2005 TDM900A(T) 5PS1-AE4 SUPPLEMENTARY SERVICE MANUAL
FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the TDM900A(T) 2005. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. TDM900(N) 2001 SERVICE MANUAL: 5PS1-AE1 TDM900(R) 2003 SUPPLEMENTARY SERVICE MANUAL: 5PS1-AE2 TDM900(S) 2004 SUPPLEMENTARY SERVICE MANUAL: 5PS1-AE3 TDM900A(T) 2005 SUPPLEMENTARY SERVICE MANUAL ©2004 by Yamaha Motor Co., Ltd.
EAS00002 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.
EAS00007 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. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to “SYMBOLS”. Each chapter is divided into sections.
EAS00008 SYMBOLS The following symbols are not relevant to every vehicle. Symbols to indicate the subject of each chapter. General information Specifications Periodic checks and adjustments Chassis Engine Cooling system Fuel injection system Electrical system Troubleshooting Symbols to indicate the following.
CONTENTS GENERAL INFORMATION FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTRUMENT PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 4 SPECIFICATIONS GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ANTI-LOCK BRAKE SYSTEM (ABS) . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ABS COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ABS CONNECTOR LOCATION CHART. . . . . . . . . . . . . . . . . . . . ECU (ABS) AND FAIL-SAFE RELAY . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE ANTI-LOCK BRAKE SYSTEM. .
FEATURES GEN INFO GENERAL INFORMATION FEATURES INSTRUMENT PANEL Clock TRIP/ODO meter SELECT button RESET button Engine trouble warning light Function indication The indications of the self-diagnosis function can be checked and inspection operations can be performed through the use of the multi-function meter on the instrument panel. Based on the signals received from the sensors, the ECU inputs the signals into the multi-function meter.
GEN INFO FEATURES CO ADJUSTMENT MODE Cylinder identification For #1 For #2 CO data Example: lean –128 DIAGNOSTIC MONITORING MODE 0 rich 128 Diagnostic monitoring code Example: code “01” Monitoring data WHEN THE COMMUNICATION ERROR OCCURRED BETWEEN ECU AND METER: Error code Example: When the error code is “Er-1” For details of error codes, refer to “FAIL-SAFE ACTION TABLE” in chapter 7. (Manual No.
FEATURES GEN INFO CO adjustment and diagnostic monitoring mode Mode Selection Normal mode CO/DIAG mode Turn “ON” the main switch • The self-diagnostic function starts a system check 1. While keeping both the SELECT and RESET buttons pressed, turn “ON” the main switch. Keep the buttons pressed for 8 seconds or more. • All the segments are “OFF” expect the clock and the trip LCD. • “DIAG” appears on the clock LCD.
SPECIAL TOOLS GEN INFO EB104000 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. When placing an order, refer to the list provided below to avoid any mistakes. Tool No. Tool name/Function Test coupler adaptor 90890-03149 This tool is used to check the ABS diagnosis.
GENERAL SPECIFICATIONS/ ENGINE SPECIFICATIONS/CHASSIS SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Model code Weight Wet (with oil and a full fuel tank) Dry (without oil and fuel) Maximum load (total of cargo, rider, passenger, and accessories) Standard Limit 2B01 (EUR) ••• 224 kg (494 lb) 193 kg (426 lb) 200 kg (441 lb) ••• ••• ••• ENGINE SPECIFICATIONS Item Throttle bodies Model (manufacturer) × quantity ID mark Standard 38EIS (MIKUNI) × 2 5PS1 11 Limit ••• ••• CHASSIS SPECIF
ELECTRICAL SPECIFICATIONS SPEC ELECTRICAL SPECIFICATIONS Item Ignition system Ignition system type Ignition timing Advancer type Pickup coil resistance/color Transistorized coil ignition unit model (manufacturer) Indicator light (voltage/wattage × quantity) Turn signal indicator light ABS warning light Starter relay Model (manufacturer) Amperage Coil resistance Front wheel sensor Model (manufacturer) Resistance Rear wheel sensor Model (manufacturer) Resistance Fail-safe relay Model (manufacturer) Fuses (a
SPEC TIGHTENING TORQUES TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Thread size Part to be tightened Lower bracket pinch bolt Upper bracket and wire guide Throttle cable adjusting nut Engine mounting: Rear upper mounting bolt and nut Rear lower mounting bolt and nut Pinch bolt Frame and rear frame Sidestand and sidestand bracket Sidestand bracket and frame Rear footrest and footrest bracket Front wheel sensor and sensor housing Rear wheel sensor and sensor housing Hydraulic unit and hydraulic unit brac
CABLE ROUTING CABLE ROUTING Clamp Front turn signal light (right) Headlight sub-wire harness Indicator light lead Stay 3 Front turn signal light (left) Meter lead Indicator light Meter Stay 1 Headlight coupler Headlight adjusting knob Throttle cables Clutch cable Left handlebar switch lead Main switch lead and immobilizer lead Cover 7 Horn lead Horn Front wheel sensor lead Front brake hose (OUT) Cover 8 Front brake hose (IN) Right handlebar switch lead Front fork 8 SPEC
CABLE ROUTING Fasten the left handlebar switch lead to the handlebar with a band. Through the left handlebar switch lead and clutch cable to the wire guide on the upper bracket. Fasten the main switch lead and immobilizer lead to the wire guide with a clamp. There should be no slack between main switch and wire guide. Cut the clamp tip leaving 3 ~ 8 mm (0.12 ~ 0.31 in). Route the main switch lead through the cover 7 so that it route beneath the left handlebar switch lead.
CABLE ROUTING Fasten the horn lead to the upper side of the under bracket as shown in the drawing. Cut the clamp tip leaving 3 ~ 8 mm (0.12 ~ 0.31 in). 10 mm (0.39 in) Fasten the turn signal light lead (right) together with the coupler to the stay 1. Clamp the white tape of headlight sub-wire harness to the stay 1. (For detail of the clamp, refer to section BB.) Fasten the wire harness and turn signal light lead (left) together with the coupler to the stay 1.
CABLE ROUTING Fasten the headlight sub-wire harness with the clamp that is passed through the center hole of stay 1.
CABLE ROUTING Stay 3 Ignition coil assembly Neutral switch lead O2 sensor lead Speed sensor lead Sidestand switch lead Pickup coil lead Fuel tank drain hose Air filter drain hose Coolant reservoir tank drain hose Battery negative lead Seat lock cable Immobilizer coupler Joint coupler Tail/brake light lead Rear turn signal light Rear turn signal light lead Rectifier/regulator lead Coolant reservoir tank Rear shock absorber Swingarm Sidestand switch O2 sensor Cylinder identification sensor lead 12 SPEC Tu
CABLE ROUTING To the headlight. Route the 6 poles water proof coupler through inside of the ECU lead, and the 12 poles coupler through outside of the ECU lead. Connect the headlight sub-wire harness coupler in front of ECU and make it not to route above the ECU lead. Fasten the wire harness to the stay 1 with a clamp. Clamp position shall be at the position shown in the drawing 1. The knot should be faced to the outside of the vehicle.
CABLE ROUTING Route the fuel drain hoses (2 hoses), air filter drain hose, and coolant reservoir tank drain hose trough the clamp. For the fuel drain hose, the white paint mark should be under the clamp. The position is regardless of ranks. Arrange the end of coolant reservoir tank drain hose, air filter case drain hose and fuel drain hose from the clamp. The O2 sensor lead should not stick out from the boss seat face to the outside of the vehicle.
CABLE ROUTING Pass the harness for the relay between ECU and the main relay. Fasten the ECU lead with the clamp installed to the plate of front side hole. Align the positioning tape and the clamp. Install the clamp to the out side of plate. Insert the terminal (white) of the spark plug lead as shown in the drawing. Pass the fuel drain hose coolant reservoir tankdrain hose and air filter drain hose behind the battery negative lead.
CABLE ROUTING Rear brake light switch lead Rear brake light switch Rear wheel sensor lead Brake fluid reservoir hose Clamp Rear brake hose (OUT) Rear brake hose (IN) Fuel tank return hose Fuel hose Fuel tank drain hose Clamp Clamp Brake hose holder Rear wheel sensor lead Clamp Seat bracket Front wheel sensor lead ECU (ABS) sub-wire harness ECU (ABS) Radiator fan motor relay ABS check coupler Brake hose holder Stay 2 Radiator Clutch cable Thermo wax hose Coolant reservoir tank hose Rear brake hose Starter m
CABLE ROUTING The right and left positions for the starter motor lead and rear wheel sensor lead can be accepted in random oder. Pass the brake fluid reservoir hose and the rearbrake light switch lead through the gap between the rear fender and rear frame and route it behind the seat bracket. Clamp the coolant reservoir tank hose and brake hose. Clamping position should be behind the protector and of the coolant reservoir tank hose.
CABLE ROUTING Route inside the brake hose holder. Attach the clamp so that its opening section faces in the direction indicated in the drawing. Clamp the grommet which is attached to the sensor lead. Make sure to insert it to the deepest point. Make sure to catch more than 3 notches. Install the pawl so that it points to the outside of the vehicle.
CABLE ROUTING SPEC Battery Rectifier/regulator Rear wheel sensor lead Starter motor lead Battery band Battery positive lead Lean angle cut-off switch Atmospheric pressure sensor Fuse (main) Starter relay Rear turn signal light lead (right) Rear turn signal light (right) Tail/brake light lead Tail/brake light Rear turn signal light lead (left) Throttle cables Handlebar switch lead (right) Front brake hose Stay Front wheel sensor lead Thermo wax hose Intake vacuum hose Sub-wire harness (air filter case) Oi
CABLE ROUTING SPEC Bracket 1 Air induction system lead Coolant temperature sensor lead Cover 2 Main switch lead and immobilizer lead Left handlebar switch lead Boot Frame Wire harness Intake vacuum hose (Joint section) Front brake hose (IN) Front brake hose (OUT) Clamp Rear turn signal light (left) Joint coupler Immobilizer coupler Seat lock cable Fuse box Battery negative lead Hydraulic unit motor coupler Coolant reservoir tank drain hose Fuel pump lead 2 Fuel pump lead 1 Sub-wire harness (throttle body
CABLE ROUTING Put the cover on the coupler for the immobilizer lead and wire harness. Install the projection part of the coupler pointing to the connector housing 2. Align the projection part of the connector housing 2 with the hole of the locking bracket. Attach the boot over the immobilizer coupler. To the air induction system. To the ECU (ABS). To the air filter case. Route the sub-wire harness (air filter case) and intake vacuum hose over or side by the brake hose. To the oil tank.
CABLE ROUTING Pass the seat locking cable through the hole section of the seat bracket of the rear frame. Either direction of the seat locking cable can be accepted. Set the immobilizer coupler and joint coupler between the ribs of the rear fender. Route the battery negative lead (black lead) above the seat locking cable. Route the battery positive lead (red lead) below the seat locking cable.
CABLE ROUTING Bundle the coolant temperature sensor lead and air induction system lead with the clamp. Cut the clamp tip leaving 3 ~ 8 mm (0.12 ~ 0.31 in). To the headlight. Secure the wire harness to the holes at the internal left side and right side of the cover 2 with the harness wrapping clamp. Bundle the main switch lead, immobilizer lead, left handlebar switch lead and right handlebar switch lead with the clamp. Point the tip of the clamp to the front side and set it between cover and wire harness.
CABLE ROUTING SPEC Hose clamp (carburetor joint upper side) Connect the intake vacuum hose joint of the air filter system assembly side and the pipe of the throttle body side. Make sure to match the white paint mark to the position right overhead. Insert the hose until its end contacts the component. Point the pawl of the clip downward. Install the clip so that its pawl is oriented within the rangeshown in the drawing. To assemble to the throttle body assembly, it is allowed to apply the silicon liquid.
CABLE ROUTING SPEC Insert the fuel tank return hose until its end con- 2. After the procedure item 1 as above is finished, insert the clamp of the fuel pump side from the tacts the component. lower side of the engine and check that the , To assemble to the carburetor joint 1, it is allowed and parts are completely equipped. to apply the engine oil. 3. After the procedure item 1 as above is finished, lay Attach the hose clamp in this direction.
CABLE ROUTING SPEC Clamp Drain plug Hydraulic unit drain hose Hydraulic unit motor coupler Hydraulic unit assembly Clamp (to the coolant reservoir tank hose) Union bolt Fail-safe relay Brake hose holder Fuel tank mold Rear brake hose (OUT) Rear brake hose (IN) Bracket 2 Frame Bracket 1 Coolant reservoir tank Wire harness assembly Relay stay Protector Oil level sensor coupler Hydraulic unit coupler Front brake hose assembly (IN) Front brake hose assembly (OUT) 26
CABLE ROUTING Insert the pin of the bracket 1 to the hydraulic unit assembly. Press front brake hose (IN) to the front brake hose assembly (out) and tighten. Insert the pin of the bracket 2 to the hydraulic unit assembly. Press brake hose to the detent pin of the hydraulic unit assembly and tighten. Clamp the wire harness assembly (for the fail-safe relay) to the bracket 1. Clamp the wire harness assembly. Clamp position should be at the white taping section of the wire harness assembly.
SWINGARM AND DRIVE CHAIN CHAS EAS00709 SWINGARM AND DRIVE CHAIN CHECKING THE DRIVE CHAIN 1. Measure: • Measure the dimension between 15-links on the inner side and outer side of the roller and calculate the dimension between pin centers. • Dimension between pin centers = (Inner dimension + Outer dimension )/2 • 15-link section of the drive chain Out of specification → Replace the drive chain, front drive sprocket and rear drive sprocket as a set. 15-link drive chain section limit (maximum) 239.3 mm (9.
SWINGARM AND DRIVE CHAIN CHAS CAUTION: This motorcycle has a drive chain with small rubber O-rings between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to clean the drive chain. High-pressure methods could force dirt or water into the drive chain’s internals, and solvents will deteriorate the O-rings. A coarse brush can also damage the O-rings. Therefore, use only kerosine to clean the drive chain. 4.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS ANTI-LOCK BRAKE SYSTEM (ABS) ABS OUTLINE Yamaha ABS features 1. The Yamaha ABS (Anti-Lock Brake System) features a dual electronic control system, which acts on the front and rear brakes independently. 2. The ABS features a compact and lightweight design to help maintain the basic maneuverability of the motorcycle. 3. The hydraulic unit, which is the main component of the ABS, is centrally located on the motorcycle to increase mass centralization.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS EAS00872 ABS The operation of the Yamaha ABS brakes is the same as conventional motorcycles, with a brake lever for operating the front wheel brake and a brake pedal for operating the rear wheel brake. When wheel lockup is detected during emergency braking, hydraulic control is performed by the hydraulic system independently. EAS00873 Useful terms • Wheel speed: The rotation speed of the front and rear wheels. • Chassis speed: The speed of the chassis.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS • Slip ratio: When the brakes are applied, slipping occurs between the tires and the road surface. This causes a difference between the wheel speed and the chassis speed. Slip ratio is the value that shows the rate of wheel slippage and is defined by the following formula. Slip ratio = Chassis speed – Wheel speed × 100 (%) Chassis speed 0%: There is no slip between the wheel and the road surface. The chassis speed is equal to the wheel speed.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS EAS00875 Wheel slip and hydraulic control The ECU (ABS) calculates the wheel speed of each wheel according to the rotation signal received from the front and rear wheel sensors. In addition, the ECU (ABS) calculates the motorcycle chassis speed and the rate of speed reduction based on the wheel speed values. The difference between the chassis speed and the wheel speed calculated in the slip ratio formula is equal to the wheel slip.
ANTI-LOCK BRAKE SYSTEM (ABS) The higher the cornering force on a tire, the less traction there is available for braking. This is true whether the motorcycle is equipped with an ABS or not. Therefore, sudden braking while cornering is not recommended. Excessive cornering force, which an ABS cannot prevent, could cause the tire to slip sideways.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS EAS00877 Electronic ABS features The Yamaha ABS (Anti-lock Brake System) has been developed with the most advanced electronic technology. The ABS control is processed with good response providing various travel conditions for motorcycles. The ABS also includes a highly developed self-diagnostic function. The ABS detects any problem conditions and allows normal braking even if the ABS is not operating properly.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS EAS000878 ABS component functions • Wheel sensors and sensor rotors Wheel sensors detect the wheel rotation speed and transmit the wheel rotation signal to the ECU (ABS). Each wheel sensor is composed of a permanent magnet and a coil. The wheel sensors are installed in the sensor housing for each wheel. Sensor rotors are pressed in the inner side of the front and rear wheel hubs and rotate with the wheels.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS EAS00879 • Hydraulic unit The hydraulic unit is composed of a hydraulic control valve (solenoid valve, flow control valve), a buffer chamber, and a hydraulic pump for each brake and an ABS motor. The hydraulic unit adjusts the front and rear wheel brake fluid pressure to control the wheel rotation speed according to signals transmitted from the ECU (ABS).
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS • Hydraulic control valve The hydraulic control valve is composed of a flow control valve and solenoid valve. When the ABS is activated, the flow control valve regulates the flow of brake fluid to each brake and the solenoid valve decreases and increases the brake fluid pressure.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS • Electronic control unit (ECU) The ECU (ABS) controls the ABS and is installed inside the right cowling. To protect the ECU (ABS) from water damage, it is protected by a cover .
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS As shown in the block diagram below, the ECU (ABS) receives wheel sensor signals from the front and rear wheels and also receives signals from other monitor circuits. Both a main microcomputer and a sub microcomputer are installed in the ECU (ABS) to provide mutual monitoring.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS • ABS control operation The ABS control operation performed in the ECU (ABS) is divided into the following two parts. • Hydraulic control • Self-diagnosis These operations are performed once every 8/1,000 of a second. When a failure is detected in the ABS, a malfunction code is stored in the memory of the ECU (ABS) for easy problem identification and troubleshooting. NOTE: Some types of failures are not recorded in the memory of the ECU (ABS) (e.g.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS • Fail-safe relay The fail-safe relay controls the power supply of the hydraulic unit and is located beside the hydraulic unit. Fail-safe relay Composition and operation The fail-safe relay is composed of the solenoid relay and ABS motor relay . The solenoid relay is activated (continuous) by signals transmitted from the ECU (ABS). As a result, the solenoid valve can be operated.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS ABS operation The ABS hydraulic circuit consists of two systems: the front wheel and rear wheel. The following describes the front system only. • Normal braking (ABS not activated) When the ABS is not activated port D of the solenoid valve is closed because a control signal has not been transmitted from the ECU (ABS) and port A and port B of the flow control valve are open.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS • Emergency braking (ABS activated) 1) Depressurized state When the front wheel is about to lockup, port D of the solenoid valve is opened by the “depres-surization” signal transmitted from the ECU (ABS). When this occurs, the spool of the flow control valve compresses the return spring to close port B . Brake fluid that has entered through port A is restricted by the orifice and the brake fluid is sent to the brake caliper via port C and port D , and the buffer chamber.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS 2) Pressurized state Port D is closed by the “pressurization” signal transmitted from the ECU (ABS). Before this occurs, the spool of the flow control valve has compressed the return spring to close port B . Brake fluid that has entered through port A is further restricted by the orifice and the brake fluid is sent to the brake calipers via port A and port C .
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS EAS00880 Self-diagnosis function • ABS warning light The ABS warning light comes on when a malfunction is detected by the ABS self-diagnosis. It is located in the meter assembly. Main switch OFF ABS warning light • Instances when the ABS warning light comes on 1) The ABS warning light comes on when the main switch is set to “ON”. The ABS warning light comes on for 2 seconds while the ABS is performing a selfdiagnosis, then goes off if there are no problems.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS 4) The ABS warning light flashes and maltifunction code is indicated on the multifunction display when a test coupler adaptor is connected to the 4-pin test coupler for troubleshooting the ABS. The 4-pin test coupler can be accessed by removing the side cowling (right). When the test coupler adaptor is connected to the 4-pin test coupler, the ABS warning light starts flashing and the multifunction display indicates all the maltifunction codes recorded in the ECU (ABS).
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS Cautions for operation ABS warning light: • When the main switch is set to “ON”, the ABS warning light comes on for 2 seconds, then goes off. • If the ABS warning light comes on while riding, stop the motorcycle, and then set the main switch to “OFF”, then set the main switch to “ON”. The ABS operation is normal if the ABS warning light comes on for 2 seconds, then off.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS EAS00882 ABS COMPONENTS Front brake hose (front brake master cylinder to hydraulic unit) ABS test coupler ABS warning light Front brake hose (hydraulic unit to front brake caliper) Front wheel sensor Front wheel sensor rotor Electronic control unit (ECU) 49 Rear brake hose (hydraulic unit to rear brake caliper) Rear brake hose (rear brake master cylinder to hydraulic unit) Hydraulic unit Rear wheel sensor rotor Rear wheel sensor Fuse box Fail-safe relay
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS EAS00889 FRONT WHEEL SENSOR AND SENSOR ROTOR 40 Nm (4.0 m•kg, 29 ft•lb) 40 Nm (4.0 m•kg, 29 ft•lb) 40 Nm (4.0 m•kg, 29 ft•lb) 72 Nm (7.2 m•kg, 52 ft•lb) 20 Nm (2.0 m•kg, 14 ft•lb) 40 Nm (4.0 m•kg, 29 ft•lb) 18 Nm (1.8 m•kg, 13 ft•lb) 18 Nm (1.8 m•kg, 13 ft•lb) 30 Nm (3.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS Maintenance of the front wheel sensor and sensor rotor • ABS wheel sensor and sensor rotor CAUTION: • Handle the ABS components with care since they have been accurately adjusted. Keep them away from dirt and do not subject them to shocks. • The ABS wheel sensor cannot be disassembled. Do not attempt to disassemble it. If faulty, replace with a new one. • Removing the front wheel sensor 1.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS 2. Measure: • front wheel sensor resistance Connect the pocket tester (Ω × 1k) to the terminals of the front wheel sensor coupler. Tester positive probe → Terminal Tester negative probe → Terminal Regulated resistance 1.2 ~ 1.6 kΩ at 20 °C Out of specification → Replace. 3. Check: • front wheel sensor rotor Cracks/damage → Replace the front wheel assembly.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS 2. Install: • front wheel sensor 30 Nm (3.0 m•kg, 22 ft•lb) • front wheel sensor lead holder • brake caliper 40 Nm (4.0 m•kg, 29 ft•lb) • brake hose holder NOTE: When installing the front wheel sensor, check the wheel sensor lead for twists and the sensor electrode for foreign materials. CAUTION: To route the front wheel sensor lead, refer to “CABLE ROUTING”. 3. Check: • front wheel sensor installation Check if the wheel sensor housing is installed properly.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS EAS00890 REAR WHEEL SENSOR AND SENSOR ROTOR 40 Nm (4.0 m•kg, 29 ft•lb) 27 Nm (2.7 m•kg, 20 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) 150 Nm (15.0 m•kg, 108 ft•lb) Order 1 2 3 4 5 6 7 8 9 10 11 Job/Part Q’ty Remarks Removing the rear wheel sensor and Remove the parts in the order listed. sensor rotor NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS Maintenance of the rear wheel sensor and sensor rotor CAUTION: • Be sure not to contact the sensor electrode to any metal part when removing the front wheel sensor from the sensor housing. • Do not operate the brake lever when removing the brake caliper. • Removing the rear wheel sensor 1. Disconnect: • rear wheel sensor 2. Remove: • clamp • rear wheel sensor lead holder 3.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS • Installing the rear wheel sensor 1. Install: • rear wheel NOTE: • Align the slot of the sensor housing with the projection of the rear brake caliper bracket , and then assemble them. • After installation, check that the projection of the rear brake caliper bracket is inserted into the projection of the sensor housing. CAUTION: Make sure there are no foreign materials in the wheel hub. Foreign materials cause damage to the inner sensor rotor and rear wheel sensor. 2.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS EAS00891 HYDRAULIC UNIT 30 Nm (3.0 m•kg, 22 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) 16 Nm (1.6 m•kg, 12 ft•lb) 16 Nm (1.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS 30 Nm (3.0 m•kg, 22 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) 16 Nm (1.6 m•kg, 12 ft•lb) 16 Nm (1.6 m•kg, 12 ft•lb) Order 6 7 8 9 10 11 Job/Part Rear brake hose Union bolt/copper washers Rear brake hose Nut Hydraulic unit Hydraulic unit bracket 2 Q’ty Remarks 1 (rear brake master cylinder to hydraulic unit) 1/2 1 (hydraulic unit to rear brake caliper) 2 1 1 For assembly, reverse the disassembly procedure.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS Maintenance of the hydraulic unit CAUTION: Do not remove the hydraulic unit to check the resistance of the solenoid valves and the ABS motor for continuity. WARNING Refill with the same type of brake fluid that is already in the system. Mixing fluids may result in a harmful chemical reaction, leading to poor braking performance. CAUTION: • Handle the ABS components with care since they have been accurately adjusted.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS • Checking the resistance of the solenoid valves and ABS motor for continuity CAUTION: When check the hydraulic unit solenoid relay and ABS motor, do not remove the brake hoses. 1. Measure:. • resistance of the solenoid valve (front) Connect a pocket tester (Ω × 1) to the terminals of the solenoid valve (front). Tester positive probe → Terminal Tester negative probe → Terminal Solenoid valve resistance 2.96 ~ 3.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS • Removing the hydraulic unit 1. Remove: • brake hose (from the front brake master cylinder) • brake hose (to the front brake caliper) • brake hose (from the rear brake master cylinder) • brake hose (to the rear brake caliper) NOTE: Do not operate the brake lever and brake pedal while removing the brake hoses. CAUTION: When removing the brake hoses, cover the area around the hydraulic unit to catch any spilt brake fluid.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS • Installing the hydraulic unit Proceed in the reverse order of disassembly. Pay attention to the following items. 1. Install: • hydraulic unit bracket 2 16 Nm (1.6 m•kg, 12 ft•lb) NOTE: Tighten the nuts in the proper sequence. 2. Install: • hydraulic unit NOTE: Do not allow any foreign materials to enter the hydraulic unit or the brake hoses when installing the hydraulic unit. CAUTION: Do not remove the rubber plugs or bolts (M10 × 1.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS 5. Fill: • brake master cylinder reservoirs Recommended brake fluid DOT 4 6. Bleed the brake system. 7. Check the operation of the hydraulic unit according to the brake lever and the brake pedal response. (Refer to “P68 Hydraulic unit operation test 1”.) CAUTION: Always check the operation of the hydraulic unit according to the brake lever and the brake pedal response. 8. Delete the malfunction codes. (Refer to “P120 Deleting the malfunction codes”.) 9.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS HYDRAULIC ABS EAS00892 Bleeding the ABS system WARNING Always bleed the brake system when the brake related parts are removed. CAUTION: Bleed the brake system in the following order.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS Bleeding instruction Hydraulic unit Brake caliper Solenoid valve Buffer chamber Hydraulic pump Brake master cylinder pressure Hydraulic pump pressure EAS00134 Bleeding the ABS brake WARNING Bleed the ABS whenever: • the system is disassembled. • a brake hose is loosened, disconnected or replaced. • the brake fluid level is very low. • brake operation is faulty.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS 1. Remove: • seat Refer to “SEAT” in chapter 3. (Manual No.: 5PS1-AE1) 2. Bleed: • ABS a. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. b. Install the diaphragm (brake master cylinder reservoir or brake fluid reservoir). c. Connect a clear plastic hose tightly to the bleed screw . Front Rear d. Place the other end of the hose into a container. e. Slowly apply the brake several times. f.
ANTI-LOCK BRAKE SYSTEM (ABS) l. CHAS Tighten the bleed screw to the specified torque. Bleed screw 6 Nm (0.6 m•kg, 4.3 ft•lb) m. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. (Manual No.: 5PS1-AE1) WARNING After bleeding the ABS, check the brake operation. • Final check Checking procedures 1. Check the brake fluid level in the brake master cylinder reservoirs. 2.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS 2. Check: • installation of the wheel sensors to the sensor housings (Refer to “P51 Maintenance of the front wheel sensor and sensor rotor” and “P55 Maintenance of the rear wheel sensor and sensor rotor”.) Wheel sensor 30 Nm (3.0 m•kg, 22 ft•lb) Hydraulic unit operation test The reaction-force pulsating action generated in the brake lever and brake pedal when the ABS is activated can be tested when the motorcycle is stopped.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS 4. Check: • battery voltage Battery voltage Higher than 12.8 V Lower than 12.8 V → Charge or replace the battery. NOTE: • If the battery voltage is lower than 12.8 V, charge the battery and perform hydraulic unit operation test 1. • If the battery voltage is lower than 10 V, the ABS warning light comes on and the ABS does not operate. 5. Connect the test coupler adaptor test coupler . to the Test coupler adaptor 90890-03149 6. Set the engine stop switch to “ ”. 7.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS 9. After releasing the start switch, operate the brake lever and the brake pedal simultaneously. NOTE: • A reaction-force pulsating action is generated in the brake lever 0.5 second after the brake lever and the brake pedal are operated simultaneously and continues for approximately 1 second. • Be sure to continue to operate the brake lever and brake pedal even after the pulsating action has stopped. 10.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS 12.Set the main switch to “OFF”. 13.Remove the test coupler adaptor from the test coupler. 14.Set the main switch to “ON”. 15.Set the engine stop switch to “ ”. • Hydraulic unit operation test 2 WARNING Securely support the motorcycle so that there is no danger of it falling over. 1. Place the motorcycle on the centerstand. 2. Set the main switch to “OFF”. 3. Remove: • seat Refer to “SEAT”. (Manual No.: 5PS1-AE1) • right side cowling Refer to “FRONT COWLINGS”.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS 6. Set the main switch to “ON” while operating the brake lever and the brake pedal simultaneously. CAUTION: When the main switch is set to “ON”, be sure to operate both the brake levers and the brake pedal simultaneously. If only the brake levers or brake pedal are operated, set the main switch to “OFF” and start the procedure again. Main switch On ABS warning light 7.
ANTI-LOCK BRAKE SYSTEM (ABS) CHAS CHECKING THE RESERVOIR TANK FLUID LEVEL 1. Check: • brake fluid level Keep the reservoir cap horizontal and check the level. Less than the low level → Add the brake fluid more than low level . Recommended brake fluid DOT #4 CAUTION: • Do not mix the brake fluids of different brands. • If the brake fluid is attached to the coated surface, plastics or rubbers, it may cause the damage. Do not allow it to attach. Wipe off the attached brake fluid immediately.
ELECTRICAL COMPONENTS ‘ EAS00729 ELECTRICAL ELECTRICAL COMPONENTS Rear brake light switch Oil level switch Radiator fan motor ECU (ABS) Horn Wire harness Ignition coil Front brake light switch Clutch switch Fail safe relay Starter relay Fuse box Battery Neutral switch Sidestand switch 74 ELEC
ELECTRICAL COMPONENTS Coolant temperature sensor Atomospheric pressure sensor Intake air tempreture sensor Intake air pressure sensor Lean angle cut-off switch Turn signal relay Fuel injection system relay Radiator fan motor relay Rear wheel sensor Starting circuit cut-off relay Speed sensor O2 sensor Crankshaft position sensor Front wheel sensor Cylinder identification sensor ECU 75 ELEC
CHECKING THE SWITCHES ELEC EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear Repair or replace. Improperly connected Properly connect. Incorrect continuity reading Replace the switch.
W W W R/W P Br 10 OFF ON G/Y MAIN B W R R 80 W W W B B B B Br/L Br/L Br/L R Br/R Br/L R Br/R 2 B W Br/L Br/R 77 76 79 78 B B B B 11 R B B R B B B B B B B L/R Br 75 BrG R/B B Br 55 5 G/Y W/L R/W R/Y R/W B B R R R Br B R/B R/W L/W G/Y R B/W R R R B B Br/L Br/W B B B/W 56 B B 73 Y/L G/L R/W B B R/G R/W Lg Y/L R/G B B 9 7 B/W R G/L Y L/R B Y/L R/W L/W R/W L/W R/W RUN OFF 57 Br Y 12 8 6 B Br/R B G/Y B L
ELECTRIC STARTING SYSTEM ELEC EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), 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 closed). • The clutch lever is pulled to the handlebar (the clutch switch is closed) and the sidestand is up (the sidestand switch is closed).
ELECTRIC STARTING SYSTEM ELEC EAS00739 EAS00757 TROUBLESHOOTING The starter motor fails to turn. Check: 1.main and ignition fuses 2.battery 3.starter motor 4.starting circuit cut-off relay 5.diode (starting circuit cut-off relay) 6.starter relay 7.main switch 8.engine stop switch 9.neutral switch 10.sidestand switch 11.clutch switch 12.start switch 13.
ELECTRIC STARTING SYSTEM EAS00759 ELEC Tester positive probe → black/yellow Tester negative probe → sky blue 4. Starting circuit cut-off relay • Disconnect the starting circuit cut-off relay from the wire harness. • Connect the pocket tester (Ω × 1) and battery (12 V) to the starting circuit cut-off relay terminals as shown.
ELECTRIC STARTING SYSTEM EAS00761 ELEC EAS00750 6. Starter relay 8. Engine stop switch • Disconnect the starter relay from the coupler. • Connect the pocket tester (Ω × 1) and battery (12 V) to the starter relay terminals as shown. • Check the engine stop switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the engine stop switch OK? YES Battery positive terminal → red/white Battery negative terminal → blue/white NO Replace the right handlebar switch.
ELECTRIC STARTING SYSTEM EAS00764 12. Start switch • Check the start switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the start switch OK? YES NO Replace the right handlebar switch. EAS00766 13. Wiring • Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the starting system’s wiring properly connected and without defects? YES The starting system circuit is OK. NO Properly connect or repair the starting system’s wiring.
W W W 1 R/W P B L L G/Y R B L Br 10 OFF ON MAIN B W R Br/R 80 W Br/L 81 82 B B B B Br/L Br/L Br/L R Br/R Br/L R Br/R 2 B W Br/L Br/R 77 76 79 78 B B B B 11 B B R B B B B B B B B L/R Br 75 BrG R/B B Br 55 5 G/Y W/L R/W R/Y R/W B R R R Br B R/B R/W L/W G/Y R R R R B B W R B/W W B B/W B 56 G/L B L 6 Y Y/L L/W R/W RUN OFF 57 Br Y 12 8 Y L/R B 74 B B 73 Y/L G/L R/W B B R/G R/W Lg Y/L R/G B B 9 7 B/W
SIGNALING SYSTEM Fuse (main) Battery Main switch Fuse (backup) Starting circuit cut-off relay Neutral switch ECU Fuel pump Oil level warning light Neutral indicator light Multi-function meter Engine trouble warning light Turn signal indicator light Oil level switch Turn signal relay Front brake light switch Horn switch Hazard switch Turn signal switch Horn Rear turn signal light (left) Rear turn signal light (right) Front turn signal light (left) Front turn signal light (right) Rear brake light switch Tail/
SIGNALING SYSTEM EAS00794 ELEC EAS00739 TROUBLESHOOTING 2. Battery • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. (Manual No.: 5PS1-AE1) Check: 1. main, signaling, hazard light and back up fuses 2. battery 3. main switch 4.
SIGNALING SYSTEM ELEC EAS00796 3. Horn CHECKING THE SIGNAL SYSTEM 1. The horn fails to sound. • Disconnect the black connector at the horn terminal. • Connect a jumper lead to the horn terminal and ground the jumper lead. • Set the main switch to “ON”. • Push the horn switch. • Does the horn sound? 1. Horn switch • Check the horn switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the horn switch OK? YES NO Replace the left handlebar switch. 2.
SIGNALING SYSTEM ELEC EAS00797 2. The tail/brake light fails to come on. 3. Voltage • Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) as shown. 1. Tail/brake light bulb and socket • Check the tail/brake light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS” in chapter 3. (Manual No.: 5PS1-AE1) • Are the tail/ brake light bulb and socket OK? YES NO Replace the tail/ brake light bulb, socket or both.
SIGNALING SYSTEM ELEC EAS00799 3. The turn signal light, turn signal indicator light or both fail to blink. • Set the main switch to “ON”. • Measure the voltage (DC 12 V) on brown/ green at the turn signal relay coupler (wire harness side). • Is the voltage within specification? 1. Turn signal indicator light bulb and socket • Check the turn signal light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS” in chapter 3. (Manual No.
SIGNALING SYSTEM ELEC EAS00800 4. The neutral indicator light fails to come on. 5. Voltage • Connect the pocket tester (DC 20 V) to the turn signal light coupler or meter assembly coupler (wire harness side) as shown. 1. Neutral indicator light bulb and socket • Check the neutral indicator light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS” in chapter 3. (Manual No.
SIGNALING SYSTEM ELEC EAS00753 3. Starting circuit cut-off relay (diode) 4. Voltage • Disconnect the starting circuit cut-off relay from the wire harness. • Connect the pocket tester (Ω × 1) to the starting circuit cut-off relay terminals as shown. • Check the starting circuit cut-off relay for continuity. • Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness side) as shown.
SIGNALING SYSTEM ELEC 2. Engine oil level switch 4. Voltage • Drain the engine oil and remove the engine oil level switch from the oil tank. • Check the engine oil level switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the engine oil level switch OK? • Connect the pocket tester (DC 20 V) to the engine oil level switch coupler as shown. YES Tester positive probe → white Tester negative probe → black NO Replace the engine oil level switch. 3.
SIGNALING SYSTEM ELEC EAS00803 6. The fuel level gauge fails to operate. 1. Fuel sender • Drain the fuel from the fuel tank and remove the fuel pump assembly from the fuel tank. • Connect the pocket tester (Ω × 1) to the fuel sender as shown. Positive tester probe → green Negative tester probe → black/white • Set the main switch to “ON”. • Measure the voltage (DC 12 V) of green and black/white at the meter assembly coupler.
SIGNALING SYSTEM EAS00805 7. The clock fails to operate. 1. Voltage • Connect the pocket tester (DC V 20) to the meter assembly (wire harness side) as shown. Positive tester probe → brown Negative tester probe → black/white • Set the main switch to “ON”. • Measure the voltage (DC 12 V). • Is the voltage within specification? YES Replace the meter assembly. NO The wiring circuit from the main switch to the meter assembly coupler is faulty and must be repaired.
W W W R/W P B L L G/Y R B L Br 10 OFF ON MAIN B W R 80 W W W Br/L 81 82 B B B B Br/L Br/L Br/L R Br/R Br/L R Br/R 2 B W Br/R Br/L Br/R 77 76 B B 79 78 B B 11 R B B R B B B B B B B L/R Br 75 BrG R/B B Br 55 5 G/Y W/L R/W R/Y R/W B B R R Br/W R Br B R/B R/W L/W G/Y R B/W R R R B B 4 B B B/W 56 G/L B L 6 Y Y/L R/W L/W R/W L/W R/W RUN OFF 57 Br Y 12 8 Y L/R B 74 B B 73 Y/L G/L R/W B B R/G R/W Lg Y/L
ANTI-LOCK BRAKE SYSTEM (ABS) Fuse (ABS) Fuse (main) Fuse (ABS motor) Battery Main switch ABS test terminal ECU (ABS) ABS wire lead Fail safe relay Hydraulic unit Front wheel sensor Rear wheel sensor Multi-function meter ABS indicator light Front brake light switch Start switch Rear brake light switch 95 ELEC
ANTI-LOCK BRAKE SYSTEM (ABS) SPEC EAS00882 ABS COMPONENTS Front brake hose (front brake master cylinder to hydraulic unit) ABS test coupler ABS warning light Front brake hose (hydraulic unit to front brake caliper) Front wheel sensor Front wheel sensor rotor Electronic control unit (ECU) Rear brake hose (hydraulic unit to rear brake caliper) 96 Rear brake hose (rear brake master cylinder to hydraulic unit) Hydraulic unit Rear wheel sensor rotor Rear wheel sensor Fuse box Fail-safe relay
ANTI-LOCK BRAKE SYSTEM (ABS) ELEC EAS00883 ABS CONNECTOR LOCATION CHART Wire harness end Wire harness end Wire harness end ECU (ABS) coupler ABS wire lead coupler Wire harness end Wire harness end ABS test terminal coupler Wire harness end Wire harness end Wire harness end Front wheel sensor coupler Fail-safe relay coupler Wire harness end Rear wheel sensor coupler Multi-function coupler 97 Wire harness end Hydraulic unit coupler
ANTI-LOCK BRAKE SYSTEM (ABS) ELEC EAS00888 ECU (ABS) AND FAIL-SAFE RELAY 10 Nm (1.0 m•kg, 7.2 ft•lb) Order Job/Part Removing the ECU (ABS) and failsafe relay Side cowling (right) Q’ty Refer to “FRONT COWLINGS” in chapter 3. (Manual No.: 5PS1-AE1) Refer to “SEAT” in chapter 3. (Manual No.: 5PS1-AE1) Refer to “FUEL TANK” in chapter 3. (Manual No.: 5PS1-AE1) Seat Fuel tank 1 2 3 4 5 6 7 8 Remarks Remove the parts in the order listed.
ANTI-LOCK BRAKE SYSTEM (ABS) ELEC 10 Nm (1.0 m•kg, 7.2 ft•lb) Order 9 Job/Part ECU (ABS) coupler Q’ty Remarks 3 Disconnect. For installation, reverse the removal procedure.
ANTI-LOCK BRAKE SYSTEM (ABS) ELEC Maintenance of the ECU (ABS) • Removing the ECU (ABS) 1. Remove: • ECU (ABS) NOTE: When removing the ECU (ABS), take care not to damage the ECU (ABS) or ECU (ABS) couplers. 2. Remove: • ECU (ABS) coupler • ECU (ABS) coupler NOTE: Do not pull the ECU (ABS) leads to remove the ECU (ABS) couplers. Always press on the locks to disconnect the ECU (ABS) couplers from the ECU (ABS). • Checking the ECU (ABS) 1. Check: • ECU (ABS) terminals Cracks/damage → Replace the ECU (ABS).
ANTI-LOCK BRAKE SYSTEM (ABS) ELEC \ Operation of solenoid relay • Checking the fail-safe relay 1. Check: • solenoid relay for continuity Connect the pocket tester (Ω × 1) to the terminals. Check for continuity between terminals and of the solenoid relay. Tester positive probe → Terminal Tester negative probe → Terminal Tester reading is “ ”. → Replace the failsafe relay. • Check for continuity between terminals and of the solenoid relay.
ANTI-LOCK BRAKE SYSTEM (ABS) ELEC 2. Check: • ABS motor relay for continuity Connect the pocket tester (Ω × 1) to the terminals of the ABS motor relay. Check for continuity between terminals and of the ABS motor relay. Tester positive probe → Terminal Tester negative probe → Terminal ABS motor relay resistance 50 ~ 150 Ω Operation of motor relay Tester reading is “ ”. → Replace the failsafe relay. Continuity Terminal number Normal condition CAUTION: Do not reverse the connections.
ANTI-LOCK BRAKE SYSTEM (ABS) TROUBLESHOOTING EB802401 2. Battery • ABS warning light fail to come on. • All ABS warning and other indicator lights fail to come on. • ABS warning light continues to come on. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. (Manual No.: 5PS1-AE1) Check: 1. ABS motor, ABS, main and signal fuses. 2. Battery. 3. Main switch. 4. Wiring (of the entire anti-lock brake system).
ANTI-LOCK BRAKE SYSTEM (ABS) CHECKING THE ANTI-LOCK BRAKE SYSTEM 1. Only the ABS warning light fail to come on when the main switch is turned ON. 3. ABS warning light circuit. • Remove the ECU coupler and check the continuity at the white/red terminal on the ECU side and the test coupler adapter side of the wire harness. • Is the ECU continuity OK? 1. ABS coupler and wire harness. • Check the ABS coupler and wire harness for continuity. • Check the ECU and ABS wire harness for continuity.
ANTI-LOCK BRAKE SYSTEM (ABS) 3. Main fuse. • Check the main fuse for continuity. Refer to “CHECKING THE FUSES” in chapter 3. (Manual No.: 5PS1-AE1) • Is the main fuse OK? YES NO Replace the fuse. 4. Wiring • Check the entire anti-lock brake system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the anti-lock brake system’s wiring properly connected and without defects? YES Check the condition of each of the antilock brake system circuits. Refer to “CHECKING THE ANTILOCK BRAKE SYSTEM”.
ANTI-LOCK BRAKE SYSTEM (ABS) ELEC 3. ABS warning light continues to come on. 1) Check the ABS fuse • Blown fuse → Replace 2) Check the battery voltage The voltage should be always higher than the regulated voltage in order to operate the ABS correctly. If the power voltage goes lower than 10 V, the ABS warning light comes on and ABS operation stops. When the power voltage recovers to be higher than 10 V, the system resumes its operation.
ANTI-LOCK BRAKE SYSTEM (ABS) ELEC TROUBLESHOOTING BY THE SELF DIAGNOSIS Arrangement and the function of test couplers • ECU becomes the malfunction diagnostic mode when the T/C terminal is grounded. • Malfunction code which the ECU generated in the malfunction diagnostic mode (rise and fall of voltage) is output at the T/F terminal. • ABS warning light terminal is used when checking the ABS warning light circuit. • To ground the T/C terminal, connect the test coupler adapter with the test coupler.
ANTI-LOCK BRAKE SYSTEM (ABS) ELEC MALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS (PRESENT MALFUNCTION) NOTE: Before proceeding to read the part of “Arrangement and the function of test coupler”. Remove the battery cover and check the location of test coupler. Connect the test coupler adapter with the test coupler in order to ground the T/C terminal (sky-blue).
ANTI-LOCK BRAKE SYSTEM (ABS) ELEC • Diagnosis by the malfunction code Malfunction codes are used to determine the malfunctions that have occurred. (Refer to “P107 ABS malfunction check by the ABS self-diagnosis (past malfunction)” and “P108 ABS malfunction check by the ABS self-diagnosis (present malfunction)”.) The malfunction codes are explained in the following table. NOTE: Record all of the malfunction codes displayed and check the check points.
ANTI-LOCK BRAKE SYSTEM (ABS) Malfunction code Problem ELEC Check point Reference Defective operation of the ABS motor is • Fail-safe relay detected. (ABS motor keeps running and will not • ABS wire harness circuit stop.
ANTI-LOCK BRAKE SYSTEM (ABS) ELEC • Malfunction code 11 (Front wheel sensor signal is not received correctly.) Set the main switch to “OFF”, then back to “ON” after removing the test coupler adaptor. 1) ABS warning light remains on. → Defective connection in the front wheel sensor circuit. • Front wheel sensor coupler is disconnected. → P51 • Front wheel sensor lead or coil is broken. → P51 • Sub-wire harness (ABS) sensor circuit is broken. → (Refer to “CIRCUIT DIAGRAM”.
ANTI-LOCK BRAKE SYSTEM (ABS) ELEC • Malfunction codes 13 (front wheel) and 14 (rear wheel) (Incorrect signal is detected from either the front or rear wheel.) 1) The wheel sensors or sensor rotors are not properly installed. Installation of the front or rear wheel sensor • Check that the wheel sensor is properly installed in the housing. → P51, 55 • Check if there is looseness between the housing and the wheel.
ANTI-LOCK BRAKE SYSTEM (ABS) ELEC • Malfunction code 31 (Disconnection is detected between the fail-safe relay and the hydraulic unit solenoid.) Check the following: 1) ABS motor fuse • Check if the ABS motor fuse beside the battery is blown. 2) Hydraulic unit solenoid coupler • Check if the hydraulic unit solenoid coupler located in the right side cover is connected properly. (Refer to “ABS CONNECTOR LOCATION CHART”.
ANTI-LOCK BRAKE SYSTEM (ABS) ELEC • Malfunction code 33 (ABS motor operation malfunction is detected. [ABS motor stops and does not rotate.]) Check the following: 1) ABS motor fuse • Check if the ABS motor fuse beside the battery is blown. 2) Fail-safe relay • Check if the fail-safe relay operates correctly. → P100 3) Wire harness and sub-wire harness (ABS) • Remove the fail-safe relay and the ABS motor fuse, and then check for continuity between the red/white (Refer to “P113–5) wire harness drawing”.
ANTI-LOCK BRAKE SYSTEM (ABS) ELEC • Malfunction code 41 (Front wheel does not recover from the locking tendency even though the signal is continuously transmitted from the ECU (ABS) to release the hydraulic pressure [when the battery voltage is normal].) Check the following: 1) Rotation of the front wheel • Check that there is no brake disc drag on the front wheel and make sure it rotates smoothly. • Check the front wheel axle for loose bearings and bends, and the brake disc for distortion.
ANTI-LOCK BRAKE SYSTEM (ABS) ELEC 5) Hydraulic unit solenoid coupler terminal • Check if the front and rear hydraulic unit solenoid coupler terminals (hydraulic unit and sub-wire harness [ABS]) are reversed. Front Rear Solenoid red, white red, green Terminal color Sub-wire harness (ABS) white, white/blue white, white/green 6) Hydraulic unit If the malfunction is not corrected after performing steps 1) to 5), replace the hydraulic unit.
ANTI-LOCK BRAKE SYSTEM (ABS) ELEC • Check that the connections of the brake hose lines from the brake master cylinder to the hydraulic unit and to the rear brake caliper from the hydraulic unit are correct. WARNING The rear brake will not function properly if the connections are reversed.
ANTI-LOCK BRAKE SYSTEM (ABS) ELEC • Malfunction code 51 (Front wheel does not recover from the locking tendency even though the signal is continuously transmitted from the ECU (ABS) to release the hydraulic pressure [when the battery voltage is low].) Check the following: 1) Rotation of the front wheel Refer to “P115 Malfunction code 41”. 2) Brake master cylinder and brake caliper Refer to “P115 Malfunction code 41”. 3) Brake fluid Refer to “P115 Malfunction code 41”.
ANTI-LOCK BRAKE SYSTEM (ABS) ELEC • Malfunction code 52 (Rear wheel does not recover from the locking tendency even though the signal is continuously transmitted from the ECU (ABS) to release the hydraulic pressure [when the battery voltage is low].) Check the following: 1) Rotation of the rear wheel Refer to “P116 Malfunction code 42”. 2) Brake master cylinder and brake caliper Refer to “P116 Malfunction code 42”. 3) Brake fluid Refer to “P116 Malfunction code 42”.
ANTI-LOCK BRAKE SYSTEM (ABS) ELEC DELETING THE MALFUNCTION CODE 1. Connect the test coupler adapter to the test coupler . Refer to “P109”. 2. Turn the main switch on. The multifunction display indicates previously recorded mulfunction codes. NOTE: The ABS error code is not displayed during the diagnosis of the fuel injection. 3. Turn the engine stop switch off.
ANTI-LOCK BRAKE SYSTEM (ABS) ON ABS waening light 6. Turn the main switch on again. Check that the ABS warning light goes on for 2 seconds, then goes out for 3 seconds and starts flashing. 7. Turn the main switch off. 8. Disconnect the test coupler adapter from the test coupler, and install the protective cap with the test coupler adapter. Deleting the malfunction code is now finished. NOTE: Do not forget to install the protective cap. ON OFF Main switch 2.0 3.0 seseconds conds ELEC Flashing 0.5 0.
ANTI-LOCK BRAKE SYSTEM (ABS) ELEC TROUBLESHOOTING ANTI-LOCK BRAKE SYSTEM (ABS) ABS TROUBLESHOOTING OUTLINE This section describes the troubleshooting about ABS in details. Read carefully this service manual before repairing various malfunctions, understand and perform the service. Electronic control unit (ECU) has the self diagnostic function. When failures occur in the system, the ABS warning light on the meter assembly indicates a mulfunction.
ANTI-LOCK BRAKE SYSTEM (ABS) TRBL SHTG “Deleting the malfunction code” When the malfunction service is finished, check the normal operation of motorcycle then delete the malfunction code (Refer to “P120”). By deleting the malfunction code memory, it is possible to pursue the cause correctly if the next defective phenomenon occurred. Self diagnosis by ECU ECU performs the static check for whole system when the main switch is turned on. It is also possible to check the malfunction while riding.
ANTI-LOCK BRAKE SYSTEM (ABS) TRBL SHTG BASIC PROCESS FOR TROUBLESHOOTING It does not go on. “P104” Warning light does not come on. [A] Goes on for 2 seconds and goes off afterward. Check the ABS warning light. Flashing Keeps coming on. “P106” Warning light keeps flashing. “P108” Present malfunction “P106” Warning light keeps coming on. “P107” Past malfunction NO YES YES NO NOTE: Display the malfunction code number and record it. “P104” Only ABS warning light does not come on.
TROUBLESHOOTING AT THE ABS WARNING LIGHT TRBL SHTG TROUBLESHOOTING AT THE ABS WARNING LIGHT When the main switch is turned “ON”. (Engine does not start.) ONLY THE ABS WARNING LIGHT DOES NOT COME ON.
TDM900A(T) 2005 WIRING DIAGRAM A.C.
YAMAHA MOTOR CO., LTD.
TDM900A(T) 2005 WIRING DIAGRAM D Br Lg Dg 3 Br/L 5 R L/R L/B Y/L R/G G/L G/L R/G Y/L B Y G/R Br/W Ch G L B/W W W/Y W/Y W B/W WIRE HARNESS HEADLIGHT SUB-WIRE HARNESS 2 WIRE HARNESS HEADLIGHT SUB-WIRE HARNESS 1 P/W Y Y P/W B/L B/L WIRE HARNESS SUB-WIRE HARNESS 2 F G R/B G/B G/B R/B Br/B R/W R/W Br/B Br R/W R/W Br R/L L L R/L B/L Br/W Br/W B/L L G/Y G/Y L WIRE HARNESS SUB-WIRE HARNESS 1 RADIATOR FAN MOTOR WIRE HARNESS RELAY SUB-WIREHARNESS WIRE HARNESS SUB-WIRE HARNESS 3 H
