2006 FJR1300AS(V) SUPPLEMENTARY SERVICE MANUAL 3P6-28197-E1
ET2D21027 FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the FJR1300AS(V). For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. FJR1300A(V) SERVICE MANUAL: 3P6-28197-E0 EAS20040 FJR1300AS(V) 2006 SUPPLEMENTARY SERVICE MANUAL ©2006 by Yamaha Motor Co., Ltd. First edition, February 2006 All rights reserved.
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 manual. 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. • The manual is divided into chapters and each chapter is divided into sections. The current section title “1” is shown at the top of each page. • Sub-section titles “2” appear in smaller print than the section title.
EAS20100 SYMBOLS The following symbols are used in this manual for easier understanding. NOTE: The following symbols are not relevant to every vehicle. 1 2 3 4 5 6 1. Serviceable with engine mounted 2. Filling fluid 3. Lubricant 4. Special tool 5. Tightening torque 6. Wear limit, clearance 7. Engine speed 8. Electrical data 9. Engine oil 10. Gear oil 11. Molybdenum-disulfide oil 12. Wheel-bearing grease 13. Lithium-soap-based grease 14. Molybdenum-disulfide grease 15.
EAS20110 CONTENTS FEATURES......................................................................................................... 1 OUTLINE OF THE YCC-S (Yamaha Chip Controlled-Shift) SYSTEM ......... 1 SPECIAL TOOLS ............................................................................................... 4 GENERAL SPECIFICATIONS ........................................................................... 6 ENGINE SPECIFICATIONS .......................................................................
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.............
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM......................................... 85 CIRCUIT DIAGRAM (1/2)........................................................................... 85 CIRCUIT DIAGRAM (2/2)........................................................................... 87 TROUBLESHOOTING ............................................................................... 89 MAINTENANCE OF THE MCU ..................................................................
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 according to preference.
FEATURES 3 4 5 2 6 7 8 9 1 12 1. 2. 3. 4. 5. 6. 7. 11 10 8. MCU (motor control unit) 9. Shift actuator 10. Clutch actuator 11. Foot shift switch 12. YCC-S speed sensor YCC-S test coupler YCC-S control relay YCC-S indicator and warning light YCC-S motor control fuse Hand shift switch Gear position sensor Neutral switch Shift pattern This vehicle is equipped with a constant-mesh 5-speed transmission. The gears can be shifted using either the shift pedal “1” or the hand shift switch “2”.
FEATURES Attention • Do not turn the main switch to “OFF” while the vehicle is moving, otherwise the electrical systems will be switched off, including the YCC-S system, which may result in loss of control or an accident. Make sure that the vehicle is stopped before turning the main switch to “OFF”. • The clutch will be engaged for a few seconds after the engine is stopped using the main switch if the transmission is not in neutral. This means that the vehicle cannot be moved by pushing or pulling it.
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. NOTE: • For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
SPECIAL TOOLS Tool name/Tool No.
GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model Weight With oil and fuel Maximum load 2D21(Europe except (B)and(F))(ZA) 2D22(B)(F) 2D23(AUS) 295.
ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Clutch Clutch type Clutch release method Clutch lever free play Friction plate thickness Wear limit Plate quantity Clutch plate thickness Plate quantity Warpage limit Clutch spring height Minimum height Spring quantity Push rod bending limit Clutch pressure plate stroke Transmission Transmission type Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Operation Gear ratio 1st 2nd 3rd 4th 5th Main axle run
CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Tire air pressure (measured on cold tires) Loading condition Front Rear Loading condition Front Rear High-speed riding Front Rear 0–90 kg (0–198 lb) 270 kPa (39 psi) (2.70 kgf/cm²) 290 kPa (42 psi) (2.90 kgf/cm²) 90–208 kg (198–459 lb) 270 kPa (39 psi) (2.70 kgf/cm²) 290 kPa (42 psi) (2.90 kgf/cm²) 270 kPa (39 psi) (2.70 kgf/cm²) 290 kPa (42 psi) (2.
ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Gear position sensor Output voltage (at neutral position) Resistance 0.71–0.91 V 4.0–6.0 kΩ Foot shift switch Output voltage Resistance 2.4–2.6 V 4.0–6.0 kΩ Grip warmer Resistance 1.21–1.
TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Item Thread Q’ty size Tightening torque Remarks Clutch fluid reservoir bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb) Clutch actuator bracket bolt M8 2 19 Nm (1.9 m·kg, 13 ft·lb) Clutch actuator bracket bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb) Gear position sensor cover M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) Gear position sensor screw M5 2 4 Nm (0.4 m·kg, 2.9 ft·lb) LT Gear position sensor bracket M5 2 9 Nm (0.
TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Item Thread Q’ty size Tightening torque Remarks Shift pedal bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb) LT Shift pedal pivot bolt M8 1 16 Nm (1.6 m·kg, 11 ft·lb) LT Pivot shaft locknut retainer bolt M6 1 10 Nm (1.0 m·kg, 7.
TIGHTENING TORQUES – 12 –
CABLE ROUTING EAS20430 CABLE ROUTING 3 B 4 1 2 A 5 C 6 7 8 L 24 23 K 21 22 J E 3 1 D A 20 19 18 F 2 17 16 F I G G 13 14 15 12 11 H 10 9 1 14 13 23 24 B-B 23 3 24 3 M 2 B 2 1 2 7 14 6 7 B A – 13 – 13
CABLE ROUTING 1. Brake hose (front brake master cylinder to hydraulic unit) 2. Right handlebar switch lead 3. Left handlebar switch lead 4. Left grip warmer lead 5. Hand shift switch lead 6. Right grip warmer lead 7. Main switch lead 8. Immobilizer unit lead 9. Left horn (low) 10. Brake hose (hydraulic unit to left front brake caliper) 11. Front wheel sensor lead 12. Brake hose (hydraulic unit to right front brake caliper) 13. Brake hose (metering valve to right front brake caliper) 14.
CABLE ROUTING R 18 5 18 18 3 5 5 Q 5 13 C-C 27 30 18 11 30 D-D 40 O E-E 27 30 S F 41 41 42 P B-B 14 15 16 17 D 18 5 N 4 39 C B A-A 6 7 8 9 10 11 12 19 E 20 21 13 23 24 5 G 4 3 1 A F 22 D CB B E 26 H 2 25 28 A 27 C 29 D K E A J F L 35 34 I 30 31 32 33 36 M 37 38 1 – 15 –
CABLE ROUTING 1. O2 sensor lead 2. Engine idling speed adjusting cable 3. Starter motor lead 4. Air deflector 5. Wire harness 6. Spark plug lead #4 7. Spark plug lead #1 8. Cylinders-#1/#4 ignition coil 9. Cylinders-#2/#3 ignition coil 10. Starter relay 11. Starter relay lead 12. Fuse box 2 13. Negative battery lead 14. Brake hose (front brake master cylinder to hydraulic unit) 15. Right handlebar switch lead 16. Throttle cable (accelerator cable) 17. Throttle cable (decelerator cable) 18. Battery stay 19.
CABLE ROUTING 2 3 D 4 5 6 7 8 9 E 10 1 A 1 B F C 15 G – 17 – 14 13 11 12
CABLE ROUTING 1. 2. 3. 4. 5. 6. 7. Rear wheel sensor lead Rear brake fluid reservoir Rear brake light switch lead Clutch actuator motor lead Clutch actuator sensor lead Hydraulic unit Brake hose (front brake master cylinder to hydraulic unit) 8. Brake hose (hydraulic unit to proportioning valve) 9. Brake hose (hydraulic unit to metering valve) 10. Brake hose (hydraulic unit to front brake calipers) 11. Brake hose (rear brake master cylinder to hydraulic unit) 12.
CABLE ROUTING 5 1 A 2 B 3 4 6 C 7 D E 8 13 12 11 10 9 – 19 –
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. Left horn (low) 11. Left horn (low) leads 12. Thermostat assembly breather hose 13. Joint coupler A. Fasten the handlebar switch leads, hand shift switch lead, and grip warmer leads to the front cowling wire harness with a plastic locking tie.
CABLE ROUTING 28 29 27 30 26 31 32 25 UP A-A D 16 4 5 6 7 Q 33 C 8 9 10 R S 11 T B A 19 35 34 30 U B 3 2 1 11 D C D E 12 13 F J A 24 B P A 23 O K N 21 M C L 20 22 14 19 G 18 – 21 – 17 16 I H 15
CABLE ROUTING 1. Grip warmer couplers 2. Hand shift switch coupler 3. Handlebar switch couplers 4. Right grip warmer lead 5. Right handlebar switch lead 6. Immobilizer unit lead 7. Main switch lead 8. Hand shift switch lead 9. Left grip warmer lead 10. Left handlebar switch lead 11. Stator coil lead 12. Air filter case breather hose 13. Gear position sensor lead 14. Foot shift switch lead 15. Fuel tank breather/overflow hose 16. Clutch hose 17. Sidestand switch 18. Sidestand switch lead 19.
CABLE ROUTING 2 20 21 11 22 11 3 H 22 27 23 26 B-B 3 25 24 G 1 A-A 5 C 6 7 1 2 3 4 8 A B B A A 9 10 C B F 19 18 13 17 16 D 14 15 E 11 12 I J 5 K L 6 6 12 C – 23 – 5 M
CABLE ROUTING 1. Wire harness 2. ECU (engine control unit) 3. ABS ECU (electronic control unit) 4. MCU (motor control unit) 5. Tail/brake light 6. Rear turn signal light 7. Tail/brake light assembly lead 8. License plate light lead 9. Seat lock cable 10. Shift actuator motor lead 11. ABS wire harness 12. Foot shift switch lead 13. Clutch fluid reservoir hose 14. Shift actuator sensor lead 15. Hydraulic unit breather hose 16. Stator coil lead 17. Rear shock absorber spring preload adjusting cable 18.
CABLE ROUTING F 12 11 3 4 5 6 7 8 9 D 13 10 14 E 15 16 17 A 2 C 1 18 19 B G P 20 H 21 22 I I 31 O 23 J N 24 M 25 26 30 27 29 L K 28 – 25 –
CABLE ROUTING L. Route the stator coil lead to the inside of the engine bracket (top) and under the crankcase breather hose. M. Route the wire harness (to sub-wire harness) under the fuel hose connector. N. Route the fuel pump/fuel sender lead under the fuel hose connector. O. Place the joint couplers in the area shown in the illustration, making sure that they do not protrude above the wire harness. P.
CABLE ROUTING 6 I A H 1 2 G B C 5 E F D 4 E 3 – 27 –
CABLE ROUTING 1. 2. 3. 4. 5. 6. A. B. C. D. E. F. G. H. I. Clutch actuator motor lead Clutch actuator sensor lead License plate light lead Tail/brake light assembly lead Seat lock cable Intake air temperature sensor 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.
PERIODIC MAINTENANCE EAS20450 PERIODIC MAINTENANCE EAS20460 INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
PERIODIC MAINTENANCE ODOMETER READING (× 1000 km) NO. ITEM CHECK OR MAINTENANCE JOB 1 ANNUAL CHECK 10 20 30 40 • Check operation and shock absorber for oil leakage. √ √ √ √ Rear suspension relay arm and connect19 * ing arm pivoting points • Check operation. √ √ √ √ 20 * Fuel injection • Adjust engine idling speed and synchronization. √ √ √ √ √ √ 21 Engine oil • Change. • Check oil level and vehicle for oil leakage. √ √ √ √ √ √ 22 Engine oil filter cartridge • Replace.
ENGINE EAS20470 NOTE: ENGINE In order to ensure a correct reading of the clutch fluid level, make sure the top of the reservoir is horizontal. EAS20890 CHECKING THE CLUTCH FLUID LEVEL 1. Stand the vehicle on a level surface. NOTE: Place the vehicle on the centerstand. 2. Remove: • Left side cover Refer to “GENERAL CHASSIS” in chapter 4. (Manual No.: 3P6-28197-E0) 3. Check: • Clutch fluid level Below the minimum level mark “a” → Add the recommended clutch fluid to the proper level.
ENGINE 1 b a 4 b. Turn the main switch to “ON” and check that the transmission is in neutral. c. Add the recommended clutch fluid to the proper level. d. Install the clutch fluid reservoir diaphragm. e. Connect the vacuum/pressure pump gauge set “2” tightly to the bleed screw “3”. l. Repeat steps (i) to (k) until all of the air bubbles have disappeared from the clutch fluid in the plastic hose of the vacuum/pressure pump gauge set. m. Tighten the bleed screw to specification. T. R.
ENGINE g. If the pressure plate stroke is out of specification, repeat steps (j) to (l) in the procedure for step “2. Bleed” until clutch pressure plate stroke is within specification. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3 d. Install a suitable bracket “4”, the magnet base B “5”, and the dial gauge & stand set “6”. Magnet base B 90890-06844 Magnetic base stand YU-A8438 Dial gauge & stand set 90890-01252 4. Install: • Swingarm Refer to “SWINGARM” in chapter 4. (Manual No.
ENGINE b. Start the engine. c. Shift the transmission from neutral to 1st gear and back to neutral ten times. d. Shift the transmission into 1st gear, and then apply the rear brake. NOTE: If the engine stalls, restart the engine, let it idle for at least 90 seconds, and then repeat steps (c) and (d). ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3.
CHASSIS EAS21140 CHASSIS ET2D21002 ADJUSTING THE SHIFT PEDAL 1. Check: • Shift pedal position NOTE: The shift pedal “1” can be adjusted to three positions to suit the rider’s preference as shown. 2. Adjust: • Shift pedal position ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the shift pedal “1” by removing the shift pedal bolt “2”. a. High position b. Standard position c. Low position b. Move the shift pedal to the desired position. c. Install the shift pedal bolt, and then tighten it to specification.
ELECTRICAL SYSTEM EAS21750 ECA13690 ELECTRICAL SYSTEM CAUTION: EAS21790 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs. 1. Remove: • Front cowling left inner panel 1 • Front cowling left inner panel 2 • Front cowling right inner panel 1 • Front cowling right inner panel 2 Refer to “GENERAL CHASSIS” on page 37. 2. Disconnect: • Headlight coupler “1” 3.
GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the front cowling assembly T. R. LT LT 9 10 Nm (1.0 m • kg, 7.2 ft • Ib) 8 21 10 22 T. R. 11 12 32 Nm (3.2 m • kg, 23 ft • Ib) 24 22 19 20 4 14 23 21 14 23 9 13 LT 17 6 21 18 16 11 12 3 5 Order 1 2 7 Job/Parts to remove Q’ty Remarks Open the accessory box lid.
GENERAL CHASSIS Removing the front cowling assembly T. R. LT LT 9 10 Nm (1.0 m • kg, 7.2 ft • Ib) 8 21 10 22 T. R. 32 Nm (3.2 m • kg, 23 ft • Ib) 11 12 24 22 19 20 4 14 23 21 14 23 9 13 LT 17 6 21 18 15 16 11 12 3 5 Order 1 2 7 Job/Parts to remove Q’ty Remarks 16 Front cowling left inner panel 2 1 17 Plastic band 2 Disconnect. 18 Plastic holder 1 Disconnect. 19 Handlebar switch coupler 2 Disconnect. 20 Hand shift switch coupler 2 Disconnect.
GENERAL CHASSIS Removing the air filter case 8 T. R. 18 Nm (1.8 m • kg, 13 ft • Ib) 5 12 New 7 T. R. 7 7 Nm (0.7 m • kg, 5.1 ft • Ib) 17 13 14 18 9 11 6 (4) 16 10 16 (11) 16 T. R. 8 Nm (0.8 m • kg, 5.8 ft • Ib) 15 19 20 (4) 4 19 3 2 T. R. 4 Nm (0.4 m • kg, 2.9 ft • Ib) Order Job/Parts to remove Q’ty 1 Remarks Left side cover Refer to “GENERAL CHASSIS” on page 37. T-bar Refer to “GENERAL CHASSIS” in chapter 4. (Manual No.
GENERAL CHASSIS Removing the air filter case 8 T. R. 18 Nm (1.8 m • kg, 13 ft • Ib) 5 12 New 7 T. R. 7 7 Nm (0.7 m • kg, 5.1 ft • Ib) 17 13 14 18 9 11 6 (4) 16 10 16 (11) 16 T. R. 8 Nm (0.8 m • kg, 5.8 ft • Ib) 15 19 20 (4) 4 19 3 2 T. R. 4 Nm (0.4 m • kg, 2.9 ft • Ib) Order 13 Job/Parts to remove Q’ty Remarks Bypass air unit inlet hose 1 Disconnect. 14 Crankcase breather hose 1 Disconnect.
HANDLEBARS EAS22850 HANDLEBARS Removing the left handlebar Order Job/Parts to remove Q’ty 1 Left handlebar 1 2 Left grip warmer lead 1 3 Hand shift switch lead 1 4 Left handlebar switch lead 1 5 Lead holder 1 1 6 Hand shift switch 1 7 Lead holder 2 1 8 Left handlebar switch 1 9 Grip end 1 10 Handlebar grip 1 Remarks For installation, reverse the removal procedure.
HANDLEBARS Removing the right handlebar Order Job/Parts to remove Q’ty 1 Front brake light switch connector 2 2 Front brake master cylinder holder 1 3 Front brake master cylinder assembly 1 4 Grip end 1 5 Throttle cable housing 2 6 Throttle cable 2 7 Throttle grip 1 8 Right handlebar 1 9 Right grip warmer lead 1 10 Right handlebar switch lead 1 11 Lead holder 1 12 Right handlebar switch 1 Remarks Disconnect. Disconnect.
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” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a thin coat of rubber adhesive onto the end of the left handlebar. 4. Install: • Left handlebar switch “1” NOTE: Align the projection “a” on the left handlebar switch with the hole “b” on the left handlebar.
HANDLEBARS NOTE: Fit the projections on each handlebar into the holes in the upper bracket, making sure that the handlebars are installed in the same position. a a a a b b b b c c c c es to the rear of the other section of the lead, and route the lead through the throttle cable housing. • When installing the throttle cable housing, align the projection “a” on the housing with the hole “b” in the right handlebar and be sure not to pinch the right grip warmer lead. • There should be 1–3 mm (0.
HANDLEBARS • First, tighten the upper bolt, then the lower bolt. b a 1 11.Adjust: • Throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in chapter 3. (Manual No.: 3P6-28197-E0) Throttle cable free play 3.0–5.0 mm (0.12–0.
SHAFT DRIVE EAS23550 SHAFT DRIVE EAS23660 INSTALLING THE DRIVE SHAFT AND FINAL DRIVE ASSEMBLY 1. Lubricate: • Drive shaft spline (final drive pinion gear side) Installed depth “a” 8.5–10.0 mm (0.33–0.39 in) 3 Recommended lubricant Molybdenum disulfide grease 1 2. Lubricate: • Drive shaft spline (universal joint side) 4 Recommended lubricant Lithium-soap-based grease 2 3.
ENGINE REMOVAL EAS23710 ENGINE REMOVAL Disconnecting the leads and hoses 5 . 12 R. 7 10 Nm (1.0 m • kg, 7.2 ft • Ib) 9 10 8 6 4 4 11 LT LT 2 3 1 T. R. Order Job/Parts to remove Q’ty 4 Nm (0.4 m • kg, 2.9 ft • Ib) Remarks Front fender Refer to “FRONT WHEEL” in chapter 4. (Manual No.: 3P6-28197-E0) Air filter case Refer to “GENERAL CHASSIS” on page 37. Throttle bodies Refer to “THROTTLE BODIES” in chapter 7. (Manual No.
ENGINE REMOVAL Disconnecting the leads and hoses 5 . 12 R. 7 10 Nm (1.0 m • kg, 7.2 ft • Ib) 9 10 8 6 4 4 11 LT LT 2 3 1 T. R. Order Job/Parts to remove 4 Nm (0.4 m • kg, 2.9 ft • Ib) Q’ty Remarks Refer to “SHIFT ACTUATOR AND SHIFT ROD” on page 57. Gear position sensor cover 1 Gear position sensor coupler 1 Disconnect. 2 Gear position sensor 1 3 Clutch release cylinder 1 4 Dowel pin 2 5 Crankcase breather hose 1 6 Stator coil coupler 1 Disconnect.
ENGINE REMOVAL ET2D21003 REMOVING THE GEAR POSITION SENSOR 1. Disconnect: • Gear position sensor coupler 2. Remove: • Gear position sensor 1 NOTE: Remove only the screws “1” when removing the gear position sensor. Do not remove the screws “2”. ET2D21004 1 2 1 2 INSTALLING THE GEAR POSITION SENSOR 1. Connect: • MCU coupler • ECU coupler Refer to “GENERAL CHASSIS” on page 37. 2. Install: • Gear position sensor “1” EC2D21002 CAUTION: ET3P61023 REMOVING THE ENGINE 1.
ENGINE REMOVAL ET2D21005 ADJUSTING THE GEAR POSITION SENSOR 1. Check: • Gear position sensor Refer to “CHECKING THE GEAR POSITION SENSOR” on page 132. 2. Adjust: • Gear position sensor angle 3. Check: • Gear position setting Refer to “Diagnostic code table (Diagnostic code No. Sh_ _65)”. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the gear position sensor coupler to the gear position sensor. b. Connect the digital circuit tester to the gear position sensor.
CLUTCH EAS25060 CLUTCH Removing the clutch actuator and clutch master cylinder T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) T. R. 19 Nm (1.9 m • kg, 13 ft • Ib) T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 1 6 4 5 7 8 T. R. 30 Nm (3.0 m • kg, 22 ft • Ib) 2 9 13 10 LS 3 New 16 New 11 15 12 14 T. R. Order 10 Nm (1.0 m • kg, 7.2 ft • Ib) Job/Parts to remove Q’ty Remarks Clutch fluid Drain. Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” on page 31. Swingarm Refer to “SWINGARM” in chapter 4.
CLUTCH Removing the clutch actuator and clutch master cylinder T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) T. R. 19 Nm (1.9 m • kg, 13 ft • Ib) T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 1 6 4 5 7 8 T. R. 30 Nm (3.0 m • kg, 22 ft • Ib) 2 9 13 10 LS 3 New 16 New 11 15 12 14 T. R. Order 10 Nm (1.0 m • kg, 7.
CLUTCH Disassembling the clutch master cylinder 2 ∗ New 1 Order Job/Parts to remove Q’ty 1 Clutch master cylinder kit 1 2 Clutch master cylinder body 1 Remarks For assembly, reverse the disassembly procedure.
CLUTCH Removing the clutch release cylinder Order Job/Parts to remove Q’ty Remarks Drain. Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” on page 31. Clutch fluid 1 Clutch hose union bolt 1 2 Copper washer 2 3 Clutch hose 1 4 Clutch release cylinder 1 5 Dowel pin 2 6 Plate 1 Disconnect. For installation, reverse the removal procedure.
CLUTCH ET2D21037 BREAKING IN THE FRICTION PLATES AFTER REPLACEMENT 1. If the friction plates are replaced, perform the following procedure to break them in. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Start the engine and warm it up until at least three segments appear on the coolant temperature meter “1” as shown in the illustration. 3. Replace: • Clutch master cylinder kit 1 NOTE: The thickness of the new shim “1” is 1.5 mm (0.06 in). b. Apply the rear brake forcefully. c.
CLUTCH ET2D21039 Pressure plate stroke Action Pressure plate stroke before replacing the clutch master cylinSelect diagnostic der kit was 2.90 mm code No. Sh_ _66 in (0.11 in) or more, or the diagnostic mode the difference in the and operate the hand pressure plate stroke shift lever switch before and after re- (shift up) three times. placing is 0.10 mm (0.004 in) or more For all other cases Select diagnostic code No.
SHIFT ACTUATOR AND SHIFT ROD ET2D21006 SHIFT ACTUATOR AND SHIFT ROD Removing the shift actuator, shift rod and foot shift switch T. R. 4 Nm (0.4 m • kg, 2.9 ft • Ib) LT LT 3 2 10 LT 4 9 11 13 14 15 LS 5 LT T. 20 Nm (2.0 m • kg, 14 ft • Ib) R. T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) LS LS LT LT 17 18 1 19 16 7 6 8 12 LT T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. 49 Nm (4.9 m • kg, 35 ft • Ib) T. R. 65 Nm (6.5 m • kg, 47 ft • Ib) T. R. 16 Nm (1.6 m • kg, 11 ft • Ib) T. R.
SHIFT ACTUATOR AND SHIFT ROD Removing the shift actuator, shift rod and foot shift switch T. R. 4 Nm (0.4 m • kg, 2.9 ft • Ib) LT LT 3 2 10 LT 4 9 11 13 14 15 LS 5 LT T. 20 Nm (2.0 m • kg, 14 ft • Ib) R. T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) LS LS LT LT 17 18 1 19 16 7 6 8 12 LT T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. 49 Nm (4.9 m • kg, 35 ft • Ib) T. R. 65 Nm (6.5 m • kg, 47 ft • Ib) T. R. 16 Nm (1.6 m • kg, 11 ft • Ib) T. R.
SHIFT ACTUATOR AND SHIFT ROD ET2D21007 REMOVING THE SHIFT ACTUATOR 1. Remove: • Shift actuator ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 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. b. Remove the shift rod “2”.
SHIFT ACTUATOR AND SHIFT ROD 4. Adjust: • Foot shift switch Refer to “ADJUSTING THE FOOT SHIFT SWITCH” on page 60. T. Shift pedal pivot bolt 16 Nm (1.6 m·kg, 11 ft·lb) LOCTITE® R. NOTE: ET2D21010 • Position the projection “a” on the shift pedal between the ends “b” of the spring on the left footrest assembly. • Be sure to fit the projections “c” on the shift pedal pivot into the holes “d” in the left footrest assembly. ADJUSTING THE FOOT SHIFT SWITCH 1.
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) T. 2 R. 3 1 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ET2D21011 INSTALLING THE LEFT FOOTREST ASSEMBLY 1. Install: • Sidestand • Left footrest assembly 1 T. R. Left footrest assembly/sidestand bolt 65 Nm (6.5 m·kg, 47 ft·lb) LOCTITE® Left footrest assembly bolt (M8) 28 Nm (2.8 m·kg, 20 ft·lb) Left footrest assembly bolt (M10) 49 Nm (4.9 m·kg, 35 ft·lb) NOTE: 2 c.
SHIFT ACTUATOR AND SHIFT ROD T. R. Shift rod front locknut 7 Nm (0.7 m·kg, 5.1 ft·lb) Shift rod rear locknut 10 Nm (1.0 m·kg, 7.2 ft·lb) h. Pull out the rod from the holes.
SHIFT SHAFT EAS25410 SHIFT SHAFT EAS25450 INSTALLING THE SHIFT SHAFT 1. Install: • Stopper lever “1” • Stopper lever spring “2” b NOTE: • Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss “3”. • Mesh the stopper lever with the shift drum segment assembly. 1 2 3 2. Install: • Shift shaft “1” NOTE: Hook the end of the shift shaft spring onto the shift shaft spring stopper “2”. 2 1 3. Install: • Front shift arm “1” T. R. Front shift arm bolt 10 Nm (1.
MIDDLE GEAR EAS25710 MIDDLE GEAR Removing the middle gear Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” in chapter 5. (Manual No.: 3P6-28197-E0) Oil pan/Oil pump Refer to “OIL PUMP” in chapter 5. (Manual No.
MIDDLE GEAR Removing the middle gear Order 14 Job/Parts to remove Q’ty Middle drive shaft assembly 1 15 Spacer 1 16 Middle driven gear 1 17 Bearing retainer 1 18 Bearing 1 19 Middle drive pinion gear shim 20 Bearing Remarks 1 For installation, reverse the removal procedure.
CRANKCASE EAS25540 CRANKCASE Separating the crankcase T. R. T. R. 1st 20 Nm (2.0 m • kg, 14 ft • Ib) 2nd 20 Nm (2.0 m • kg, 14 ft • Ib) Final Specified angle 115–125˚ T. (10) R. 24 Nm (2.4 m • kg, 17 ft • Ib) (10) T. R. (4) E E E E E 10 Nm (1.0 m • kg, 7.2 ft • Ib) R. (2) T. (2) 12 Nm (1.2 m • kg, 8.7 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) E E E 10 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. 12 Nm (1.2 m • kg, 8.
CRANKCASE Separating the crankcase T. R. T. R. 1st 20 Nm (2.0 m • kg, 14 ft • Ib) 2nd 20 Nm (2.0 m • kg, 14 ft • Ib) Final Specified angle 115–125˚ T. (10) R. 24 Nm (2.4 m • kg, 17 ft • Ib) (10) T. R. (4) E E E E E 10 Nm (1.0 m • kg, 7.2 ft • Ib) R. (2) T. (2) 12 Nm (1.2 m • kg, 8.7 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) E E E 10 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. 12 Nm (1.2 m • kg, 8.7 ft • Ib) LT LT 11 3 New 11 LT LT 9 11 8 2 LT 1 5 R. Order 7 T.
TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Crankcase Separate. Refer to “CRANKCASE” in chapter 5. (Manual No.: 3P6-28197-E0) Stopper lever Refer to “SHIFT SHAFT” in chapter 5. (Manual No.
TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty 13 Shift drum assembly 1 14 Shift fork-C 1 15 Main axle assembly 1 Remarks For installation, reverse the removal procedure.
TRANSMISSION – 70 –
B L/Y (BLACK) (BLACK) (BLACK) L B 74 Br/B L B 77 L L G/Y R B (BLACK) L B 76 Br/B Br/B R/W R B 75 L/Y L/Y Br/B G/Y 73 R/W – 71 – R/B R ON OFF P 1 78 B Lg/W (BLUE) R/B G/L Br/L Br/L Br/L Br/L Br/R Br/L Br/R R R Br/L Br/R W/Y B/G (BLUE) Br W/B 71 70 69 68 67 R Br/L Br L/R B Lg/W 72 Br/B R/W R/Y Br/R R/Y R/Y B B W W W R W W W G/L R/B R/Y G/L R/Y Y/W Y/W G/L (BLACK) 66 2 R Br/L 3 (GRAY) WWW R R Br/L Br/R B B/W G/L R/W R/
ELECTRIC STARTING SYSTEM 1. Main switch 7. Main fuse 8. Battery 10.Starter relay 11.Starter motor 12.Diode 1 17.Coupler 2 (wire harness–front cowling wire harness) 18.Neutral switch 25.Rear brake light switch 27.Brake light relay 33.Coupler 3 (wire harness–front cowling wire harness) 34.Sidestand switch 56.MCU (motor control unit) 64.YCC-S control relay 65.Coupler 6 (wire harness–front cowling wire harness) 68.Signaling system fuse 70.
R/B Br/L (BLACK) (BLACK) B B R/B Br/L 123 R/B R L/W R/B L/R Br/B Br R/Y R/W G/L (GRAY) Br Br/L (GRAY) Br R Br/L 122 B B Br/B L/R R/B L/Y Br/R G/L R/W R/Y Br 65 L/W Br R/W R/Y Br/B G/L L/R – 73 – R/G R/B B/R B Br Sb Sb Br/R Lg R 121 Br B Br/Y B (BLACK) B Br/B (BLACK) B B/R R/B Lg Sb Sb/W Br R/G Lg Sb/W R/B B/R B 79 Br/B R/B B/R L/R B L/R Br/G 80 B Y B B B B L/R B B B B L/R 117 (BLACK) L/B G Y G/L Ch R/Y Sb/W P L/B Br/G Dg Lg Br/G R/B W/L R
ELECTRIC STARTING SYSTEM 17.Coupler 2 (front cowling wire harness–wire harness) 33.Coupler 3 (front cowling wire harness–wire harness) 65.Coupler 6 (front cowling wire harness–wire harness) 82.Front brake light switch 83.Engine stop switch 84.Start switch 92.Relay unit 93.
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 operate if at least one of the following conditions is met: • The transmission is in neutral (the neutral switch is
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 1. Check the fuses. (Main, signaling system, and ignition) Refer to “CHECKING THE FUSES” in chapter 8. (Manual No.: 3P628197-E0) NG → Replace the fuse(s). OK ↓ 2. Check the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 8. (Manual No.
ELECTRIC STARTING SYSTEM 7. Check the starter relay. Refer to “CHECKING THE RELAYS” on page 130. NG → Replace the starter relay. OK ↓ 8. Check the brake light relay. Refer to “CHECKING THE RELAYS” on page 130. NG → Replace the brake light relay. OK ↓ 9. Check the YCC-S control relay. Refer to “CHECKING THE RELAYS” on page 130. NG → Replace the YCC-S control relay. OK ↓ 10.Check the main switch. Refer to “CHECKING THE SWITCHES” on page 127. NG → Replace the main switch/immobilizer unit. OK ↓ 11.
ELECTRIC STARTING SYSTEM 17.Check the entire starting system wiring. Refer to “CIRCUIT DIAGRAM (1/2)” on page 71 and “CIRCUIT DIAGRAM (2/2)” on page 73. NG → Properly connect or repair the starting system wiring. OK ↓ Replace the MCU or diode 1.
L/Y (BLACK) B (BLACK) L B 74 Br/B L B 77 L L G/Y R (BLACK) B (BLACK) L B 76 Br/B Br/B R/W R B 75 L/Y L/Y Br/B G/Y 73 R/W – 79 – R/B R ON OFF P 1 W/Y B/G B Lg/W 78 (BLUE) (BLUE) 71 70 69 68 67 R Br/L Br L/R B Lg/W 72 Br/B R/W R/Y Br/R Br W/B R Br/L Br/R R/B G/L Br/L Br/L Br/L Br/L Br/R Br/L Br/R R R/Y R/Y B B W W W R W W W G/L R/B R/Y G/L R/Y Y/W Y/W G/L (BLACK) 66 2 R Br/L 3 L (GRAY) WWW R R Br/L Br/R B B/W G/L R/W
GRIP WARMER SYSTEM 1. Main switch 7. Main fuse 8. Battery 43.ECU (engine control unit) 65.Coupler 6 (wire harness–front cowling wire harness) 66.Headlight (on/off)/grip warmer relay 68.Signaling system fuse 69.Headlight fuse 72.
GRIP WARMER SYSTEM ET2D21016 CIRCUIT DIAGRAM (2/2) Front cowling wire harness R L/W R L/W L/Y R/W L/G B/R S R/B R/W 81 Br Dg W/L R/W G/Y Ch Br/G B R/W L/W R/B R/B 83 82 Dg Br W/L 84 8 B Br/W Ch G/Y Br G/Y B R 65 Br R/Y R/W G/L R L/W R/B L/R Br/B L/W Br R/W R/Y Br/B G/L L/R G/L R/W R/Y Br Br/B L/R R/B L/Y Br/R R/B L/R 80 Br/G 86 Br/B Br/Y B 79 R/B (BLACK) R/Y Br/G Br/G Dg Lg B B Y Lg Dg Br/W L/R Ch R/Y Sb/W P L/B L/B P Sb R/Y Ch Y 87 88 89 DOWN B 122 123
GRIP WARMER SYSTEM 65.Coupler 6 (front cowling wire harness–wire harness) 122.Right grip warmer 123.
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: • Before troubleshooting, remove the following part(s): 1. Front cowling assembly The grip warmers do not become warm at all. 1. Check the fuses. (Main, signaling system, and headlight) Refer to “CHECKING THE FUSES” in chapter 8. (Manual No.
GRIP WARMER SYSTEM 2. Disconnect the grip warmer control unit coupler (white/yellow and black/green) and check that the temperature does not drop while the engine is running. NG → Replace the ECU. OK ↓ Replace the grip warmer control unit. The grip warmers do not become very warm while the vehicle is traveling. 1.
L/Y (BLACK) L (BLACK) (BLACK) L B 74 Br/B B B 77 L L G/Y R B (BLACK) L B 76 Br/B Br/B R/W R B 75 L/Y L/Y Br/B G/Y 73 R/W – 85 – R/B R ON OFF P 1 W/Y B/G B Lg/W 78 (BLUE) (BLUE) 71 70 69 68 67 R Br/L Br L/R B Lg/W 72 Br/B R/W R/Y Br/R Br W/B R Br/L Br/R R/B G/L Br/L Br/L Br/L Br/L Br/R Br/L Br/R R R/Y R/Y B B W W W R W W W G/L R/B R/Y G/L R/Y Y/W Y/W G/L (BLACK) 66 2 R Br/L 3 (GRAY) WWW R R Br/L Br/R B B/W G/L R/W R/
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM 1. Main switch 7. Main fuse 8. Battery 14.Coupler 1 (wire harness–front cowling wire harness) 17.Coupler 2 (wire harness–front cowling wire harness) 20.ABS ECU (electronic control unit) 25.Rear brake light switch 27.Brake light relay 33.Coupler 3 (wire harness–front cowling wire harness) 34.Sidestand switch 43.ECU (engine control unit) 52.Shift actuator motor 53.Shift actuator sensor 54.Clutch actuator sensor 55.Clutch actuator motor 56.
– 87 – R/B Br/L (BLACK) (BLACK) B B R/B Br/L 123 R/B R L/W R/B L/R Br/B Br R/Y R/W G/L (GRAY) Br Br/L (GRAY) Br R Br/L 122 B B Br/B L/R R/B L/Y Br/R G/L R/W R/Y Br 65 L/W Br R/W R/Y Br/B G/L L/R R/G R/B B/R B Br Sb Sb Br/R Lg R 121 Br B Br/Y B (BLACK) B Br/B (BLACK) B B/R R/B Lg Sb Sb/W Br R/G Lg Sb/W R/B B/R B 79 Br/B R/B B/R L/R B L/R Br/G 80 B Br Dg Y B B B B L/R B B B B L/R 117 (BLACK) L/B G Y G/L Ch R/Y Sb/W P L/B Br/G Dg Lg Br/G R/B
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM 14.Coupler 1 (front cowling wire harness–wire harness) 17.Coupler 2 (front cowling wire harness–wire harness) 33.Coupler 3 (front cowling wire harness–wire harness) 58.Coupler 4 (front cowling wire harness–wire harness) 60.Coupler 5 (front cowling wire harness–wire harness) 65.Coupler 6 (front cowling wire harness–wire harness) 82.Front brake light switch 83.Engine stop switch 84.Start switch 92.Relay unit 93.Starting circuit cut-off relay 100.
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. Front cowling assembly 1. Check the fuses. (Main, ignition and signaling system) Refer to “CHECKING THE FUSES” in chapter 8. (Manual No.: 3P628197-E0). NG → Replace the fuse(s). OK ↓ 2. Check the battery.
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM The transmission gear display on the multi-function meter fails to indicate the selected gear. 1. Check the gear position sensor. Refer to “CHECKING THE GEAR POSITION SENSOR” on page 132 and “ADJUSTING THE GEAR POSITION SENSOR” on page 50. NG → Replace the gear position sensor. OK ↓ 2. Check the gear position setting. Refer to “Diagnostic code table (Diagnostic code No. Sh_ _65)”. NG → Replace the MCU (motor control unit). OK ↓ Replace the meter assembly.
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM 3 SHIFT 1 2 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. a b c d a. Main switch “OFF” b. Main switch “ON” c. YCC-S indicator and warning light off c d.
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Able/unAble/unable to Malfunction detecting condition able to start change the shift Fault code No. Symptom Sh_ _13* Overcurrent to clutch actuator motor Detected current in clutch actuator Unable motor is too high. Unable Sh_ _14* Overcurrent to shift actuator motor Detected current in shift actuator motor is too high. Unable Unable Sh_ _15* Abnormal current is detected in clutch or shift actuator motor drive circuit.
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Symptom Able/unAble/unable to Malfunction detecting condition able to start change the shift Sh_ _31 Engine speed signal is abnormal. Engine speed signal from ECU does not match multi-function meter engine speed. Unable Unable Sh_ _32* YCC-S speed sensor signal is abnormal. YCC-S speed sensor signal does not match multi-function meter ve- Unable hicle speed. Unable Sh_ _34 TPS (throttle position sensor) signal is abnormal.
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Symptom Able/unAble/unable to Malfunction detecting condition able to start change the shift Sh_ _47 Braking signal is not detected while braking. No braking signal is received by MCU (motor control unit) when ve- Able hicle is braking. Sh_ _48* Improper engine idling Engine speed at engine start-up speed adjustment. exceeds the set limit.
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM 5. Erase the malfunction history in the diagnostic mode. Refer to “Diagnostic code table (Diagnostic code No. Sh_ _62)”. NOTE: Turning the main switch to “OFF” will not erase the malfunction history. ET2D21031 DIAGNOSTIC MODE Setting the diagnostic mode 1. Turn the main switch to “OFF”. 2. Remove the front cowling left inner panel 1 to access the YCC-S test coupler “1”. 3. Remove the protective cap from the YCC-S test coupler. 4.
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Diagnostic code table Diagnostic code No. Item Data displayed on meter (reference value) Checking method 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 history, the hand shift select indicator light • (First displays Sh_ will come on. _61 for 6 seconds, and then displays each fault code number that is stored in the malfunction history.
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Diagnostic code No. Item Sh_ _63 Clutch actuation operation Data displayed on meter (reference value) Sh_ _63 The clutch actuator can be operated in this mode. 1. The hand shift select indicator light comes on when the clutch is engaged. 2. Set the engine stop switch to “ ” and push the hand shift select button simultaneously. The clutch will disengage and the hand shift select indicator light will go off. 3.
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Diagnostic code No. Item Data displayed on meter (reference value) Sh_ _65 Gear position setting Sh_ _65 Checking method The gear position can be set in this mode. 1. Make sure that the transmission is in neutral. 2. Push the start switch. If the gear position sensor output signal is correct for the neutral position, the hand shift select indicator light will come on for 0.5 second. 3.
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Diagnostic code No. Item Sh_ _66 Adjust the clutch engagement position Data displayed on meter (reference value) Sh_ _66 Checking method This mode adjust the clutch engagement point manually. The clutch engagement point while the vehicle is starting off can be adjusted manually to 21 engine speed settings in this mode. The initial setting of the clutch engagement point varies according to the vehicle.
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 cause Check or maintenance job 1 Connections • Wire harness MCU (motor control unit) coupler • Check the coupler for any pins Repairing the that may be pulled out. cause of the • Check the locking condition of malfunction. the coupler. • If there is a malfunction, repair it and connect the coupler securely.
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _13 Symptom Over current to clutch actuator motor. Order Item/components and probable cause Check or maintenance job Reinstatement method 1 Connections • Wire harness MCU (motor control unit) coupler • Clutch actuator motor coupler • Check the coupler for any pins that may be pulled out. • Check the locking condition of the coupler. • If there is a malfunction, repair it and connect the coupler securely.
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _14 Symptom Over current to shift actuator motor. Order Item/components and probable cause Check or maintenance job Reinstatement method 1 • Connections • Wire harness MCU (motor control unit) coupler • Shift actuator motor coupler • Check the coupler for any pins that may be pulled out. • Check the locking condition of the coupler. • If there is a malfunction, repair it and connect the coupler securely.
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 cause Check or maintenance job Reinstatement method 1 Connections • Wire harness MCU (motor control unit) coupler • Clutch actuator motor coupler • Shift actuator motor coupler • Check the coupler for any pins that may be pulled out. • Check the locking condition of the coupler.
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 cause Check or maintenance job Reinstatement method 1 Connections • Wire harness MCU (motor control unit) coupler • Clutch actuator motor coupler • Shift actuator motor coupler • Check the coupler for any pins that may be pulled out. • Check the locking condition of the coupler.
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _17 Symptom Detected clutch actuator position is incorrect. Order Item/components and probable cause Check or maintenance job Reinstatement method 1 Connections • Wire harness MCU (motor control unit) coupler • Clutch actuator motor coupler • Check the coupler for any pins that may be pulled out. • Check the locking condition of the coupler. • If there is a malfunction, repair it and connect the coupler securely.
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _18 Symptom Detected shift actuator position is incorrect. Order Item/components and probable cause Check or maintenance job Reinstatement method 1 Connections • Wire harness MCU (motor control unit) coupler • Shift actuator motor coupler • Check the coupler for any pins that may be pulled out. • Check the locking condition of the coupler. • If there is a malfunction, repair it and connect the coupler securely.
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _19 Symptom Output signal of shift actuator sensor is abnormal. Order Item/components and probable cause Check or maintenance job Reinstatement method 1 Connections • Wire harness MCU (motor control unit) coupler • Shift actuator sensor coupler • Check the coupler for any pins that may be pulled out. • Check the locking condition of the coupler. • If there is a malfunction, repair it and connect the coupler securely.
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _21 Symptom Output signal of gear position sensor is abnormal. Order Item/components and probable cause Check or maintenance job 1 Connections • Wire harness MCU (motor control unit) coupler • Gear position sensor coupler • Check the coupler for any pins Repairing the that may be pulled out. cause of the • Check the locking condition of malfunction. the coupler. • If there is a malfunction, repair it and connect the coupler securely.
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _23 Symptom No input signal from sidestand switch. Order Item/components and probable cause Check or maintenance job 1 Connections • Wire harness MCU (motor control unit) coupler • Check the coupler for any pins Repairing the that may be pulled out. cause of the • Check the locking condition of malfunction. the coupler. • If there is a malfunction, repair it and connect the coupler securely. 2 Open circuit in wire harness.
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 cause Check or maintenance job Reinstatement method 1 Clutch fluid • Check for clutch fluid leakage. • Check the clutch fluid level. Refer to “CHECKING THE CLUTCH FLUID LEVEL” on page 31. Turning the main switch to “OFF”. See NOTE. 2 Air in hydraulic clutch system • Check the clutch stroke.
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _31 Symptom Engine speed signal is abnormal. Order Item/components and probable cause Check or maintenance job 1 Connections • Wire harness MCU (motor control unit) coupler • Wire harness ECU coupler • Check the coupler for any pins Repairing the that may be pulled out. cause of the • Check the locking condition of malfunction. the coupler. • If there is a malfunction, repair it and connect the coupler securely.
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _34 Symptom TPS (throttle position sensor) signal is abnormal. Order Item/components and probable cause Check or maintenance job 1 Connections • Wire harness MCU (motor control unit) coupler • Wire harness ECU coupler • Check the coupler for any pins Repairing the that may be pulled out. cause of the • Check the locking condition of malfunction. the coupler. • If there is a malfunction, repair it and connect the coupler securely.
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _36 Symptom Output signal of clutch actuator sensor is abnormal. Order Item/components and probable cause Check or maintenance job 1 Connections • Wire harness MCU (motor control unit) coupler • Clutch actuator sensor coupler • Check the coupler for any pins Repairing the that may be pulled out. cause of the • Check the locking condition of malfunction. the coupler. • If there is a malfunction, repair it and connect the coupler securely.
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 cause Check or maintenance job Reinstatement method 1 Connections • Wire harness MCU (motor control unit) coupler • Clutch actuator motor coupler • Shift actuator motor coupler • Check the coupler for any pins that may be pulled out. • Check the locking condition of the coupler.
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 cause Check or maintenance job 1 Connections • Wire harness MCU (motor control unit) coupler • Hand shift switch coupler • Check the coupler for any pins Repairing the that may be pulled out. cause of the • Check the locking condition of malfunction. the coupler.
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _41 Symptom Coolant temperature sensor signal is abnormal. Order Item/components and probable cause Check or maintenance job 1 Connections • Wire harness MCU (motor control unit) coupler • Wire harness ECU coupler • Check the coupler for any pins Repairing the that may be pulled out. cause of the • Check the locking condition of malfunction. the coupler. • If there is a malfunction, repair it and connect the coupler securely.
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 cause Check or maintenance job 1 Connections • Wire harness MCU (motor control unit) coupler • ABS ECU coupler • Check the coupler for any pins Repairing the that may be pulled out. cause of the • Check the locking condition of malfunction. the coupler.
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 cause Check or maintenance job Reinstatement method 1 Shift rod • Check the shift rod pin hole location. • Check the shift rod groove location. • Adjust or replace if defective. Refer to “CHECKING THE SHIFT ROD” on page 59 and “INSTALLING THE SHIFT ACTUATOR” on page 61. Turning the main switch to “OFF”. See NOTE. 2 Defective shift actuator.
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 cause Check or maintenance job 1 Connections • Wire harness MCU (motor control unit) coupler • Brake light relay coupler • Check the coupler for any pins Repairing the that may be pulled out. cause of the • Check the locking condition of malfunction. the coupler. • If there is a malfunction, repair it and connect the coupler securely.
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 cause Check or maintenance job Reinstatement method 1 Clutch operation. • Check the clutch stroke. Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” on page 31. Turning the main switch to “OFF”. See NOTE. 2 Clutch slippage. • Check the friction plate thickness and replace the friction plates if necessary.
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM Fault code No. Sh_ _52 Symptom Main switch signal is abnormal. Order Item/components and probable cause Check or maintenance job Reinstatement method 1 Connections • Wire harness MCU (motor control unit) coupler • Check the coupler for any pins that may be pulled out. • Check the locking condition of the coupler. • If there is a malfunction, repair it and connect the coupler securely. Turning the main switch to “OFF”. See NOTE.
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM – 122 –
ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 2 3 4 1 5 6 7 19 20 18 8 17 9 10 16 15 11 14 13 – 123 – 12
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. Sidestand switch 12. YCC-S speed sensor 13. Oil level switch 14. Rear brake light switch 15. Left horn (low) 16. Right horn (high) 17. Ignition coil 18. Main fuse 19. Diode 1 20.
ELECTRICAL COMPONENTS 3 2 1 4 21 5 20 6 19 7 18 17 8 9 16 10 15 14 11 13 12 – 125 –
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. Cylinder identification sensor 11. O2 sensor 12. Crankshaft position sensor 13. Accessory box solenoid 14. Headlight relay (dimmer) 15. Radiator fan motor relay 16. Headlight (on/off)/grip warmer relay 17. Brake light relay 18. YCC-S control relay 19.
ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES B L/B Y Lg Dg Br/W P Sb R/Y Ch 14 R/Y Y 15 Lg B Sb UP 13 1 DOWN R/Y L/B 16 Dg Br/W Ch 12 B P Br O/W Br/L O/B B G/Y R/B G/R B/L G/B 10 11 O/W B/L O/B G/R B/L G/B 2 Shift down Shift up 9 B/L Br/L R Br/L Br/R PUSH ON OFF P Dg Br R/W L/W R/B B Br/W Ch G/Y 8 3 R/W R/B 7 B B (BROWN) L/W B 6 Dg Br/W Ch 4 Sb 5 B B (BLUE) – 127 – Br/R R Br/L
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. Hand shift lever switch (shift down) 12. Horn switch 13. Dimmer switch 14. Pass switch 15. Windshield position switch 16.
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 Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, replace the relay. Result Continuity (between “3” and “4”) Relay unit (fuel pump relay) Pocket tester 90890-03112 Analog pocket tester YU-03112-C 1. Disconnect the relay from the wire harness. 2. Connect the pocket tester (Ω × 1) and battery (12 V) to the relay terminals as shown. Check the relay operation. Out of specification → Replace. 1. 2. 3. 4.
ELECTRICAL COMPONENTS Headlight relay (dimmer) Brake light relay First step: First step: 2 1 3 1 2 B Br/ B Br G/Y G L/B Y Y/G G/L 1. Positive tester probe 2. Negative tester probe 1. Positive tester probe 2. Negative tester probe 3. Negative tester probe Result Continuity (between “1” and “2”) No continuity (between “1” and “3”) Result Continuity (between “1” and “2”) Second step: 4 Second step: + 3 3 5 4 1 Br/ B Br G/Y 2 1 B Y /G G L/B Y G/L 1. 2. 3. 4. 5.
ELECTRICAL COMPONENTS Result No continuity (between “1” and “2”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (DC 20 V) to the YCC-S speed sensor coupler (wire harness side) as shown. Second step: Pocket tester 90890-03112 Analog pocket tester YU-03112-C 3 + 4 2 • Positive tester probe → white/yellow “1” • Negative tester probe → black/blue “2” 1 Y/G G L/Y L/W 1. 2. 3. 4.
ELECTRICAL COMPONENTS Resistance 4.0–6.0 kΩ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Positive tester probe → blue “1” • Negative tester probe → black/blue “2” a. Connect the pocket tester (Ω × 1k) to the gear position sensor terminals as shown. 2 1 Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Positive tester probe → blue “1” • Negative tester probe → black/blue “2” 1 B O L b. Measure the foot shift switch maximum resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2 3.
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. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ET2D21025 CHECKING THE GRIP WARMER CONTROL UNIT 1. Check: • Grip warmer control unit continuity Out of specification → Replace. NOTE: The pocket tester and the analog pocket tester readings are shown in the following table.
ELECTRICAL COMPONENTS – 135 –
EAS28740 WIRING DIAGRAM FJR1300AS(V) 2006 1. Main switch 2. Rectifier/regulator 3. AC magneto 4. ABS ECU fuse 5. Fuel injection system fuse 6. Backup fuse (odometer, clock, immobilizer system, and windshield drive system) 7. Main fuse 8. Battery 9. ABS motor fuse 10. Starter relay 11. Starter motor 12. Diode 1 13. Immobilizer unit 14. Coupler 1 (wire harness–front cowling wire harness) 15. Fuel pump 16. Fuel sender 17. Coupler 2 (wire harness–front cowling wire harness) 18. Neutral switch 19.
P/W R/B R/G R/L R/W R/Y Sb/W W/B W/G W/L W/Y Y/B Y/G Y/L Y/W Pink/White Red/Black Red/Green Red/Blue Red/White Red/Yellow Sky blue/White White/Black White/Green White/Blue White/Yellow Yellow/Black Yellow/Green Yellow/Blue Yellow/White
YAMAHA MOTOR CO., LTD.
FJR1300AS(V) 2006 WIRING DIAGRAM (1/2) FJR1300AS(V) 2006 SCHALTPLAN (1/2) FJR1300AS(V) 2006 SCHÉMA DE CÂBLAGE (1/2) A B L O L B/L O/G WIRE HARNESS C Sb W/Y W O Sb B G/R Lg O/G B/L WIRE HARNESS SUB-LEAD 1 W W/Y ABS WIRE HARNESS E D L/W W/L Y Br/W Br/W Y/G W/L L/W B Br/B B/W G/Y G/Y B/W Br/B B Lg G/R B FJR1300AS(V) 2006 DIAGRAMA ELÉCTRICO (1/2) FJR1300AS(V) 2006 SCHEMA ELETTRICO (1/2) WIRE HARNESS B/W R/L ABS WIRE HARNESS B/W R/L WIRE HARNESS ABS WIRE HARNESS F L R/L R/B G/
FJR1300AS(V) 2006 WIRING DIAGRAM (2/2) Front cowling wire harness FJR1300AS(V) 2006 SCHALTPLAN (2/2) Frontverkleidungs-Kabelbaum FJR1300AS(V) 2006 SCHÉMA DE CÂBLAGE (2/2) Faisceau de fils au carénage avant 92 R/B L/W L/W R 93 R L/W FJR1300AS(V) 2006 DIAGRAMA ELÉCTRICO (2/2) Mazo de cables del carenado delantero FJR1300AS(V) 2006 SCHEMA ELETTRICO (2/2) Cablaggio elettrico del cupolino Sb/W 94 R/B W/L R/L L/G L/W L/Y R/W L/G B/R Sb B/R Sb/W R/W R/B R/W 81 Br Dg W/L R/W G/Y Ch Br/G B R/W L/
