATOR AND SHIFT ROD Shift actuator rear bolt 20 Nm (2.0 m·kg, 14 ft·lb) Shift actuator front bolt 20 Nm (2.0 m·kg, 14 ft·lb) L LLL L LLL L LLL L LLL L LLL ET2D21011 INSTALLING THE LEFT FOOTREST ASSEMBLY 1.
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SHIFT ACTUATOR AND SHIFT ROD Shift rod front locknut 7 Nm (0.7 m·kg, 5.1 ft·lb) Shift rod rear locknut 10 Nm (1.0 m·kg, 7.2 ft·lb) h. Pull out the rod from the holes. L LLL L LLL L LLL L LLL L LLL –...
SHIFT SHAFT EAS25410 SHIFT SHAFT EAS25450 INSTALLING THE SHIFT SHAFT 1. Install: • Stopper lever “1” • Stopper lever spring “2” NOTE: • Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss “3”. •...
CRANKCASE EAS25540 CRANKCASE Separating the crankcase 10 Nm (1.0 m kg, 7.2 ft 20 Nm (2.0 m kg, 14 ft • • • • 2nd 20 Nm (2.0 m kg, 14 ft • • (10) 24 Nm (2.4 m kg, 17 ft •...
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CRANKCASE Separating the crankcase 10 Nm (1.0 m kg, 7.2 ft 20 Nm (2.0 m kg, 14 ft • • • • 2nd 20 Nm (2.0 m kg, 14 ft (10) • • 24 Nm (2.4 m kg, 17 ft •...
TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” in chapter 5. (Man- ual No.: 3P6-28197-E0) Refer to “SHIFT SHAFT” in chapter 5. (Man- Stopper lever ual No.: 3P6-28197-E0) Gear position sensor bracket Oil seal...
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TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Shift drum assembly Shift fork-C Main axle assembly For installation, reverse the removal proce- dure. – 69 –...
ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” (the switch circuit is closed), the main switch is turned “ON” (the switch circuit is closed), and the brake lever is squeezed (the front brake light switch circuit is open) or the brake pedal is depressed (the rear brake light switch circuit is open), the starter motor can only op- erate if at least one of the following conditions is met: •...
ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar 4. Throttle bodies NG → 1. Check the fuses. (Main, signaling system, and igni- tion) Replace the fuse(s).
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ELECTRIC STARTING SYSTEM NG → 7. Check the starter relay. Refer to “CHECKING THE RE- Replace the starter relay. LAYS” on page 130. OK ↓ NG → 8. Check the brake light relay. Refer to “CHECKING THE RE- Replace the brake light relay. LAYS”...
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ELECTRIC STARTING SYSTEM NG → 17.Check the entire starting system wiring. Properly connect or repair the starting sys- Refer to “CIRCUIT DIAGRAM (1/2)” tem wiring. on page 71 and “CIRCUIT DIA- GRAM (2/2)” on page 73. OK ↓ Replace the MCU or diode 1. –...
GRIP WARMER SYSTEM ET2D21017 TROUBLESHOOTING • The grip warmers do not become warm at all. • The grip warmers are abnormally hot while the engine is idling. • The grip warmers do not become very warm while the vehicle is traveling. NOTE: •...
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GRIP WARMER SYSTEM NG → 2. Disconnect the grip warmer control unit coupler (white/yellow and black/green) and check that the Replace the ECU. temperature does not drop while the engine is running. OK ↓ Replace the grip warmer control unit. The grip warmers do not become very warm while the vehicle is traveling.
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM ET2D21035 TROUBLESHOOTING • The hand shift select indicator light fails to come on. • The transmission gear display on the multi-function meter fails to indicate the selected gear. NOTE: • Before troubleshooting, remove the following part(s): 1.
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM The transmission gear display on the multi-function meter fails to indicate the selected gear. NG → 1. Check the gear position sensor. Refer to “CHECKING THE GEAR POSITION SENSOR” on page 132 Replace the gear position sensor.
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM SHIFT Checking the YCC-S indicator and warning light The YCC-S indicator and warning light come on for 1.4 seconds after the main switch has been turned to “ON” and they come on while the start switch is being pushed. If the YCC-S indicator and warning light does not come on under these conditions, the warning light (LED) may be defective.
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YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Able/un- Fault Able/un- able to Symptom Malfunction detecting condition code No. able to start change the shift Overcurrent to clutch Detected current in clutch actuator Sh_ _13* Unable Unable actuator motor motor is too high.
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YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Able/un- Fault Able/un- able to Symptom Malfunction detecting condition code No. able to start change the shift Engine speed signal from ECU Engine speed signal Sh_ _31 does not match multi-function Unable Unable is abnormal.
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Able/un- Fault Able/un- able to Symptom Malfunction detecting condition code No. able to start change the shift Braking signal is not No braking signal is received by Sh_ _47 detected while brak- MCU (motor control unit) when ve-...
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM 5. Erase the malfunction history in the diagnos- tic mode. Refer to “Diagnostic code table (Di- agnostic code No. Sh_ _62)”. NOTE: Turning the main switch to “OFF” will not erase the malfunction history. ET2D21031...
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YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Diagnostic code table Diagnos- Data displayed on tic code Item meter (reference Checking method value) Sh_ _61 Malfunction history code display • No history Sh_ _61 — • History exists Fault code numbers If fault codes are stored in the malfunction Sh_ _11–Sh_ _52...
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YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Diagnos- Data displayed on tic code Item meter (reference Checking method value) Sh_ _63 Clutch actuation op- Sh_ _63 The clutch actuator can be operated in this eration mode. 1. The hand shift select indicator light NOTE: comes on when the clutch is engaged.
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YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Diagnos- Data displayed on tic code Item meter (reference Checking method value) Sh_ _65 Gear position setting Sh_ _65 The gear position can be set in this mode. 1. Make sure that the transmission is in neutral.
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Diagnos- Data displayed on tic code Item meter (reference Checking method value) Sh_ _66 Adjust the clutch en- Sh_ _66 This mode adjust the clutch engagement gagement position point manually. The clutch engagement point while the ve-...
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YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _11 Symptom Too low or too high voltage is supplied to the YCC-S system. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the •...
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YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _13 Symptom Over current to clutch actuator motor. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the • Wire harness MCU (motor control that may be pulled out.
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YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _14 Symptom Over current to shift actuator motor. Order Item/components and probable Check or maintenance job Reinstatement cause method • Connections • Check the coupler for any pins Turning the • Wire harness MCU (motor control that may be pulled out.
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YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _15 Symptom Abnormal current is detected in clutch or shift actuator motor drive circuit. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
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YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _16 Symptom Malfunction of clutch or shift actuator motor drive circuit in the MCU (motor control unit). Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
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YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _17 Symptom Detected clutch actuator position is incorrect. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the • Wire harness MCU (motor control that may be pulled out.
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YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _18 Symptom Detected shift actuator position is incorrect. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the • Wire harness MCU (motor control that may be pulled out.
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YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _19 Symptom Output signal of shift actuator sensor is abnor- mal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
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YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _21 Symptom Output signal of gear position sensor is abnor- mal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the •...
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YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _23 Symptom No input signal from sidestand switch. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the • Wire harness MCU (motor control that may be pulled out.
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YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _26 Symptom Abnormal clutch movement is detected during check when main switch is turned to “ON”. Order Item/components and probable Check or maintenance job Reinstatement cause method Clutch fluid • Check for clutch fluid leakage.
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YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _31 Symptom Engine speed signal is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the • Wire harness MCU (motor control that may be pulled out.
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YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _34 Symptom TPS (throttle position sensor) signal is abnor- mal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the •...
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YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _36 Symptom Output signal of clutch actuator sensor is ab- normal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the •...
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YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _37 Symptom Power supply to clutch or shift actuator motor is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
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YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _38 Symptom Malfunction of hand shift lever switch (shift up or shift down). Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the •...
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YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _41 Symptom Coolant temperature sensor signal is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the • Wire harness MCU (motor control that may be pulled out.
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YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _43 Symptom Communication between MCU (motor control unit) and ABS ECU is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the •...
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YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _45 Symptom Shift operation and gear position do not match. Order Item/components and probable Check or maintenance job Reinstatement cause method Shift rod • Check the shift rod pin hole lo- Turning the cation.
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YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _47 Symptom Braking signal is not detected while braking. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Repairing the • Wire harness MCU (motor control that may be pulled out.
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YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _49 Symptom Engine idling speed is too high when vehicle is started. Order Item/components and probable Check or maintenance job Reinstatement cause method Clutch operation. • Check the clutch stroke. Turning the Refer to “BLEEDING THE HY-...
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YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _52 Symptom Main switch signal is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the • Wire harness MCU (motor control that may be pulled out.
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YCC-S (Yamaha Chip Controlled-Shift) SYSTEM – 122 –...
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ELECTRICAL COMPONENTS 1. Windshield drive unit 2. Battery 3. Starter relay 4. ABS motor fuse 5. Front brake light switch 6. Fuse box 2 7. Fuse box 1 8. Right radiator fan motor 9. Left radiator fan motor 10. Neutral switch 11.
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ELECTRICAL COMPONENTS 1. Coolant temperature sensor 2. Throttle position sensor 3. Intake air pressure sensor 4. Intake air temperature sensor 5. ABS motor relay 6. Hydraulic unit 7. MCU (motor control unit) 8. ECU (engine control unit) 9. ABS (ECU) 10.
ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES Br/W R/Y Y Lg B Sb DOWN R/Y L/B Dg Br/W Ch O/W Br/L O/B B R/B G/R B/L G/B Shift down Shift up Br/L Br/L Br/R Br/R PUSH Br/L B Br/W Ch R/W R/B (BROWN) L/W B Br/W...
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ELECTRICAL COMPONENTS 1. Front brake light switch 2. Main switch 3. Rear brake light switch 4. Neutral switch 5. Sidestand switch 6. Hazard switch 7. Start switch 8. Engine stop switch 9. Hand shift select button 10. Hand shift lever switch (shift up) 11.
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ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 CAUTION: Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
ELECTRICAL COMPONENTS EAS28040 CHECKING THE RELAYS Result Check each switch for continuity with the pocket Continuity tester. If the continuity reading is incorrect, re- (between “3” and “4”) place the relay. Relay unit (fuel pump relay) Pocket tester 90890-03112 Analog pocket tester YU-03112-C 1.
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ELECTRICAL COMPONENTS Headlight relay (dimmer) Brake light relay First step: First step: 1. Positive tester probe 1. Positive tester probe 2. Negative tester probe 2. Negative tester probe 3. Negative tester probe Result Continuity Result (between “1” and “2”) Continuity (between “1”...
ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM Result a. Connect the pocket tester (DC 20 V) to the No continuity YCC-S speed sensor coupler (wire harness (between “1” and “2”) side) as shown. Second step: Pocket tester 90890-03112 Analog pocket tester...
ELECTRICAL COMPONENTS • Positive tester probe → Resistance blue “1” 4.0–6.0 kΩ • Negative tester probe → black/blue “2” M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester (Ω × 1k) to the gear position sensor terminals as shown.
ELECTRICAL COMPONENTS ET2D21026 CHECKING THE DIODE 2 1. Check: • Diode 2 Out of specification → Replace. Pocket tester 90890-03112 Analog pocket tester YU-03112-C c. Measure the grip warmer resistance. NOTE: L LLL L LLL L LLL L LLL L LLL The pocket tester and the analog pocket tester readings are shown in the following table.
FJR1300AS(V) 2006 FJR1300AS(V) 2006 FJR1300AS(V) 2006 FJR1300AS(V) 2006 FJR1300AS(V) 2006 WIRING DIAGRAM (1/2) SCHALTPLAN (1/2) DIAGRAMA ELÉCTRICO (1/2) SCHÉMA DE CÂBLAGE (1/2) SCHEMA ELETTRICO (1/2) L R/L R/B G/B G/B R/B R/L L W/Y W Sb W Br/W Y/G W/L L/W Y Gy/W L/B O/B L/W W/L Y Br/W O/B L/B Gy/W Y...
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FJR1300AS(V) 2006 FJR1300AS(V) 2006 FJR1300AS(V) 2006 FJR1300AS(V) 2006 FJR1300AS(V) 2006 WIRING DIAGRAM (2/2) SCHALTPLAN (2/2) DIAGRAMA ELÉCTRICO (2/2) SCHÉMA DE CÂBLAGE (2/2) SCHEMA ELETTRICO (2/2) Front cowling wire harness Faisceau de fils au carénage avant Frontverkleidungs-Kabelbaum Cablaggio elettrico del cupolino Mazo de cables del carenado delantero Sb/W R L/W...