Yamaha Grizzly YF70GG, YF70GPG, YF70GPSG. Service manual (2016) - part 18

 

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Yamaha Grizzly YF70GG, YF70GPG, YF70GPSG. Service manual (2016) - part 18

 

 

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REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
EBS30257
EBS30262
CHECKING THE REAR DRIVE SHAFT
ASSEMBLING THE FINAL DRIVE PINION
1. Check:
GEAR ASSEMBLY
• Drive shaft splines
1. Install:
• Coupling sleeve splines
• Rear drive shaft yoke nut “1”
Wear/damage → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a.
Place a folded rag as shown.
EBS30258
b.
Secure the final drive pinion gear in the vise.
CHECKING THE FINAL DRIVE ASSEMBLY
1. Check:
• Final drive case
1
• Final drive case cover
Cracks/damage → Replace.
TIP
When the final drive case and/or the final drive
case cover are replaced, be sure to adjust the
shim of the final drive pinion gear and/or final
driven pinion gear.
c.
Tighten the rear drive
shaft yoke nut.
2. Check:
(temporarily)
• Gear teeth
Pitting/galling/wear → Replace the final drive
Rear drive shaft yoke nut (tempo-
pinion gear and final driven pinion gear as a
rarily)
set.
82 Nm (8.2 m·kgf, 59 ft·lbf)
TIP
LOCTITE®
When the final drive pinion gear, final driven pin-
d.
Secure the final drive pinion gear bearing
ion gear and/or wheel gear are replaced, be sure
housing in a vice, and then turn the nut with a
to adjust the shim of the final drive pinion gear,
torque wrench to check the starting torque.
final driven pinion gear and/or wheel gear.
• Oil seals
Final drive pinion gear starting
• O-ring
torque (final drive pinion gear
Damage → Replace.
preload)
0.8-1.3 Nm (0.08-0.13 m·kgf,
3. Check:
0.58-0.94 ft·lbf)
• Bearings
Damage → Replace.
e.
Out of specification → Tighten the nut further.
EBS30410
f.
Repeat steps (d) and (e) until the starting
ASSEMBLING THE FINAL DRIVE CASE
torque is within specification.
1. Install:
TIP
• Oil seals “1”
• Be careful not to exceed the specified starting
torque.
Installed depth of oil seal “a”
5.5 mm (0.22 in)
• If the specified starting torque is exceeded, re-
place the expander with a new one and reas-
semble the final drive pinion gear assembly.
• Make sure that the distance “a” is 67.5-68.1
mm (2.66-2.68 in) as shown.
1
1
a
a
8-24

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REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
a
1
A
c
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
d
b
2. Check:
a
• Final drive assembly operation
Unsmooth operation → Replace the final
drive assembly.
Insert the double offset joint into the final
drive assembly, and turn the gears back and
forth.
EBS30413
SELECTING THE FINAL DRIVE PINION
GEAR SHIM(S)
Example:
1. Select:
“a” = 55
• Final drive pinion gear shim(s) “1”
If “-02” is stamped on the final drive pinion
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
gear,
a. To find the final drive pinion gear shim thick-
“b” = 22.2 - 0.02
ness “A”, use the following formula.
= 22.18
Final drive pinion gear shim thickness
“A” = “a” + (“c” - “b”) - “d”
b
“a” = 55 mm
“b” = a numeral (usually a decimal number)
on the final drive pinion gear either added to
or subtracted from “22.2”
“c” = a numeral (usually a decimal number)
on the final drive pinion gear bearing housing
either added to or subtracted from “67.8”
“d” = a numeral (usually a decimal number)
on the final drive case either added to or sub-
If “-05” is stamped on the final drive pinion
tracted from “100”
gear bearing housing,
“c” = 67.8 - 0.05
= 67.75
c
8-25

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REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
If “-01” is stamped on the final drive case,
“e” = a numeral (usually a decimal number)
“d” = 100 - 0.01
on the final drive case either added to or sub-
= 99.99
tracted from “71.6”
“f” = a numeral (usually a decimal number) on
the final driven pinion gear either added to or
subtracted from “51.0”
“g” = a numeral (usually a decimal number)
on the final driven pinion gear either added to
or subtracted from “24.0”
d
“h” = 49.8
e
f
g
Therefore, “A” is 0.58.
“A” = 55 + (67.75 - 22.18) - 99.99
= 0.58
Round off the hundredth digit and select the
appropriate shim(s).
In the example above, the calculated number
is 0.58. The chart instructs you to round off 8
to 10 at the hundredth place. Thus, the shim
thickness is 0.60 mm (0.024 in).
Hundredth
Rounded value
0, 1, 2
0
3, 4, 5, 6, 7
5
8, 9
10
1
Shims are supplied in the following thickness-
2
es.
Final drive pinion gear shims
Thickness (mm)
0.25 0.30 0.35 0.40 0.45 0.50
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30412
SELECTING THE FINAL DRIVEN PINION
GEAR SHIM (FINAL DRIVE CASE SIDE) AND
THRUST WASHER
1. Select:
h
B
• Final driven pinion gear shim (final drive case
side) “1”
Example:
• Thrust washer “2”
If “-03” is stamped on the final drive case,
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
“e” = 71.6 - 0.03
a. To find the final driven pinion gear shim (final
= 71.57
drive case side) and thrust washer thickness
“B”, use the following formula.
Final driven pinion gear shim (final drive case
side) and thrust washer thickness
“B” = “h” - (“e” - “f” + “g”)
8-26

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REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
Hundredth
Rounded value
3, 4, 5, 6, 7
5
8, 9
10
Shim and thrust washer are supplied in the
e
following thicknesses.
Final driven pinion gear shims (fi-
nal drive case side) “1”
Thickness (mm)
If “-12” is stamped on the outside of the final
0.25 0.30 0.35 0.40 0.45 0.50
driven pinion gear,
“f” = 51.0 - 0.12
Thrust washer “2”
= 50.88
Thickness (mm)
4.50 4.80 5.10 5.40
f
TIP
Be sure to use one of each of the final driven pin-
ion gear shim (final drive case side) “1” and
thrust washer “2” to obtain the shim and thrust
washer thickness.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30411
If “-05” is stamped on the outside of the final
SELECTING THE FINAL DRIVEN PINION
driven pinion gear,
GEAR SHIM (FINAL DRIVE CASE COVER
“g” = 24.0 - 0.05
SIDE)
= 23.95
1. Measure:
• Final driven pinion gear thrust clearance “C”
g
C
“h” = 49.8
Therefore, shim and thrust washer thickness
“B” is 5.16.
“B” = 49.8 - (71.57 - 50.88 + 23.95)
= 5.16
Round off the hundredth digit and select the
appropriate shim(s).
In the example above, the calculated number
is 5.16. The chart instructs you to round off 6
to 5 at the hundredth place.
Thus, the shim and thrust washer thickness is
5.15 mm.
Hundredth
Rounded value
0, 1, 2
0
8-27

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REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
TIP
a. Place four pieces of Plastigauge® between
Measure the thickness of the originally fitted
the originally fitted shim(s) and the final driv-
shim(s), and then calculate the required new
en pinion gear assembly.
shim thickness to bring the
final driven pinion
b. Install the final driven pinion gear assembly,
gear thrust clearance within the specified limits.
final driven pinion gear shim (final drive case
side) and thrust washer, and tighten the bolts
b. Repeat the measurement steps until the final
to specification.
driven pinion gear thrust
clearance is within
the specified limits.
Final drive case cover bolt
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
23 Nm (2.3 m·kgf, 17 ft·lbf)
EBS30414
SELECTING THE WHEEL GEAR SHIM(S)
TIP
1. Measure:
Do not turn the final drive pinion gear, wheel
• Wheel gear thrust clearance “D”
gear, and driven pinion gear when measuring
the clearance with Plastigauge®.
c. Remove the final driven pinion gear assem-
bly.
d. Measure the thrust clearance. Calculate the
width of the flattened Plastigauge® “1”.
Final driven pinion gear thrust
clearance
0.08-0.12 mm (0.0031-0.0047 in)
1
D
e. If out of specification, remove the originally fit-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
ted shim(s), and then select the correct
a. Place four pieces of Plastigauge® between
shim(s).
the originally fitted wheel gear shim(s) and
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
the wheel gear.
b. Install the wheel gear and tighten the bolts to
2. Select:
specification.
• Final driven pinion gear shim (final drive case
cover side)
Final drive case cover bolt
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
23 Nm (2.3 m·kgf, 17 ft·lbf)
a. Select suitable final driven pinion gear shims
(final drive case cover side) using the follow-
TIP
ing chart.
Do not turn the drive pinion gear, wheel gear, or
Final driven pinion gear shims (fi-
driven pinion gear when measuring the clear-
nal drive case cover side)
ance with Plastigauge®.
Thickness (mm)
c. Remove the wheel gear.
0.25 0.30 0.35 0.40 0.45 0.50
d. Measure the thrust clearance. Calculate the
width of the flattened Plastigauge® “1”.
8-28

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REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
ECB01250
Wheel gear thrust clearance
NOTICE
0.03-0.07 mm (0.0012-0.0028 in)
Finger tighten the bolt until it holds the ring
gear. Otherwise, the ring gear will be dam-
1
aged.
4. Attach:
• Final gear backlash band “2”
• Dial gauge “3”
Final gear backlash band
90890-01511
Middle drive gear lash tool
YM-01230
e. If out of specification, remove the originally fit-
ted shim(s), and then select the correct
1
shim(s).
3
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Select:
• W heel gear shim(s)
2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Select suitable wheel gear shims using the
following chart.
a
b
Wheel gear shims
a. Measuring point is 31.5 mm (1.24 in)
Thickness (mm)
b. Measuring point is 32.1 mm (1.26 in)
0.25 0.30 0.35 0.40 0.45 0.50
5. Measure:
TIP
• Gear backlash
Measure the thickness of the originally fitted
Gently rotate the final drive pinion gear from
shim(s), and then calculate the required new
engagement to engagement.
shim thickness to bring the wheel gear thrust
Final gear backlash
clearance within the specified limits.
0.10-0.20 mm (0.004-0.008 in)
b. Repeat the measurement steps until the
wheel gear thrust clearance is within the
TIP
specified limits.
• When measuring the gear backlash, be sure
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
the right side (gear oil level check bolt side) of
EBS30260
the final drive case assembly is facing down-
MEASURING THE FINAL GEAR BACKLASH
ward.
1. Secure the final drive case in a vise or anoth-
• Measure the gear backlash at four positions.
er supporting device.
Rotate the final drive pinion gear 90° each
2. Remove:
time.
• Drain plug
• Gasket
EBS30261
3. Install:
ADJUSTING THE FINAL GEAR BACKLASH
• Ring gear fix bolt (M14) “1”
1. Remove:
(into the drain plug hole)
• Final driven pinion gear assembly “1”
• Final driven pinion gear shim (final drive case
Ring gear fix bolt (M14)
side) “2”
90890-01524
• Thrust washer “3”
Ring gear fix bolt (M14)
• Final driven pinion gear shim (final drive case
YM-01524
cover side) “4”
8-29

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REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
Final driven pinion gear shims (fi-
nal drive case cover side) “4”
1
Thickness (mm)
0.25 0.30 0.35 0.40 0.45 0.50
2
4
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3
2. Adjust:
• Gear backlash
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Select a suitable shim(s) and thrust wash-
er(s) using the following chart.
Final gear backlash is in-
Thinner shim
creased.
Final gear backlash is de-
Thicker shim
creased.
b. If increased by more than 0.2 mm (0.008 in):
Reduce the final driven pinion gear shim (final
drive case cover side) “4” thickness by 0.2
mm (0.008 in) for every 0.2 mm (0.008 in) that
the final driven pinion gear shim (final drive
case side) “2” and thrust washer “3” are in-
creased.
c. If reduced by more than 0.2 mm (0.008 in):
Increase the final driven pinion gear shim (fi-
nal drive case cover side) “4” thickness by 0.2
mm (0.008 in) for every 0.2 mm (0.008 in) that
the final driven pinion gear shim (final drive
case side) “2” and thrust washer “3” are de-
creased.
Final driven pinion gear shims (fi-
nal drive case side) “2”
Thickness (mm)
0.25 0.30 0.35 0.40 0.45 0.50
Thrust washers “3”
Thickness (mm)
4.50 4.80 5.10 5.40
TIP
Be sure to use one of each of the final driven pin-
ion gear shim (final drive case side) “2” and
thrust washer “3” to obtain the shim and thrust
washer thickness.
8-30

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REAR CONSTANT VELOCITY SHAFT ASSEMBLIES, FINAL
DRIVE ASSEMBLY AND REAR DRIVE SHAFT
8-31

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ELECTRICAL SYSTEM
IGNITION SYSTEM
9-1
CIRCUIT DIAGRAM
9-1
TROUBLESHOOTING
9-3
ELECTRIC STARTING SYSTEM
9-5
CIRCUIT DIAGRAM
9-5
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION
9-7
TROUBLESHOOTING
9-8
CHARGING SYSTEM
9-11
CIRCUIT DIAGRAM
9-11
TROUBLESHOOTING
9-13
LIGHTING SYSTEM
9-15
CIRCUIT DIAGRAM
9-15
TROUBLESHOOTING
9-17
SIGNALING SYSTEM
9-19
CIRCUIT DIAGRAM
9-19
TROUBLESHOOTING
9-21
COOLING SYSTEM
9-25
CIRCUIT DIAGRAM
9-25
TROUBLESHOOTING
9-27
FUEL INJECTION SYSTEM
9-29
CIRCUIT DIAGRAM
9-29
ECU SELF-DIAGNOSTIC FUNCTION
9-31
TROUBLESHOOTING METHOD
9-32
YAMAHA DIAGNOSTIC TOOL
9-32
TROUBLESHOOTING DETAILS (FUEL INJECTION SYSTEM)
9-35
FUEL PUMP SYSTEM
9-59
CIRCUIT DIAGRAM
9-59
TROUBLESHOOTING
9-61
2WD/4WD SELECTING SYSTEM
9-63
CIRCUIT DIAGRAM
9-63
9
TROUBLESHOOTING
9-65

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EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models)
9-67
CIRCUIT DIAGRAM
9-67
EPS CONTROL UNIT’S SELF-DIAGNOSTIC FUNCTION
9-69
EPS WARNING LIGHT DURING NORMAL OPERATION
9-69
DIAGNOSTIC MODE
9-70
SELF-DIAGNOSTIC FUNCTION TABLE (EPS SYSTEM)
9-72
TROUBLESHOOTING DETAILS (EPS SYSTEM)
9-73
ELECTRICAL COMPONENTS
9-77
CHECKING THE SWITCHES
9-81
CHECKING THE BULBS AND BULB SOCKETS
9-83
CHECKING THE FUSES
9-84
CHECKING AND CHARGING THE BATTERY
9-85
CHECKING THE RELAYS
9-88
CHECKING THE DIODE
9-90
CHECKING THE SPARK PLUG CAP
9-90
CHECKING THE IGNITION COIL
9-91
CHECKING THE CRANKSHAFT POSITION SENSOR
9-91
CHECKING THE LEAN ANGLE SENSOR
9-92
CHECKING THE STARTER MOTOR OPERATION
9-92
CHECKING THE STATOR COIL
9-93
CHECKING THE RECTIFIER/REGULATOR
9-93
CHECKING THE FUEL SENDER
9-93
CHECKING THE SPEED SENSOR
9-94
CHECKING THE RADIATOR FAN MOTOR
9-94
CHECKING THE RADIATOR FAN MOTOR CIRCUIT BREAKER
9-95
CHECKING THE COOLANT TEMPERATURE SENSOR
9-95
CHECKING THE THROTTLE POSITION SENSOR
9-96
CHECKING THE FUEL INJECTOR
9-96
CHECKING THE AIR INDUCTION SYSTEM SOLENOID
9-96
CHECKING THE INTAKE AIR PRESSURE SENSOR
9-97
CHECKING THE INTAKE AIR TEMPERATURE SENSOR
9-97
CHECKING THE EPS MOTOR (for EPS models)
9-98
CHECKING THE EPS TORQUE SENSOR (for EPS models)
9-98

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A
Br
Br
Br Br Br L L
L
L
L
B
B
11
L L
L L L
Br
Br Br Br Br
R/L
R/L R/L R/W R/W R/W R/W
W W
A
B
R/L R/L R/W R/W
WW
R/L
R/W
R/W
R/Y Br/Y L/B R/G G/RW/GY
B
B
R
Y/R
B
P/L
Br/L
O
B/L Gy
Gy
B/L
(B)
R/B
17
(B)
B
Br/W W Gy P Y/G P/WSb O/L Y/W B/GGy/GW/BL/R B/WG/R Br
O
Gy B
Lg
G/Y R/L G/WB/Y L/Y
Y/L Y
W/R B/R
L B/L L/W R/W
18
1
(B)
W
W
Gy
O
W W
W
2
W
W
3
R
R/L
R/B
W
W
G/W
(Gy)
R/W
19
(Gy)
G/W
R/B
R/B
R/L
B
W/G R/W
R/G
Br/W B/L
R
R/W
Br/L R/W P/L
20
(B)
R
14
R/W
(B)
Br/W
Br/W
B/L
5
R
R/G
P/L
R/G
G/Y
B/L
Br Br/L R
15
P/L
21
(B)
(Gy)
R
R
Br/B
R/B
W/G
W/GBr/L
G/Y
G/Y
B/L
R
R
Br/B
Br/L
L
L/Y
W L/Y
L W
R Br/L Br
Br/B R/W
Br/B
B
R
Br
W
W
W
22
B/L
B/L
R/L
12
R
Y/W
L/Y
L
B/L
B/L
6
R/B
L/R
R/Y
16
4
7
G/RY/B
ON
R/Y
R/L
L/R
W/B
OFF
B
R/L
13
B/R
B/L
8
Y/W
Y/W
Y
Y
23
B/L
Y
L
B
L/Y
L
Br/L
B
B
B
B/Y
(B)
Br
A
B
Br/B R/W
L/R
L
9
10
R/L
24
B/L
P
L
L/Y R/Y
P
L/W
P
(B)
G/R
W/R
B/L
59
LgY/R
Gy/GL/B
Br/YR/W
(B)
R/Y
Sb
26
Y
Y/L
Br/Y
R/W
(B)
60
P/W
Br/Y
Br/L
Br/Y
Br Br
Br Br
O/L
B/L
B/L
61
B/G
Y/G
Y/G
25
L Y/G B/L
R/L
G/Y
Sb
Gy/G
L
Br/L
Br
42
41
L/B
W/R
(Gy)
62
B/Y
Br/B
L PGyW
Br
Br/B
R/L B B/W
G/Y
39
27
65
63
B/Y
Br
40
B/W
B
B
G W/B
P
P
Br
Br
Y/B
G/R
Br
B
G/R
(Gy)
L
P
L/B
Sb
Br
B
Y/B
B B
B B
Gy
W
W/R Gy/G
G W/B
64
(B)
(B)
B B/W
R/W
R
P B
B B
R/Y
Br R/B
L/Y
Lg
43
L
Br/Y Br/Y Br/Y Br/Y B/W B/W B/W B/W B/W
L L/Y
R/Y
R/Y Y
L
47
B B B B B B
R/W R/B R/B R/B
B B
B Lg L/Y
L/Y
Lg
B
46
45
44
29
28
67
Br R/B
R/B
Br
OFFPUSH
66
G/Y
Y/L
B/W
11
B
(Gy)
(Gy)
Y
Br
B/W
R/W
B
L/Y
Br/B
B/W
B/W
R/B
B/L
B
B
B/W
B
L
B
B/W
R/B
B/L
11
L
Y
B/W
R/B
B/L
B/L
R/W
Br
G/Y
Br/B
Br/YBr/Y
B
B/L
Y
Y/L
Br
B/W
Br/Y
B
B/L
R/W
G
51
30
B
B/L
R/B
58
Br/Y
Br/Y
L
B
(B)
Br/Y
B
B/L
Br
Y/R
B
BB
(B)
B
G
O/L
B/Y W/B
31
L
B
B
L/Y
G
P/W B/G
Br/B
B/R
B
R/BY/R
55
54
L
G
L/W
G/R
32
Br/Y
B
B B B B B/L B/L B/L B/L B/L B/L B/L B/L
R/B
50
Y
B Br/Y
L/Y
B
B/G P/W
W/B B/R B O/L Br/B
B/Y
38
37
2WD
33
Y
Y/W
(B)
4WD
68
Br
Br
B
Y
B
Y
Y
(Gy)
LOCK
OFF
Y
B/Y
L/W G/R
34
ON
57
B/Y.
B
B
B
B
Y/W
Y
53
B
P
B
B
(B)
Y
G
Y
G
Y L
35
(B)
P
B
B
Y
L
G/R L/W
B/W
49
49
B/W
B
B
B
L
52
36
(B)
B L
L
48
L Y
G Y
G Y
B
B
B
69
L
B
56
B
Y L
Y G
B
Y G
B
B
B
B
B
B

-------------------------------------------------------------------------------------------------------------------------------------------------------------

IGNITION SYSTEM
1. Crankshaft position sensor
4. Main switch
5. Main fuse
6. Battery
9. Engine ground
11.Joint coupler
16.ECU (Engine Control Unit)
17.Ignition coil
18.Spark plug
25.Lean angle sensor
46.Engine stop switch
61.Ignition fuse
66.Frame ground 1
A. Wire harness
B. Negative battery sub-wire harness
9-2

-------------------------------------------------------------------------------------------------------------------------------------------------------------

IGNITION SYSTEM
EBS30265
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP
• Before troubleshooting, remove the following part(s):
1. Seat
2. Battery cover
3. Top cover
4. Side panels (left and right)
5. Storage compartment
6. V-belt cooling exhaust duct
1.
Check the fuses.
NG →
(Main and ignition)
Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 9-84.
OK ↓
2.
Check the battery.
NG →
Refer to “CHECKING AND
• Clean the battery terminals.
CHARGING THE BATTERY” on
• Recharge or replace the battery.
page 9-85.
OK ↓
3.
Check the spark plug.
NG →
Refer to “CHECKING THE SPARK
Re-gap, clean, or replace the spark plug.
PLUG” on page 3-4.
OK ↓
4.
Check the spark plug cap.
NG →
Refer to “CHECKING THE SPARK
Replace the spark plug cap.
PLUG CAP” on page 9-90.
OK ↓
5.
Check the ignition coil.
NG →
Refer to “CHECKING THE IGNI-
Replace the ignition coil.
TION COIL” on page 9-91.
OK ↓
6.
Check the crankshaft position sen-
NG →
sor.
The crankshaft position sensor is faulty.
Refer to “CHECKING THE CRANK-
Replace the crankshaft position sen-
SHAFT POSITION SENSOR” on
sor/stator assembly.
page 9-91.
OK ↓
7.
Check the main switch.
NG →
Refer to “CHECKING THE
Replace the main switch.
SWITCHES” on page 9-81.
OK ↓
9-3

-------------------------------------------------------------------------------------------------------------------------------------------------------------

IGNITION SYSTEM
8. Check the engine stop switch.
NG →
The engine stop switch is faulty. Replace
Refer to “CHECKING THE
the handlebar switch (left).
SWITCHES” on page 9-81.
OK ↓
9. Check the lean angle sensor.
NG →
Refer to “CHECKING THE LEAN
Replace the lean angle sensor.
ANGLE SENSOR” on page 9-92.
OK ↓
10.Check the entire ignition system
NG →
wiring.
Properly connect or repair the ignition sys-
Refer to “CIRCUIT DIAGRAM” on
tem wiring.
page 9-1.
OK ↓
Replace the ECU.
9-4

-------------------------------------------------------------------------------------------------------------------------------------------------------------

A
Br
Br
Br Br Br L L
L
L
L
B
B
11
L L
L L L
Br
Br Br Br Br
R/L
R/L R/L R/W R/W R/W R/W
W W
A
B
R/L R/L R/W R/W
WW
R/L
R/W
R/W
R/Y Br/Y L/B R/G G/RW/GY
B
B
R
Y/R
B
P/L
Br/L
O
B/L Gy
Gy
B/L
(B)
R/B
17
(B)
B
Br/W W Gy P Y/G P/WSb O/L Y/W B/GGy/GW/BL/R B/WG/R Br
O
Gy B
Lg
G/Y R/L G/WB/Y L/Y
Y/L Y
W/R B/R
L B/L L/W R/W
18
1
(B)
W
W
Gy
O
W W
W
2
W
W
3
R
R/L
R/B
W
W
G/W
(Gy)
R/W
19
(Gy)
G/W
R/B
R/B
R/L
B
W/G R/W
R/G
Br/W B/L
R
R/W
Br/L R/W P/L
20
(B)
R
14
R/W
(B)
Br/W
Br/W
B/L
5
R
R/G
P/L
R/G
G/Y
B/L
Br Br/L R
15
P/L
21
(B)
(Gy)
R
R
Br/B
R/B
W/G
W/GBr/L
G/Y
G/Y
B/L
R
R
Br/B
Br/L
L
L/Y
W L/Y
L W
R Br/L Br
Br/B R/W
Br/B
B
R
Br
W
W
W
22
B/L
B/L
R/L
12
R
Y/W
L/Y
L
B/L
B/L
6
R/B
L/R
R/Y
16
4
7
G/RY/B
ON
R/Y
R/L
L/R
W/B
OFF
B
R/L
13
B/R
B/L
8
Y/W
Y/W
Y
Y
23
B/L
Y
L
B
L/Y
L
Br/L
B
B
B
B/Y
(B)
Br
A
B
Br/B R/W
L/R
L
9
10
R/L
24
B/L
P
L
L/Y R/Y
P
L/W
P
(B)
G/R
W/R
B/L
59
LgY/R
Gy/GL/B
Br/YR/W
(B)
R/Y
Sb
26
Y
Y/L
Br/Y
R/W
(B)
60
P/W
Br/Y
Br/L
Br/Y
Br Br
Br Br
O/L
B/L
B/L
61
B/G
Y/G
Y/G
25
L Y/G
B/L
R/L
G/Y
Sb
Gy/G
L
Br/L
Br
42
41
L/B
W/R
(Gy)
62
B/Y
Br/B
L PGyW
Br
Br/B
R/L B B/W
G/Y
39
27
65
63
B/Y
Br
40
B/W
B
B
G W/B
P
P
Br
Br
Y/B
G/R
Br
B
G/R
(Gy)
L
P
L/B
Sb
Br
B
Y/B
B B
B B
Gy
W
W/R Gy/G
G W/B
64
(B)
(B)
B B/W
R/W
R
P B
B B
R/Y
Br R/B
L/Y
Lg
43
L
Br/Y Br/Y Br/Y Br/Y B/W B/W B/W B/W B/W
L L/Y
R/Y
R/Y Y
L
47
B B B B B B
R/W R/B R/B R/B
B B
B Lg L/Y
L/Y
Lg
B
46
45
44
29
28
67
Br R/B
R/B
Br
OFFPUSH
66
G/Y
Y/L
B/W
11
B
(Gy)
(Gy)
Y
Br
B/W
R/W
B
L/Y
Br/B
B/W
B/W
R/B
B/L
B
B
B/W
B
L
B
B/W
R/B
B/L
11
L
Y
B/W
R/B
B/L
B/L
R/W
Br
G/Y
Br/B
Br/YBr/Y
B
B/L
Y
Y/L
Br
B/W
Br/Y
B
B/L
R/W
G
51
30
B
B/L
R/B
58
Br/Y
Br/Y
L
B
(B)
Br/Y
B
B/L
Br
Y/R
B
BB
(B)
B
G
O/L
B/Y W/B
31
L
B
B
L/Y
G
P/W B/G
Br/B
B/R
B
R/BY/R
55
54
L
G
L/W
G/R
32
Br/Y
B
B B B B B/L B/L B/L B/L B/L B/L B/L B/L
R/B
50
Y
B Br/Y
L/Y
B
B/G P/W
W/B B/R B O/L Br/B
B/Y
38
37
2WD
33
Y
Y/W
(B)
4WD
68
Br
Br
B
Y
B
Y
Y
(Gy)
LOCK
OFF
Y
B/Y
L/W G/R
34
ON
57
B/Y.
B
B
B
B
Y/W
Y
53
B
P
B
B
(B)
Y
G
Y
G
Y L
35
(B)
P
B
B
Y
L
G/R L/W
B/W
49
49
B/W
B
B
B
L
52
36
(B)
B L
L
48
L Y
G Y
G Y
B
B
B
69
L
B
56
B
Y L
Y G
B
Y G
B
B
B
B
B
B

-------------------------------------------------------------------------------------------------------------------------------------------------------------

ELECTRIC STARTING SYSTEM
4. Main switch
5. Main fuse
6. Battery
8. Starter relay
9. Engine ground
10.Starter motor
11.Joint coupler
16.ECU (Engine Control Unit)
27.Gear position switch
45.Start switch
46.Engine stop switch
54.Rear brake light switch
60.Signaling system fuse
61.Ignition fuse
66.Frame ground 1
A. Wire harness
B. Negative battery sub-wire harness
9-6

-------------------------------------------------------------------------------------------------------------------------------------------------------------

ELECTRIC STARTING SYSTEM
EBS30267
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION
If the engine stop switch is set to “
” and the main switch is set to “
” (on) (both switch circuits are
closed), the starter motor can only operate if at least one of the following conditions is met:
• The transmission is in neutral (the neutral switch circuit of the gear position switch is closed).
• The transmission is in park (the park switch circuit of the gear position switch is closed).
• The rear brake lever is pulled to the handlebar or the brake pedal is pushed down (the rear brake light
switch circuit is closed).
13
12
1
2
3
7
4
8
5
6
10
9
11
1. Battery
2. Main fuse
3. Main switch
4. Ignition fuse
5. Engine stop switch
6. Start switch
7. Signaling system fuse
8. Rear brake light switch
9. ECU (Engine Control Unit)
10.Park switch (gear position switch)
11.Neutral switch (gear position switch)
12.Starter relay
13.Starter motor
9-7

-------------------------------------------------------------------------------------------------------------------------------------------------------------

ELECTRIC STARTING SYSTEM
EBS30268
TROUBLESHOOTING
The starter motor fails to turn.
TIP
• Before troubleshooting, remove the following part(s):
1. Seat
2. Battery cover
3. Top cover
4. Side panels (left and right)
5. V-belt cooling exhaust duct
1.
Check the fuses.
NG →
(Main, ignition and signaling sys-
tem)
Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 9-84.
OK ↓
2.
Check the battery.
NG →
Refer to “CHECKING AND
• Clean the battery terminals.
CHARGING THE BATTERY” on
• Recharge or replace the battery.
page 9-85.
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” on page
with step 5.
9-92.
NG ↓
4.
Check the starter motor.
NG →
Refer to “CHECKING THE START-
Repair or replace the starter motor.
ER MOTOR” on page 5-42.
OK ↓
5.
Check the starter relay.
NG →
Refer to “CHECKING THE RE-
Replace the starter relay.
LAYS” on page 9-88.
OK ↓
6.
Check the main switch.
NG →
Refer to “CHECKING THE
Replace the main switch.
SWITCHES” on page 9-81.
OK ↓
7.
Check the engine stop switch.
NG →
The engine stop switch is faulty. Replace
Refer to “CHECKING THE
the handlebar switch (left).
SWITCHES” on page 9-81.
OK ↓
9-8

-------------------------------------------------------------------------------------------------------------------------------------------------------------

ELECTRIC STARTING SYSTEM
8. Check the start switch.
NG →
The start switch is faulty. Replace the han-
Refer to “CHECKING THE
dlebar switch (left).
SWITCHES” on page 9-81.
OK ↓
9. Check the rear brake light switch.
NG →
Refer to “CHECKING THE
Replace the rear brake light switch.
SWITCHES” on page 9-81.
OK ↓
10.Check the gear position switch.
NG →
Refer to “CHECKING THE
Replace the gear position switch.
SWITCHES” on page 9-81.
OK ↓
11.Check the entire starting system
NG →
wiring.
Properly connect or repair the starting sys-
Refer to “CIRCUIT DIAGRAM” on
tem wiring.
page 9-5.
OK ↓
Replace the ECU.
9-9

 

 

 

 

 

 

 

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