Yamaha Grizzly YF70GG, YF70GPG, YF70GPSG. Service manual (2016) - part 19

 

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Yamaha Grizzly YF70GG, YF70GPG, YF70GPSG. Service manual (2016) - part 19

 

 

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ELECTRIC STARTING SYSTEM
9-10

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CHARGING SYSTEM
EBS20076
CHARGING SYSTEM
EBS30269
CIRCUIT DIAGRAM
A
B
B
Br
Br Br
L
L
Br
Br
L
L
L
A
B
L
L
L
L
L
11
R/L
R/L
R/L
R/W
R/W
R/L
R/L
R/W
R/W
W
W
R/L
R/W
R/W
B
R
B/L Gy
Gy
B/L
(B)
B
Gy B
1
W
W
W W
W
2
W
W
3
R
W
W
(Gy)
B
R
R
R
5
Br Br/L R
(Gy)
R
R
Br/B
Br/B
R
R
Br/B R/W
R Br/L Br
Br/B
R/L
12
6
R/B
L/R
4
7
ON
R/Y
R/
OFF
B
8
B
L/Y
Br/L
B
B
Br
A
B
Br/B
R/W
9
10
L/Y
R/Y
(B)
59
R/Y
60
Y
Br/L
Br/Y
Br Br
61
Br/L
Br
42
62
B/
Br
65
B/Y
63
B
G W/B
P
P
Br
Br
Y/B
Br
B
Y/B
B B
G W/B
64
(B)
R/W
R
P B
B B
R/Y
Br R/B
L/Y
Lg
43
L
L/Y
R/Y
R/Y
Y
L
47
B B
B
Lg
L/Y
L/Y
Lg
B
46
45
44
OFF
67
Br R/B
R/B
Br
PUSH
66
B
(Gy)
(Gy)
Y
B
B
B
L
L/Y
B
B/W
B
R/W
Br
L
Y
Y
R/W
G
51
58
Br/Y
Br/Y
R/B
L
B
Br
Y/R
(B)
B
G
R/BY/R
L/Y
G
55
54
L
G
R/B
50
Y
L/Y
B
Y
Y/W
(B)
Y
B
Y Y
Y
B/Y
57
B/Y.
Y/W
Y
53
B
Y L
B
B
(B)
Y
G
Y
G
B
B
Y
L
49
49
L
52
B L
48
L
L Y
G Y
G Y
B
B
B
56
9-11

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CHARGING SYSTEM
2. AC magneto
3. Rectifier/regulator
5. Main fuse
6. Battery
9. Engine ground
66.Frame ground 1
67.Frame ground 2
A. Wire harness
B. Negative battery sub-wire harness
9-12

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CHARGING SYSTEM
EBS30270
TROUBLESHOOTING
The battery is not being charged.
TIP
• Before troubleshooting, remove the following part(s):
1. Seat
2. Battery cover
3. Top cover
4. Side panel (right)
5. V-belt cooling exhaust duct
1.
Check the fuse.
NG →
(Main)
Replace the fuse.
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 stator coil.
NG →
The stator coil is faulty. Replace the crank-
Refer to “CHECKING THE STATOR
shaft position sensor/stator assembly.
COIL” on page 9-93.
OK ↓
4.
Check the rectifier/regulator.
NG →
Refer to “CHECKING THE RECTI-
Replace the rectifier/regulator.
FIER/REGULATOR” on page 9-93.
OK ↓
5.
Check the entire charging system
NG →
wiring.
Properly connect or repair the charging
Refer to “CIRCUIT DIAGRAM” on
system wiring.
page 9-11.
OK ↓
The charging system circuit is OK.
9-13

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CHARGING SYSTEM
9-14

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A
Br Br Br
L
L
Br Br
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
L/W
G/R
32
50
G
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
Y
B Br/Y
L/Y
B
B/G P/W
W/B B/R B O/L Br/B
B/Y
37
2WD
33
(B)
38
68
Br
Br
B
Y
Y/W
Y
(Gy)
4WD
LOCK
OFF
Y
Y
B/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

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

LIGHTING SYSTEM
4. Main switch
5. Main fuse
6. Battery
9. Engine ground
11.Joint coupler
47.Light switch
48.Handle mounted light
49.Headlight
50.Headlight relay 2
51.Headlight relay 1
52.Tail/brake light
59.Headlight fuse
66.Frame ground 1
A. Wire harness
B. Negative battery sub-wire harness
9-16

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LIGHTING SYSTEM
EBS30272
TROUBLESHOOTING
Any of the following fail to light: Handle mounted light, headlight or taillight.
TIP
• Before troubleshooting, remove the following part(s):
1. Seat
2. Battery cover
3. Handle mounted light cover
1.
Check the condition of handle
NG →
mounted light bulb and bulb socket.
Refer to “CHECKING THE BULBS
Replace the bulb and bulb socket.
AND BULB SOCKETS” on page
9-83.
OK ↓
2.
Check the fuses.
NG →
(Main and headlight)
Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 9-84.
OK ↓
3.
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 ↓
4.
Check the main switch.
NG →
Refer to “CHECKING THE
Replace the main switch.
SWITCHES” on page 9-81.
OK ↓
5.
Check the light switch.
NG →
The light switch is faulty. Replace the han-
Refer to “CHECKING THE
dlebar switch (left).
SWITCHES” on page 9-81.
OK ↓
6.
Check the headlight relay 1.
NG →
Refer to “CHECKING THE RE-
Replace the headlight relay 1.
LAYS” on page 9-88.
OK ↓
7.
Check the headlight relay 2.
NG →
Refer to “CHECKING THE RE-
Replace the headlight relay 2.
LAYS” on page 9-88.
OK ↓
9-17

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

LIGHTING SYSTEM
8. Check the entire lighting system
NG →
wiring.
Properly connect or repair the lighting sys-
Refer to “CIRCUIT DIAGRAM” on
tem wiring.
page 9-15.
OK ↓
Replace the headlight unit or tail/brake
light unit.
9-18

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A
Br Br Br
L
L
Br
Br
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
L/W
G/R
32
50
G
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
Y
B Br/Y
L/Y
B
B/G P/W
W/B B/R B O/L Br/B
B/Y
37
2WD
33
(B)
38
68
Br
Br
B
Y
Y/W
Y
(Gy)
4WDLOCK
OFF
Y
Y
B/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

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SIGNALING SYSTEM
4. Main switch
5. Main fuse
6. Battery
9. Engine ground
11.Joint coupler
14.Reverse switch
16.ECU (Engine Control Unit)
21.Coolant temperature sensor
22.Speed sensor
27.Gear position switch
29.Multi-function meter
31.Coolant temperature warning light
32.Park indicator light
33.Reverse indicator light
34.Neutral indicator light
35.High-range indicator light
36.Low-range indicator light
38.Differential motor
39.Fuel sender
44.Override switch
52.Tail/brake light
53.Diode
54.Rear brake light switch
55.Front brake light switch
60.Signaling system fuse
61.Ignition fuse
66.Frame ground 1
68.Horn switch (except for CDN)
69.Horn (except for CDN)
A. Wire harness
B. Negative battery sub-wire harness
9-20

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

SIGNALING SYSTEM
EBS30274
TROUBLESHOOTING
• Any of the following fail to light: warning light, brake light or an indicator light.
• The fuel meter fails to come on.
• The speedometer fails to operate.
• The horn fails to sound. (except for CDN)
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
6. Rear fender
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 main switch.
NG →
Refer to “CHECKING THE
Replace the main switch.
SWITCHES” on page 9-81.
OK ↓
4. Check the entire signaling system
NG →
wiring.
Properly connect or repair the signaling
Refer to “CIRCUIT DIAGRAM” on
system wiring.
page 9-19.
OK ↓
Check the condition of each of the sig-
naling system circuits. Refer to
“Checking the signaling system”.
Checking the signaling system
The tail/brake light fails to come on.
1. Check the front brake light switch.
NG →
Refer to “CHECKING THE
Replace the front brake light switch.
SWITCHES” on page 9-81.
OK ↓
9-21

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

SIGNALING SYSTEM
2. Check the rear brake light switch.
NG →
Refer to “CHECKING THE
Replace the rear brake light switch.
SWITCHES” on page 9-81.
OK ↓
3. Check the diode.
NG →
Refer to “CHECKING THE DIODE”
Replace the diode.
on page 9-90.
OK ↓
4. Check the entire signaling system
NG →
wiring.
Properly connect or repair the signaling
Refer to “CIRCUIT DIAGRAM” on
system wiring.
page 9-19.
OK ↓
Replace the tail/brake light unit or
ECU.
The neutral, park, high-range, and/or low-range indicator light fails to come on.
1. Check the gear position switch.
NG →
Refer to “CHECKING THE
Replace the gear position switch.
SWITCHES” on page 9-81.
OK ↓
2. Check the entire signaling system
NG →
wiring.
Properly connect or repair the signaling
Refer to “CIRCUIT DIAGRAM” on
system wiring.
page 9-19.
OK ↓
Replace the meter assembly or ECU.
The reverse indicator light fails to come on.
1. Check the reverse switch.
NG →
Refer to “CHECKING THE
Replace the reverse switch.
SWITCHES” on page 9-81.
OK ↓
2. Check the entire signaling system
NG →
wiring.
Properly connect or repair the signaling
Refer to “CIRCUIT DIAGRAM” on
system wiring.
page 9-19.
OK ↓
Replace the meter assembly or ECU.
9-22

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

SIGNALING SYSTEM
The differential gear lock indicator light and /or four-wheel-drive indicator light fails to come on.
1. Check the four-wheel-drive motor
NG →
switch (differential motor).
Replace the differential motor.
Refer to “CHECKING THE
SWITCHES” on page 9-81.
OK ↓
2. Check the entire signaling system
NG →
wiring.
Properly connect or repair the signaling
Refer to “CIRCUIT DIAGRAM” on
system wiring.
page 9-19.
OK ↓
Replace the meter assembly or ECU.
While the override switch is pushed, the segments of the speedometer digits will not appear as shown
in the illustration.
1. Check the override switch.
NG →
The override switch is faulty. Replace the
Refer to “CHECKING THE
handlebar switch (left).
SWITCHES” on page 9-81.
OK ↓
2. Check the entire signaling system
NG →
wiring.
Properly connect or repair the signaling
Refer to “CIRCUIT DIAGRAM” on
system wiring.
page 9-19.
OK ↓
Replace the meter assembly or ECU.
The coolant temperature warning light fails to come on.
1. Check the coolant temperature sen-
NG →
sor.
Refer to “CHECKING THE COOL-
Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR”
on page 9-95.
OK ↓
9-23

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

SIGNALING SYSTEM
2. Check the entire signaling system
NG →
wiring.
Properly connect or repair the signaling
Refer to “CIRCUIT DIAGRAM” on
system wiring.
page 9-19.
OK ↓
Replace the meter assembly or ECU.
The fuel level indicator fails to come on.
1. Check the fuel sender.
NG →
Refer to “CHECKING THE FUEL
Replace the fuel pump assembly.
SENDER” on page 9-93.
OK ↓
2. Check the entire signaling system
NG →
wiring.
Properly connect or repair the signaling
Refer to “CIRCUIT DIAGRAM” on
system wiring.
page 9-19.
OK ↓
Replace the meter assembly.
The speedometer fails to operate.
1. Check the speed sensor.
NG →
Refer to “CHECKING THE SPEED
Replace the speed sensor.
SENSOR” on page 9-94.
OK ↓
2. Check the entire signaling system
NG →
wiring.
Properly connect or repair the signaling
Refer to “CIRCUIT DIAGRAM” on
system wiring.
page 9-19.
OK ↓
Replace the meter assembly or ECU.
The horn fails to sound (except for CDN).
1. Check the horn switch.
NG →
Refer to “CHECKING THE
Replace the horn switch.
SWITCHES” on page 9-81.
OK ↓
2. Check the entire signaling system
NG →
wiring.
Properly connect or replace the wire har-
Refer to “CIRCUIT DIAGRAM” on
ness.
page 9-19.
OK ↓
Replace the horn.
9-24

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

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
B
Y
Y
(Gy)
LOCK
OFF
Y
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

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

COOLING SYSTEM
4. Main switch
5. Main fuse
6. Battery
9. Engine ground
11.Joint coupler
16.ECU (Engine Control Unit)
21.Coolant temperature sensor
56.Radiator fan motor
57.Radiator fan motor circuit breaker
58.Radiator fan motor relay
61.Ignition fuse
64.Radiator fan motor fuse
66.Frame ground 1
A. Wire harness
B. Negative battery sub-wire harness
9-26

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

COOLING SYSTEM
EBS30276
TROUBLESHOOTING
The radiator fan 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. Front fenders
1.
Check the fuses.
NG →
(Main, ignition and radiator fan mo-
tor)
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 main switch.
NG →
Refer to “CHECKING THE
Replace the main switch.
SWITCHES” on page 9-81.
OK ↓
4.
Check the radiator fan motor.
NG →
The radiator fan motor is faulty and must
Refer to “CHECKING THE RADIA-
be replaced.
TOR FAN MOTOR” on page 9-94.
OK ↓
5.
Check the radiator fan motor relay.
NG →
Refer to “CHECKING THE RE-
Replace the radiator fan motor relay.
LAYS” on page 9-88.
OK ↓
6.
Check the radiator fan motor circuit
NG →
breaker.
Replace the radiator fan motor circuit
Refer to “CHECKING THE RADIA-
breaker.
TOR FAN MOTOR CIRCUIT
BREAKER” on page 9-95.
OK ↓
7.
Check the coolant temperature sen-
NG →
sor.
Refer to “CHECKING THE COOL-
Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR”
on page 9-95.
OK ↓
9-27

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

COOLING SYSTEM
8. Check the entire cooling system
NG →
wiring.
Properly connect or repair the cooling sys-
Refer to “CIRCUIT DIAGRAM” on
tem wiring.
page 9-25.
OK ↓
Replace the ECU.
9-28

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

A
Br Br Br
L
L
Br Br
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

 

 

 

 

 

 

 

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