FJR AS 2006 Manual Técnico Suplemento

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.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
EAS20070
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-
cle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
EAS20080
IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death

WARNING to the vehicle operator, a bystander or a person checking or repairing the ve-
hicle.
A CAUTION indicates special precautions that must be taken to avoid dam-

CAUTION: age to the vehicle.
NOTE: A NOTE provides key information to make procedures easier or clearer.

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.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
3 2
4
5
7
EAS20100
1. Serviceable with engine mounted
SYMBOLS 2. Filling fluid
The following symbols are used in this manual 3. Lubricant
for easier understanding. 4. Special tool
NOTE: 5. Tightening torque
The following symbols are not relevant to every 6. Wear limit, clearance
vehicle. 7. Engine speed
8. Electrical data
9. Engine oil
1 2 3 10. Gear oil
11. Molybdenum-disulfide oil
12. Wheel-bearing grease
13. Lithium-soap-based grease
4 5 6 14. Molybdenum-disulfide grease
15. Apply locking agent (LOCTITE®)
16. Replace the part
T.
R.
7 8
9 10 11
E G M
12 13 14
B LS M
15 16
LT New
EAS20110
CONTENTS
FEATURES......................................................................................................... 1
OUTLINE OF THE YCC-S (Yamaha Chip Controlled-Shift) SYSTEM ......... 1
SPECIAL TOOLS ............................................................................................... 4
GENERAL SPECIFICATIONS ........................................................................... 6
ENGINE SPECIFICATIONS ............................................................................... 7
CHASSIS SPECIFICATIONS ............................................................................. 8
ELECTRICAL SPECIFICATIONS ...................................................................... 9
TIGHTENING TORQUES ................................................................................. 10

ENGINE TIGHTENING TORQUES............................................................ 10
CHASSIS TIGHTENING TORQUES.......................................................... 11
CABLE ROUTING ............................................................................................ 13
PERIODIC MAINTENANCE ............................................................................. 29

INTRODUCTION ........................................................................................ 29
PERIODIC MAINTENANCE AND LUBRICATION CHART........................ 29
ENGINE ............................................................................................................ 31
CHECKING THE CLUTCH FLUID LEVEL ................................................. 31
BLEEDING THE HYDRAULIC CLUTCH SYSTEM .................................... 31
CHECKING THE VEHICLE AFTER BLEEDING THE HYDRAULIC
CLUTCH SYSTEM .................................................................................... 33
CLEANING THE AIR FILTER ELEMENT................................................... 34
CHASSIS .......................................................................................................... 35
ADJUSTING THE SHIFT PEDAL............................................................... 35
ELECTRICAL SYSTEM.................................................................................... 36
REPLACING THE HEADLIGHT BULBS .................................................... 36
GENERAL CHASSIS........................................................................................ 37
HANDLEBARS ................................................................................................. 41
INSTALLING THE HANDLEBARS ............................................................. 43
SHAFT DRIVE .................................................................................................. 46
INSTALLING THE DRIVE SHAFT AND FINAL DRIVE ASSEMBLY ......... 46
ENGINE REMOVAL ......................................................................................... 47

REMOVING THE GEAR POSITION SENSOR .......................................... 49
REMOVING THE ENGINE ......................................................................... 49
INSTALLING THE GEAR POSITION SENSOR......................................... 49
ADJUSTING THE GEAR POSITION SENSOR ......................................... 50
CLUTCH ........................................................................................................... 51
BREAKING IN THE FRICTION PLATES AFTER REPLACEMENT........... 55
REPLACING THE CLUTCH MASTER CYLINDER.................................... 55
INSTALLING THE CLUTCH ACTUATOR .................................................. 56
SHIFT ACTUATOR AND SHIFT ROD ............................................................. 57

REMOVING THE SHIFT ACTUATOR........................................................ 59
CHECKING THE SHIFT ROD .................................................................... 59
INSTALLING THE FOOT SHIFT SWITCH................................................. 59
ADJUSTING THE FOOT SHIFT SWITCH ................................................. 60
INSTALLING THE LEFT FOOTREST ASSEMBLY.................................... 61
INSTALLING THE SHIFT ACTUATOR ...................................................... 61
SHIFT SHAFT................................................................................................... 63
INSTALLING THE SHIFT SHAFT .............................................................. 63
MIDDLE GEAR ................................................................................................. 64
CRANKCASE ................................................................................................... 66
TRANSMISSION............................................................................................... 68
ELECTRIC STARTING SYSTEM ..................................................................... 71

CIRCUIT DIAGRAM (1/2)........................................................................... 71
CIRCUIT DIAGRAM (2/2)........................................................................... 73
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ........................... 75
TROUBLESHOOTING ............................................................................... 76
GRIP WARMER SYSTEM ................................................................................ 79

CIRCUIT DIAGRAM (1/2)........................................................................... 79
CIRCUIT DIAGRAM (2/2)........................................................................... 81
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM......................................... 85
CIRCUIT DIAGRAM (1/2)........................................................................... 85
CIRCUIT DIAGRAM (2/2)........................................................................... 87
MAINTENANCE OF THE MCU .................................................................. 90
MCU (motor control unit) SELF-DIAGNOSTIC FUNCTION ....................... 90
SELF-DIAGNOSTIC FUNCTION TABLE ................................................... 91
TROUBLESHOOTING METHOD............................................................... 94
DIAGNOSTIC MODE ................................................................................. 95
TROUBLESHOOTING DETAILS ............................................................... 99
ELECTRICAL COMPONENTS....................................................................... 123

CHECKING THE SWITCHES .................................................................. 127
CHECKING THE RELAYS ....................................................................... 130
CHECKING THE YCC-S SPEED SENSOR............................................. 132
CHECKING THE GEAR POSITION SENSOR......................................... 132
CHECKING THE FOOT SHIFT SWITCH................................................. 133
CHECKING THE GRIP WARMERS......................................................... 133
CHECKING THE GRIP WARMER CONTROL UNIT ............................... 134
CHECKING THE DIODE 2 ....................................................................... 134
FJR1300AS(V) 2006 WIRING DIAGRAM

FEATURES
EAS20170
FEATURES
ET2D21013
OUTLINE OF THE YCC-S (Yamaha Chip Controlled-Shift) SYSTEM
Concept
YCC-S offers more enjoyable and easy riding by eliminating the need for the user to operate the clutch,
which also reduces fatigue during long touring.
YCC-S is not an automatic transmission, although it allows the user to shift gears by foot or hand ac-
cording to preference.
When shifting, a signal is sent to the MCU (motor control unit), which ensures optimum clutch operation,
shifting, and engine control. Therefore, the user never needs to operate the clutch, which in turn, reduc-
es fatigue and allows the user to concentrate while riding.
When stopping at traffic lights or in traffic jams, YCC-S operates the clutch instead of the user.
Basic function
To shift gears after starting the engine, the user must use the shift pedal. However, depending on the
user’s preference, the transmission can be shifted by hand after setting the hand shift select button to
“ON”.
When the engine is started, the MCU disengages the clutch. A signal is sent to the MCU when the trans-
mission is shifted from neutral to 1st gear by hand or foot. When the throttle is opened, the MCU then
engages the clutch according to engine r/min. Clutch engagement is controlled optimally by the MCU.
Clutch engagement is not constant in order to provide smooth shifting according to engine require-
ments and conditions.
The YCC-S system will not shift up if the engine r/min is lower than a specified value. Even if the user
shifts up, if the specified value is not met (engine r/min is too low), the YCC-S system will not shift up
until the above-mentioned specified value is met.
Likewise, the YCC-S system will not shift down if the specified value is not met (engine r/min is too
high).
In this case, the throttle must be closed so that the MCU can disengage the clutch until the specified
value is met to prevent the engine from stopping. During this period, a coasting condition will be felt.
The user must shift down properly in order for the YCC-S system to provide a smooth stopping condi-
tion.
The YCC-S system is constantly performing a self-diagnosis when the engine is running. If any trouble
is detected, the MCU automatically stops the YCC-S system and shifting is impossible.
–1–
FEATURES
3 4 5
2 6 7 8 9
12 11 10
1. YCC-S test coupler 8. MCU (motor control unit)

2. YCC-S control relay 9. Shift actuator
3. YCC-S indicator and warning light 10. Clutch actuator
4. YCC-S motor control fuse 11. Foot shift switch
5. Hand shift switch 12. YCC-S speed sensor
6. Gear position sensor
7. 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”. The hand shift switch has to be enabled by pressing
the hand shift select button “3” prior to being used. The gear positions are shown in the illustration.
–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.
To move the vehicle, turn the main switch to “ON”, and then apply the front or rear brake to disengage
the clutch. A click will be heard when the clutch is disengaged.
• Always stop the engine and turn the main switch to “LOCK” when parking the vehicle.
YCC-S indicator and warning light

• The YCC-S system is constantly performing a self-diagnosis.
• The YCC-S system also performs a self-diagnosis when the main switch is turned to “ON”. The YCC-
S indicator and warning light “1” come on during this self-diagnosis. After the self-diagnosis is com-
pleted, if there were no problems found, the YCC-S indicator and warning light will go off.
• If the YCC-S indicator and warning light come on while riding, stop the vehicle, park it in a safe place,
and then contact a Yamaha dealer.
Because the YCC-S system stops automatically when the YCC-S indicator and warning light come
on, it is impossible to shift since clutch operation is stopped. To move the vehicle, turn the main switch
to “OFF” and place the vehicle on the centerstand. While rotating the rear wheel, push the shift rod
forward and shift the transmission into neutral.
–3–
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-”.
• For others, use part number starting with “90890-”.
Reference
Tool name/Tool No. Illustration
pages
Vacuum/pressure pump gauge set 32
90890-06756
Mityvac brake bleeding tool
YS-42423
Magnet base B 33
90890-06844
Magnetic base stand
YU-A8438
Dial gauge & stand set 33

90890-01252
Fork seal driver weight 46

90890-01184
Fork seal driver attachment 46

90890-01186
Replacement 27 mm
YM-A9409-1
Oil seal installing tool 46

90890-01512
Pivot shaft wrench 49

90890-01471
Frame spanner socket
YM-01471
–4–
SPECIAL TOOLS
Reference
Tool name/Tool No. Illustration
pages
Pivot shaft wrench adapter 49
90890-01476
Digital circuit tester 50, 60

90890-03174
Model 88 Multimeter with tachometer
YU-A1927
Test coupler adapter 95

90890-03149
Pocket tester 129, 130, 132,

90890-03112 133, 134
Analog pocket tester
YU-03112-C
–5–
GENERAL SPECIFICATIONS
EAS20280
GENERAL SPECIFICATIONS
Model
Model 2D21(Europe except (B)and(F))(ZA)
2D22(B)(F)
2D23(AUS)
Weight
With oil and fuel 295.0 kg (650 lb)
Maximum load 208 kg (459 lb)
–6–
ENGINE SPECIFICATIONS
EAS20290
ENGINE SPECIFICATIONS
Clutch
Clutch type Wet, multiple-disc
Clutch release method Hydraulic inner push
Clutch lever free play 1.9–20.7 mm (0.07–0.81 in)
Friction plate thickness 2.90–3.10 mm (0.114–0.122 in)
Wear limit 2.80 mm (0.1102 in)
Plate quantity 9 pcs
Clutch plate thickness 1.90–2.10 mm (0.075–0.083 in)
Plate quantity 8 pcs
Warpage limit 0.10 mm (0.0039 in)
Clutch spring height 6.78 mm (0.27 in)
Minimum height 6.4 mm (0.25 in)
Spring quantity 1 pc
Push rod bending limit 0.370 mm (0.0146 in)
Clutch pressure plate stroke 2.8 mm (0.11 in) or more
Transmission
Transmission type Constant mesh 5-speed
Primary reduction system Spur gear
Primary reduction ratio 75/48 (1.563)
Secondary reduction system Shaft drive
Secondary reduction ratio 35/37 × 21/27 × 33/9 (2.698)
Operation Left foot and left hand operation
Gear ratio
1st 43/17 (2.529)
2nd 39/22 (1.773)
3rd 31/23 (1.348)
4th 28/26 (1.077)
5th 26/28 (0.929)
Main axle runout limit 0.08 mm (0.0032 in)
Drive axle runout limit 0.08 mm (0.0032 in)
–7–
CHASSIS SPECIFICATIONS
EAS20300
CHASSIS SPECIFICATIONS
Tire air pressure (measured on cold tires)
Loading condition 0–90 kg (0–198 lb)
Front 270 kPa (39 psi) (2.70 kgf/cm²)
Rear 290 kPa (42 psi) (2.90 kgf/cm²)
Loading condition 90–208 kg (198–459 lb)
High-speed riding
–8–
ELECTRICAL SPECIFICATIONS
EAS20310
ELECTRICAL SPECIFICATIONS
Gear position sensor
Output voltage (at neutral position) 0.71–0.91 V
Resistance 4.0–6.0 kΩ
Foot shift switch

Output voltage 2.4–2.6 V
Resistance 4.0–6.0 kΩ
Grip warmer
Resistance 1.21–1.48 Ω at 20 °C (68 °F)
Fuses
Main fuse 50.0 A
Headlight fuse 25.0 A
Signaling system fuse 15.0 A
Ignition fuse 10.0 A
Radiator fan fuse 15.0 A × 2
Auxiliary DC jack fuse 3.0 A
Hazard fuse 10.0 A
Fuel injection system fuse 15.0 A
ABS motor fuse 30.0 A
ABS control unit fuse 10.0 A
YCC-S motor control fuse 30.0 A
Backup fuse 10.0 A
Reserve fuse 30.0 A
Reserve fuse 25.0 A
Reserve fuse 15.0 A
Reserve fuse 10.0 A
Reserve fuse 3.0 A
–9–
TIGHTENING TORQUES
EAS20320
TIGHTENING TORQUES
EAS20340
ENGINE TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
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 (0.9 m·kg, 6.5 ft·lb) LT
Shift actuator front bolt M8 1 20 Nm (2.0 m·kg, 14 ft·lb)

Shift actuator rear bolt M8 1 20 Nm (2.0 m·kg, 14 ft·lb)
Shift rod bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Shift rod bolt M8 1 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Shift rod front locknut M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)

Shift rod rear locknut M8 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Foot shift switch screw M5 2 4 Nm (0.4 m·kg, 2.9 ft·lb) LT
Front shift arm bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)

Neutral switch M10 1 20 Nm (2.0 m·kg, 14 ft·lb)
YCC-S speed sensor bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
– 10 –
TIGHTENING TORQUES
EAS20350
CHASSIS TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
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, 7.2 ft·lb) LT
– 11 –
TIGHTENING TORQUES
– 12 –
CABLE ROUTING
EAS20430
CABLE ROUTING
4
3 B
1
2 A
5
L
24 23 C E
K 6
21 22 J 7 3 1
8
D
20 A
19
18 F 2
17
16
F
I
G
G
13 12 11 H 10 9
15 14
1
14
13
24 23
B-B
3 23 24
M 2
B
2
1
2
7 14
6
7
13
B
A
– 13 –
CABLE ROUTING
1. Brake hose (front brake master cylinder to M. Fasten the right handlebar switch lead, right grip
hydraulic unit) warmer lead, and main switch lead with a plastic
2. Right handlebar switch lead locking tie at the location shown in the illustration.
Position the buckle of the plastic locking tie under
3. Left handlebar switch lead the leads, with the end facing inward, and then cut
4. Left grip warmer lead off the excess end of the tie.
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. Brake hose (hydraulic unit to front brake calipers)
15. Right horn (high)
16. Headlight (on/off)/grip warmer relay
17. Radiator fan motor relay
18. Main fuse
19. Brake light relay
20. YCC-S control relay
21. Positive battery lead
22. ABS test coupler
23. Throttle cable (accelerator cable)
24. Throttle cable (decelerator cable)
A. Route the right handlebar switch lead and right
grip warmer lead under the handlebar.
B. Route the left handlebar switch lead, left grip
warmer lead, and hand shift switch lead under the
handlebar.
C. Pass the hand shift switch lead, right grip warmer
lead, left grip warmer lead, right handlebar switch
lead, and left handlebar switch lead through the
guide.
D. Fasten the right handlebar switch lead, right grip
warmer lead, main switch lead, and immobilizer
unit lead with a plastic locking tie.
E. Temporarily tighten the brake hose joint bolt, union
bolt, and brake hose holder bolt in the proper
tightening sequence as shown. Then, tighten the
bolts to the specified torque, making sure to tighten
the brake hose joint bolt “1” last.
F. To front cowling wire harness
G. Install the horn L-shaped connectors so that the
leads are routed outward.
H. Fasten the grommet on the front wheel sensor lead
with the holder.
I. Connect the coupler that has blue tape wrapped
around its leads to the radiator fan motor relay.
J. Install the ABS test coupler completely onto the
tab on the battery stay.
K. Pass the brake hose (front brake master cylinder to
hydraulic unit), right handlebar switch lead, right
grip warmer lead, and throttle cables through the
guide as shown in the illustration.
L. Fasten the right grip warmer lead to the throttle
cables with a plastic locking tie 10 mm (0.39 in) or
less from the end of the throttle cable boot. Face
the end of the plastic locking tie upward or
downward, and then cut off the excess end of the
tie.
– 14 –
CABLE ROUTING
R
18 5 18 18
5 3
Q 5
13 5
C-C 27
30
30 27 30
18 D-D E-E
40 O
11
S
F
41
P 41 42
B-B 14 15
16
17
D
5 18
19 E
N 20
13 21 F
4 12 22
11
39 10 23
9 24
8
C 7
B 6
A-A 5
G
25
4 CB D E
3 B 26
H
2
1 A 28
A 27
C 29
D K E
A J I
30
L F
31
35 34
32
33
36
M
37
38
– 15 –
CABLE ROUTING
1. O2 sensor lead F. Route the positive battery lead between the

battery stay and the battery box.
2. Engine idling speed adjusting cable
G. To front cowling wire harness
3. Starter motor lead
H. Align the rear end of the right radiator fan motor
4. Air deflector coupler with the tape on the wire harness as
5. Wire harness shown in the illustration.
6. Spark plug lead #4 I. Fasten the wire harness, right horn (high) leads,
7. Spark plug lead #1 and right radiator fan motor lead with a plastic
locking tie, making sure to install the tie on the fan
8. Cylinders-#1/#4 ignition coil motor lead’s protective sleeve. Face the end of the
9. Cylinders-#2/#3 ignition coil plastic locking tie outward. Do not cut off the
10. Starter relay excess end of the plastic locking tie.
11. Starter relay lead J. To front right turn signal light
12. Fuse box 2 K. Fasten the wire harness, right radiator fan motor
lead, negative battery lead, and starter motor lead
13. Negative battery lead to the battery stay with a plastic locking tie, making
14. Brake hose (front brake master cylinder to sure to install the tie on the fan motor lead’s
hydraulic unit) protective sleeve and to position the tie in front of
15. Right handlebar switch lead the air deflector. Face the end of the plastic locking
tie outward, and then cut off the excess end of the
16. Throttle cable (accelerator cable) tie.
17. Throttle cable (decelerator cable) L. Fasten the wire harness to the battery stay with a
18. Battery stay plastic locking tie. Face the end of the plastic
19. Battery locking tie upward, and then cut off the excess end
of the tie.
M. Fasten the negative battery lead at the blue tape,
21. Main fuse starter motor lead, and water pump breather hose
22. YCC-S control relay with a plastic locking tie, making sure to install the
23. Brake light relay tie around the end of the hose’s protective sleeve,
and then cut off the excess end of the tie. Do not
24. Headlight (on/off)/grip warmer relay kink the water pump breather hose and do not face
25. Front cowling wire harness the end of the plastic locking tie downward.
26. Radiator fan motor relay N. Route the wire harness to the outside of the spark
27. Right horn (high) leads plug leads.
28. Positive battery lead coupler O. Route the ignition coil primary leads to the inside
of the fuse box leads.
29. Front right turn signal light lead
P. Route the fuse box leads, starter relay lead, and
30. Right radiator fan motor lead ignition coil primary leads between the battery stay
31. Ground lead coupler and the guide.
32. Brake hose (hydraulic unit to right front brake Q. Make sure that the wire harness does not protrude
caliper) to the outside of the guide.
33. Brake hose (metering valve to right front brake R. Pass the plastic locking tie between the guide and
caliper) the wire harness.
34. Right horn (high) S. Position the plastic locking tie to the rear of the
35. Right horn (high) connectors bend in the battery stay.
36. Water pump breather hose
37. Right radiator fan
38. Crankshaft position sensor lead
39. Spark plug leads
40. Ignition coil primary leads
41. Fuse box leads
42. Guide
A. Route the O2 sensor lead to the inside of the
engine idling speed adjusting cable.
B. Make sure that the wire harness and spark plug
leads are positioned in the indentation on the right
side of the air deflector.
C. Route the spark plug leads to the inside of the
battery stay pipe.
D. Fasten the negative battery lead at the blue tape
and the starter motor lead to the battery box with a
plastic locking tie. Face the end of the plastic
locking tie downward. Do not cut off the excess
end of the plastic locking tie.
E. Fasten the negative battery lead and starter motor
lead to the battery box with a plastic locking tie.
Face the end of the plastic locking tie rearward. Do
not cut off the excess end of the plastic locking tie.
– 16 –
CABLE ROUTING
2 3 D 4 5 6 7 8 9
E
10
11
12
1 A
1
B F
C
15 G 14 13
– 17 –
CABLE ROUTING
1. Rear wheel sensor lead

2. Rear brake fluid reservoir
3. Rear brake light switch lead
4. Clutch actuator motor lead
5. Clutch actuator sensor lead
6. Hydraulic unit
7. 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)
11. Brake hose (rear brake master cylinder to
hydraulic unit)
12. Brake pipe (metering valve to right front brake
caliper)
13. Clutch hose
14. Rear brake light switch
15. Brake hose (proportioning valve to rear brake
caliper)
A. Route the rear wheel sensor lead to the inside of
the swingarm, making sure that the lead does not
protrude above the swingarm.
B. 45–55 mm (1.77–2.17 in)
C. 10–20 mm (0.39–0.79 in)
D. Route the rear brake light switch lead under the
rear wheel sensor lead.
E. Fasten the clutch actuator motor lead and clutch
actuator sensor lead to the brake hose (hydraulic
unit to front brake calipers) with the plastic locking
tie, making sure to face the end of the tie forward.
Do not cut off the excess end of the plastic locking
tie.
F. To clutch actuator
G. Fasten the rear wheel sensor lead to the brake
hose (proportioning valve to rear brake caliper)
with the two holders, making sure that the fastener
of each holder faces inward.
– 18 –
CABLE ROUTING
5
1 A 2 B 3 4 6
C
7
D
E
8
13
12
11
10
– 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.
Face the end of the plastic locking tie rearward,
along the side of the accessory box. Do not cut off
the excess end of the plastic locking tie.
B. Fasten the wire harness and left radiator fan motor
lead with the holder.
C. Route the grip warmer control unit leads to the
outside of the thermostat assembly breather hose.
D. Fasten the front cowling wire harness to the
radiator inlet hose with a plastic locking tie, making
sure to install the tie on the harness’ protective
sleeve, and then cut off the excess end of the tie.
E. After connecting the couplers, cover them
completely with the cover, and then push them in
between the radiator inlet hose and the thermostat
inlet hose 2.
– 20 –
CABLE ROUTING
28 29
27 30
26 31 32
25
A-A
UP
D 33
16 Q C
8 9 10
6 7
5 R
4
S
11
T 19
B 35 30 U 34
A
B
3
2
11
1
D
C
D E
12 13
J F
24 A
B
P
23 O A
K
N
21 C
M L
20
22 14
19 15
G
18 17 16 I H
– 21 –
CABLE ROUTING
1. Grip warmer couplers E. Fasten the sidestand switch lead, stator coil lead,
2. Hand shift switch coupler and oil level switch lead with a plastic locking tie,
making sure to bundle and fasten the sidestand
3. Handlebar switch couplers switch lead so that the coupler is positioned to the
4. Right grip warmer lead front of the tie. Face the end of the plastic locking
5. Right handlebar switch lead tie outward. Do not cut off the excess end of the
plastic locking tie.
6. Immobilizer unit lead
F. To fuel tank
7. Main switch lead
G. Pass the fuel tank breather/overflow hose through
8. Hand shift switch lead the guide on the universal joint dust cover.
9. Left grip warmer lead H. Pass the air filter case breather hose through the
10. Left handlebar switch lead guide on the muffler bracket.
11. Stator coil lead I. Fasten the clutch hose with the pivot shaft locknut
12. Air filter case breather hose retainer.
13. Gear position sensor lead J. 43–53 mm (1.69–2.09 in)
14. Foot shift switch lead K. 60–70 mm (2.36–2.76 in)
15. Fuel tank breather/overflow hose L. Fasten the grommets on the front wheel sensor
16. Clutch hose lead and the brake hose (hydraulic unit to left front
brake caliper) with the holder.
17. Sidestand switch
M. Route the front wheel sensor lead to the outside of
18. Sidestand switch lead the left front brake caliper lower mounting boss and
19. Oil level switch lead the boss for the left front fork compression
20. Coolant reservoir breather hose damping force adjusting screw.
21. Brake hose (hydraulic unit to left front brake N. Fasten the grommet on the front wheel sensor lead
caliper) with the holder.
22. Front wheel sensor O. Route the front wheel sensor lead between the left
front brake caliper and the brake hose (hydraulic
23. Front wheel sensor lead unit to left front brake caliper).
24. Front left turn signal light lead P. Fasten the front wheel sensor lead to the brake
25. Brake pipe (metering valve to right front brake hose (hydraulic unit to left front brake caliper) with
caliper) the two holders, making sure to position the lead to
26. Brake pipe (hydraulic unit to front brake calipers) the inside of the hose.
27. Brake pipe (front brake master cylinder to hydraulic Q. Route the fuel tank breather/overflow hose to the
unit) front of the clutch hose, then through the opening
between the frame and the swingarm.
28. Wire harness
R. Face the ends of the clamp to the left, making sure
29. Crankshaft position sensor lead that the lower end contacts the wire harness.
30. Starter motor lead S. Fasten the oil level switch lead and starter motor
31. Neutral switch coupler lead with the clamp.
32. YCC-S speed sensor T. To sidestand switch
33. Oil level switch coupler U. Route the starter motor lead between the rear
34. Upper crankcase balancer cover bolt and the rib on the crankcase.
35. Rear balancer cover
A. Secure the plastic band by inserting the projection
on the band into the hole in the windshield drive
unit/meter assembly stay, and then fasten the
handlebar switch leads, grip warmer leads and
hand shift switch lead with the band, making sure
that the end of the band faces down. Do not cut off
the excess end of the plastic band.
B. Secure the plastic band by inserting the projection
on the band into the hole in the windshield drive
unit/meter assembly stay, and then fasten the
handlebar switch leads, grip warmer leads, hand
shift switch lead and front wheel sensor lead with
the band, making sure that the end of the band
faces down. Do not cut off the excess end of the
plastic band.
C. To oil level switch
D. Fasten the leads (to oil level switch and crankshaft
position sensor) that branch off from the wire
harness to the guide on the holder with a plastic
locking tie, making sure that the end of the tie faces
upward. Do not cut off the excess end of the plastic
locking tie.
– 22 –
CABLE ROUTING
2
20
21
11
11 22 3 H
22
27 23
26 B-B
3
25
24 G
A-A
5
C
6
7
1 2 3 4
8 A
B
B
A A 9
10
11
C
12
D
B 13
14 5 J K
I L
15
6
16 E 6
17
F 19 18
12
C 5 M
– 23 –
CABLE ROUTING
1. Wire harness L. Route the leads between the left tail/brake light
2. ECU (engine control unit) bulb socket and the rear left turn signal light bulb
socket.
3. ABS ECU (electronic control unit)
M. Route the tail/brake light assembly lead between
4. MCU (motor control unit) the tail/brake light assembly and its bracket.
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. Rectifier/regulator
19. Rectifier/regulator lead
20. Brake hose (hydraulic unit to metering valve)
21. Hydraulic unit
22. Rear wheel sensor lead
23. Rear brake light switch lead
24. Brake hose (front brake master cylinder to
hydraulic unit)
26. Brake hose (rear brake master cylinder to
hydraulic unit)
27. Brake hose (hydraulic unit to proportioning valve)
A. Pass the license plate light lead through the hole in
the rear fender.
B. Route the wire harness to the inside of the seat
lock cable.
C. Fasten the shift actuator motor lead, shift actuator
sensor lead, and foot shift switch lead to the ABS
wire harness with a plastic locking tie, making sure
to position the harness to the outside of the other
leads. Face the end of the plastic locking tie
inward, without cutting off the excess end.
D. Fasten the ABS wire harness with the holder.
E. Route the stator coil lead and rectifier/regulator
lead to the outside of the rear shock absorber
spring preload adjusting cable and under the
hydraulic unit breather hose and clutch fluid
reservoir hose.
F. Pass the stator coil lead, rectifier/regulator lead,
and hydraulic unit breather hose through the guide
on the frame, making sure to route the hose to the
outside of the leads.
G. Fasten the leads (to ABS wire harness and rear
brake light switch) that branch off from the wire
harness with the holder.
H. When installing the ABS ECU, be sure not to pinch
the rear wheel sensor lead and ABS wire harness
between the ABS ECU and the rear fender.
I. Route the rear right turn signal light lead under the
right tail/brake light bulb socket.
J. Route the tail/brake light assembly lead between
the left tail/brake light bulb socket and the
mounting boss on the tail/brake light assembly.
K. Route the rear right turn signal light lead and right
tail/brake light lead over the left tail/brake light bulb
socket.
– 24 –
CABLE ROUTING
F
12
11
3 4 5 6 7 8 9 D
13
10
14
E
15
16
17
2 A
C 18
1
19
B
G
P
20
H
21
22
I
I
31 O 23
N
24
M
25
26
30 27
29 L K
28
– 25 –
CABLE ROUTING
1. Spark plug lead #1 L. Route the stator coil lead to the inside of the
2. Spark plug lead #2 engine bracket (top) and under the crankcase
breather hose.
3. Front wheel sensor lead
M. Route the wire harness (to sub-wire harness)
4. Immobilizer unit lead under the fuel hose connector.
5. Main switch lead N. Route the fuel pump/fuel sender lead under the
6. Throttle cable (accelerator cable) fuel hose connector.
7. Throttle cable (decelerator cable) O. Place the joint couplers in the area shown in the
8. Brake hose (hydraulic unit to front brake calipers) illustration, making sure that they do not protrude
above the wire harness.
9. Brake hose (metering valve to right front brake
caliper) P. Route the throttle cables over the immobilizer unit
lead, main switch lead, spark plug lead #2, and
10. Brake hose (front brake master cylinder to wire harness, and under spark plug lead #1.
hydraulic unit)
11. Main fuse
14. Negative battery lead
15. Fuse box 1 (identified by blue tape on lead)
16. Starter relay
17. Fuse box 2
18. Cylinders-#2/#3 ignition coil connectors (white)
19. Cylinders-#1/#4 ignition coil connectors (black)
20. Spark plug lead #3
21. Coolant temperature sensor
22. Spark plug lead #4
23. Cylinder identification sensor lead
24. O2 sensor coupler
25. Throttle position sensor
26. Fuel hose
27. Fuel pump/fuel sender lead
28. Crankcase breather hose
29. Stator coil lead
30. Intake air pressure sensor
31. Joint couplers
A. Fasten the immobilizer unit lead and front wheel
sensor lead to the wire harness with a plastic
locking tie, making sure to align the tie with the
white tape on the harness. Face the end of the
plastic locking tie forward. Do not cut off the excess
end of the plastic locking tie.
B. Position the plastic locking tie 0–20 mm (0–0.79
in) from the end of the protective sleeve of the front
wheel sensor lead.
C. Position the plastic locking tie 10–30 mm (0.39–
1.18 in) from the end of the protective sleeve of the
immobilizer unit lead.
D. Route the throttle cables and brake hoses through
the right opening in the frame.
E. Install the immobilizer unit coupler holder so that
the end with the bolt is facing forward.
F. Install the immobilizer unit coupler cover onto the
coupler.
G. Route the wire harness over the spark plug leads.
H. To cylinder identification sensor
I. To fuel tank
J. Fasten the cylinder identification sensor lead with
the holder on the throttle body.
K. Fasten the fuel pump/fuel sender lead and air
induction system solenoid lead to sub-wire
harness with a plastic locking tie, making sure that
the end of the tie faces forward. Do not cut off the
excess end of the plastic locking tie.
– 26 –
CABLE ROUTING
I
A
H 1
2
F
D
E 3
– 27 –
CABLE ROUTING
1. Clutch actuator motor lead

2. Clutch actuator sensor lead
3. License plate light lead
4. Tail/brake light assembly lead
5. Seat lock cable
6. Intake air temperature sensor
A. Connect the clutch actuator motor lead and clutch
actuator sensor lead, install the rubber cover
around the leads, and then place the cover
between the hydraulic unit and the frame. When
closing the rubber cover, make sure that the thick
section at the base of each projection (four
locations) on one side of the cover is pulled
through its corresponding hole on the other side.
Face the side of the rubber cover with the
projections outward.
B. Fasten the clutch actuator motor lead and clutch
actuator sensor lead with the band that is used to
secure the MCU (motor control unit).
C. Make sure that the projection on the storage
compartment fits into the indentation in the MCU
(motor control unit). The MCU should not be
resting on top of the projection.
D. Route the tail/brake light assembly lead and
license plate light lead between the rib and the U-
lock holder on the rear fender, making sure that the
leads are not routed on top of the holder.
E. Fasten the tail/brake light assembly lead and
license plate light lead with the holder.
F. Route the tail/brake light assembly lead and
license plate light lead between the ribs on the rear
fender.
G. To shift actuator
H. Route the intake air temperature sensor lead
under the wire harness.
I. Fasten the intake air temperature sensor lead to
the air filter case with the holder.
– 28 –
PERIODIC MAINTENANCE
EAS20450
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 long-
er 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. All service technicians should be
familiar with this entire chapter.
EAU17705
PERIODIC MAINTENANCE AND LUBRICATION CHART

NOTE:
• The annual checks must be performed every year, except if a kilometer-based maintenance is
performed instead.
• From 50000 km, repeat the maintenance intervals starting from 10000 km.
• Items marked with an asterisk should be performed by a -Yamaha dealer as they require special tools,
data and technical skills.
ODOMETER READING (× 1000 km) ANNU-

NO. ITEM CHECK OR MAINTENANCE JOB AL
1 10 20 30 40 CHECK
1 * Fuel line • Check fuel hoses for cracks or damage. √ √ √ √ √

• Check condition. √ √
2 * Spark plugs • Clean and regap.
• Replace. √ √
3 * Valves • Check valve clearance. Every 40000 km

• Adjust.
• Clean. √ √
4 * Air filter element
• Replace. √ √
• Check operation, fluid level and vehicle for fluid
5 * YCC-S clutch leakage. √ √ √ √ √
• Check operation, fluid level and vehicle for fluid √ √ √ √ √ √

6 * Front brake leakage.
• Replace brake pads. Whenever worn to the limit
• Check operation, fluid level and vehicle for fluid √ √ √ √ √ √
7 * Rear brake leakage.
• Replace brake pads. Whenever worn to the limit
• Check for cracks or damage. √ √ √ √ √
8 * Brake hoses
• Replace. Every 4 years
9 * Wheels • Check runout and for damage. √ √ √ √
• Check tread depth and for damage.
• Replace if necessary.
10 * Tires • Check air pressure. √ √ √ √ √
• Correct if necessary.
11 * Wheel bearings • Check bearing for looseness or damage. √ √ √ √
• Check operation and for excessive play. √ √ √ √
12 * Swingarm
• Lubricate with lithium-soap-based grease. Every 50000 km
• Check bearing play and steering for roughness. √ √ √ √ √
13 * Steering bearings
• Lubricate with lithium-soap-based grease. Every 20000 km
14 * Chassis fasteners • Make sure that all nuts, bolts and screws are prop- √ √ √ √ √
erly tightened.
Sidestand, center- • Check operation.
15 √ √ √ √ √
stand • Lubricate.
16 * Sidestand switch • Check operation. √ √ √ √ √ √
17 * Front fork • Check operation and for oil leakage. √ √ √ √
– 29 –
ODOMETER READING (× 1000 km) ANNU-

NO. ITEM CHECK OR MAINTENANCE JOB AL
1 10 20 30 40 CHECK
Shock absorber as-

18 * sembly • Check operation and shock absorber for oil leakage. √ √ √ √
Rear suspension re- • Check operation. √ √ √ √

lay arm and connect-
19 * ing arm pivoting
• Lubricate with lithium-soap-based grease. √ √
points
20 * Fuel injection • Adjust engine idling speed and synchronization. √ √ √ √ √ √
21 Engine oil • Change. √ √ √ √ √ √

• Check oil level and vehicle for oil leakage.
Engine oil filter car-
22 • Replace. √ √ √
tridge
• Check coolant level and vehicle for coolant leakage. √ √ √ √ √
23 * Cooling system
• Change. Every 3 years
24 Final gear oil • Check oil level and vehicle for oil leakage. √ √ √ √ √
• Change.
Front and rear brake
25 * • Check operation. √ √ √ √ √ √
switches
Moving parts and ca-
26 bles • Lubricate. √ √ √ √ √
Throttle grip hous- • Check operation and free play.

27 * • Adjust the throttle cable free play if necessary. √ √ √ √ √
ing and cable • Lubricate the throttle grip housing and cable.
28 * Muffler and exhaust • Check the screw clamp for looseness. √ √ √ √ √

pipe
Lights, signals and • Check operation.
29 * √ √ √ √ √ √
switches • Adjust headlight beam.
EAU40550
NOTE:
• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
• Hydraulic brake and YCC-S clutch service
• Regularly check and, if necessary, correct the brake and YCC-S clutch fluid levels.
• Every two years replace the internal components of the brake master cylinders and calipers as well
as YCC-S clutch master and release cylinders, and change the brake and YCC-S clutch fluids.
• Replace the brake and YCC-S clutch hoses every four years and if cracked or damaged.
– 30 –
ENGINE
EAS20470
NOTE:
ENGINE
In order to ensure a correct reading of the clutch
EAS20890 fluid level, make sure the top of the reservoir is
CHECKING THE CLUTCH FLUID LEVEL horizontal.
1. Stand the vehicle on a level surface.
4. Install:
NOTE: • Left side cover
Place the vehicle on the centerstand. Refer to “GENERAL CHASSIS” in chapter 4.
2. Remove: (Manual No.: 3P6-28197-E0)
• Left side cover ET2D21001
Refer to “GENERAL CHASSIS” in chapter 4. BLEEDING THE HYDRAULIC CLUTCH
(Manual No.: 3P6-28197-E0) SYSTEM
3. Check: EWA13000
• Clutch fluid level WARNING

Below the minimum level mark “a” → Add the Bleed the hydraulic clutch system whenever:
recommended clutch fluid to the proper level. • the system was disassembled,
• a clutch hose was loosened or removed,
Recommended fluid • the clutch fluid level is very low,
DOT 4 • clutch operation is faulty.
NOTE:
• Before bleeding the hydraulic clutch system,
shift the transmission into neutral to engage
the clutch.
• Be careful not to spill any clutch fluid or allow
the clutch fluid reservoir to overflow.
• When bleeding the hydraulic clutch system,
make sure that there is always enough clutch
fluid in the reservoir before pumping out the flu-
EWA13370 id using the vacuum/pressure gauge set. Ig-
WARNING noring this precaution could allow air to enter
• Use only the designated clutch fluid. Other the hydraulic clutch system, considerably
clutch fluids may cause the rubber seals to lengthening the bleeding procedure.
deteriorate, causing leakage and poor • If bleeding is difficult, it may be necessary to let
clutch performance. the clutch fluid settle for a few hours. Repeat
• Refill with the same type of clutch fluid that the bleeding procedure when the tiny bubbles
is already in the system. Mixing clutch flu- in the hose have disappeared.
ids may result in a harmful chemical reac- 1. Remove:
tion, leading to poor clutch performance. • Air filter case
• When refilling, be careful that water does Refer to “GENERAL CHASSIS” on page 37.
not enter the clutch fluid reservoir. Water • Rear wheel
will significantly lower the boiling point of Refer to “REAR WHEEL” in chapter 4. (Man-
the clutch fluid and could cause vapor lock. ual No.: 3P6-28197-E0)
ECA13420 • Swingarm
CAUTION: Refer to “SWINGARM” in chapter 4. (Manual
Clutch fluid may damage painted surfaces or No.: 3P6-28197-E0)
plastic parts. Therefore, always clean up any 2. Bleed:
spilt clutch fluid immediately. • Hydraulic clutch system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fasten the clutch fluid reservoir “1” to the
frame with a suitable strap, etc., as shown in
the illustration so that it is not tilted.
– 31 –
ENGINE
b a
4
b. Turn the main switch to “ON” and check that l. Repeat steps (i) to (k) until all of the air bub-
the transmission is in neutral. bles have disappeared from the clutch fluid in
c. Add the recommended clutch fluid to the the plastic hose of the vacuum/pressure
proper level. pump gauge set.
d. Install the clutch fluid reservoir diaphragm. m. Tighten the bleed screw to specification.
e. Connect the vacuum/pressure pump gauge
set “2” tightly to the bleed screw “3”. Bleed screw
6 Nm (0.6 m·kg, 4.3 ft·lb)
T.
R.
Vacuum/pressure pump gauge
set n. Manually engage and disengage the clutch
90890-06756 30 times using the manual clutch operation
Mityvac brake bleeding tool bolt.
YS-42423 o. Add the recommended clutch fluid to the
proper level.
3 Refer to “CHECKING THE CLUTCH FLUID
LEVEL” on page 31.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Check:
• Pressure plate stroke
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2 a. Remove the pickup rotor cover bolts “1”.
b. Remove the clutch cover “2”.
Refer to “CLUTCH” in chapter 5. (Manual
f. Loosen the bleed screw. No.: 3P6-28197-E0)
g. Pump out the clutch fluid using the vacu-
um/pressure pump gauge set.
h. Tighten the bleed screw.
i. Disengage the clutch by turning the manual
clutch operation bolt “4” in direction “a” until it
stops. 2
j. Loosen the bleed screw and then retighten it.
1
k. Engage the clutch by turning the manual
clutch operation bolt in direction “b” until it
stops. c. Manually engage and disengage the clutch
NOTE: using the clutch operation bolt “3” five times,
The following illustration shows the manual each time for less than 1 second.
clutch operation bolt when viewed from the rear NOTE:
of the vehicle with the swingarm removed. Turn the clutch operation bolt in a continuous
motion, without allowing the pressure plate to
stop in mid-stroke.
– 32 –
ENGINE
g. If the pressure plate stroke is out of specifica-

tion, repeat steps (j) to (l) in the procedure for
step “2. Bleed” until clutch pressure plate
stroke is within specification.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• Swingarm
Refer to “SWINGARM” in chapter 4. (Manual
3 No.: 3P6-28197-E0)
• Rear wheel
d. Install a suitable bracket “4”, the magnet base
Refer to “REAR WHEEL” in chapter 4. (Man-
B “5”, and the dial gauge & stand set “6”.
ual No.: 3P6-28197-E0)
Magnet base B • Air filter case
90890-06844 Refer to “GENERAL CHASSIS” on page 37.
Magnetic base stand
ET2D21036
YU-A8438
CHECKING THE VEHICLE AFTER
Dial gauge & stand set
90890-01252 BLEEDING THE HYDRAULIC CLUTCH
SYSTEM
1. Check:
• Rear wheel drag torque
Rear wheel does not rotate/drag torque does
not progressively increase in the following or-
der: neutral, 1st gear, and when rear wheel
starts to rotate in 1st gear → Check the pres-
5
sure plate stroke.
6
Refer to “BLEEDING THE HYDRAULIC
4 CLUTCH SYSTEM” on page 31.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place the vehicle on the centerstand.
b b. Turn the main switch to “ON”.
c c. Shift the transmission into neutral, and then
rotate the rear wheel by hand.
d
a e
f
a
g
a. 100 mm (3.94 in)
b. 20 mm (0.79 in)
c. 1.5 mm (0.06 in)
d. 64 mm (2.52 in) d. Shift the transmission into 1st gear, and then
e. M6 × 40 mm bolt rotate the rear wheel by hand.
f. 5 mm (0.20 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
g. 60 mm (2.36 in)
2. Check:
e. Disengage the clutch by turning the manual • Shift operation
clutch operation bolt. Engine stalls → Check the pressure plate
f. Measure the clutch pressure plate stroke. stroke.
Clutch pressure plate stroke CLUTCH SYSTEM” on page 31.
2.8 mm (0.11 in) or more ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place the vehicle on the centerstand.
– 33 –
ENGINE
b. Start the engine. • Left side cover

c. Shift the transmission from neutral to 1st gear Refer to “GENERAL CHASSIS” on page 37.
and back to neutral ten times. • Shift actuator
d. Shift the transmission into 1st gear, and then Refer to “SHIFT ACTUATOR AND SHIFT
apply the rear brake. ROD” on page 57.
NOTE: • Air filter case cover
If the engine stalls, restart the engine, let it idle • Air filter element
for at least 90 seconds, and then repeat steps (c) Refer to “GENERAL CHASSIS” on page 37.
and (d). 2. Clean:
• Air filter element
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Apply compressed air to the outer surface of
3. Check: the air filter element.
• Starting-off performance of vehicle
Abnormal vehicle vibration/abnormal start-
ing-off performance/sudden acceleration
compared to before the hydraulic clutch sys-
tem was serviced → Select diagnostic code
No. Sh_ _66 in the diagnostic mode and op-
erate the hand shift lever switch (shift up) two
times.
Refer to “Diagnostic code table (Diagnostic
code No. Sh_ _66)”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
3. Check:
a. Place the vehicle on the centerstand. • Air filter element
b. Start the engine and warm it up until at least Damage → Replace.
EC3P61043
three segments appear on the coolant tem-
CAUTION:
perature meter “1” as shown in the illustra-
tion. Never operate the engine without the air filter
element installed. Unfiltered air will cause
1 rapid wear of engine parts and may damage
the engine. Operating the engine without the
air filter element will also affect throttle body
synchronization, leading to poor engine per-
formance and possible overheating.
4. Install:
• Air filter element
• Air filter case cover
Refer to “GENERAL CHASSIS” on page 37.
c. Shift the transmission into 1st gear, and then • Shift actuator
slowly turn the throttle grip and check that the Refer to “SHIFT ACTUATOR AND SHIFT
rear wheel rotates. ROD” on page 57.
d. Check that the transmission can be shifted • Left side cover
into 2nd gear. • Rider seat
e. Shift the transmission into neutral, and then Refer to “GENERAL CHASSIS” on page 37.
raise the centerstand.
NOTE:
f. Shift the transmission into 1st gear, and then
slowly turn the throttle grip and check the When installing the air filter element into the air
starting-off performance of the vehicle. filter case cover, make sure their sealing surfac-
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
es are aligned to prevent any air leaks.
EAS20920
CLEANING THE AIR FILTER ELEMENT

1. Remove:
• Rider seat
– 34 –
CHASSIS
EAS21140
CHASSIS
ET2D21002
ADJUSTING THE SHIFT PEDAL

1. Check:
• Shift pedal position
NOTE:
The shift pedal “1” can be adjusted to three po-
sitions to suit the rider’s preference as shown.
2. Adjust:
• Shift pedal position
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
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.
Shift pedal bolt

7 Nm (0.7 m·kg, 5.1 ft·lb)
T.
R.
LOCTITE®
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
– 35 –
ELECTRICAL SYSTEM
EAS21750 ECA13690
ELECTRICAL SYSTEM CAUTION:

Avoid touching the glass part of the head-
EAS21790
light bulb to keep it free from oil, otherwise
REPLACING THE HEADLIGHT BULBS
the transparency of the glass, the life of the
The following procedure applies to both of the
bulb and the luminous flux will be adversely
headlight bulbs.
affected. If the headlight bulb gets soiled,
1. Remove:
thoroughly clean it with a cloth moistened
• Front cowling left inner panel 1
with alcohol or lacquer thinner.
• Front cowling right inner panel 1 7. Attach:
• Front cowling right inner panel 2 • Headlight bulb holder
Refer to “GENERAL CHASSIS” on page 37. 8. Install:
2. Disconnect: • Headlight bulb cover
• Headlight coupler “1” 9. Connect:
3. Remove: • Headlight coupler
• Headlight bulb cover “2” 10.Install:
• Front cowling right inner panel 2
• Front cowling right inner panel 1
Refer to “GENERAL CHASSIS” on page 37.
2
4. Detach:
• Headlight bulb holder “1”
5. Remove:
• Headlight bulb “2”
2
EWA13320
WARNING
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
6. Install:
• Headlight bulb New
Secure the new headlight bulb with the head-
light bulb holder.
– 36 –
GENERAL CHASSIS
EAS21830
GENERAL CHASSIS
Removing the front cowling assembly
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
LT
LT
9 8
21
10
22
32 Nm (3.2 m • kg, 23 ft • Ib)
T.
R.
11 22
24 19
12
14
20
4 23 21
14
21
23 9 13
LT 15
17 18 16
11
6 12
3
5
1
7 2
Order Job/Parts to remove Q’ty Remarks

Open the accessory box lid.
1 Left side panel 1
2 Left side cowling 1
3 Front left turn signal light coupler 1 Disconnect.
4 Right side panel 1
5 Right side cowling 1
6 Front right turn signal light coupler 1 Disconnect.
7 Bottom cowling 1
8 Front cowling right inner panel 1 1
9 Headlight beam adjusting knob 2
10 Front cowling right inner panel 2 1
11 Adjusting knob shaft 2
12 Headlight beam adjusting cable 2 Disconnect.
13 Front cowling left inner panel 1 1
14 Grip warmer control unit coupler 2 Disconnect.
15 Grip warmer control unit 1
– 37 –
GENERAL CHASSIS
Removing the front cowling assembly

10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
LT
LT
9 8
21
10
22
32 Nm (3.2 m • kg, 23 ft • Ib)
T.
R.
11 22
24 19
12
14
20
4 23 21
14
21
23 9 13
LT 15
17 18 16
11
6 12
3
5
1
7 2

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.
21 Front cowling wire harness coupler 6 Disconnect.
22 Horn connector 4 Disconnect.
23 Grip warmer coupler 2 Disconnect.
24 Front cowling assembly 1
For installation, reverse the removal proce-
dure.
– 38 –
GENERAL CHASSIS
Removing the air filter case

8
18 Nm (1.8 m • kg, 13 ft • Ib)
7
5
T.
R.
12
New
7 Nm (0.7 m • kg, 5.1 ft • Ib) 7
T.
R.
13 17
14
18 9
11
(4) 6
16 10
(11)
16 16
8 Nm (0.8 m • kg, 5.8 ft • Ib)
T.
R.
15
19
20
(4)
4
19
3
4 Nm (0.4 m • kg, 2.9 ft • Ib)

2 1
T.
R.

Left side cover Refer to “GENERAL CHASSIS” on page 37.
Refer to “GENERAL CHASSIS” in chapter 4.
T-bar (Manual No.: 3P6-28197-E0)
Refer to “FUEL TANK” in chapter 7. (Manual
Fuel tank No.: 3P6-28197-E0)
Refer to “SHIFT ACTUATOR AND SHIFT
Shift actuator ROD” on page 57.
1 Air shroud 1
2 Air duct 1
3 Air filter case cover 1
4 Air filter element 1
5 Tool kit 1
6 ECU coupler 1 Disconnect.
7 MCU coupler 2 Disconnect.
8 MCU 1
9 Storage compartment 1
10 ECU (engine control unit) 1
11 Rear lower fuel tank bracket 1
12 Intake air temperature sensor 1
– 39 –
GENERAL CHASSIS
Removing the air filter case

8
18 Nm (1.8 m • kg, 13 ft • Ib)
7
5
T.
R.
12
New
7 Nm (0.7 m • kg, 5.1 ft • Ib) 7
T.
R.
13 17
14
18 9
11
(4) 6
16 10
(11)
16 16
8 Nm (0.8 m • kg, 5.8 ft • Ib)
T.
R.
15
19
20
(4)
4
19
3
4 Nm (0.4 m • kg, 2.9 ft • Ib)

2 1
T.
R.

13 Bypass air unit inlet hose 1 Disconnect.
14 Crankcase breather hose 1 Disconnect.
Air induction system hose (air filter case joint
15 1 Disconnect.
assembly to 3-way joint)
16 Air filter case joint clamp screw 4 Loosen.
17 Air filter case joint assembly 1
18 Air filter case 1
19 Air filter case breather hose 2
20 Filter assembly 1
dure.
– 40 –
HANDLEBARS
EAS22850
HANDLEBARS
Removing the left handlebar

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
dure.
– 41 –
HANDLEBARS
Removing the right handlebar

1 Front brake light switch connector 2 Disconnect.
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 Disconnect.
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
dure.
– 42 –
HANDLEBARS
EAS22900
INSTALLING THE HANDLEBARS

1. Stand the vehicle on a level surface.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Install:
• Handlebar grip
• Grip end “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 4. Install:
a. Apply a thin coat of rubber adhesive onto the • Left handlebar switch “1”
end of the left handlebar. NOTE:
Recommended adhesive Align the projection “a” on the left handlebar

switch with the hole “b” on the left handlebar.
Three Bond 1530®
b. Slide the handlebar grip onto the left handle-

bar.
c. Wipe off any excess rubber adhesive with a
clean rag.
EWA13700
WARNING
Do not touch the handlebar grip until the rub-
ber adhesive has fully dried.
NOTE: 5. Install:
There should be 1–3 mm (0.04–0.12 in) of clear- • Hand shift switch “1”
ance “a” between the handlebar grip and the grip • Lead holder 2 “2”
end. NOTE:
• Align the projection “a” on the hand shift switch
with hole “b” on the left handlebar.
• When installing the hand shift switch, route the
left grip warmer lead “3” and left handlebar
switch lead “4” through the switch as shown in
the illustration, making sure to fasten the left
grip warmer lead with the lead holder 2.
• After installing the hand shift switch, check that
the left grip warmer lead does not interfere with
the movement of the hand shift lever.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
1 b
• Right handlebar switch “1”
NOTE: a
Align the projection “a” on the right handlebar
switch with the hole “b” on the right handlebar.
4 2 3
6. Install:
• Right handlebar
• Left handlebar
– 43 –
HANDLEBARS
NOTE: es to the rear of the other section of the lead,

Fit the projections on each handlebar into the and route the lead through the throttle cable
holes in the upper bracket, making sure that the housing.
handlebars are installed in the same position. • 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 (0.04–0.12 in) of
a a a a clearance “c” between the throttle grip and the
grip end.
b b b b
c c c c
a. Front position 1
3
b. Standard position
c. Rear position
1
7. Install:
• Handlebar bolts “1”
(temporarily)
• Handlebar nuts “2”
(temporarily)
2
1
2
8. Tighten:
• Handlebar bolts
• Handlebar nuts
Handlebar bolt
23 Nm (2.3 m·kg, 17 ft·lb)
T.
R.
Handlebar nut
65 Nm (6.5 m·kg, 47 ft·lb)
10.Install:
• Front brake master cylinder assembly
NOTE:
• Front brake master cylinder holder “1”
First tighten the bolts, then tighten the nuts.
9. Install: Front brake master cylinder hold-
er bolt
• Throttle grip
T.
R.
10 Nm (1.0 m·kg, 7.2 ft·lb)

• Throttle cables
• Throttle cable housing “1”
NOTE:
• Grip end “2”
• Install the brake master cylinder holder with the
NOTE:
“UP” mark facing up.
• Make a loop in the right grip warmer lead “3” as • Align the projection “a” on the front brake mas-
shown in the illustration, making sure that the ter cylinder with hole “b” on the right handlebar.
section of the lead from the grip warmer cross-
– 44 –
HANDLEBARS
• First, tighten the upper bolt, then the lower bolt.
a
1
11.Adjust:
• Throttle cable free play
Refer to “ADJUSTING THE THROTTLE CA-
BLE FREE PLAY” in chapter 3. (Manual No.:
3P6-28197-E0)
Throttle cable free play

3.0–5.0 mm (0.12–0.20 in)
– 45 –
SHAFT DRIVE
EAS23550
SHAFT DRIVE
EAS23660
INSTALLING THE DRIVE SHAFT AND FINAL Installed depth “a”

DRIVE ASSEMBLY 8.5–10.0 mm (0.33–0.39 in)
1. Lubricate:
• Drive shaft spline (final drive pinion gear side)
Recommended lubricant 3
Molybdenum disulfide grease
2. Lubricate: 1
• Drive shaft spline (universal joint side) 4
Recommended lubricant 2
Lithium-soap-based grease
3. Install:
• Oil seal “1” New
• Washer “2”
a
(with the fork seal driver weight “3” and fork
seal driver attachment “4”)
Fork seal driver weight

90890-01184
Fork seal driver attachment
90890-01186
Replacement 27 mm 6. Install:
YM-A9409-1 • Universal joint
• Final drive assembly
NOTE:
Align the drive shaft splines with the driven yoke
of the universal joint.
3 7. Tighten:
• Final drive assembly nuts
4 Final gear case nut
2 42 Nm (4.2 m·kg, 30 ft·lb)
T.
R.
1 New
8. Install:
4. Install:
• Sidestand
• Circlip New • Left footrest assembly
5. Install: Refer to “SHIFT ACTUATOR AND SHIFT
• Drive shaft “1” ROD” on page 57.
(to the final drive pinion gear) 9. Install:
• Oil seal “2” • Rear wheel
(to the final gear case with the fork seal driver Refer to “REAR WHEEL” in chapter 4. (Man-
weight “3” and oil seal installing tool “4”) ual No.: 3P6-28197-E0)
10.Fill:
Fork seal driver weight
• Final gear case
90890-01184
Oil seal installing tool Refer to “CHECKING THE FINAL GEAR OIL
90890-01512 LEVEL” in chapter 3. (Manual No.: 3P6-
28197-E0)
– 46 –
ENGINE REMOVAL
EAS23710
ENGINE REMOVAL
Disconnecting the leads and hoses
5
12 10 Nm (1.0 m • kg, 7.2 ft • Ib)
.
R.
9 10
7
8
4
11 LT
LT
3
2 1
4 Nm (0.4 m • kg, 2.9 ft • Ib)
T.
R.

Refer to “FRONT WHEEL” in chapter 4.
Front fender (Manual No.: 3P6-28197-E0)
Air filter case Refer to “GENERAL CHASSIS” on page 37.
Refer to “THROTTLE BODIES” in chapter 7.
Throttle bodies (Manual No.: 3P6-28197-E0)
Refer to “AIR INDUCTION SYSTEM” in
Air cut-off valve/Reed valves chapter 7. (Manual No.: 3P6-28197-E0)
Refer to “THERMOSTAT” in chapter 6.
Thermostat/Thermostat inlet pipe 1 (Manual No.: 3P6-28197-E0)
Drain.
Engine oil/Oil filter cartridge Refer to “CHANGING THE ENGINE OIL” in
chapter 3. (Manual No.: 3P6-28197-E0)
Refer to “OIL COOLER” in chapter 6. (Manu-
Oil cooler al No.: 3P6-28197-E0)
Refer to “WATER PUMP” in chapter 6. (Man-
Water pump ual No.: 3P6-28197-E0)
Refer to “ELECTRIC STARTER” in chapter
Starter motor 5. (Manual No.: 3P6-28197-E0)
Left footrest assembly/Sidestand ROD” on page 57.
– 47 –
ENGINE REMOVAL
Disconnecting the leads and hoses
5
12 10 Nm (1.0 m • kg, 7.2 ft • Ib)
.
R.
9 10
7
8
4
11 LT
LT
3
2 1
4 Nm (0.4 m • kg, 2.9 ft • Ib)
T.
R.

Gear position sensor cover ROD” on page 57.
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.
7 Oil level switch coupler 1 Disconnect.
8 Crankshaft position sensor coupler 1 Disconnect.
9 Neutral switch coupler 1 Disconnect.
10 YCC-S speed sensor coupler 1 Disconnect.
11 Ground lead 1 Disconnect.
12 Spark plug cap 4
dure.
– 48 –
ENGINE REMOVAL
ET2D21003
REMOVING THE GEAR POSITION SENSOR

1. Disconnect:
• Gear position sensor coupler
2. Remove:
• Gear position sensor
NOTE: 1
Remove only the screws “1” when removing the
gear position sensor. Do not remove the screws
“2”.
ET2D21004
1 INSTALLING THE GEAR POSITION SENSOR

2 1. Connect:
• MCU coupler
1
• ECU coupler
2 Refer to “GENERAL CHASSIS” on page 37.
2. Install:
• Gear position sensor “1”
EC2D21002
CAUTION:
Shift the transmission into neutral before in-
ET3P61023
stalling the gear position sensor, otherwise
REMOVING THE ENGINE
the sensor may be damaged.
1. Loosen:
• Spacer bolt NOTE:
NOTE: Fit the end “a” of the shift drum assembly into the
Loosen the spacer bolt with the pivot shaft opening “b” in the gear position sensor “1”, and
wrench “1” and pivot shaft wrench adapter “2”. then rotate the sensor counterclockwise and
temporarily install the screws.
Pivot shaft wrench
90890-01471 1
Frame spanner socket
YM-01471
Pivot shaft wrench adapter
90890-01476
a
b
2. Remove:
• Engine
NOTE:
Make sure that the engine does not strike the 3. Adjust:
clutch actuator “1” when removing it. • Gear position sensor
Refer to “ADJUSTING THE GEAR POSI-
TION SENSOR” on page 50.
– 49 –
ENGINE REMOVAL
ET2D21005
3. Check:
ADJUSTING THE GEAR POSITION SENSOR
• Gear position setting
1. Check:
Refer to “CHECKING THE GEAR POSITION
SENSOR” on page 132.
2. Adjust:
• Gear position sensor angle
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the gear position sensor coupler to
the gear position sensor.
b. Connect the digital circuit tester to the gear
position sensor.
• Positive tester probe →
yellow “1”
• Negative tester probe →
black/blue “2”
Digital circuit tester

90890-03174
Model 88 Multimeter with ta-
chometer
YU-A1927
c. Turn the main switch to “ON”.

d. Measure the gear position sensor voltage.
e. Adjust the gear position sensor angle so that
the voltage is within the specified range.
Output voltage (at neutral posi-

tion)
0.71–0.91 V
f. After adjusting the gear position sensor an-

gle, tighten the gear position sensor screws
“3” to specification.
Gear position sensor screw

4 Nm (0.4 m·kg, 2.9 ft·lb)
T.
R.
LOCTITE®
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
– 50 –
CLUTCH
EAS25060
CLUTCH
Removing the clutch actuator and clutch master cylinder
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)
T.
R.
1
6
5 4
7
8
30 Nm (3.0 m • kg, 22 ft • Ib)

2
T.
R.
9
13 LS
10 3
New
New 11 16
15
12
14
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.

Drain.
Clutch fluid Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM” on page 31.
Refer to “SWINGARM” in chapter 4. (Manual
Swingarm No.: 3P6-28197-E0)
1 Rear brake hose/rear wheel sensor lead holder 1
2 Clutch actuator motor coupler 1 Disconnect.
3 Clutch actuator sensor coupler 1 Disconnect.
4 Clutch actuator bracket 1
5 Clutch fluid reservoir cap 1
6 Clutch fluid reservoir diaphragm holder 1
7 Clutch fluid reservoir diaphragm 1
8 Clutch fluid reservoir 1
9 Clutch fluid reservoir hose 1
10 Clutch hose union bolt 1
11 Copper washer 2
12 Clutch hose 1 Disconnect.
– 51 –
CLUTCH
Removing the clutch actuator and clutch master cylinder

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)
T.
R.
1
6
5 4
7
8
30 Nm (3.0 m • kg, 22 ft • Ib)

2
T.
R.
9
13 LS
10 3
New
New 11 16
15
12
14
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.

13 Clutch master cylinder 1
14 Shim (clutch master cylinder kit) 1
15 O-ring (clutch master cylinder kit) 1
16 Clutch actuator 1
dure.
– 52 –
CLUTCH
Disassembling the clutch master cylinder
∗
New 1

1 Clutch master cylinder kit 1
2 Clutch master cylinder body 1
For assembly, reverse the disassembly pro-
cedure.
* Apply silicon grease
– 53 –
CLUTCH
Removing the clutch release cylinder

Drain.
Clutch fluid Refer to “BLEEDING THE HYDRAULIC
1 Clutch hose union bolt 1
2 Copper washer 2
3 Clutch hose 1 Disconnect.
4 Clutch release cylinder 1
5 Dowel pin 2
6 Plate 1
dure.
– 54 –
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 tem-
perature meter “1” as shown in the illustra-
tion.
1 3. Replace:
• Clutch master cylinder kit
NOTE:
The thickness of the new shim “1” is 1.5 mm
(0.06 in).
b. Apply the rear brake forcefully.

c. Shift the transmission into 1st gear.
d. Turn the throttle grip to 1/4 “a” of the fully a
open position ten times, each time for less 1
than 0.5 second.
NOTE:
It is not unusual for the engine to stall when per- a. 1.5 mm (0.06 in)
forming this procedure. If the engine stalls, re-
4. Bleed:
start the engine, let it idle for at least 90 seconds,
• Hydraulic clutch system
and then repeat steps (b) to (d).
5. Check:
a 6. Adjust:
• Clutch engagement point
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ a. If the thickness of the shim installed on the
ET2D21038
vehicle is 1.0 mm (0.04 in), refer to the follow-
REPLACING THE CLUTCH MASTER ing table.
CYLINDER
1. Check:
2. Measure
• Shim (clutch master cylinder kit) “1” thickness
– 55 –
CLUTCH
ET2D21039
Pressure plate INSTALLING THE CLUTCH ACTUATOR
Action
stroke 1. Install:
Pressure plate stroke • Clutch actuator
before replacing the • Clutch master cylinder
clutch master cylin- Select diagnostic • Clutch hose
der kit was 2.90 mm code No. Sh_ _66 in • Clutch fluid reservoir hose
(0.11 in) or more, or the diagnostic mode 2. Bleed:
the difference in the and operate the hand • Hydraulic clutch system
pressure plate stroke shift lever switch Refer to “BLEEDING THE HYDRAULIC
before and after re- (shift up) three times. CLUTCH SYSTEM” on page 31.
placing is 0.10 mm 3. Check:
(0.004 in) or more
Select diagnostic Refer to “BLEEDING THE HYDRAULIC
code No. Sh_ _66 in CLUTCH SYSTEM” on page 31.
the diagnostic mode 4. Adjust:
For all other cases
and operate the hand • Clutch engagement point
shift lever switch
(shift up) one time.
b. If the thickness of the shim installed on the NOTE:
vehicle is 1.5 mm (0.06 in), refer to the follow- Adjust the clutch engagement point if the clutch
ing table. actuator was replaced.
Pressure plate ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Action
stroke a. Select diagnostic code No. Sh_ _66 in the
Pressure plate stroke diagnostic mode and operate the hand shift
before replacing the lever switch (shift up) until the clutch en-
clutch master cylin- Select diagnostic gagement point is at the maximum setting.
der kit was 2.90 mm code No. Sh_ _66 in NOTE:
(0.11 in) or more, or the diagnostic mode The hand shift select indicator light stops coming
the difference in the and operate the hand on when the maximum setting is reached.
pressure plate stroke shift lever switch
before and after re- (shift up) two times. b. Operate the hand shift lever switch (shift
placing is 0.10 mm down) ten times and check that the hand shift
(0.004 in) or more select indicator light comes on.
No adjustment is nec- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
For all other cases
essary. 5. Check:
• Rear wheel drag torque
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Refer to “CHECKING THE VEHICLE AFTER
7. Check: BLEEDING THE HYDRAULIC CLUTCH
• Rear wheel drag torque SYSTEM” on page 33.
Refer to “CHECKING THE VEHICLE AFTER 6. Check:
BLEEDING THE HYDRAULIC CLUTCH • Shift operation
SYSTEM” on page 33. Refer to “CHECKING THE VEHICLE AFTER
• Shift operation SYSTEM” on page 33.
Refer to “CHECKING THE VEHICLE AFTER 7. Check:
BLEEDING THE HYDRAULIC CLUTCH • Starting-off performance of vehicle
SYSTEM” on page 33. Refer to “CHECKING THE VEHICLE AFTER
• Starting-off performance of vehicle SYSTEM” on page 33.
Refer to “CHECKING THE VEHICLE AFTER
BLEEDING THE HYDRAULIC CLUTCH
SYSTEM” on page 33.
– 56 –
SHIFT ACTUATOR AND SHIFT ROD
ET2D21006

Removing the shift actuator, shift rod and foot shift switch
4 Nm (0.4 m • kg, 2.9 ft • Ib)
T.
R.
LT
LT
3
9
11
2 13
4 LT 10 14
LS
15
LT 5
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
LS
LS
LT
LT
19
17
1 18 16 7
6
8
12
LT LT
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.
28 Nm (2.8 m • kg, 20 ft • Ib)

T.
R.

Refer to “GENERAL CHASSIS” in chapter 4.
Rider seat/Left side cover (Manual No.: 3P6-28197-E0)
Air shroud Refer to “GENERAL CHASSIS” on page 37.
1 Gear position sensor cover 1
2 Shift rod 1
3 Shift actuator sensor coupler 1 Disconnect.
4 Shift actuator motor coupler 1 Disconnect.
5 Shift actuator 1
6 Sidestand switch coupler 1 Disconnect.
7 Left footrest assembly 1
8 Sidestand 1
9 Foot shift switch coupler 1 Disconnect.
10 Foot shift switch 1
11 Holder 1
12 Shift pedal pivot bolt 1
13 Shift pedal pivot 1
– 57 –
Removing the shift actuator, shift rod and foot shift switch
4 Nm (0.4 m • kg, 2.9 ft • Ib)
T.
R.
LT
LT
3
9
11
2 13
4 LT 10 14
LS
15
LT 5
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LS
T.
R.
LS
LT
LT
19
17
1 18 16 7
6
8
12
LT LT
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.
28 Nm (2.8 m • kg, 20 ft • Ib)

T.
R.

14 Wave washer 1
15 Washer 1
16 Shift pedal 1
17 Ball 1
18 Spring 1
19 Washer 1
dure.
– 58 –
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”.
EC2D21001
CAUTION:
2. Check:
Do not loosen the rear shift arm bolt “3”
• Shift rod groove
when removing the shift rod, otherwise the
Groove and end of rod cover are not aligned
rear shift arm and shift actuator could be-
→ Replace.
come misaligned, preventing the shift rod
from being installed correctly during assem-
bly. 2
1
c. Pull out the rod from the holes.
3 1. Shift rod groove

2. End of shift rod cover
1 3. Check:
d. Disconnect the shift actuator sensor coupler • Shift rod
and shift actuator motor coupler. Bends → Replace.
e. Remove the shift actuator front bolt “4”, and ET2D21009
then remove the rear bolt “5”. INSTALLING THE FOOT SHIFT SWITCH
1. Lubricate:
• Washers
• Shift pedal pivot
• Spring
• Ball
• Wave washer
• Shift pedal spring
• Shift pedal projection
4 5
Recommended lubricant
f. Remove the shift actuator. Lithium-soap-based grease
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ET2D21008
2. Install:
CHECKING THE SHIFT ROD • Washer “1”
1. Check: • Spring “2”
• Shift rod operation • Ball “3”
Rough movement → Replace. • Shift pedal “4”
(to the left footrest assembly)
• Washer “5”
• Wave washer “6”
• Shift pedal pivot “7”
• Shift pedal pivot bolt
– 59 –
4. Adjust:
Shift pedal pivot bolt • Foot shift switch
16 Nm (1.6 m·kg, 11 ft·lb) Refer to “ADJUSTING THE FOOT SHIFT
T.
R.
LOCTITE® SWITCH” on page 60.
NOTE: ET2D21010
ADJUSTING THE FOOT SHIFT SWITCH

• Position the projection “a” on the shift pedal be-
1. Check:
tween the ends “b” of the spring on the left foot-
• Foot shift switch
rest assembly.
Refer to “CHECKING THE FOOT SHIFT
• Be sure to fit the projections “c” on the shift
SWITCH” on page 133.
pedal pivot into the holes “d” in the left footrest
2. Adjust:
assembly.
• Foot shift switch angle
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
d a. Connect the foot shift switch coupler to the
7 6 5 foot shift switch.
b. Connect the digital circuit tester to the foot
c b shift switch coupler.
a • Positive tester probe →
3 2 orange “1”
1 • Negative tester probe →
4 black “2”
b
3. Install:
• Holder “1” Digital circuit tester
• Foot shift switch “2” 90890-03174
Model 88 Multimeter with ta-
NOTE: chometer
• Be sure to align the cutouts “a” in the holder YU-A1927
with the projections “b” on the shift pedal pivot.
• Fit the foot shift switch onto the holder, and c. Turn the main switch to “ON”.
then rotate the switch counterclockwise and d. Measure the foot shift switch voltage.
temporarily install the screws. Be sure to fit the e. Adjust the foot shift switch angle so that the
section “c” of the holder into the opening “d” voltage is within the specified range.
shown in the illustration.
Output voltage
b 1 2.4–2.6 V
a c
2 f. After adjusting the foot shift switch angle,
tighten the foot shift switch screws “3” to
a specification.
Foot shift switch screw

b 4 Nm (0.4 m·kg, 2.9 ft·lb)
T.
R.
LOCTITE®
d
– 60 –
Shift actuator rear bolt

2 20 Nm (2.0 m·kg, 14 ft·lb)
T.
3
R.
Shift actuator front bolt
20 Nm (2.0 m·kg, 14 ft·lb)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ET2D21011
INSTALLING THE LEFT FOOTREST

ASSEMBLY 1 2
1. Install:
• Sidestand c. Connect the shift actuator motor coupler and
• Left footrest assembly shift actuator sensor coupler.
d. Pass a suitable 5 mm diameter rod “3”
Left footrest assembly/sidestand
through the holes in the rear shift arm and
bolt
T.
shift actuator to secure the shift rod.

R.
65 Nm (6.5 m·kg, 47 ft·lb)

e. Install the shift rod “4”.
LOCTITE®
Left footrest assembly bolt (M8) NOTE:
28 Nm (2.8 m·kg, 20 ft·lb) Check that the hole “a” in the shift rod is aligned
Left footrest assembly bolt (M10) with the hole “b” in the front shift arm. If the holes
49 Nm (4.9 m·kg, 35 ft·lb) are not aligned, loosen the shift rod rear locknut
“5” and front locknut “6”, and then turn the shift
NOTE: rod to adjust its length.
Install the left footrest assembly/sidestand bolts
“1”, left footrest assembly bolts (M8) “2” and left Direction “c”
footrest assembly bolt (M10) “3” temporarily and Shift rod length is increased.
then tighten them to the specified torques in the Direction “d”
proper tightening sequence as shown. Shift rod length is decreased.
2
6
d 5
c
b
4
1 a 3
3
ET2D21012 f. Tighten the shift rod bolts to specification.

INSTALLING THE SHIFT ACTUATOR
1. Install: Shift rod bolt
• Shift actuator 10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the shift actuator front bolt “1” tempo- g. If the shift rod front locknut and rear locknut
rarily. were loosened, tighten them to specification.
b. Tighten the shift actuator rear bolt “2”, and
then tighten the front bolt “1” to specification.
– 61 –
Shift rod front locknut

7 Nm (0.7 m·kg, 5.1 ft·lb)
T.
R.
Shift rod rear locknut

10 Nm (1.0 m·kg, 7.2 ft·lb)
h. Pull out the rod from the holes.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
– 62 –
SHIFT SHAFT
EAS25410
SHIFT SHAFT
EAS25450
INSTALLING THE SHIFT SHAFT

1. Install: b
• Stopper lever “1” 1
• Stopper lever spring “2”
NOTE:
a
• 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 seg-
ment assembly.
2 3
2. Install:
• Shift shaft “1”
NOTE:
Hook the end of the shift shaft spring onto the
shift shaft spring stopper “2”.
3. Install:
• Front shift arm “1”
Front shift arm bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
NOTE:
Align the punch mark “a” on the front shift arm
with the punch mark “b” on the shift shaft.
– 63 –
MIDDLE GEAR
EAS25710
MIDDLE GEAR
Removing the middle gear

Refer to “ENGINE REMOVAL” in chapter 5.
Engine (Manual No.: 3P6-28197-E0)
Refer to “OIL PUMP” in chapter 5. (Manual
Oil pan/Oil pump No.: 3P6-28197-E0)
1 Middle gear case cover 1
2 Middle gear case cover gasket 1
3 Dowel pin 2
4 Damper cover 1
5 Damper 1
6 Middle drive shaft bearing housing 1
7 Bearing 1
8 Middle driven shaft end cover 1
9 Middle driven shaft assembly 1
10 Middle driven pinion gear shim
11 Middle drive pinion gear nut 1
12 Lock washer 1
13 Middle drive pinion gear 1
– 64 –
MIDDLE GEAR
Removing the middle gear

14 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 1
dure.
– 65 –
CRANKCASE
EAS25540
CRANKCASE
Separating the crankcase
1st 20 Nm (2.0 m • kg, 14 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
2nd 20 Nm (2.0 m • kg, 14 ft • Ib) (10) 24 Nm (2.4 m • kg, 17 ft • Ib)
T.
R.
T.
R.
Final Specified angle 115–125˚ (10) 10 Nm (1.0 m • kg, 7.2 ft • Ib)
(2) (2)
T.
R.
12 Nm (1.2 m • kg, 8.7 ft • Ib)
(4)
T.
R.
E
E E
E E E
E
E
10
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
12 Nm (1.2 m • kg, 8.7 ft • Ib)
T.
R.
LT
LT
11
3 New
LT
LT 11
9
11 8
2
LT
7
6
1 5
4 20 Nm (2.0 m • kg, 14 ft • Ib)
T.
R.

Refer to “ENGINE REMOVAL” in chapter 5.
Engine (Manual No.: 3P6-28197-E0)
Refer to “CYLINDER HEAD” in chapter 5.
Cylinder head (Manual No.: 3P6-28197-E0)
Refer to “GENERATOR AND STARTER
Starter clutch CLUTCH” in chapter 5. (Manual No.: 3P6-
28197-E0)
Refer to “PICKUP ROTOR” in chapter 5.
Pickup rotor (Manual No.: 3P6-28197-E0)
Refer to “OIL PUMP” in chapter 5. (Manual
Oil pump No.: 3P6-28197-E0)
Refer to “MIDDLE GEAR” in chapter 5.
Middle drive shaft assembly (Manual No.: 3P6-28197-E0)
Refer to “CLUTCH” in chapter 5. (Manual
Clutch housing No.: 3P6-28197-E0)
1 Timing chain 1
2 Oil pump drive chain guide 1
3 Oil pump drive chain 1
4 Oil pump drive sprocket 1
– 66 –
CRANKCASE
Separating the crankcase

1st 20 Nm (2.0 m • kg, 14 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
2nd 20 Nm (2.0 m • kg, 14 ft • Ib) (10) 24 Nm (2.4 m • kg, 17 ft • Ib)
T.
R.
T.
R.
Final Specified angle 115–125˚ (10) 10 Nm (1.0 m • kg, 7.2 ft • Ib)
(2) (2)
T.
R.
12 Nm (1.2 m • kg, 8.7 ft • Ib)
(4)
T.
R.
E
E E
E E E
E
E
10
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
12 Nm (1.2 m • kg, 8.7 ft • Ib)
T.
R.
LT
LT
11
3 New
LT
LT 11
9
11 8
2
LT
7
6
1 5
4 20 Nm (2.0 m • kg, 14 ft • Ib)
T.
R.

5 Spacer 1
6 Collar 1
7 Spring washer 1
8 Neutral switch 1
9 YCC-S speed sensor 1
10 Lower crankcase 1
11 Dowel pin 3
dure.
– 67 –
TRANSMISSION
EAS26240
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks

Separate.
Crankcase Refer to “CRANKCASE” in chapter 5. (Man-
ual No.: 3P6-28197-E0)
Refer to “SHIFT SHAFT” in chapter 5. (Man-
Stopper lever ual No.: 3P6-28197-E0)
1 Gear position sensor bracket 1
2 Oil seal 1
3 Drive axle assembly 1
4 Bearing 1
5 Washer 1
6 Bearing 1
7 Shift drum retainer 1
8 Long shift fork guide bar 1
9 Shift fork-L 1
10 Shift fork-R 1
11 Short shift fork guide bar 1
12 Spring 4
– 68 –
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks

13 Shift drum assembly 1
14 Shift fork-C 1
15 Main axle assembly 1
dure.
– 69 –
TRANSMISSION
– 70 –
EAS27170
EAS27160
A B C D E F G
L R/L R/B G/B G/B R/B R/L L

O L L O W/Y W Sb Sb W W/Y O/R B/L B O
L/W W/L Y Br/W Br/W Y/G W/L L/W B/W B/W Y Gy/W L/B O/B O/B L/B Gy/W Y Br/B Br/B
B/L O/G O/G B/L B G/R Lg Lg G/R B G/Y B/W Br/B B R/L R/L P/W B/L B W/B L L
B Br/B B/W G/Y W/B B B/L P/W
(GRAY) (BLACK) (BLACK)
(GRAY)
WIRE HARNESS SUB-LEAD 1 WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS SUB-WIRE HARNESS 1 WIRE HARNESS ABS WIRE HARNESS WIRE HARNESS SUB-LEAD 2
4
Br/L Br/W
5
Br/L Br/R 13
B/W BB R/G R/G B2 B
6 Y/L G/B R/W R/W Lg Y/L
R R/G
BB R/G B/W
R/W Y/L G/B
R
7 R R/G
R R 17
L/W P
R
R R B/R Y/W B/Y R/L
R/G R/L B/R L/Y L/Y B/R R/L R/G
CIRCUIT DIAGRAM (1/2)
R R B/R
R R R/L L/Y Sb G/Y R/B R/B G/Y Sb
1 Br/R Br/R W W R/B W W W/B Br/B W/L Br/W R/B B W/G W/L W/Y Br/B R/L
W W R R R/L R/L
2 3 G/B L Y/L Y/W B/Y G/Y
ON W W 9 L/W R/W Y/L B B B/W G/R G/Y W/Y Lg Y/G Sb B2 L/W R/W D
OFF R R G/W W/L Y/G L/W
8 Y/G 14 (BLACK) (BLACK)
P Br/L Br/L L/W Sb R/L
G/W P B/R G/B G/R
B
WWW 10
Br/L B (GRAY)
(GRAY) B Sb W
Br/R W Gy W W B
B R/W L G/R B 21
B R B R/W W/L BB
B B B/Y Y/W Y/L L Sb Sb Sb WB
(BLACK) B/W B/G R/W L/W Y/G W/L G/W W W
B B Gy W
11 12 B 22 W B
L/W G/R G/B B/R P
Br/R W
R B B (BLACK) B
67 B/W L/W (GRAY) Sb Br/W C Br/W Br/W B/W B/W C B/W B/W
R Br/R L/R Sb Sb B Sb Sb
R/W 65 Sb B
18 19 Lg Lg B Lg Lg
Br/B Y/G Lg G/R G/R G/R B G/R G/R
68 L/R L/Y L/Y W/Y W/Y B W/Y
R/W G/Y 73 Br/L Br Br
R/L G/W
G/Y R/Y R/L
Br/B 64 B
G/L R/L R/W
R/B L/W R/W R/L
W/L C W/L W/L
20 R/B
Br/B Br/B
R/W L/W 15 16 Br/B F Br/B Br/B 23
L/W C L/W L/W R/W W/B
ELECTRIC STARTING SYSTEM
69 R/Y Y/W G L/Y R/B

Br/B B/L
76 74 Br/L R/Y R/Y G/L Y/G G R 52 G/Y W/B R/B
B B W/G W/B
Br R/Y R/W G/L (BLACK) R/L B
W/L
66 R L/W R/B L/R Br/B R B B/L R (DARK GREEN) G/Y Br/B W/Y
L L/Y
Y/G
C Br/B R/W
L G/W B Y/G
G/Y R/W R/W R/B
L L/Y R/Y G/Y 53 C
G/L R/W R/Y Br
G/L B/L C B B2
Br/B L/R R/B L/Y Br/R Br/B G W R R/W R/W R/W
L Y G/Y L
B B R/Y Y/W R Y G W R
B B/L R/L W/Y W/L W/G
L 77 L 75 B/L
E (GRAY) (GRAY)
G/Y 24
(BLACK) (BLACK) 70 L2 A L L R/L
Br/L R/W R/L O A O O
B B L O B/L O/G B R B B/W R/B
L/W B/L2 A B/L B/L Gy/W E Gy/W
B B 54 C (GRAY) (GRAY)
(GRAY)
L L/Y L O/G A O/G O/G B
42 O W/G W/Y B/W
B/L Y L Y Y R B B/W R/W 47 35 W/L
– 71 –
(BLACK) (BLACK) 71 63 B/L R/W Br/R
Br/L Br/B G B/W B/W R/B
(BLACK) Gy/W B/L B B/W
L R/W R/W 55 O G 36 36
W/Y W/Y D
62 R/L B
B/L B/W
R/B G/L Br W/B B B B R/W Br/R
25
W L/Y L W/Y R/L B
(BLUE) G/L Y/L E Gy/R B B
(BLUE) B/L B/L 56 Gy/W B/L W L
72 R/B Br/B 37
(BLACK) B (BROWN)
B Lg/W W/Y B/G Y/B (BLACK)
B/R R/L
R/W Br/R Br/B
B B G B/L L/W O 36 36
Y/W B Br/B
L O B 61 O O G O/R O/R L/Y Gy/R Y
B Lg/W B/L P L Sb (BROWN) G/Y
L L G L B/Y
(BLACK) W/B B/R Y/G
L 48 B/L R/L
Br 27
R/B R/W Y/G
L W/B W L/Y 26
Lg/W L/W 38
B Y/G B/L B/L Gy/W O/B R/L R/L O/B (GRAY) Y/G Y/G Y
R
B W/B E W/B W/B G/Y Br Br/B
B Br/L Gy Gy O/B O/B E O/B
L/Y L/Y B/L 39
R/B B L/Y L Y B/L R/L L/B (BLACK)
Y L/B L/B E L/B L/B R/L (GRAY) Br/B
57 49 Gy Gy 43
78 R/B L 44 Br
(BLACK) B B/L
B (BLACK)
Y/G O/G Lg O/B L/Y Br/L B/L 40
L/G Br/L L B/L G/B G/B E G/B G/B R/L R/L G/B (GRAY)
Y G/Y Lgr/W W/Y G/B Br/B O/W G/R Lg P/W B/L L
R/B B/L Y E Y Y
O/R L L2 L/W Y/B G/R R/L O/B G/B 50
(BLACK) P/W P/W E P/W P/W
R/B R/B E R/B
R/B O L/G G O/W Y/L B/L2 B/L E B/L B/L 41
R/B R/L R/L R/B (GRAY)
(BLACK) L E L L
60 Lg/W G/Y
Y/G
Y/W
W Y/L
58 R/B Y/B W/Y
B/R L/W P R/B B B/W B/L G/R G/B B/L Lg
Br B Y/W B/Y R/B B R/W R O/W O/B Br/L Br/W
Lg/W R/B R/B Lg/W G/W L/W Y W/Y P/W R/W Br/W B/W W/B Gy/W L R/B G/B L/B O/B Y/B B3 O Gy/R
(BLACK) W W W Lg B/R G/Y Y/G Sb R/W Y/L B/L Y/W L/Y G/W Gy R/L Lg/W Br/R
B
B G/B G/R B/W B3 (BLACK)
Br/L O/B O/W Br/W B/L Lg/W
B1 BB B/L Br/W
W W
(BLACK) 45
B2 B1 51
BB 46 L/R Ch L/R
B1 G/W B/L 29 Y Dg
B/L G/W
BB3
(GREEN)
59 BB4 B/W 33
B/L
31 32
BB2 Dg 28
BB1 Ch
30 30
B Ch Dg B B Dg Ch
L/G B/L L/G B/W L Y Dg
B/W L/G B/L
BB3 BB2 B B B Ch B
BB4 BB1 B B
L/G
B
Dg Y L/R
B B B L/G Ch B
34 (BLUE)
(BLUE)
B
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
harness)
34.Sidestand switch
56.MCU (motor control unit)
64.YCC-S control relay
harness)
68.Signaling system fuse
70.Ignition fuse
– 72 –
ET3P61003
R/B
92 L/W L/W R Sb/W
93 94
R L/W 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 W/L R/L Sb B/R

B/R L/Y
Sb 17
L/Y
R/L
R/B R/B
81 R/W W/L B/R
G/Y
R/G L/Y B/R R/L R/G R/G R/L B/R L/Y
R/B G/Y Sb Sb G/Y R/B

Front cowling wire harness
83 84 85
Br Dg W/L R/W R/W L/W Dg Br
82
G/Y Ch Br/G B R/B R/B B Br/W Ch G/Y
Br G/Y B Dg Ch
R Br/G
65 L Y/G B/L
L/W
Br R/Y R/W G/L G/L R/W R/Y Br Br Ch Dg R/G B/W G/R Sb B/L Lg/W W G/B
R/W Br B/R L/W Y/W P B/Y R/W G/W Y/L Sb/W Y
107
R L/W R/B L/R Br/B Br/B L/R R/B L/Y Br/R
R/Y
Br/B
G/L 95 96 Sb/W W/L
R/B L/R L/R 80 Br/G Br B B/L L
Y/G
Br/B 86 R/Y (BLACK) 97 G/B
B 99 L
Br/Y B 98 Y/G
Br/G B G/B
79 Br/G Dg Lg Y B Y Lg Dg Br/W
(BLACK) 87 88 89 90 91 Sb G/R G/R
L/R Ch R/Y Sb/W P L/B L/B P Sb R/Y Ch R/W B/R B/R
UP 14 B/Y Y/W Y/L L
R/B Br L/W L/W
B DOWN L/W Y/G W/L G/W
Y/W
123 122 B Br/B Lg/W Lg/W P G/R G/B B/R P
(BLACK) P 58 W W B/Y
R/B Y/W (GRAY)
R/B Br/L B B Br Br/L B B
P
Y L/B Lg Sb/W Dg Ch B B/Y Y/L
(BLACK) (GRAY) R/B Lg/W G/W
(BLACK) (GRAY) Br/G
W 100 Y/L L Y/L Y/W B/Y
Br/L Br/L G/W
– 73 –
R/G B/L G/W W/L Y/G L/W
B/W B/L B/W P B/R G/B G/R
Lg/W R/B
Br Sb P
108 (GRAY)
W
114 Br
G/L 101
Lg P B B
Sb/W 102 (GRAY)
121 R/B R/B G/L Y G 114 Br
B/R B/R B B B L/B
B Y B/W B/L
103 (GRAY)
L/B G B 120
R Br Sb Sb/W Br R/G (BLACK) 104
Y
Br/R Lg B B Lg Sb
L/G
Dg
105
R/B B/R B/R R/B 33
106
Dg Ch Ch B/W
B/L
R/G
Ch
116 115 Dg B Dg Ch
117 L/R L/R Y G Y G B B/L L/G B/W
G B B B B
B L/R B B Y B O/B Br/L O/W
118 118 G/B B/L G/R R/B B Ch Dg B
119 119 G B Dg B Ch 109 R/B
L/R B B Y B B/W L/G B/L
B B
B
B B B B O/W Br/L O/B
B R/B
G/R B/L G/B
113
110 111 112
PUSH
Shift up Shift down
O/W O/B G/R G/B Br/L B
O/W B/L
B/L
G/R G/B B/L B G/B G/R O/B
O/W O/B Br/L
60 G/R
Br/L O/B O/W
G/B
Br/L
17.Coupler 2 (front cowling wire harness–wire

harness)
harness)
harness)
82.Front brake light switch
83.Engine stop switch
84.Start switch
92.Relay unit
93.Starting circuit cut-off relay
– 74 –
EAS27180
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION

If the engine stop switch is set to “ ” (the switch circuit is closed), the main switch is turned “ON” (the
switch circuit is closed), and the brake lever is squeezed (the front brake light switch circuit is open) or
the brake pedal is depressed (the rear brake light switch circuit is open), the starter motor can only op-
erate if at least one of the following conditions is met:
• The transmission is in neutral (the neutral switch is closed).
• The sidestand is up (the sidestand switch circuit is closed).
The starting circuit cut-off relay prevents the starter motor from operating when neither of these condi-
tions has been met. In this instance, the starting circuit cut-off relay stays open so current cannot reach
the starter motor. When at least one of the above conditions has been met, the starting circuit cut-off
relay is closed and the engine can be started by pushing the start switch “ ”.
19
18 17
1
2
3 15
16
5
6 7 13
12
8
14
8 11
8
10 9
a b
a. WHEN THE TRANSMISSION IS IN 9. Sidestand switch

NEUTRAL 10. Neutral switch
b. WHEN THE SIDESTAND IS UP 11. Start switch
1. Battery 12. Front brake light switch
2. Main fuse 13. Brake light relay
3. Main switch 14. Rear brake light switch
4. Ignition fuse 15. YCC-S control relay
5. Signaling system fuse 16. MCU (motor control unit)
6. Engine stop switch 17. Diode 1
7. Starting circuit cut-off relay 18. Starter relay
8. Relay unit (diode) 19. Starter motor
– 75 –
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. NG →

(Main, signaling system, and igni-
tion)
Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” in chapter 8. (Manual No.: 3P6-
28197-E0)
OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND
• Clean the battery terminals.
CHARGING THE BATTERY” in
• Recharge or replace the battery.
chapter 8. (Manual No.: 3P6-
28197-E0)
OK ↓
3. Check the starter motor operation. OK →
Starter motor is OK. Perform the electric
Refer to “CHECKING THE START-
starting system troubleshooting, starting
ER MOTOR OPERATION” in chap-
with step 5.
ter 8. (Manual No.: 3P6-28197-E0)
NG ↓
4. Check the starter motor. NG →
Refer to “CHECKING THE START-
Repair or replace the starter motor.
ER MOTOR” in chapter 5. (Manual
No.: 3P6-28197-E0)
OK ↓
5. Check the relay unit (starting circuit NG →
cut-off relay).
Replace the relay unit.
Refer to “CHECKING THE RE-
LAYS” on page 130.
OK ↓
6. Check the relay unit (diode). NG →
Refer to “CHECKING THE RELAY
Replace the relay unit.
UNIT (DIODE)” in chapter 8. (Man-
ual No.: 3P6-28197-E0)
OK ↓
– 76 –
7. Check the starter relay. NG →

Refer to “CHECKING THE RE- Replace the starter relay.
OK ↓
8. Check the brake light relay. NG →
Refer to “CHECKING THE RE- Replace the brake light relay.
OK ↓
9. Check the YCC-S control relay. NG →
Refer to “CHECKING THE RE- Replace the YCC-S control relay.
OK ↓
10.Check the main switch. NG →
Refer to “CHECKING THE Replace the main switch/immobilizer unit.
SWITCHES” on page 127.
OK ↓
11.Check the engine stop switch. NG →
Refer to “CHECKING THE Replace the right handlebar switch.
OK ↓
12.Check the neutral switch. NG →
Refer to “CHECKING THE Replace the neutral switch.
OK ↓
13.Check the sidestand switch. NG →
Refer to “CHECKING THE Replace the sidestand switch.
OK ↓
14.Check the front brake light switch. NG →
Refer to “CHECKING THE Replace the front brake light switch.
OK ↓
15.Check the rear brake light switch. NG →
Refer to “CHECKING THE Replace the rear brake light switch.
OK ↓
16.Check the start switch. NG →
Refer to “CHECKING THE Replace the right handlebar switch.
OK ↓
– 77 –
17.Check the entire starting system NG →

wiring.
Properly connect or repair the starting sys-
Refer to “CIRCUIT DIAGRAM (1/2)”
tem wiring.
on page 71 and “CIRCUIT DIA-
GRAM (2/2)” on page 73.
OK ↓
Replace the MCU or diode 1.
– 78 –
ET2D21015
ET2D21014
A B C D E F G

(GRAY)
4
Br/L Br/W
5
Br/L Br/R 13
B/W BB R/G R/G B2 B
R R/G
BB R/G B/W
R/W Y/L G/B
R
7 R R/G
R R 17
L/W P
R
R R B/R Y/W B/Y R/L
R R B/R R/G R/L B/R L/Y L/Y B/R R/L R/G

W W R R R/L R/L
G/W P B/R G/B G/R
B
WWW 10
Br/L B (GRAY)
(GRAY) B Sb W
Br/R W Gy W W B
B R/W L G/R B 21
B R B R/W W/L BB
B B B/Y Y/W Y/L L Sb
GRIP WARMER SYSTEM
Sb Sb WB
B B Gy W
11 12 B 22 W B
L/W G/R G/B B/R P
Br/R W
R B B (BLACK) B
R/W 65 Sb B
18 19 Lg Lg B Lg Lg
R/L G/W
G/Y R/Y R/L
Br/B 64 B
G/L R/L R/W
R/B L/W R/W R/L
W/L C W/L W/L
20 R/B
Br/B Br/B
Br/B B/L
76 74 Br/L R/Y R/Y G/L Y/G G R G/Y W/B R/B
52 B B W/G W/B
W/L
66 R L/W R/B L/R Br/B B/L R (DARK GREEN) G/Y Br/B W/Y
L L/Y R B
Y/G
C Br/B R/W
L G/W B Y/G
G/Y R/W R/W R/B
L L/Y R/Y G/Y C
G/L R/W R/Y Br 53
G/L B/L C B B2
R/Y Y/W L Y G/Y L
B B R Y G W R W/Y W/L W/G
L B B/L R/L
L 77 L 75 B/L
E (GRAY) (GRAY)
G/Y 24
(BLACK) (BLACK) 70 L2 A L L R/L
(GRAY)
O W/G W/Y B/W
– 79 –
71 B/L Y L 63 Y Y R B B/W R/W 47 42 35 W/L
(BLACK) (BLACK) B/L R/W Br/R
L R/W R/W 55 O G 36 36
W/Y W/Y D
62 R/L B
B/L B/W
25
W L/Y L W/Y R/L B
72 R/B Br/B 37
(BLACK) B (BROWN)
B/R R/L
R/W Br/R Br/B
B B G B/L L/W O 36 36
Y/W B Br/B
L L G L B/Y
(BLACK) W/B B/R Y/G
L 48 B/L R/L
Br 27
R/B R/W Y/G
L W/B W L/Y 26
Lg/W L/W 38
R
L/Y L/Y B/L 39
57 49 Gy Gy 43
78 R/B L 44 Br
(BLACK) B B/L
B (BLACK)
R/B B/L Y E Y Y
R/B R/B E R/B
(BLACK) L E L L
60 Lg/W G/Y
Y/G
Y/W
W Y/L
58 R/B Y/B W/Y
B
B1 BB B/L Br/W
W W
(BLACK) 45
B2 B1 51
BB 46 L/R Ch L/R
B1 G/W B/L 29 Y Dg
B/L G/W
BB3 (GREEN)
59 BB4 B/W 33
B/L
31 32
BB2 Dg 28
BB1 Ch
30 30
B Ch Dg B B Dg Ch
B/W L/G B/L
BB3 BB2 B B B Ch B
BB4 BB1 B B
L/G
B
Dg Y L/R
B B B L/G Ch B
34 (BLUE)
(BLUE)
B
GRIP WARMER SYSTEM
GRIP WARMER SYSTEM
1. Main switch
7. Main fuse
8. Battery
43.ECU (engine control unit)
harness)
66.Headlight (on/off)/grip warmer relay
69.Headlight fuse
72.Grip warmer control unit
– 80 –
GRIP WARMER SYSTEM
ET2D21016
R L/W R
L/W L/Y R/W L/G B/R S
R/B
81 R/W W/L
83 84 8
82
Br G/Y B
R
65
L/W
Br R/Y R/W G/L G/L R/W R/Y Br Br
R/W
R/Y
Br/B
G/L
R/B L/R L/R 80 Br/G
Br/B 86 R/Y
Br/Y B
79 (BLACK)
Br/G
Br/G Dg Lg Y B B Y Lg Dg Br/W
87 88 89 90
L/R Ch R/Y Sb/W P L/B L/B P Sb R/Y Ch
UP
R/B Br
B DOWN
123 122 B Br/B
(BLACK)
Y L/B Lg Sb/W
(BLACK) (BLACK) (GRAY) (GRAY)
Br/L Br/L
Br Sb
G/L
Lg
Sb/W
121 R/B
B/R
R/B
B/R B B
G/L Y
B
G
L/B
B Y
L/B G B
120
R Br Sb Sb/W Br R/G (BLACK)
Br/R Lg B B Lg Sb
R/B B/R B/R R/B
R/G
116
117 L/R L/R Y G Y G
G B B
B L/R B B Y B
118 118 119 119 G B Dg
B L/R B B Y B
B B B B
– 81 –
GRIP WARMER SYSTEM

harness)
122.Right grip warmer
123.Left grip warmer
– 82 –
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:
The grip warmers do not become warm at all.

(Main, signaling system, and head-
light)
28197-E0)
OK ↓
2. Check that the engine is started. NG → Start the engine.
OK ↓
NG → Replace the headlight (on/off)/grip warmer
3. Check that the headlight is on.
relay.
OK ↓
4. Check the grip warmers. NG →
Refer to “CHECKING THE GRIP Replace the grip warmer(s).
WARMERS” on page 133.
OK ↓
5. Check the entire grip warmer sys- NG →
tem wiring.
Properly connect or repair the grip warmer
system wiring.
OK ↓
Replace the grip warmer control unit.
The grip warmers are abnormally hot while the engine is idling.
1. Check that the grip warmer adjust- NG → Adjust the grip warmer temperature using
ing knob is set to the “LO” position. the grip warmer adjusting knob.
OK ↓
– 83 –
GRIP WARMER SYSTEM
2. Disconnect the grip warmer control NG →

unit coupler (white/yellow and
black/green) and check that the Replace the ECU.
temperature does not drop while
the engine is running.
OK ↓
The grip warmers do not become very warm while the vehicle is traveling.
1. Disconnect the ECU coupler and NG →
grip warmer control unit coupler
(black and light green/white) and The wiring system from ECU coupler to
check for continuity between the the grip warmer control unit coupler (black
light green/white terminal of the and light green/white) is faulty and must be
ECU coupler and the light repaired.
green/white terminal of the grip
warmer control unit coupler.
OK ↓
2. Check that the grip warmer adjust- NG → Adjust the grip warmer temperature using
ing knob is set to the “HI” position. the grip warmer adjusting knob.
OK ↓
3. Execute the diagnostic mode (Diag- NG →
nostic code No. 57).
Refer to “Actuator operation table Replace the ECU.
(Diagnostic code No.57)” in chapter
8. (Manual No.: 3P6-28197-E0)
OK ↓
– 84 –
ET2D21019
ET2D21018
A B C D E F G

(GRAY)
4
Br/L Br/W
5
Br/L Br/R 13
B/W BB R/G R/G B2 B
R R/G
BB R/G B/W
R/W Y/L G/B
R
7 R R/G
R R 17
L/W P
R
R R B/R Y/W B/Y
R/L
W W R R R/L R/L
G/W P B/R G/B G/R
B
WWW 10
Br/L B (GRAY)
(GRAY) B Sb W
Br/R W Gy W W B
B R/W L G/R B 21
B R B R/W W/L BB
B B B/Y Y/W Y/L L Sb Sb Sb WB
B B Gy W
11 12 B 22 W B
L/W G/R G/B B/R P
Br/R W
R B B (BLACK) B
R/W 65 Sb B
18 19 Lg Lg B Lg Lg
R/L G/W
G/Y R/Y R/L
Br/B 64 B
G/L R/L R/W
R/B L/W R/W R/L
W/L C W/L W/L
20 R/B
Br/B Br/B
Br/B B/L
76 74 Br/L R/Y R/Y G/L Y/G G R G/Y W/B R/B
52 B B W/G W/B
W/L
66 R L/W R/B L/R Br/B (DARK GREEN) G/Y Br/B W/Y
L L/Y R B B/L R
Y/G
C Br/B R/W
L G/W B Y/G
G/Y R/W R/W R/B
L L/Y R/Y G/Y C
G/L R/W R/Y Br 53
G/L B/L C B B2
B B R/Y Y/W L Y G/Y L
R R/L Y G W R W/Y W/L W/G
B/L B B/L
L 77 L 75 E (GRAY)
G/Y (GRAY)
(BLACK) (BLACK) 70 L2 A L L R/L 24
(GRAY)
O
– 85 –
42 W/G W/Y B/W
B/L Y L Y Y R B B/W R/W 47 35
(BLACK) (BLACK) 71 63 B/L R/W Br/R W/L
L R/W R/W 55 O G 36 36
W/Y W/Y D
62 R/L B
B/L B/W
25
W L/Y L W/Y R/L B
72 R/B Br/B 37
(BLACK) B (BROWN)
B/R R/L
R/W Br/R Br/B
B B G B/L L/W O 36 36
Y/W B Br/B
L L G L B/Y
(BLACK) W/B B/R Y/G
L 48 B/L R/L
Br 27
R/B R/W Y/G
L W/B
YCC-S (Yamaha Chip Controlled-Shift) SYSTEM
Lg/W W L/Y 26
L/W 38
R
L/Y L/Y B/L 39
57 49 Gy Gy 43
78 R/B L 44 Br
(BLACK) B B/L
B (BLACK)
R/B B/L Y E Y Y
R/B R/B E R/B
(BLACK) L E L L
60 Lg/W G/Y
Y/G
Y/W
W Y/L
58 R/B Y/B W/Y
B
B1 BB B/L Br/W
W W
(BLACK) 45
B2 B1 51
BB 46 L/R Ch L/R
B1 G/W B/L 29 Y Dg
B/L G/W
BB3 (GREEN)
59 BB4 B/W 33
B/L
31 32
BB2 Dg 28
BB1 Ch
30 30
B Ch Dg B B Dg Ch
B/W L/G B/L
BB3 BB2 B B B Ch B
BB4 BB1 B B
L/G
B
Dg Y L/R
B B B L/G Ch B
34 (BLUE)
(BLUE)
B
1. Main switch
7. Main fuse
8. Battery
harness)
harness)
20.ABS ECU (electronic control unit)
25.Rear brake light switch
27.Brake light relay
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.MCU (motor control unit)
57.YCC-S test coupler
harness)
harness)
61.Foot shift switch
62.YCC-S speed sensor
63.Gear position sensor
64.YCC-S control relay
harness)
70.Ignition fuse
78.YCC-S motor control fuse
– 86 –
ET2D21020
R/B
92 L/W L/W R Sb/W
93 94
R/W W/L R/L Sb B/R

L/Y
Sb 17
L/Y
R/L
R/B R/B
81 R/W W/L B/R
G/Y

83 84 85
82
Br G/Y B Dg Ch
R Br/G
65 L Y/G B/L
L/W
Br R/Y R/W G/L G/L R/W R/Y Br Br Ch Dg R/G B/W G/R Sb B/L Lg/W W G/B
107
R/Y
Br/B
G/L 95 96 Sb/W W/L
Y/G
B 99 L
Br/Y B 98 Y/G
Br/G B G/B
79 Br/G Dg Lg Y B Y Lg Dg Br/W
(BLACK) 87 88 89 90 91 Sb G/R G/R
L/R Ch R/Y Sb/W P L/B L/B P Sb R/Y Ch R/W B/R B/R
UP 14 B/Y Y/W Y/L L
R/B Br L/W L/W
Y/W
R/B Y/W (GRAY)
P
(BLACK) (GRAY) Br/G
Br/L Br/L G/W
– 87 –
Lg/W R/B
Br Sb P
108 (GRAY)
W
114 Br
G/L 101
Lg P B B
Sb/W 102 (GRAY)
121 R/B R/B G/L Y G 114 Br
B/R B/R B B B L/B
B Y B/W B/L
103 (GRAY)
L/B G B 120
R Br Sb Sb/W Br R/G (BLACK) 104
Y
Br/R Lg B B Lg Sb
L/G
Dg
105
R/B B/R B/R R/B 33
106
Dg Ch Ch B/W
B/L
R/G
Ch
116 115 Dg B Dg Ch
G B B B B
118 118 G/B B/L G/R R/B B Ch Dg B
119 119 G B Dg B Ch 109 R/B
B B
B
B R/B
G/R B/L G/B
113
110 111 112
PUSH
B/R
Shift up Shift down
O/W B/L
B/L
O/W O/B Br/L
60 G/R
Br/L O/B O/W
G/B
Br/L

harness)
harness)
harness)
harness)
harness)
harness)
82.Front brake light switch
83.Engine stop switch
84.Start switch
92.Relay unit
93.Starting circuit cut-off relay
100.Multi-function meter
102.Engine trouble warning light
109.Hand shift switch
110.Hand shift lever switch (shift up)
111.Hand shift lever switch (shift down)
112.Hand shift select button
113.Hand shift select indicator light
– 88 –
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:

(Main, ignition and signaling sys-
tem)
28197-E0).
OK ↓
2. Check the battery. NG →
• Clean the battery terminals.
• Recharge or replace the battery.
28197-E0)
OK ↓
3. Check the main switch. NG →
Refer to “CHECKING THE
Replace the main switch/immobilizer unit.
SWITCHES” in chapter 8. (Manual
No.: 3P6-28197-E0)
OK ↓
4. Check the entire YCC-S system NG →
wiring.
Properly connect or repair the YCC-S sys-
tem wiring.
OK ↓
Check the condition of each of the
YCC-S system circuits. Refer to
“Checking the YCC-S system”.
Checking the YCC-S system

The hand shift select indicator light fails to come on.
1. Check the hand shift select button. NG →
Refer to “CHECKING THE Replace the hand shift switch.
OK ↓
Replace the MCU (motor control unit).
– 89 –
The transmission gear display on the multi-function meter fails to indicate the selected gear.
1. Check the gear position sensor. NG →
Refer to “CHECKING THE GEAR
POSITION SENSOR” on page 132 Replace the gear position sensor.
and “ADJUSTING THE GEAR PO-
SITION SENSOR” on page 50.
OK ↓
2. Check the gear position setting. NG →
Refer to “Diagnostic code table (Di- Replace the MCU (motor control unit).
agnostic code No. Sh_ _65)”.
OK ↓
Replace the meter assembly.
ET2D21021
MAINTENANCE OF THE MCU
Checking the MCU

1. Check:
• Terminals “1” of the MCU
Cracks/damages → Replace the MCU.
• Terminals “2” of the MCU couplers
Connection defective, contaminated, come- 1
off → Correct or clean. 2
NOTE:
If the MCU couplers are clogged with mud or dirt,
clean with compressed air.
ET2D21028
MCU (motor control unit) SELF-DIAGNOSTIC FUNCTION

The MCU (motor control unit) is equipped with a self-diagnostic function in order to ensure that the
YCC-S system is operating normally. If this function detects a malfunction in the YCC-S system, it im-
mediately operates the system under substitute characteristics and lights the YCC-S indicator and
warning light to alert the rider that a malfunction has occurred in the system. Once a malfunction has
been detected, a fault code is stored in the memory of the MCU (motor control unit). After the engine
has been stopped, the lowest fault code number appears on the odometer/tripmeter/fuel reserve trip-
meter LCD. Once a fault code has been displayed, it remains stored in the memory of the MCU (motor
control unit) until it is deleted.
NOTE:
If the engine trouble indicator “1”, YCC-S indicator “2”, and engine trouble warning light “3” all come on,
malfunctions have been detected in both the fuel injection system and the YCC-S system. If this occurs,
the fault codes for the fuel injection system take priority over those for the YCC-S system, so only the
fuel injection system fault codes will appear in the multi-function display. The fault codes for the YCC-
S system will be displayed in the multi-function display after all of the fault codes for the fuel injection
system have been deleted using the reinstatement method.
– 90 –
SHIFT 3
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 c
a. Main switch “OFF” d. YCC-S indicator and warning light on for 1.4
b. Main switch “ON” seconds
c. YCC-S indicator and warning light off
ET2D21029
SELF-DIAGNOSTIC FUNCTION TABLE

If the MCU (motor control unit) detects an abnormal signal from a sensor while the vehicle is being driv-
en, the MCU (motor control unit) lights the YCC-S indicator and warning light and provides the YCC-S
system with alternate operating instructions that are appropriate for the type of malfunction.
When an abnormal signal is received from a sensor, the MCU (motor control unit) processes the spec-
ified values that are programmed for each sensor in order to provide the YCC-S system with alternate
operating instructions that enable the system to continue operating or stop operating, depending on the
conditions.
Self-Diagnostic Function table

Able/un-
Fault Able/unable to
Symptom Malfunction detecting condition
code No. able to start change the
shift
Too low or too high
Voltage is below 8 V or above 16
Sh_ _11 voltage is supplied to Unable Unable
V.
the YCC-S system.
Malfunction of power Faulty power source relay cut-off
cut-off function in function is detected during the
Sh_ _12 Unable Unable
MCU (motor control YCC-S system check when main
unit) switch is turned to “ON”.
– 91 –
Able/un-
shift
Overcurrent to clutch Detected current in clutch actuator
Sh_ _13* Unable Unable
actuator motor motor is too high.
Overcurrent to shift Detected current in shift actuator
actuator motor motor is too high.
Abnormal current is Detected current in clutch actuator
detected in clutch or motor or shift actuator motor is dif-
shift actuator motor ferent from MCU (motor control
drive circuit. unit) signals.
Malfunction of clutch
or shift actuator mo-
Drive circuit in MCU (motor control
Sh_ _16* tor drive circuit in Unable Unable
unit) is not working properly.
MCU (motor control
unit)
Detected clutch actu- Detected clutch actuator position
Sh_ _17* ator position is incor- is different from MCU (motor con- Unable Unable
rect. trol unit) signals.
Detected shift actua- Detected shift actuator position is
Sh_ _18* tor position is incor- different from MCU (motor control Unable Unable
rect. unit) signals.
Output signal of shift
Output signal of shift actuator sen-
Sh_ _19* actuator sensor is ab- Unable Unable
sor is below 0.5 V or above 4.5 V.
normal.
Output signal of gear
Output signal of gear position sen-
Sh_ _21 position sensor is ab- Unable Unable
sor is below 0.3 V or above 4.7 V.
normal.
Output signal of foot
Output signal of foot shift switch is
Sh_ _22 shift switch is abnor- Able Able
below 0.9 V or above 4.1 V.
mal.
No signal is received from side-
No input signal from
Sh_ _23 stand switch while vehicle is driv- Able Able
sidestand switch.
en.
Error has occurred in
actuator drive circuit
Drive circuit error is detected dur-
in MCU (motor control
Sh_ _25 ing YCC-S system check when Unable Unable
unit) when main
main switch is turned to “ON”.
switch is turned to
“ON”.
Abnormal clutch
movement is detect- Detected clutch motor current
Sh_ _26* ed during check when when main switch is turned to Unable Unable
main switch is turned “ON” is too high.
to “ON”.
Diagnostic mode is Diagnostic mode signal is received
Sh_ _27* activated at engine when vehicle is started (YCC-S Able Able
start-up. test coupler is connected).
– 92 –
Able/un-
shift
Engine speed signal from ECU
Engine speed signal
Sh_ _31 does not match multi-function Unable Unable
is abnormal.
meter engine speed.
YCC-S speed sensor signal does
YCC-S speed sensor
Sh_ _32* not match multi-function meter ve- Unable Unable
signal is abnormal.
hicle speed.
TPS (throttle position
TPS (throttle position sensor) sig-
Sh_ _34 sensor) signal is ab- Unable Able
nal voltage is too low or too high
normal.
Start switch signal is Signal is received from start switch
Sh_ _35 Able Able
abnormal. while vehicle is driven.
Signals received from clutch actu-
Output signal of clutch
ator sensor 1 and clutch actuator
Sh_ _36 actuator sensor is ab- Unable Unable
sensor 2 are different or signal
normal.
voltage is too low or too high.
Power supply to
Battery voltage is good, but motor
Sh_ _37* clutch or shift actuator Unable Unable
terminal voltage is too low.
motor is abnormal.
Both the on and off circuits of the
Malfunction of hand
hand shift lever switch (shift up or
Sh_ _38 shift lever switch (shift Able Able
shift down) are closed at the same
up or shift down)
time.
Ignition timing retard Detected ignition retard signal
Sh_ _39 output signal is abnor- from MCU (motor control unit) to Able Able
mal. ECU is abnormal.
Coolant temperature
Coolant temperature sensor signal
Sh_ _41 sensor signal is ab- Able Able
is too high or too low
normal.
Communication be-
Error detected in communication
tween ECU and multi-
Sh_ _42 signal between ECU and multi- Unable Able
function meter is ab-
function meter.
normal.
Communication be-
tween MCU (motor ABS ECU continuously sends sig-
Sh_ _43 Able Able
control unit) and ABS nals to activate ABS.
ECU is abnormal.
Clutch is completely engaged, but
Clutch actuator sen-
signal sent from clutch actuator
Sh_ _44* sor signal is abnor- Unable Unable
sensor indicates clutch is disen-
mal.
gaged.
Shift operation and Gear position has not changed af-
Sh_ _45* gear position do not ter shifting by shift actuator (mis- Unable Unable
match. shift occurs repeatedly).
Engine speed and
Gear position calculated by MCU
gear position sensor
Sh_ _46* (motor control unit) is different Unable Unable
signal do not match
from foot shift switch signal.
while vehicle is driven.
– 93 –
Able/un-
shift
Braking signal is not No braking signal is received by
Sh_ _47 detected while brak- MCU (motor control unit) when ve- Able Able
ing. hicle is braking.
Improper engine idling Engine speed at engine start-up
speed adjustment. exceeds the set limit.
Engine idling speed is
Engine speed when vehicle is
Sh_ _49* too high when vehicle Able Able
starting off exceeds the set limit.
is started.
Shift rod is not in neutral position
Shift actuator sensor
Sh_ _51 when shift actuator is not operat- Unable Unable
signal is abnormal.
ing.
Main switch “OFF” signal is re-
Main switch signal is
Sh_ _52* ceived even though engine is run- Able Able
abnormal.
ning.
*If the main switch is turned to “OFF”, the fault code number will disappear from the display and will not
be displayed again when the main switch is turned back to “ON”. Therefore, use the engine stop switch
to stop the engine, not the main switch. If the fault code number has disappeared, activate the diagnos-
tic mode and select diagnostic code No. Sh_ _61. The fault code numbers can be confirmed in the mal-
function history. Refer to “Diagnostic code table (Diagnostic code No. Sh_ _61)”.
ET2D21030
The YCC-S indicator and warning light come
TROUBLESHOOTING METHOD
on.
NOTE: 1. Check:
If the engine trouble indicator “1”, YCC-S indica- • Fault code number
tor “2”, and engine trouble warning light “3” all ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
come on, malfunctions have been detected in a. Check the fault code number displayed on
both the fuel injection system and the YCC-S the meter and diagnostic code Sh_ _61.
system. If this occurs, the fault codes for the fuel Refer to “Diagnostic code table (Diagnostic
injection system take priority over those for the code No. Sh_ _61)”.
YCC-S system, so only the fuel injection system b. Identify the faulty system with the fault code.
fault codes will appear in the multi-function dis- Refer to “Self-Diagnostic Function table”.
play. The fault codes for the YCC-S system will ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
be displayed in the multi-function display after all 2. Check and repair the probable cause of the
of the fault codes for the fuel injection system malfunction.
have been deleted using the reinstatement Refer to “TROUBLESHOOTING DETAILS”
method. on page 99.
3. Perform the reinstatement action for the
YCC-system.
Refer to “Reinstatement method” in the ap-
propriate table in “TROUBLESHOOTING
DETAILS”.
SHIFT 3 4. Turn the main switch to “OFF” and back to
“ON”, then check that no fault code number is
1 displayed.
NOTE:
2
If fault codes are displayed, repeat steps (1) to
(4) until no fault code number is displayed.
– 94 –
5. Erase the malfunction history in the diagnos-

tic mode. Refer to “Diagnostic code table (Di-
agnostic code No. Sh_ _62)”.
NOTE:
Turning the main switch to “OFF” will not erase
the malfunction history.
ET2D21031
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. Connect the test coupler adapter “2” to the YCC-S test coupler.
Test coupler adapter

90890-03149
2
1
5. Push and hold the hand shift select button “1”, turn the main switch “2” to “ON”, and continue to push
the button for 8 seconds or more.
NOTE:
• All displays on the meter disappear except the odometer/tripmeter/fuel reserve tripmeter displays.
• “Sh_ _61” appears on the odometer/tripmeter/fuel reserve tripmeter LCD.
6. Select the diagnostic code number corresponding to the fault code number by pushing the hand shift
select button and operating the brake lever (or brake pedal) simultaneously.
7. Turn the main switch to “OFF” to cancel the diagnostic mode.
– 95 –
Diagnostic code table

Diagnos- Data displayed on
tic code Item meter (reference Checking method
No. value)
Sh_ _61 Malfunction history
code display
• No history Sh_ _61 —
• History exists Fault code numbers If fault codes are stored in the malfunction
Sh_ _11–Sh_ _52 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 mal-
function history.
If more than one
code number is
detected, the dis-
play alternates ev-
ery two seconds
to show all the de-
tected code num-
bers.
When all of the
code numbers
have been shown,
the display re-
peats the same
process.)
Sh_ _62 Malfunction history
code erasure
• No history Sh_ _62 —
• History exists 01-09 • If fault codes are stored in the malfunc-
• First displays Sh_ tion history, the hand shift select indicator
_62 for 6 seconds, light will come on.
and then displays To erase the history, set the engine stop
the total number switch from “ ” to “ ”.
of malfunctions, After the history is erased, the hand shift
including the cur- select indicator light will go off.
rent malfunction,
that have oc-
curred since the
history was last
erased.
• If there are nine or
more of fault
codes stored in
the malfunction
history, “09” is dis-
played.
– 96 –

No. value)
Sh_ _63 Clutch actuation op- Sh_ _63 The clutch actuator can be operated in this
eration mode.
NOTE: 1. The hand shift select indicator light
The checking meth- comes on when the clutch is engaged.
od for the diagnostic 2. Set the engine stop switch to “ ” and
code (Sh_ _63) can- push the hand shift select button simul-
not be performed taneously. The clutch will disengage
when any of the fol- and the hand shift select indicator light
lowing fault codes will go off.
are detected. 3. Set the engine stop switch to “ ” and
Sh_ _11, Sh_ _12, push the hand shift select button simul-
Sh_ _13, Sh_ _15, taneously. The clutch will engage and
Sh_ 16, Sh_ _17, the hand shift select indicator light will
Sh_ _25, Sh_ _26, come on.
Sh_ _36, Sh_ _37, 4. If the clutch actuator sensor is malfunc-
and Sh_ _44 tioning, the hand shift select indicator
light will flash.
Sh_ _64 Shift actuator opera- Sh_ _64 The shift actuator can be operated in this
tion mode.
NOTE: 1. Make sure that the transmission is in
The checking meth- neutral.
od for the diagnostic 2. Set the engine stop switch to “ ” and
code (Sh_ _64) can- operate the hand shift lever switch (shift
not be performed up) simultaneously. The MCU (motor
when any of the fol- control unit) operates the shift actuator
lowing fault codes once.
are detected. The shift actuator is operated once
Sh_ _11, Sh_ _12, each time two switches are operated.
Sh_ _14, Sh_ _15, 3. The MCU (motor control unit) detects
Sh_ 16, Sh_ _18, the signal from the shift actuator sensor.
Sh_ _19, Sh_ _25, If the signal received after upshifting is
Sh_ _37, and Sh_ correct, the hand shift select indicator
_51 light will come on.
If the signal received after upshifting in
incorrect, the hand shift select indicator
light will flash.
4. Set the engine stop switch to “ ” and
operate the hand shift lever switch (shift
down) simultaneously. The MCU (motor
control unit) operates the shift actuator
once.
The shift actuator is operated once
each time two switches are operated.
5. The MCU (motor control unit) detects
the signal from the shift actuator sensor.
If the signal received after downshifting
is correct, the hand shift select indicator
light will come on.
If the signal received after downshifting
is incorrect, the hand shift select indica-
tor light will flash.
– 97 –

No. value)
Sh_ _65 Gear position setting Sh_ _65 The gear position can be set in this mode.
1. Make sure that the transmission is in
neutral.
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. Shift the transmission into 1st gear us-
ing the hand shift lever switch (shift up),
and then rotate the rear wheel at least
1/2 turn by hand to ensure that the dog
completely engages the 1st gear.
is correct for the 1st gear position, the
5. Repeat steps 3 and 4 for each gear up
to the 5th gear and make sure that the
hand shift select indicator light comes
on for 0.5 second each time the start
switch is pushed.
6. Shift the transmission into 4th gear us-
ing the hand shift lever switch (shift
down), and then rotate the rear wheel at
least 1/2 turn by hand to ensure that the
dog completely engages the 4th gear.
is correct for the 4th gear position, the
8. Repeat steps 6 and 7 for each gear
down to the 1st gear and make sure
that the hand shift select indicator light
comes on for 0.5 second each time the
start switch is pushed.
9. Shift the transmission into neutral.
10.After the above procedure is complet-
ed, all of the gear position data is tem-
porarily stored and ready to be written
on EEPROM.
11.Operate the brake lever or brake pedal
to write the data on EEPROM.
If all of the data has been written suc-
cessfully on EEPROM, the hand shift
select indicator light will come on for 2
seconds.
If the data is not written successfully,
the hand shift select indicator light will
flash.
– 98 –

No. value)
Sh_ _66 Adjust the clutch en- Sh_ _66 This mode adjust the clutch engagement
gagement position point manually.
The clutch engagement point while the ve-
hicle is starting off can be adjusted manu-
ally to 21 engine speed settings in this
mode. The initial setting of the clutch en-
gagement point varies according to the ve-
hicle.
• Hand shift lever switch operation (shift
up)
To increase the clutch engagement point
by approximately 100–150 r/min, oper-
ate the hand shift lever switch (shift up)
four times. After the switch is operated,
the hand shift select indicator light will
• Hand shift lever switch operation (shift
down)
To decrease the clutch engagement point
by approximately 100–150 r/min, oper-
ate the hand shift lever switch (shift
down) four times. After the switch is oper-
ated, the hand shift select indicator light
will come on for 0.3 second.
To write the changed setting on EE-
PROM, push the hand shift select button
for 0.3 second. After the button is
pushed, the hand shift select indicator
light will come on for 2 seconds.
ET2D21032
TROUBLESHOOTING DETAILS
This section describes the measures per fault code number displayed on the meter. Select diagnostic
code No. Sh_ _61, and then confirm the fault code numbers in the malfunction history. Check and ser-
vice the items or components that are the probable cause of the malfunction following the order given.
After the check and service of the malfunctioning part has been completed, reset the meter display ac-
cording to the reinstatement method. Then select diagnostic code No. Sh_ _62 in the diagnostic mode
to erase the malfunction history.
Fault code No.:
Code number displayed on the meter when the engine failed to work normally. Refer to “Self-Diagnostic
Function table”.
– 99 –
Fault code No. Sh_ _11 Symptom Too low or too high voltage is supplied to the
YCC-S system.
Order Item/components and probable Check or maintenance job Reinstatement
cause method
1 Connections • Check the coupler for any pins Repairing the
• Wire harness MCU (motor control that may be pulled out. cause of the
unit) coupler • Check the locking condition of malfunction.
the coupler.
• If there is a malfunction, repair it
and connect the coupler se-
curely.
2 Faulty battery • Replace or charge the battery.
28197-E0)
3 Malfunction in rectifier/regulator • Replace if detective.
Refer to “CHARGING SYS-
TEM” in chapter 8. (Manual No.:
3P6-28197-E0)
4 Open or short circuit in wire harness. • Repair or replace if there is an
open or short circuit.
• Between battery and main
switch coupler.
(red–red)
• Between main switch coupler
and signaling system fuse.
(brown/blue–brown/blue)
• Between signaling system fuse
and MCU (motor control unit)
coupler.
(brown–brown)
Fault code No. Sh_ _12 Symptom Malfunction of power cut-off function in the
MCU (motor control unit).
cause method
1 Malfunction in MCU (motor control Replace the MCU (motor control Repairing the
unit). unit). cause of the
malfunction.
– 100 –
Fault code No. Sh_ _13 Symptom Over current to clutch actuator motor.
cause method
1 Connections • Check the coupler for any pins Turning the
• Wire harness MCU (motor control that may be pulled out. main switch to
unit) coupler • Check the locking condition of “OFF”.
• Clutch actuator motor coupler the coupler. See NOTE.
curely.
• Between clutch actuator motor
coupler and MCU (motor con-
trol unit) coupler.
(black/white–black/white)
(red/white–red/white)
• Between battery and YCC-S
fuse terminal.
(red–red)
• Between YCC-S fuse and MCU
(motor control unit).
(red/black–red/black)
3 YCC-S fuse • Replace if defective.
4 Stuck clutch actuator motor. • Replace the clutch actuator.
NOTE:
If the main switch is turned to “OFF”, the fault code number will disappear from the display and will not
function history.
– 101 –
Fault code No. Sh_ _14 Symptom Over current to shift actuator motor.
cause method
1 • Connections • Check the coupler for any pins Turning the
• Shift actuator motor coupler the coupler. See NOTE.
curely.
• Between shift actuator motor
trol unit) coupler.
(black/blue–black/blue)
(red–red)
fuse terminal.
(red–red)
4 Stuck shift actuator motor. • Replace the shift actuator.
NOTE:
function history.
– 102 –
Fault code No. Sh_ _15 Symptom Abnormal current is detected in clutch or shift
actuator motor drive circuit.
cause method
• Shift actuator motor coupler • If there is a malfunction, repair it
curely.
trol unit) coupler.
trol unit) coupler.
(red–red)
fuse terminal.
(red–red)
4 Defective clutch or shift actuator mo- • Replace the clutch actuator or
tor drive circuit. shift actuator.
5 Confirm the operation of the main • Execute the diagnostic mode.
switch after repairing the malfunction (Code No. Sh_ _63 and Sh_
or correcting the cause. _64)
NOTE:
function history.
– 103 –
Fault code No. Sh_ _16 Symptom Malfunction of clutch or shift actuator motor
drive circuit in the MCU (motor control unit).
cause method
curely.
trol unit) coupler.
trol unit) coupler.
(red–red)
3 Malfunction in MCU (motor control Replace the MCU (motor control
unit). unit).
NOTE:
function history.
– 104 –
Fault code No. Sh_ _17 Symptom Detected clutch actuator position is incorrect.
cause method
curely.
trol unit) coupler.
3 Stuck clutch actuator motor or clutch • Replace the clutch actuator.
actuator gear
switch after repairing the malfunction (Code No. Sh_ _63)
or correcting the cause.
NOTE:
function history.
– 105 –
Fault code No. Sh_ _18 Symptom Detected shift actuator position is incorrect.
cause method
• Shift actuator motor coupler the coupler. See NOTE.
curely.
trol unit) coupler.
(red–red)
3 Stuck shift actuator motor or shift ac- • Replace the shift actuator.
tuator gear
NOTE:
function history.
– 106 –
Fault code No. Sh_ _19 Symptom Output signal of shift actuator sensor is abnor-
mal.
cause method
• Shift actuator sensor coupler the coupler. See NOTE.
curely.
• Between shift actuator sensor
trol unit) coupler.
(green/yellow–green/yellow)
(blue–blue)
3 Defective shift actuator sensor. • Replace the shift actuator.
NOTE:
function history.
– 107 –
Fault code No. Sh_ _21 Symptom Output signal of gear position sensor is abnor-
mal.
cause method
• Gear position sensor coupler the coupler.
curely.
• Between gear position sensor
trol unit) coupler.
(yellow–yellow)
(blue–blue)
3 Defective gear position sensor. • Adjust or replace if defective.
Refer to “ADJUSTING THE
GEAR POSITION SENSOR” on
page 50 and “CHECKING THE
GEAR POSITION SENSOR” on
page 132.
4 Gear position setting • Execute the diagnostic mode.
(Code No. Sh_ _65)
Fault code No. Sh_ _22 Symptom Output signal of foot shift switch is abnormal.
cause method
• Foot shift switch coupler the coupler.
curely.
2 Open or short circuit in wire harness • Repair or replace if there is an
and/or sub-lead 2. open or short circuit.
• Between foot shift switch cou-
pler and MCU (motor control
unit) coupler.
(orange/red–orange/black)
(blue–blue)
3 Defective foot shift switch. • Adjust or replace if defective.
Refer to “ADJUSTING THE
FOOT SHIFT SWITCH” on
page 60 and “CHECKING THE
FOOT SHIFT SWITCH” on
page 133.
– 108 –
Fault code No. Sh_ _23 Symptom No input signal from sidestand switch.
cause method
the coupler.
curely.
2 Open circuit in wire harness. • Repair or replace if there is an
open circuit.
• Between sidestand switch cou-
unit) coupler.
(blue/green–blue/green)
3 Defective sidestand switch. • Check and replace if defective.
SWITCHES” in chapter 8.
(Manual No.: 3P6-28197-E0)
Fault code No. Sh_ _25 Symptom Error has occurred in the actuator drive circuit
in MCU (motor control unit) when main switch is
turned to “ON”.
cause method
1 Malfunction in MCU (motor control Replace the MCU (motor control Replacing the
unit). unit). MCU (motor
control unit).
– 109 –
Fault code No. Sh_ _26 Symptom Abnormal clutch movement is detected during
check when main switch is turned to “ON”.
cause method
1 Clutch fluid • Check for clutch fluid leakage. Turning the
• Check the clutch fluid level. main switch to
Refer to “CHECKING THE “OFF”.
CLUTCH FLUID LEVEL” on See NOTE.
page 31.
2 Air in hydraulic clutch system • Check the clutch stroke.
• Bleed the hydraulic clutch.
Refer to “BLEEDING THE HY-
DRAULIC CLUTCH SYSTEM”
on page 31.
NOTE:
function history.
Fault code No. Sh_ _27 Symptom Diagnosis mode is activated at engine start-up.
cause method
1 YCC-S test coupler • Check that the test coupler Turning the
adapter is not connected. main switch to
Refer to “DIAGNOSTIC MODE” “OFF”.
on page 95. See NOTE.
2 Short circuit in wire harness. • Repair or replace if there is a
short circuit.
• Between YCC-S test coupler
coupler.
(blue/yellow–blue/yellow)
NOTE:
function history.
– 110 –
Fault code No. Sh_ _31 Symptom Engine speed signal is abnormal.
cause method
• Wire harness ECU coupler the coupler.
curely.
• Between ECU coupler and
MCU (motor control unit) cou-
pler.
(yellow/black–yellow/black)
Fault code No. Sh_ _32 Symptom YCC-S speed sensor signal is abnormal.
cause method
• YCC-S speed sensor coupler the coupler. See NOTE.
curely.
• Between YCC-S speed sensor
trol unit) coupler.
(white/yellow–white/yellow)
(blue–blue)
3 Defective YCC-S speed sensor. • Replace if detective.
YCC-S SPEED SENSOR” on
page 132.
NOTE:
function history.
– 111 –
Fault code No. Sh_ _34 Symptom TPS (throttle position sensor) signal is abnor-
mal.
cause method
curely.
pler.
(yellow/blue–yellow/blue)
Fault code No. Sh_ _35 Symptom Start switch signal is abnormal.
cause method
• Relay unit coupler the coupler.
• Right handlebar switch coupler • If there is a malfunction, repair it
curely.
and/or front cowling wire harness. open or short circuit.
• Between right handlebar switch
coupler and relay unit coupler.
(white/blue–white/blue)
• Between relay unit coupler and
pler.
(blue/white–blue/white)
3 Defective relay unit. • Check and replace relay unit.
LAYS” in chapter 8. (Manual
No.: 3P6-28197-E0)
4 Defective start switch. • Check and replace right handle-
bar switch.
SWITCHES” in chapter 8.
(Manual No.: 3P6-28197-E0)
– 112 –
Fault code No. Sh_ _36 Symptom Output signal of clutch actuator sensor is ab-
normal.
cause method
• Clutch actuator sensor coupler the coupler.
curely.
and/or sub-lead 1. open or short circuit.
• Between clutch actuator sen-
sor coupler and MCU (motor
control unit) coupler.
(orange–orange)
(orange/green–orange/green)
(blue–blue)
3 Defective clutch actuator sensor. • Replace clutch actuator.
– 113 –
Fault code No. Sh_ _37 Symptom Power supply to clutch or shift actuator motor is
abnormal.
cause method
curely.
trol unit) coupler.
trol unit) coupler.
(red–red)
3 Defective clutch or shift actuator mo- • Replace the clutch actuator or
tor. shift actuator.
NOTE:
function history.
– 114 –
Fault code No. Sh_ _38 Symptom Malfunction of hand shift lever switch (shift up
or shift down).
cause method
• Hand shift switch coupler the coupler.
curely.
• Between hand shift switch cou-
unit) coupler.
(orange/white–orange/white)
(orange/black–orange/black)
(green/red–green/red)
(green/black–green/black)
3 Defective hand shift lever switch (shift • Replace hand shift switch.
up or shift down). Refer to “CHECKING THE
Fault code No. Sh_ _39 Symptom Ignition timing retard output signal is abnormal.
cause method
curely.
pler.
(light green–light green)
– 115 –
Fault code No. Sh_ _41 Symptom Coolant temperature sensor signal is abnormal.
cause method
curely.
pler.
Fault code No. Sh_ _42 Symptom Communication between ECU and multi-func-
tion meter is abnormal.
cause method
• YCC-S speed sensor coupler the coupler.
curely.
• Between YCC-S speed sensor
trol unit) coupler.
– 116 –
Fault code No. Sh_ _43 Symptom Communication between MCU (motor control
unit) and ABS ECU is abnormal.
cause method
• ABS ECU coupler the coupler.
curely.
• Between ABS ECU coupler and
pler.
(brown/black–brown/black)
Fault code No. Sh_ _44 Symptom Clutch actuator sensor signal is abnormal.
cause method
1 Defective clutch actuator sensor. • Replace clutch actuator. Turning the
2 Confirm the operation of the main • Execute the diagnostic mode. main switch to
switch after repairing the malfunction (Code No. Sh_ _63) “OFF”.
or correcting the cause. See NOTE.
NOTE:
function history.
– 117 –
Fault code No. Sh_ _45 Symptom Shift operation and gear position do not match.
cause method
1 Shift rod • Check the shift rod pin hole lo- Turning the
cation. main switch to
• Check the shift rod groove loca- “OFF”.
tion. See NOTE.
• Adjust or replace if defective.
SHIFT ROD” on page 59 and
“INSTALLING THE SHIFT AC-
TUATOR” on page 61.
2 Defective shift actuator. • Replace shift actuator.
NOTE:
function history.
Fault code No. Sh_ _46 Symptom Engine speed and gear position sensor signal
do not match while vehicle is driven.
cause method
1 Gear position setting. • Execute the diagnostic mode. Turning the
(Code No. Sh_ _65) main switch to
“OFF”.
See NOTE.
NOTE:
function history.
– 118 –
Fault code No. Sh_ _47 Symptom Braking signal is not detected while braking.
cause method
• Brake light relay coupler the coupler.
curely.
switch coupler.
(red–red)
and brake light relay coupler.
(brown–brown)
• Between brake light relay cou-
unit) coupler.
(yellow/green–yellow/green)
3 Defective brake light relay. • Replace if defective.
LAYS” in chapter 8. (Manual
No.: 3P6-28197-E0)
Fault code No. Sh_ _48 Symptom Improper engine idling speed adjustment.
cause method
1 Engine idling speed • Check and adjust the engine Turning the
idling speed. main switch to
Refer to “ADJUSTING THE EN- “OFF”.
GINE IDLING SPEED” in chap- See NOTE.
ter 3. (Manual No.: 3P6-28197-
E0)
2 Defective fast idle unit. • Replace the throttle bodies.
Refer to “THROTTLE BODIES”
in chapter 7. (Manual No.: 3P6-
28197-E0)
NOTE:
function history.
– 119 –
Fault code No. Sh_ _49 Symptom Engine idling speed is too high when vehicle is
started.
cause method
1 Clutch operation. • Check the clutch stroke. Turning the
Refer to “BLEEDING THE HY- main switch to
DRAULIC CLUTCH SYSTEM” “OFF”.
on page 31. See NOTE.
2 Clutch slippage. • Check the friction plate thick-
ness and replace the friction
plates if necessary.
FRICTION PLATES” in chapter
5. (Manual No.: 3P6-28197-E0)
NOTE:
function history.
Fault code No. Sh_ _51 Symptom Shift actuator sensor signal is abnormal.
cause method
1 Shift rod • Check the shift rod pin hole lo- Repairing the
cation. cause of the
• Check the shift rod groove loca- malfunction.
tion.
• Adjust or replace the shift rod.
SHIFT ROD” on page 59 and
“INSTALLING THE SHIFT AC-
TUATOR” on page 61.
2 Defective shift actuator sensor. • Replace the shift actuator.
– 120 –
Fault code No. Sh_ _52 Symptom Main switch signal is abnormal.
cause method
the coupler. See NOTE.
curely.
switch coupler.
(red–red)
coupler.
(brown–brown)
NOTE:
function history.
– 121 –
– 122 –
ELECTRICAL COMPONENTS
EAS27970
2 3
4
5
1
7
20
19
18
17
10
16
15
11
14
12
13
– 123 –
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
15. Left horn (low)
16. Right horn (high)
17. Ignition coil
18. Main fuse
19. Diode 1
20. Diode 2
– 124 –
3
1 2
4
21
5
20
19
7
18
17
8
16 9
10
15
14
13 11
12
– 125 –
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
18. YCC-S control relay
19. Turn signal/hazard relay
20. Relay unit
21. Lean angle sensor
– 126 –
EAS27980
CHECKING THE SWITCHES
B Y Lg Dg Br/W
L/B P Sb R/Y Ch
14
R/Y Y
15
Lg B Sb
UP
13
R/Y L/B
DOWN 1
16
Dg Br/W Ch
12
B P
Br G/Y
O/W Br/L O/B

B R/B
G/R B/L G/B
10 11
O/W B/L O/B G/R B/L G/B
Shift up Shift down 2

9
B/L Br/L R Br/L Br/R Br/R
PUSH
ON
OFF R
P Br/L
R/W L/W Dg Br
R/B B Br/W Ch G/Y
8
R/W R/B 3
7 B B
(BROWN)
L/W B
6
Dg Br/W Ch
4
Sb
5
B B
(BLUE)
– 127 –
1. Front brake light switch

2. Main 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. Turn signal switch
– 128 –
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.
Pocket tester
90890-03112
YU-03112-C
NOTE:
• Before checking for continuity, set the pocket tester to “0” and to the “Ω × 1” range.
• When checking for continuity, switch back and forth between the switch positions a few times.
The switches and their terminal connections are illustrated as in the following example of the main
switch.
The switch positions “a” are shown in the far left column and the switch lead colors “b” are shown in the
top row.
The continuity (i. e., a closed circuit) between switch terminals at a given switch position is indicated by
“ ”. There is continuity between red, brown/blue, and brown/red when the switch is set to “ON”
and between red and brown/red when the switch is set to “ ”.
b
R Br/L Br/R
ON
a OFF
P
R
Br/R
Br/L
– 129 –
EAS28040
CHECKING THE RELAYS Result

Check each switch for continuity with the pocket Continuity
tester. If the continuity reading is incorrect, re- (between “3” and “4”)
place the relay.
Pocket tester Relay unit (fuel pump relay)

90890-03112
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.
Starter relay 1. Positive battery terminal

2. Negative battery terminal
3 3. Positive tester probe
4. Negative tester probe
R
R/L Result
L/W R/W Continuity
B
1 2 Headlight (on/off)/grip warmer relay
4
3
1. Positive battery terminal
2. Negative battery terminal 4 +
3. Positive tester probe
4. Negative tester probe 2 1
Y/W R/Y
Result G/L
Continuity R/Y
(between “3” and “4”)
Relay unit (starting circuit cut-off relay) 2. Negative battery terminal
Result
Continuity

– 130 –
Headlight relay (dimmer) Brake light relay

First step: First step:
1 2
3
2 1
B G L/B Br/ B Br G/Y
Y
G/L Y/G
1. Positive tester probe 1. Positive tester probe

2. Negative tester probe 2. Negative tester probe
Result
Result Continuity
Continuity (between “1” and “2”)
No continuity Second step:
(between “1” and “3”) 4
Second step: 3 +
3
2 1
5 +
4 Br/ B Br G/Y
2 1 Y /G
B G L/B
Y 1. Positive battery terminal
G/L 2. Negative battery terminal
1. Positive battery terminal 4. Negative tester probe
Result
4. Negative tester probe No continuity
5. Negative tester probe (between “3” and “4”)
Result YCC-S control relay

No continuity
(between “3” and “4”) First step:
Continuity
1
2
G Y/G
L/Y
L/W

– 131 –
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Result a. Connect the pocket tester (DC 20 V) to the
No continuity YCC-S speed sensor coupler (wire harness
(between “1” and “2”) side) as shown.
Second step: Pocket tester
3 90890-03112
4 + YU-03112-C
2 • Positive tester probe →

1 white/yellow “1”
G Y/G • Negative tester probe →
L/Y black/blue “2”
L/W

2. Negative battery terminal 1
4. Negative tester probe W L/Y L W/Y
B/L B/L
Result
Continuity
(between “3” and “4”) 2
b. Turn the main switch to “ON”.

Radiator fan motor relay c. Elevate the rear wheel and slowly rotate it.
d. Measure the voltage of white/yellow and
3
black/blue. With each full rotation of the rear
4 + wheel, the voltage reading should cycle from
0.6 V to 4.8 V to 0.6 V to 4.8 V.
2 1 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ET2D21022
G/Y R/W
CHECKING THE GEAR POSITION SENSOR
Br/B
1. Remove:
R
1. Positive battery terminal NOTE:
2. Negative battery terminal Remove only the screws “1” when removing the
3. Positive tester probe gear position sensor. Do not remove the screws
4. Negative tester probe “2”.
Result 1
Continuity 2
1
EAS28240 2
CHECKING THE YCC-S SPEED SENSOR
1. Check:
• YCC-S speed sensor output voltage
2. Check:
Output voltage reading cycle
• Gear position sensor maximum resistance
0.6 V to 4.8 V to 0.6 V to 4.8 V
Out of specification → Replace the gear posi-
tion sensor.
– 132 –

Resistance blue “1”
4.0–6.0 kΩ • 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
YU-03112-C
• Positive tester probe → B O L

blue “1”
• Negative tester probe →
black/blue “2” b. Measure the foot shift switch maximum resis-
tance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1 2 3. Install:
Refer to “INSTALLING THE FOOT SHIFT
SWITCH” on page 59.
ET2D21024
CHECKING THE GRIP WARMERS

L Y B/L The following procedure applies to both of the
grip warmers.
b. Measure the gear position sensor maximum 1. Check:
resistance. • Grip warmer resistance
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Out of specification → Replace the grip
3. Install: warmer.
Grip warmer resistance
Refer to “INSTALLING THE GEAR POSI- 1.21–1.48 Ω at 20 °C (68 °F)
TION SENSOR” on page 49.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
ET2D21023
a. Disconnect the grip warmer coupler from the
CHECKING THE FOOT SHIFT SWITCH
front cowling wire harness.
1. Remove:
b. Connect the pocket tester (Ω × 1) to the grip
warmer coupler as shown.
2. Check:
• Foot shift switch maximum resistance Pocket tester
Out of specification → Replace the foot shift 90890-03112
switch. Analog pocket tester
YU-03112-C
Resistance
4.0–6.0 kΩ
black “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 1k) to the foot • Negative tester probe →
shift switch terminals as shown. black “2”
Pocket tester
90890-03112
YU-03112-C
– 133 –
ET2D21026
CHECKING THE DIODE 2

1. Check:
• Diode 2
Pocket tester
90890-03112
YU-03112-C
c. Measure the grip warmer resistance.
NOTE:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
The pocket tester and the analog pocket tester
ET2D21025
readings are shown in the following table.
CHECKING THE GRIP WARMER CONTROL
UNIT
1. Check: Continuity
Positive tester probe → yellow
• Grip warmer control unit continuity
“1”
Out of specification → Replace. Negative tester probe → yel-
low/green “2”
Grip warmer control unit continu-
No continuity
ity
Positive tester probe → yel-
On
low/green “2”
Continuity
Negative tester probe → yellow
Off
“1”
No continuity
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the grip warmer control unit cou- 1
plers from the front cowling wire harness.
b. Connect the pocket tester (Ω × 1) to the grip Y
warmer control unit coupler as shown.
Y/G
Pocket tester
90890-03112
Analog pocket tester 2
YU-03112-C
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Positive tester probe → a. Remove the diode 2 from the wire harness.
brown “1” b. Connect the pocket tester (Ω × 1) to the diode
• Negative tester probe → 2 terminals as shown.
black/green “2” c. Check the diode 2 for continuity.
d. Check the diode 2 for no continuity.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1
Br
W/B
HI
W/Y
LO
B/G
OFF
c. Measure the grip warmer control unit resis-

tance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
– 134 –
– 135 –
EAS28740
52. Shift actuator motor 107.Lean angle sensor
WIRING DIAGRAM 53. Shift actuator sensor 108.Thermistor
FJR1300AS(V) 2006 54. Clutch actuator sensor 109.Hand shift switch
1. Main switch 55. Clutch actuator motor 110.Hand shift lever switch (shift
2. Rectifier/regulator 56. MCU (motor control unit) up)
3. AC magneto 57. YCC-S test coupler 111.Hand shift lever switch (shift
4. ABS ECU fuse 58. Coupler 4 (wire harness–front down)
5. Fuel injection system fuse cowling wire harness) 112.Hand shift select button
6. Backup fuse (odometer, clock, 59. Anti-theft alarm (OPTION) 113.Hand shift select indicator light
immobilizer system, and wind- 60. Coupler 5 (wire harness–front 114.Horn
shield drive system) cowling wire harness) 115.Front left turn signal light
7. Main fuse 61. Foot shift switch 116.Front right turn signal light
8. Battery 62. YCC-S speed sensor 117.Headlight assembly
9. ABS motor fuse 63. Gear position sensor 118.Auxiliary light
10. Starter relay 64. YCC-S control relay 119.Headlight
11. Starter motor 65. Coupler 6 (wire harness–front 120.Headlight relay (dimmer)
12. Diode 1 cowling wire harness) 121.Windshield drive unit
13. Immobilizer unit 66. Headlight (on/off)/grip warmer 122.Right grip warmer
14. Coupler 1 (wire harness–front relay 123.Left grip warmer
cowling wire harness) 67. Hazard lighting fuse
15. Fuel pump 68. Signaling system fuse EAS28750
16. Fuel sender 69. Headlight fuse COLOR CODE

17. Coupler 2 (wire harness–front 70. Ignition fuse B Black
cowling wire harness) 71. Auxiliary DC jack fuse Br Brown
18. Neutral switch 72. Grip warmer control unit Ch Chocolate
73. Radiator fan motor relay Dg Dark green
19. ABS test coupler
G Green
20. ABS ECU (electronic control 74. Left radiator fan motor fuse
Gy Gray
unit) 75. Left radiator fan motor L Blue
21. Front wheel sensor 76. Right radiator fan motor fuse Lg Light green
22. Rear wheel sensor 77. Right radiator fan motor O Orange
23. ABS motor relay 78. YCC-S motor control fuse P Pink
24. Hydraulic unit 79. Auxiliary DC jack R Red
25. Rear brake light switch 80. Turn signal/hazard relay Sb Sky blue
26. Diode 2 81. Right handlebar switch W White
27. Brake light relay 82. Front brake light switch Y Yellow
28. License plate light 83. Engine stop switch B/G Black/Green
84. Start switch B/L Black/Blue
29. Taillight assembly
B/R Black/Red
30. Tail/brake light 85. Hazard switch
B/W Black/White
31. Rear left turn signal light 86. Left handlebar switch B/Y Black/Yellow
32. Rear right turn signal light 87. Pass switch Br/B Brown/Black
33. Coupler 3 (wire harness–front 88. Dimmer switch Br/G Brown/Green
cowling wire harness) 89. Windshield position switch Br/L Brown/Blue
34. Sidestand switch 90. Turn signal switch Br/R Brown/Red
35. Cylinders-#1/#4 ignition coil 91. Horn switch Br/W Brown/White
36. Spark plug 92. Relay unit Br/Y Brown/Yellow
37. Cylinders-#2/#3 ignition coil 93. Starting circuit cut-off relay G/B Green/Black
94. Fuel pump relay G/L Green/Blue
38. Injector #4
G/R Green/Red
39. Injector #3 95. Accessory box solenoid
G/W Green/White
40. Injector #2 96. Meter assembly G/Y Green/Yellow
41. Injector #1 97. Neutral indicator light Gy/R Gray/Red
42. Air induction system solenoid 98. ABS warning light Gy/W Gray/White
43. ECU (engine control unit) 99. Immobilizer system indicator L/B Blue/Black
44. Crankshaft position sensor light L/G Blue/Green
45. Intake air temperature sensor 100.Multi-function meter L/R Blue/Red
46. Coolant temperature sensor 101.Oil level warning light L/W Blue/White
47. O2 sensor 102.Engine trouble warning light L/Y Blue/Yellow
103.Meter light Lg/W Light green/White
48. Cylinder identification sensor O/B Orange/Black
49. Throttle position sensor 104.High beam indicator light
O/G Orange/Green
50. Intake air pressure sensor 105.Right turn signal indicator light
O/R Orange/Red
51. Oil level switch 106.Left turn signal indicator light O/W Orange/White
P/W Pink/White
R/B Red/Black
R/G Red/Green
R/L Red/Blue
R/W Red/White
R/Y Red/Yellow
Sb/W Sky blue/White
W/B White/Black
W/G White/Green
W/L White/Blue
W/Y White/Yellow
Y/B Yellow/Black
Y/G Yellow/Green
Y/L Yellow/Blue
Y/W Yellow/White
YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
FJR1300AS(V) 2006 FJR1300AS(V) 2006 FJR1300AS(V) 2006 FJR1300AS(V) 2006 FJR1300AS(V) 2006
WIRING DIAGRAM (1/2) SCHÉMA DE CÂBLAGE (1/2) SCHALTPLAN (1/2) SCHEMA ELETTRICO (1/2) DIAGRAMA ELÉCTRICO (1/2)
A B C D E F G

(GRAY) (GRAY) (BLACK) (BLACK)
4
Br/L Br/W
5
Br/L Br/R 13
B/W BB R/G R/G B2 B
R R/G
BB R/G B/W
R/W Y/L G/B
7 R
R
R/G
17
R R
L/W P
R
R R B/R Y/W B/Y R/L
1 Br/R Br/R
2
W
W
W
W 3 R R R/L
G/B L Y/L Y/W B/Y
R/B
G/Y
W W W/B Br/B W/L Br/W R/B B W/G W/L W/Y Br/B R/L R/L
ON
OFF R R
W W
8 9 L/W R/W Y/L
Y/G 14 G/W W/L Y/G L/W
B B B/W G/R G/Y W/Y Lg Y/G Sb B2 L/W R/W D
P Br/L Br/L L/W Sb (BLACK) (BLACK) R/L

G/W P B/R G/B G/R
B
Br/L
WWW
B
10 (GRAY)
(GRAY) B Sb W
Br/R
B
B R/W
R/W L G/R W B 21 Gy W W B
B R W/L B/Y Y/W Y/L L BB
B B Sb Sb Sb WB W
(BLACK) B/W B/G
11 12 R/W
L/W
L/W Y/G W/L G/W
G/R G/B B/R P
W
B
B B 22 Gy W W B
Br/R W
R 67 B/W
B B
L/W
(BLACK) (GRAY) Sb Br/W C Br/W Br/W
B
B/W B/W C B/W B/W
R R/W
Br/R L/R 65 18 Sb Sb B Sb Sb
Sb B
19 Lg Lg B Lg Lg
R/W
Br/B
G/Y 73 68 L/R L/Y L/Y
Y/G Lg G/R G/R G/R B G/R G/R
W/Y W/Y B W/Y
Br/L Br Br
R/L G/W
Br/B G/Y R/Y
G/L 64 B
R/L
R/L R/W
R/B L/W
W/L C W/L W/L
20 R/W R/L
Br/B Br/B
R/W L/W 15 16 Br/B F Br/B Br/B
R/W
R/B
W/B 23
69 R/Y Y/W Br/B G L/Y
L/W C L/W L/W
R/B
76 74 Br/L R/Y R/Y G/L Y/G G
B/L
R 52 B B
G/Y W/B
W/G
R/B
W/B
L L/Y
66 R L/W R/B L/R Br/B R B B/L R (DARK GREEN) G/Y Br/B
W/L
W/Y
Y/G
C Br/B R/W
L G/W B Y/G
G/Y R/W R/W R/B
L L/Y R/Y
G/L
G/L R/W R/Y Br G/Y 53 C
C
Br/B L/R R/B L/Y Br/R B/L B B2
Br/B G W R R/W R/W R/W
R/Y Y/W L Y G/Y L
B B R Y G W R W/Y W/L W/G
L 77 L 75 B/L
B B/L R/L
(GRAY)
(BLACK) (BLACK) 70 G/Y
L2 A L L
E
R/L 24 (GRAY)

L/W B/L2 A B/L B/L
B B 54 (GRAY)
Gy/W E Gy/W
C (GRAY) (GRAY)
L L/Y
71 B/L Y L 63
L
Y Y
O/G A O/G O/G
R B B/W R/W 47 42 O
35 B
W/G W/Y B/W
W/L
(BLACK) (BLACK) B/L R/W Br/R
(BLACK)
L R/W R/W 55 Gy/W B/L
O G 36 36 B B/W
62 W/Y W/Y R/L B

D
R/B G/L Br W/B

B/L
B B B R/W Br/R
25 B/W
W L/Y L W/Y R/L B

(BLUE) (BLUE)
72 G/L
R/B B/L B/L 56 Y/L
Br/B
Gy/W B/L W L E
B
Gy/R
37 B B
(BROWN)
Y/B (BLACK)
B Lg/W W/Y B/G (BLACK) R/L
B/R
B B G B/L L/W
R/W Br/R
O 36 36 B Br/B
Br/B
B Lg/W
L O B 61 O
L
O
L
G O/R
G L
O/R
B/L
Y/W
P L
L/Y
Sb
Gy/R
(BROWN) G/Y
Y
B/Y
(BLACK)
L 48 W/B
B/L
B/R
R/L
Y/G
Br 27
R/B
Lg/W
L W/B W L/Y R/W
L/W 38
Y/G
26
R
L/Y L/Y
B L/Y L Y B/L
B/L 39 (BLACK)
78
R/B
R/B 57 49 Y
L
Gy
44 Gy 43 L/B L/B E L/B L/B R/L R/L L/B (GRAY) Br/B
Br
(BLACK) B B/L
Y/G O/G Lg O/B L/Y Br/L B/L
L/G Br/L
B (BLACK)
B/L
40 R/L G/B (GRAY)
P/W B/L L L G/B G/B E G/B G/B R/L
Y G/Y Lgr/W W/Y G/B Br/B O/W G/R Lg
R/B
O/R L L2 L/W Y/B G/R R/L O/B G/B 50 B/L
P/W
Y E Y
P/W E P/W
Y
P/W
R/B O L/G G O/W Y/L B/L2
(BLACK)
B/L E B/L B/L
R/B R/B E R/B 41 R/L R/B (GRAY)
R/B R/L
(BLACK) 60 Lg/W
L E L L
Y/G
G/Y
Y/W
58 W
R/B
Y/L
Y/B W/Y
B
B1 BB B/L Br/W
W W
(BLACK) 45
B2 B1 51
BB 46 29 L/R Ch L/R
B1 G/W B/L Y Dg
B/L G/W
BB3
59 BB4 (GREEN)
33 31
B/W
B/L 32
BB2
BB1
Dg 30 30 28
Ch
B Ch Dg B B Dg Ch
B/W L/G B/L
BB3 BB2 B B B Ch B
BB4 BB1 B B
L/G
B
Dg Y L/R
34 B B
(BLUE)
B L/G Ch B
(BLUE)
B
FJR1300AS(V) 2006 FJR1300AS(V) 2006 FJR1300AS(V) 2006 FJR1300AS(V) 2006 FJR1300AS(V) 2006
WIRING DIAGRAM (2/2) SCHÉMA DE CÂBLAGE (2/2) SCHALTPLAN (2/2) SCHEMA ELETTRICO (2/2) DIAGRAMA ELÉCTRICO (2/2)
Front cowling wire harness Faisceau de fils au carénage avant Frontverkleidungs-Kabelbaum Cablaggio elettrico del cupolino Mazo de cables del carenado delantero
R/B
92 L/W L/W R Sb/W
93 94
R/W W/L R/L Sb B/R

B/R L/Y
Sb
L/Y
17
R/L
R/B R/B
81 R/W W/L B/R
G/Y
83 84 85
82
Br G/Y B Dg Ch
R Br/G
65 L Y/G B/L
L/W
Ch Dg R/G B/W G/R Sb B/L Lg/W W G/B
Br R/Y R/W G/L G/L R/W R/Y Br Br
107
R/Y
Br/B
G/L 95 96 Sb/W W/L
Y/G
B 99 L
Br/Y B 98 Y/G
79 (BLACK)
Br/G
Br/G Dg Lg Y B B Y Lg Dg Br/W
87 88 89 90 91 Sb G/R
G/B
G/R
L/R Ch R/Y Sb/W P L/B L/B P Sb R/Y Ch
R/B Br
UP
R/W B/R
L/W
B/R
L/W 14 B/Y Y/W Y/L L

Y/W
R/B Y/W (GRAY)
P
(BLACK) (GRAY) Br/G
Br/L Br/L G/W
Lg/W R/B
Br Sb P
W
108 (GRAY)
G/L
114 Br
101
Lg P B B
Sb/W 102 (GRAY)
121 R/B
B/R
R/B
B/R B B
G/L Y
B
G
L/B
114 Br
B Y 103 B/W B/L

(GRAY)
L/B G B 120
R Br Sb Sb/W Br R/G (BLACK)
Y
104
Br/R Lg B B Lg Sb
L/G
Dg
105
R/B B/R B/R R/B 33
106
Dg Ch Ch B/W
B/L
R/G
Ch
116 115 Dg B Dg Ch
G B B B B
118 118 119 119 G B Dg B Ch 109 G/B B/L G/R R/B B
R/B
Ch Dg B

B B
B
B R/B
G/R B/L G/B
113
110 111 112
PUSH
Shift up Shift down
O/W B/L
B/L
O/W O/B Br/L Br/L O/B O/W
60 G/R
G/B
Br/L

FJR AS 2006 Manual Técnico Suplemento

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2006

IMPORTANT MANUAL INFORMATION

Failure to follow WARNING instructions could result in severe injury or death

A CAUTION indicates special precautions that must be taken to avoid dam-

NOTE: A NOTE provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL

SPECIAL TOOLS ............................................................................................... 4

GENERAL SPECIFICATIONS ........................................................................... 6

ENGINE SPECIFICATIONS ............................................................................... 7

CHASSIS SPECIFICATIONS ............................................................................. 8

ELECTRICAL SPECIFICATIONS ...................................................................... 9

TIGHTENING TORQUES ................................................................................. 10

CABLE ROUTING ............................................................................................ 13

PERIODIC MAINTENANCE ............................................................................. 29

ENGINE REMOVAL ......................................................................................... 47

SHIFT ACTUATOR AND SHIFT ROD ............................................................. 57

MIDDLE GEAR ................................................................................................. 64

ELECTRIC STARTING SYSTEM ..................................................................... 71

GRIP WARMER SYSTEM ................................................................................ 79

ELECTRICAL COMPONENTS....................................................................... 123

FJR1300AS(V) 2006 WIRING DIAGRAM

OUTLINE OF THE YCC-S (Yamaha Chip Controlled-Shift) SYSTEM

1. YCC-S test coupler 8. MCU (motor control unit)

YCC-S indicator and warning light

Dial gauge & stand set 33

Fork seal driver weight 46

Fork seal driver attachment 46

Oil seal installing tool 46

Pivot shaft wrench 49

Digital circuit tester 50, 60

Test coupler adapter 95

Pocket tester 129, 130, 132,

Foot shift switch

ENGINE TIGHTENING TORQUES

Gear position sensor bracket M5 2 9 Nm (0.9 m·kg, 6.5 ft·lb) LT

Shift actuator front bolt M8 1 20 Nm (2.0 m·kg, 14 ft·lb)

Shift rod bolt M8 1 10 Nm (1.0 m·kg, 7.2 ft·lb) LT

Shift rod front locknut M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)

Front shift arm bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)

CHASSIS TIGHTENING TORQUES

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, 7.2 ft·lb) LT

1. O2 sensor lead F. Route the positive battery lead between the

1. Rear wheel sensor lead

1. Clutch actuator motor lead

PERIODIC MAINTENANCE AND LUBRICATION CHART

ODOMETER READING (× 1000 km) ANNU-

1 * Fuel line • Check fuel hoses for cracks or damage. √ √ √ √ √

3 * Valves • Check valve clearance. Every 40000 km

• Check operation, fluid level and vehicle for fluid √ √ √ √ √ √

ODOMETER READING (× 1000 km) ANNU-

Shock absorber as-

Rear suspension re- • Check operation. √ √ √ √

21 Engine oil • Change. √ √ √ √ √ √

Throttle grip hous- • Check operation and free play.

28 * Muffler and exhaust • Check the screw clamp for looseness. √ √ √ √ √

• Clutch fluid level WARNING

g. If the pressure plate stroke is out of specifica-

b. Start the engine. • Left side cover