Yamaha Grizzly YF70GG, YF70GPG, YF70GPSG. Service manual (2016) - part 21

 

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Yamaha Grizzly YF70GG, YF70GPG, YF70GPSG. Service manual (2016) - part 21

 

 

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FUEL INJECTION SYSTEM
Fault code No.
41
Item
Lean angle sensor: open or short circuit detected.
1
Connection of lean angle sen-
Improperly connected → Con-
Turn the main switch to “
”
sor coupler.
nect the coupler securely or re-
(on), then to “
” (off), and then
Check the locking condition of
place the wire harness.
back to “
” (on).
the coupler.
Fault code number is not dis-
Disconnect the coupler and
played → Service is finished.
check the pins (bent or broken
Fault code number is displayed
terminals and locking condition
→ Go to item 2.
of the pins).
2
Connection of ECU coupler.
Improperly connected → Con-
Turn the main switch to “
”
Check the locking condition of
nect the coupler securely or re-
(on), then to “
” (off), and then
the coupler.
place the wire harness.
back to “
” (on).
Disconnect the coupler and
Fault code number is not dis-
check the pins (bent or broken
played → Service is finished.
terminals and locking condition
Fault code number is displayed
of the pins).
→ Go to item 3.
3
Wire harness continuity.
Open or short circuit → Replace
Turn the main switch to “
”
the wire harness.
(on), then to “
” (off), and then
Between lean angle sensor
back to “
” (on).
coupler and ECU coupler.
Fault code number is not dis-
yellow/green-yellow/green
played → Service is finished.
Between lean angle sensor
Fault code number is displayed
coupler and joint coupler.
→ Go to item 4.
blue-blue
black/blue-black/blue
Between joint coupler and ECU
coupler.
blue-blue
black/blue-black/blue
4
Defective lean angle sensor.
Execute the diagnostic mode.
Turn the main switch to “
”
(Code No. 08)
(on), then to “
” (off), and then
An indicated value is out of the
back to “
” (on).
specified range → Check the
Fault code number is not dis-
lean angle sensor.
played → Service is finished.
Replace if defective.
Fault code number is displayed
Refer to “CHECKING THE
→ Go to item 5.
LEAN ANGLE SENSOR” on
page 9-92.
5
Malfunction in ECU.
Replace the ECU.
Fault code No. 42
TIP
If fault code numbers “37” and “42” are both indicated, take the actions specified for fault code number
“42” first.
Fault code No.
42
Speed sensor: no normal signals are received from the speed sen-
Item
sor.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No.
07
Vehicle speed pulse
Indicated
0-999
9-50

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

FUEL INJECTION SYSTEM
Fault code No.
42
Speed sensor: no normal signals are received from the speed sen-
Item
sor.
Check that the number increases when the rear wheels are rotated. The
Procedure
number is cumulative and does not reset each time the wheel is stopped.
Probable cause of malfunc-
Confirmation of service com-
Item
Maintenance job
tion and check
pletion
1
Connection of speed sensor
Improperly connected → Con-
Turn the main switch to “
”
coupler.
nect the coupler securely or re-
(on), and then rotate the rear
Check the locking condition of
place the wire harness.
wheel by hand.
the coupler.
Fault code number is not dis-
Disconnect the coupler and
played → Go to item 6.
check the pins (bent or broken
Fault code number is displayed
terminals and locking condition
→ Go to item 2.
of the pins).
2
Connection of ECU coupler.
Improperly connected → Con-
Turn the main switch to “
”
Check the locking condition of
nect the coupler securely or re-
(on), and then rotate the rear
the coupler.
place the wire harness.
wheel by hand.
Disconnect the coupler and
Fault code number is not dis-
check the pins (bent or broken
played → Go to item 6.
terminals and locking condition
Fault code number is displayed
of the pins).
→ Go to item 3.
3
Wire harness continuity.
Open or short circuit → Replace
Turn the main switch to “
”
the wire harness.
(on), and then rotate the rear
Between speed sensor coupler
wheel by hand.
and joint coupler.
Fault code number is not dis-
white-white
played → Go to item 6.
Between joint coupler and ECU
Fault code number is displayed
coupler.
→ Go to item 4.
white-white
Between speed sensor coupler
and joint coupler.
blue-blue
black/blue-black/blue
Between joint coupler and ECU
coupler.
blue-blue
black/blue-black/blue
4
Defective speed sensor.
Execute the diagnostic mode.
Turn the main switch to “
”
(Code No. 07)
(on), and then rotate the rear
While the rear wheels and
wheel by hand.
stopped, check that the indicat-
Fault code number is not dis-
ed value does not change.
played → Go to item 6.
Rotate the rear wheel by hand
Fault code number is displayed
and check that the indicated
→ Go to item 5.
value increases.
Malfunction → Replace the
speed sensor.
5
Malfunction in ECU.
Replace the ECU.
6
Delete the fault code.
Start the engine, and input the
vehicle speed signals by operat-
ing the vehicle at 20 to 30 km/h
(12 to 19 mph).
Check that the fault code num-
ber is not displayed.
9-51

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

FUEL INJECTION SYSTEM
Fault code No. 43
Fault code No.
43
Fuel system voltage: incorrect voltage supplied to the fuel injector
Item
and fuel pump.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No.
09, 50
Fuel system voltage (battery voltage)
Indicated
Approximately 12.0
09
Turn the main switch to “
” (on), and then compare the actually mea-
Procedure
sured battery voltage with the display value. (If the actually measured
battery voltage is low, recharge the battery.)
Actuates the fuel injection system relay five times at one-second inter-
vals.
The “CHECK” indicator and “
” on the Yamaha diagnostic tool screen
Actuation
come on each time the relay is actuated.
(When the relay is on, the “CHECK” indicator and “
” on the Yamaha di-
50
agnostic tool screen go off. When the relay is off, the “CHECK” indicator
and “
” on the Yamaha diagnostic tool screen come on.)
Check that the fuel injection system relay is actuated five times by listen-
Procedure
ing for the operating sound.
Probable cause of malfunc-
Confirmation of service com-
Item
Maintenance job
tion and check
pletion
1
Connection of fuel injection sys-
Improperly connected → Con-
Start the engine and let it idle
tem relay coupler.
nect the coupler securely or re-
for approximately 5 seconds.
Check the locking condition of
place the wire harness.
Fault code number is not dis-
the coupler.
played → Service is finished.
Disconnect the coupler and
Fault code number is displayed
check the pins (bent or broken
→ Go to item 2.
terminals and locking condition
of the pins).
2
Connection of ECU coupler.
Improperly connected → Con-
Start the engine and let it idle
Check the locking condition of
nect the coupler securely or re-
for approximately 5 seconds.
the coupler.
place the wire harness.
Fault code number is not dis-
Disconnect the coupler and
played → Service is finished.
check the pins (bent or broken
Fault code number is displayed
terminals and locking condition
→ Go to item 3.
of the pins).
9-52

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

FUEL INJECTION SYSTEM
Fault code No.
43
Fuel system voltage: incorrect voltage supplied to the fuel injector
Item
and fuel pump.
3
Wire harness continuity.
Open or short circuit → Replace
Start the engine and let it idle
the wire harness.
for approximately 5 seconds.
Between fuel injection system
Fault code number is not dis-
relay coupler and ECU coupler.
played → Service is finished.
blue/red-blue/red
Fault code number is displayed
Between fuel injection system
→ Go to item 4.
relay coupler and joint coupler.
red/blue-red/blue
Between joint coupler and ECU
coupler.
red/blue-red/blue
Between fuel injection system
relay coupler and starter relay
coupler.
brown/black-brown/black
Between fuel injection system
relay coupler and joint coupler.
red/black-red/black
Between joint coupler and han-
dlebar switch (left).
red/black-red/black
4
Defective fuel injection system
Execute the diagnostic mode.
Start the engine and let it idle
relay.
(Code No. 50)
for approximately 5 seconds.
No operating sound → Replace
Fault code number is not dis-
the fuel injection system relay.
played → Service is finished.
Fault code number is displayed
→ Go to item 5.
5
Defective fuel injection system
Execute the diagnostic mode.
Start the engine and let it idle
relay.
(Code No. 09)
for approximately 5 seconds.
Fuel system voltage is below
Fault code number is not dis-
3 V → Replace the fuel injection
played → Service is finished.
system relay.
Fault code number is displayed
→ Go to item 6.
6
Malfunction in ECU.
Replace the ECU.
Fault code No. 44
Fault code No.
44
EEPROM fault code number: an error is detected while reading or
Item
writing on EEPROM.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No.
60
The fault code No. 44 detected EEPROM errors are indicated.
Indicated
00 indication: Normal status
Procedure
—
Probable cause of malfunc-
Confirmation of service com-
Item
Maintenance job
tion and check
pletion
1
Locate the malfunction.
Execute the diagnostic mode.
—
(Code No. 60)
2
Malfunction in ECU.
Replace the ECU.
9-53

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

FUEL INJECTION SYSTEM
Fault code No. 46
TIP
If fault code numbers “37” and “46” are both indicated, take the actions specified for fault code number
“46” first.
Fault code No.
46
Item
Charging voltage is abnormal.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No.
—
Indicated
—
Procedure
—
Probable cause of malfunc-
Confirmation of service com-
Item
Maintenance job
tion and check
pletion
1
Malfunction in charging system.
Check the charging system.
Start the engine and let it idle
Refer to “CHARGING SYS-
for approximately 5 seconds.
TEM” on page 9-11.
Fault code number is not dis-
Defective rectifier/regulator or
played → Service is finished.
AC magneto → Replace.
Fault code number is displayed
Defective connection in the
→ Repeat the maintenance job.
charging system circuit → Prop-
erly connect or replace the wire
harness.
Fault code No. 50
Fault code No.
50
Faulty ECU (Engine Control Unit) memory. (When this malfunction is
Item
detected in the ECU, the fault code number might not appear.)
Unable to start engine
Fail-safe system
Unable to drive vehicle
Diagnostic code No.
—
Indicated
—
Procedure
—
Probable cause of malfunc-
Confirmation of service com-
Item
Maintenance job
tion and check
pletion
1
Malfunction in ECU.
Replace the ECU.
Turn the main switch to “
”
(on).
Check that the fault code num-
ber is not displayed.
Fault code No. Er-1
Fault code No.
Er-1
ECU (Engine Control Unit) internal malfunction (output signal error):
Item
signals cannot be transmitted between the ECU and the multi-func-
tion meter.
Able to start engine (unable when ECU is malfunctioning)
Fail-safe system
Able to drive vehicle (unable when ECU is malfunctioning)
Diagnostic code No.
—
9-54

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

FUEL INJECTION SYSTEM
Fault code No.
Er-1
ECU (Engine Control Unit) internal malfunction (output signal error):
Item
signals cannot be transmitted between the ECU and the multi-func-
tion meter.
Indicated
—
Procedure
—
Probable cause of malfunc-
Confirmation of service com-
Item
Maintenance job
tion and check
pletion
1
Connection of meter assembly
Improperly connected → Con-
Turn the main switch to “
”
coupler.
nect the coupler securely or re-
(on).
Check the locking condition of
place the wire harness.
Fault code number is not dis-
the coupler.
played → Service is finished.
Disconnect the coupler and
Fault code number is displayed
check the pins (bent or broken
→ Go to item 2.
terminals and locking condition
of the pins).
2
Connection of ECU coupler.
Improperly connected → Con-
Turn the main switch to “
”
Check the locking condition of
nect the coupler securely or re-
(on).
the coupler.
place the wire harness.
Fault code number is not dis-
Disconnect the coupler and
played → Service is finished.
check the pins (bent or broken
Fault code number is displayed
terminals and locking condition
→ Go to item 3.
of the pins).
3
Wire harness continuity.
Open or short circuit → Replace
Turn the main switch to “
”
the wire harness.
(on).
Between meter assembly cou-
Fault code number is not dis-
pler and ECU coupler.
played → Service is finished.
yellow/blue-yellow/blue
Fault code number is displayed
→ Go to item 4.
4
Defective meter assembly.
Replace the meter assembly.
Turn the main switch to “
”
(on).
Fault code number is not dis-
played → Service is finished.
Fault code number is displayed
→ Go to item 5.
5
Malfunction in ECU.
Replace the ECU.
Fault code No. Er-2
Fault code No.
Er-2
ECU (Engine Control Unit) internal malfunction (output signal error):
Item
no signals are received from the ECU within the specified duration.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No.
—
Indicated
—
Procedure
—
Probable cause of malfunc-
Confirmation of service com-
Item
Maintenance job
tion and check
pletion
9-55

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

FUEL INJECTION SYSTEM
Fault code No.
Er-2
ECU (Engine Control Unit) internal malfunction (output signal error):
Item
no signals are received from the ECU within the specified duration.
1
Connection of meter assembly
Improperly connected → Con-
Turn the main switch to “
”
coupler.
nect the coupler securely or re-
(on).
Check the locking condition of
place the wire harness.
Fault code number is not dis-
the coupler.
played → Service is finished.
Disconnect the coupler and
Fault code number is displayed
check the pins (bent or broken
→ Go to item 2.
terminals and locking condition
of the pins).
2
Connection of ECU coupler.
Improperly connected → Con-
Turn the main switch to “
”
Check the locking condition of
nect the coupler securely or re-
(on).
the coupler.
place the wire harness.
Fault code number is not dis-
Disconnect the coupler and
played → Service is finished.
check the pins (bent or broken
Fault code number is displayed
terminals and locking condition
→ Go to item 3.
of the pins).
3
Wire harness continuity.
Open or short circuit → Replace
Turn the main switch to “
”
the wire harness.
(on).
Between meter assembly cou-
Fault code number is not dis-
pler and ECU coupler.
played → Service is finished.
yellow/blue-yellow/blue
Fault code number is displayed
→ Go to item 4.
4
Defective meter assembly.
Replace the meter assembly.
Turn the main switch to “
”
(on).
Fault code number is not dis-
played → Service is finished.
Fault code number is displayed
→ Go to item 5.
5
Malfunction in ECU.
Replace the ECU.
Fault code No. Er-3
Fault code No.
Er-3
ECU (Engine Control Unit) internal malfunction (output signal error):
Item
data from the ECU cannot be received correctly.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No.
—
Indicated
—
Procedure
—
Probable cause of malfunc-
Confirmation of service com-
Item
Maintenance job
tion and check
pletion
1
Connection of meter assembly
Improperly connected → Con-
Turn the main switch to “
”
coupler.
nect the coupler securely or re-
(on).
Check the locking condition of
place the wire harness.
Fault code number is not dis-
the coupler.
played → Service is finished.
Disconnect the coupler and
Fault code number is displayed
check the pins (bent or broken
→ Go to item 2.
terminals and locking condition
of the pins).
9-56

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

FUEL INJECTION SYSTEM
Fault code No.
Er-3
ECU (Engine Control Unit) internal malfunction (output signal error):
Item
data from the ECU cannot be received correctly.
2
Connection of ECU coupler.
Improperly connected → Con-
Turn the main switch to “
”
Check the locking condition of
nect the coupler securely or re-
(on).
the coupler.
place the wire harness.
Fault code number is not dis-
Disconnect the coupler and
played → Service is finished.
check the pins (bent or broken
Fault code number is displayed
terminals and locking condition
→ Go to item 3.
of the pins).
3
Wire harness continuity.
Open or short circuit → Replace
Turn the main switch to “
”
the wire harness.
(on).
Between meter assembly cou-
Fault code number is not dis-
pler and ECU coupler.
played → Service is finished.
yellow/blue-yellow/blue
Fault code number is displayed
→ Go to item 4.
4
Defective meter assembly.
Replace the meter assembly.
Turn the main switch to “
”
(on).
Fault code number is not dis-
played → Service is finished.
Fault code number is displayed
→ Go to item 5.
5
Malfunction in ECU.
Replace the ECU.
Fault code No. Er-4
Fault code No.
Er-4
ECU (Engine Control Unit) internal malfunction (input signal error):
Item
non-registered data has been received from the meter assembly.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No.
—
Indicated
—
Procedure
—
Probable cause of malfunc-
Confirmation of service com-
Item
Maintenance job
tion and check
pletion
1
Connection of meter assembly
Improperly connected → Con-
Turn the main switch to “
”
coupler.
nect the coupler securely or re-
(on).
Check the locking condition of
place the wire harness.
Fault code number is not dis-
the coupler.
played → Service is finished.
Disconnect the coupler and
Fault code number is displayed
check the pins (bent or broken
→ Go to item 2.
terminals and locking condition
of the pins).
2
Connection of ECU coupler.
Improperly connected → Con-
Turn the main switch to “
”
Check the locking condition of
nect the coupler securely or re-
(on).
the coupler.
place the wire harness.
Fault code number is not dis-
Disconnect the coupler and
played → Service is finished.
check the pins (bent or broken
Fault code number is displayed
terminals and locking condition
→ Go to item 3.
of the pins).
9-57

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

FUEL INJECTION SYSTEM
Fault code No.
Er-4
ECU (Engine Control Unit) internal malfunction (input signal error):
Item
non-registered data has been received from the meter assembly.
3
Wire harness continuity.
Open or short circuit → Replace
Turn the main switch to “
”
the wire harness.
(on).
Between meter assembly cou-
Fault code number is not dis-
pler and ECU coupler.
played → Service is finished.
yellow/blue-yellow/blue
Fault code number is displayed
→ Go to item 4.
4
Defective meter assembly.
Replace the meter assembly.
Turn the main switch to “
”
(on).
Fault code number is not dis-
played → Service is finished.
Fault code number is displayed
→ Go to item 5.
5
Malfunction in ECU.
Replace the ECU.
9-58

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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
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

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

FUEL PUMP SYSTEM
4. Main switch
5. Main fuse
6. Battery
7. Fuel injection system fuse
9. Engine ground
11.Joint coupler
12.Fuel injection system relay
16.ECU (Engine Control Unit)
40.Fuel pump
46.Engine stop switch
61.Ignition fuse
66.Frame ground 1
A. Wire harness
B. Negative battery sub-wire harness
9-60

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

FUEL PUMP SYSTEM
EBS30283
TROUBLESHOOTING
If the fuel pump fails to operate.
TIP
• Before troubleshooting, remove the following part(s):
1. Seat
2. Battery cover
3. Top cover
4. Side panels (left and right)
5. Rear fender
1.
Check the fuses.
NG →
(Main, ignition and fuel injection
system)
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 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 ↓
5.
Check the fuel injection system re-
NG →
lay.
Replace the fuel injection system relay.
Refer to “CHECKING THE RE-
LAYS” on page 9-88.
OK ↓
6.
Check the fuel pump.
NG →
Refer to “CHECKING THE FUEL
Replace the fuel pump.
PUMP BODY” on page 7-2.
OK ↓
7.
Check the entire fuel pump system
NG →
wiring.
Properly connect or repair the fuel pump
Refer to “CIRCUIT DIAGRAM” on
system wiring.
page 9-59.
OK ↓
Replace the ECU.
9-61

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

FUEL PUMP SYSTEM
9-62

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

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

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

2WD/4WD SELECTING SYSTEM
4. Main switch
5. Main fuse
6. Battery
9. Engine ground
11.Joint coupler
16.ECU (Engine Control Unit)
37.On-Command four-wheel-drive motor switch
and differential lock switch
38.Differential motor
41.Four-wheel-drive motor relay 1
42.Four-wheel-drive motor relay 2
61.Ignition fuse
62.Four-wheel-drive motor fuse
66.Frame ground 1
A. Wire harness
B. Negative battery sub-wire harness
9-64

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

2WD/4WD SELECTING SYSTEM
EBS30285
TROUBLESHOOTING
The four-wheel-drive motor indicator light fails to come on.
TIP
• Before troubleshooting, remove the following part(s):
1. Battery cover
1.
Check the fuses.
NG →
(Main, Ignition and four-wheel-drive
motor)
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 On-Command four-
NG →
wheel-drive motor switch and differ-
Replace the On-Command four-wheel-
ential lock switch.
drive motor switch and differential lock
Refer to “CHECKING THE
switch.
SWITCHES” on page 9-81.
OK ↓
5.
Check the four-wheel-drive motor
NG →
relay 1.
Replace the four-wheel-drive motor relay
Refer to “CHECKING THE RE-
1.
LAYS” on page 9-88.
OK ↓
6.
Check the four-wheel-drive motor
NG →
relay 2.
Replace the four-wheel-drive motor relay
Refer to “CHECKING THE RE-
2.
LAYS” on page 9-88.
OK ↓
7.
Check the differential motor.
NG →
Refer to “CHECKING THE DIF-
Replace the differential motor.
FERENTIAL MOTOR OPERATION”
on page 8-11.
OK ↓
9-65

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

2WD/4WD SELECTING SYSTEM
8. Check the entire 2WD/4WD select-
NG →
ing system wiring.
Properly connect or repair the 2WD/4WD
Refer to “CIRCUIT DIAGRAM” on
selecting system wiring.
page 9-63.
OK ↓
Replace the ECU.
9-66

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

A
B
Br Br
Br
L
L
Br
Br Br L L L
B
B
B
B
(B)
(B)
12
L L
L L L
Br Br Br Br Br Br
R/L
R/L R/L R/W R/W R/W R/W W W W
A
B
B
C
R/L R/L R/W R/W
WW
R/L
R/W
R/W W
R/YOW 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
22
(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
B
G R
13
14
B R
Lg
G/Y R/L G/WB/Y L/Y
Y/L Y
W/R B/R
L B/L L/W R/W
23
1
B W
WRG B R
B
(B)
(Gy)
(Gy)
W
W
WRG B R
B
Gy
O
W W
W
2
W
W
3
R
R GW B
R B
O/W
R/L
R/B
W
W
W
G/W
(Gy)
G/R
R/W
24
(Gy)
R/B
G
O
O/W
16
G/W
R/B
R/B
R/L
B
B
15
L/B
L/B
B
Br
G
W/G R/W
R/G
Br/W B/L
R/B
R
L/B Br
O
L
R/W
Br/L R/W P/L
25
(B)
R
R
R/B
G
G W G/R
G/R
O/W Br
W
L/B
19
R/W
(B)
Br/W
Br/W
B/L
5
R/B
6
R
(Gy)
(Gy)
(B)
(B)
R/G
P/L R/G
G/Y B/L
Br Br/L R
20
P/L
26
(B)
(Gy)
R
R
R
Br/B
R/B
W/G
W/GBr/L
G/Y
G/Y
B/L
R
R
Br/B R/W
Br/B
Br/L
L
L/Y
W L/Y
L W
R Br/L Br
Br/B
B
R
Br
W
W
W
27
B/L
B/L
R/L
17
R
Y/W
L/Y
L
B/L
B/L
7
R/B
L/R
R/Y
21
4
8
G/RY/B
R/Y
R/L
L/R
W/B
ONOFF
B
18
B/R
B/L
B
9
R/L
Y/W
Y/W
Y
Y
28
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
10
11
L/Y R/Y
R/LL/W
P
P
29
B/L
P
L
(B)
G/R
W/R
B/L
65
LgY/R
Gy/GL/B
Br/YR/W
(B)
R/Y
Sb
31
66
Y
Y/L
Br/Y
R/W
(B)
Br/L
Br/Y
Br Br
Br Br
P/WO/L
Br/YB/L
B/L
B/G
Y/G
Y/G
30
L Y/G
B/L
67
R/L
G/Y
Sb
Gy/G
L
Br/L
Br
48
47
L/B
W/R
(Gy)
68
B/Y
Br/B
Br
Br/B
R/L B B/W
G/Y
45
L PGyW
32
71
B/Y
Br
46
B/W
B
B
G W/B
P
P
69
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
70
(B)
(B)
B B/W
R/W
R
P B
B B
R/Y
Br R/B
L/Y
Lg
49
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
53
B B B B B B
R/W R/B R/B R/B
B B
B Lg L/Y
L/Y
Lg
B
52
51
50
34
33
73
Br R/B
R/B
Br
OFFPUSH
72
B
(Gy)
Y
G/Y
Y/L
B/W
12
B
(Gy)
Br
B/W
R/W
B
B
L
L/Y
Br/B
B/W
B/W
R/B
B/L
B
B/W
B
B/W
R/B
B/L
B/L
12
R/W
Br
L
Y
G/Y G/R Br/B
B/WBr/Y
R/B
B/L
Y
Y/L
Br
B/W
Br/Y
B
B/L
B/L
R/W
G
57
35
Br/Y
BB
B/L
R/B
64
Br/Y
Br/Y
L
B
(B)
Br/Y
B
B/L
Br
Y/R
B
B
(B)
B
G
O/L
B/Y W/B
36
L
B
BB
L/Y
G
P/W B/G
Br/B
B/R
B
R/BY/R
61
60
L
L/W
G/R
37
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
56
Y
B Br/Y
L/Y
B
B/G P/W
W/B B/R B O/L Br/B
B/Y
43
38
Y
Y/W
(B)
44
2WD4WD
74
Br
Br
B
Y
B
Y
Y
(Gy)
LOCK
OFF
Y
B/Y
L/W G/R
39
ON
63
B/Y.
B
B
B
B
Y/W
Y
59
B
P
B
B
(B)
Y
G
Y
G
Y L
40
(B)
P
B
B
Y
L
G/R L/W
B/W
55
55
B/W
B
B
B
L
58
41
(B)
B L
L
L Y
G Y
G Y
54
B
B
B
42
G/R
75
L
B
62
B
Y L
Y G
B
Y G
B
B
B
B
B
B

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

EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models)
4. Main switch
5. EPS fuse
6. Main fuse
7. Battery
10.Engine ground
12.Joint coupler
13.EPS torque sensor
14.EPS motor
15.EPS (electric power steering) control unit
16.EPS self-diagnosis signal connector
21.ECU (Engine Control Unit)
27.Speed sensor
42.EPS warning light
67.Ignition fuse
72.Frame ground 1
A. Wire harness
B. Negative battery sub-wire harness
C. EPS (electric power steering) control unit
9-68

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

EPS (ELECTRIC POWER STEERING) SYSTEM (for EPS models)
EBS30287
EPS CONTROL UNIT’S SELF-DIAGNOSTIC FUNCTION
The EPS control unit is equipped with a self-diagnostic function. If this function detects a malfunction in
the EPS system, it lights the EPS warning light to alert the rider that a malfunction has occurred in the
system. Once a malfunction has been detected, it becomes stored in the EPS control unit memory in
the form of a fault code.
• The EPS warning light comes on when the main switch is turned to “
” (on), and then goes off once
the engine is started. If the warning light remains on or comes on after the engine is started, the EPS
system may be defective.
• The electrical circuit of the warning light can be checked by turning the main switch to “
” (on). If the
warning light does not come on, the electrical circuit may be defective.
1
1. EPS warning light
TIP
• If the engine is stopped using the engine stop switch and the main switch is in the “
” (on) position,
the EPS warning light comes on to indicate that the power assistance for the steering is not function-
ing.
• If the steering usage is too heavy (i.e., excessive steering use when the vehicle is traveling at a slow
speed), the power assist is reduced to protect the EPS motor from overheating.
EBS30288
EPS WARNING LIGHT DURING NORMAL OPERATION
The EPS warning light comes on initially for 2 seconds after the main switch is turned to “
” (on). How-
ever, the warning light remains on until the engine is started.
In addition, if a malfunction is detected while the warning light comes on initially, the warning light re-
mains on.
Furthermore, the warning light comes on whenever a malfunction has occurred.
TIP
The EPS system does not operate while the EPS warning light is on.
e
d
a
g
f
i
b
g
c f
h
a. Main switch
c. EPS warning light (malfunction detected)
b. EPS warning light (no malfunction detected)
d.
“
” (off)
9-69

 

 

 

 

 

 

 

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