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BT1100 5JN4-AE1
SUPPLEMENTARY
SERVICE MANUAL
FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the Yamaha
BT1100 (2005).
For complete service information procedures it is necessary to use this Supplementary Service Manual to-
gether with the following manuals.
BT1100 2005
SUPPLEMENTARY SERVICE MANUAL
© 2004 by Yamaha Motor Italia S.p.A.
First edition, September 2004
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor Italia S.p.A.
is expressly prohibited.
Printed in Italy
NOTICE
This manual was produced by the Yamaha Motor Italia S.p.A. primarily for use by Yamaha dealers and
their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so
it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha motorcy-
cles has a basic understanding of the mechanical ideas and the procedures of motorcycle repair. Repairs
attempted by anyone without this knowledge are likely to render the motorcycle unsafe and unfit for use.
Yamaha Motor Italia S.p.A. is continually striving to improve all its models. Modifications and significant
changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will ap-
pear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFE-
TY IS INVOLVED!
WARNING Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, a bystander or a person inspecting or repairing the mo-
torcycle.
CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
ELEC TRBL
SHTG ? Illustrated symbols 9 to y are used to identify
9 0 the specifications appearing in the text.
9 Can be serviced with engine mounted
0 Filling fluid
q Lubricant
q w w Special tool
e Torque
r Wear limit, clearance
t Engine speed
y Electrical data
e r
t y
SPECIFICATIONS
GENERAL SPECIFICATIONS.................................................................................... 1
MAINTENANCE SPECIFICATIONS – ENGINE ........................................................ 4
LUBRICATION CHART .............................................................................................. 10
TIGHTENING TORQUES – ENGINE ........................................................................ 11
MAINTENANCE SPECIFICATIONS – CHASSIS ...................................................... 14
TIGHTENING TORQUES – CHASSIS ...................................................................... 16
MAINTENANCE SPECIFICATIONS – ELECTRICAL ................................................ 18
GENERAL TORQUE SPECIFICATIONS .................................................................. 20
CONVERSION TABLE .............................................................................................. 20
LUBRICATION POINTS AND LUBRICANT TYPES .................................................. 21
LUBRICATION DIAGRAMS ...................................................................................... 23
CABLE ROUTING ...................................................................................................... 26
ENGINE
ENGINE REMOVAL .................................................................................................. 34
CARBURETION
CARBURETOR .......................................................................................................... 36
CHASSIS
FRONT BRAKE MASTER CYLINDER ...................................................................... 37
FRONT BRAKE CALIPERS ...................................................................................... 39
HANDLEBAR.............................................................................................................. 41
STEERING HEAD – LOWER BRACKET .................................................................. 45
ELECTRICAL
ELECTRICAL COMPONENTS .................................................................................. 47
SWITCHES ................................................................................................................ 49
CHECKING THE BULBS AND BULB SOCKETS ...................................................... 52
IMMOBILIZER SYSTEM ............................................................................................ 55
SELF-DIAGNOSIS DEVICE ...................................................................................... 63
IGNITION SYSTEM.................................................................................................... 68
ELECTRIC STARTING SYSTEM .............................................................................. 73
CHARGING SYSTEM ................................................................................................ 83
LIGHTING SYSTEM .................................................................................................. 86
SIGNALING SYSTEM ................................................................................................ 91
FUEL PUMP SYSTEM .............................................................................................. 99
CARBURETOR HEATER SYSTEM .......................................................................... 104
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING.................................................................... 107
WIRING DIAGRAM
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard
Model code: BT1100: 5JN4
Dimensions:
Overall length 2,200 mm
Overall width 800 mm
Overall height 1,140 mm
Seat height 812 mm
Wheelbase 1,530 mm
Ground clearance 168 mm
Minimum turning radius 2,980 mm
Weight:
Dry (without oil and fuel) 233 kg
Wet (with oil and a full fuel tank) 254 kg
Bias weight (dry) front 109.5 kg
Bias weight (dry) rear 123.5 kg
Bias weight (wet) front 122 kg
Bias weight (wet) rear 132 kg
Maximum load-except motorcycle: 200 kg
Engine:
Engine type Air cooled 4-stroke,
SOHC
Cylinder arrangement V-type 2-cylinder
Displacement 1,063 L
Bore stroke 95 75 mm
Compression ratio 8.3 : 1
Compression pressure (STD) 1,000 kPa (10 kg/cm2, 10 bar) at 400 r/min
Starting system Electric starter
Lubrication system: Wet sump
Engine oil:
Type SAE20W40SE or SAE10W30SE
Temp. °C
Recommended engine oil classification:
API Service SE, SF, SG or higher
1
GENERAL SPECIFICATIONS
SPEC
Item Standard
Air filter: Dry type element
Fuel:
Type Regular unleaded gasoline
Fuel tank capacity 20 L
Fuel reserve amount 5.8 L
Carburetor:
Type/quantity BSR37/2
Manufacturer MIKUNI
Spark plug:
Type BPR7ES/W22EPR-U
Manufacturer NGK/DENSO
Spark plug gap 0.7 0.8 mm
Clutch type: Wet, multiple-disc
Transmission:
Primary reduction system Spur gear
Primary reduction ratio 78/47 (1.660)
Secondary reduction system Shaft drive
Secondary reduction ratio 44/47 19/18 32/11 (2.875)
Transmission type Constant mesh 5-speed
Operation Left foot operation
Gear ratio 1st 40/17 (2.353)
2nd 40/24 (1.667)
3rd 36/28 (1.286)
4th 32/31 (1.032)
5th 29/34 (0.853)
Chassis:
Frame type Twin tube Backbone
Caster angle 25°
Trail 106 mm
Tire:
Type Tubeless
Size front 120/70-ZR17 (58W)
rear 170/60-ZR17 (72W)
Manufacturer front DUNLOP / METZELER
rear DUNLOP / METZELER
Type front D205F TL / MEZ3F TL
rear D205 TL / MEZ3 TL
Tire pressure (cold tire):
0 ~ 90 kg load * front 230 kPa (2.30 kg/cm2) (2.30 bar)
rear 250 kPa (2.50 kg/cm2) (2.50 bar)
90 kg (198 lb) ~ Maximum load * front 250 kPa (2.50 kg/cm2) (2.50 bar)
rear 270 kPa (2.70 kg/cm2) (2.70 bar)
* Load is the total weight of the cargo, rider,
passenger and accessories.
Maximum load: 200 kg (total weight of rider, passenger,
cargo and accessories)
2
GENERAL SPECIFICATIONS
SPEC
Item Standard
Brake:
Front brake type Dual disc brake
operation Right hand operation
Rear brake type Single disc brake
operation Right foot operation
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm (link suspension)
Shock absorber:
Front shock absorber Coil spring/Oil damper
Rear shock absorber Coil spring/Gas-oil damper/Spring preload
adjustable
Wheel travel:
Front wheel travel 130 mm
Rear wheel travel 113 mm
Electrical system:
Ignition system T.C.I. (digital)
Generator system A.C. magneto
Battery type GT14B-4
Battery capacity 12V 12Ah
Headlight type: Quartz bulb (halogen)
Bulb voltage, wattage x quantity:
Headlight 12 V 60 W/55 W x 1
Auxiliary light 12 V 5 W x 1
Tail/brake light 12 V 5 W / 21 W x 1
License plate light 12 V 5 W x 1
Front turn signal indicator light 12 V 10 W x 2
Rear turn signal indicator light 12 V 10 W x 2
Meter lighting LED x 12
Neutral indicator light LED x 1
Turn signal light LED x 1
Oil level warning light LED x 1
High beam indicator light LED x 1
Fuel level warning light LED x 1
Immobilizer system light LED x 1
3
MAINTENANCE SPECIFICATIONS
SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Cylinder:
Bore size 95.00 95.01 mm 95.1 mm
Measuring point 40 mm •••
Max. out of round ••• 0.01 mm
Camshaft:
Drive method Chain drive (left & right) •••
Cam cap inside diameter 25.000 25.021 mm •••
Camshaft outside diameter 24.96 24.98 mm •••
Shaft-to-cap clearance 0.020 0.061 mm •••
Cam dimensions:
4
MAINTENANCE SPECIFICATIONS
SPEC
Valve dimensions:
5
MAINTENANCE SPECIFICATIONS
SPEC
Direction of winding
(top view) IN Clockwise •••
EX Clockwise •••
Piston:
Piston to cylinder clearance 0.025 0.050 mm 0.15 mm
Piston size “D” 94.960 94.975 mm •••
6
MAINTENANCE SPECIFICATIONS
SPEC
7
MAINTENANCE SPECIFICATIONS
SPEC
8
MAINTENANCE SPECIFICATIONS
SPEC
9
MAINTENANCE SPECIFICATIONS
SPEC
Item Standard
Lubrication chart:
Main axle
Pressure feed
Pinin drive
Splashed
Rocker arm (EX) Camshaft (EX) Rocker arm (EX) Rocker arm (IN) Camshaft (IN) Rocker arm (IN)
Oil filter
Oil pan
10
MAINTENANCE SPECIFICATIONS
SPEC
Cylinder head tightening sequence:
11
MAINTENANCE SPECIFICATIONS
SPEC
Tightening torques
Tightening
Part Thread
Part to be tightened Q’ty torque Remarks
name size
N·m m·kg
Cylinder head Nut M12 8 50 5.0
Cylinder head Nut M10 2 35 3.5
Plate Bolt M8 2 20 2.0
Cylinder head cover Screw M6 4 4 0.4
Cylinder head (exhaust pipe) Stud bolt M8 4 12.5 1.25
Rocker arm shaft Union M16 2 37.5 3.75
bolt
Camshaft sprocket cover Bolt M6 4 10 1.0
Tappet cover Bolt M6 8 10 1.0
Rocker arm shaft Bolt M16 4 38 3.8
(oil passage)
Stopper plate (camshaft) Bolt M8 4 20 2.0 Use lock
washer
Spark plug – M14 2 20 2.0
Cylinder Bolt M6 2 10 1.0
Lower cylinder head cover Bolt M6 6 10 1.0
Upper cylinder head cover Screw M6 8 5 0.5
Connecting rod Nut M9 4 48 4.8
Rotor Nut M16 1 175 17.5
Valve adjusting locknut Nut M8 4 27 2.7
Camshaft sprocket Bolt M10 2 55 5.5
Timing chain tensioner Bolt M6 4 10 1.0
Timing chain tentioner cap Bolt M6 2 8 0.8
Timing chain guide Bolt M6 4 10 1.0
Oil pump Bolt M6 3 10 1.0
Oil strainer cover Bolt M6 3 10 1.0
Oil filter cover Bolt M6 5 10 1.0
Oil pump gear Bolt M6 1 12 1.2
Oil pump cap Bolt M6 1 10 1.0
Oil delivery pipe (cylinder head) Union M16 2 20 2.0
bolt
(crankcase) Union M10 1 20 2.0
bolt
Oil drain bolt – M14 1 43 4.3
Air filter:
Air filter cover fastener Screw M5 2 2 0.2
Carburetor cover fastener Screw M5 4 4.5 0.45
A.I.S. system:
A.I.S. system fastener
(pump and piping) Screw M6 4 10 1.0
A.I.S. system pipe fastener
to engine starter Screw M6 1 10 1.0
A.I.S. pump fastener
to A.I.S. bracket Screw M5 2 8 0.8
Exhaust system:
Cylinder head and exhaust pipe joint Nut M8 4 20 2.0
Exhaust pipe bracket Screw M8 2 25 2.5
Exhaust pipe/exhaust pipe
guard fastener (rear) Screw M8 2 20 2.0
Exhaust pipe strap Screw M8 3 18 1.8
Silencer fastener to passenger
board support Screw M10 2 47 4.7
Exhaust pipe guard fastener Screw M6 2 7 0.7
12
MAINTENANCE SPECIFICATIONS
SPEC
Tightening
Part Thread
Part to be tightened Q’ty torque Remarks
name size
N·m m·kg
Crankcase (cylinder) Stud bolt M12 8 24 2.4
Crankcase (cylinder) Stud bolt M10 2 20 2.0
Crankcase Bolt M10 3 38.5 3.85
Crankcase Bolt M6 10 10 1.0
Bearing retainer (middle drive pinion gear) Bolt M8 3 25 2.5
Crankcase cover (left) Bolt M6 13 10 1.0
Crankcase cover (right) Bolt M6 11 10 1.0
Clamp Bolt M6 1 10 1.0
One-way clutch Bolt M6 8 12 1.2
Primary drive gear Nut M20 1 110 11.0 Use lock
washer
Clutch spring Bolt M6 6 8 0.8
Clutch adjuster Nut M8 1 12 1.2
Clutch boss Nut M20 1 70 7.0 Use lock
washer
Push lever axle Screw M8 1 12 1.2
Middle drive pinion gear Nut M44 1 110 11.0 Stake
Bearing retainer (middle driven shaft) Nut M88 1 110 11.0 Stake
Yoke (middle driven shaft) Nut M14 1 – – Stake
Bearing housing (middle drive shaft) Bolt M8 4 25 2.5
Shift lever stopper Bolt M8 1 22 2.2
Use lock
washer
13
MAINTENANCE SPECIFICATIONS
SPEC
CHASSIS
14
MAINTENANCE SPECIFICATIONS
SPEC
15
MAINTENANCE SPECIFICATIONS
SPEC
Tightening torques
Tightening
Part to be tightened Thread torque Remarks
size
N·m m·kg
Headlight assembly/Cowling:
Lower headlight support M6 10 1.0
Upper headlight support (right and left) M6 7 0.7
Headlight bracket (right and left) M6 10 1.0
Plastic cover M5 4 0.4
Front flasher lights (right and left) M12 10 1.0
Handlebar/Front fork assembly:
Upper bracket and inner tube M8 25 2.5
Lower bracket and inner tube M8 25 2.5
Front fork cap nut and steering shaft M22 110 11.0
Ring nut (steering shaft) – 18 1.8 See “Note”
Meter bracket and upper bracket M6 10 1.0
Handlebar holder (lower) and upper bracket M10 32 3.2
Handlebar holder (lower) and handlebar M8 23 2.3
(upper)
Throttle cable M5 4.5 0.45
Clutch lever assembly M6 11 1.1
Handlebar weight (right and left) M8 25 2.5
Front fender fastening screw M6 7 0.7
Front wheel:
Front brake caliper (right and left) M10 42 4.2
Front brake disc (right and left) M8 25 2.5
Front wheel axle M18 75 7.5
Front wheel axle pinch bolt M8 25 2.5
Rear wheel:
Rear brake disc M8 25 2.5
Rear brake caliper M10 35 3.5
Rear wheel axle nut M16 110 11.0
Rear wheel axle pinch bolt M8 22 2.2
Dust cover fastening screw M5 4 0.4
Swingarm assembly:
Pivot shaft M16 92 9.2
Swingarm pinch bolt M8 22 2.2
Shock absorber fastener (upper) M10 42 4.2
Shock absorber fastener (lower) M10 50 5.0
Connecting arm M12 50 5.0
Relay arm M10 50 5.0
Final gear case fastening cap nut M10 50 5.0
Sidestand/Shift pedal:
Sidestand M8 19 1.9
Sidestand switch M5 4.5 0.45
Shift rod M6 7 0.7
Ball-and-joint socket M6 8 0.8
Shift boss M6 7 0.7
Shift pedal M8 16 1.6
Front brake:
Brake hose union bolt M10 28 2.8
Front master cylinder M6 10 1.0
Front master cylinder cover – 2 0.2
Front brake joint fastening screw M6 10 1.0
Brake hose holder fastening screw M6 10 1.0
16
MAINTENANCE SPECIFICATIONS
SPEC
Tightening
Part to be tightened Thread torque Remarks
size
N·m m·kg
Rear brake/Footrests:
Brake caliper torque rod M8 25 2.5
Rear brake adjuster M6 10 1.0
Rear brake pedal fastening screw (special) M8 16 1.6
Rear master cylinder fastening screw M6 10 1.0
Rear brake fluid reservoir fastening screw M6 7 0.7
Special screw for fastening rear brake hose M10 28 2.8
to brake caliper
Special screw for fastening rear brake M10 25 2.5
hose to master cylinder
Brake caliper bleed screw M6 5.5 0.55
Front footrest bracket fastening screw M10 55 5.5
(aluminium)
Front footrest bracket fastening screw M8 23 2.3
(steel)
Footrest damper fastening screw M5 4 0.4
Rear footrest fastening screw M6 7 0.7
Rear footrest bracket fastening screw M8 23 2.3
Rear lights/Rear fender/Panel assembly:
Side panel fastening screw M6 7 0.7
Battery receptacle fastening screws M6 7 0.7
Battery receptacle cover fastening screws M6 7 0.7
Plastic rear fender fastening screws M6 7 0.7
Plastic license bracket fastening screws M6 7 0.7
Rear fender cover fastening screw
(aluminium) M8 23 2.3
Seat lock fastening screw M6 7 0.7
Rear flasher lights (right and left) M12 10 1.0
Tail light fastening screw M6 7 0.7
Fuel tank:
Fastening screw (front) M6 10 1.0
Fastening screw (rear) M6 10 1.0
Bracket fastening screw (rear) M6 7 0.7
Tank cap fastening screw M5 6 0.6
Tank cover fastening screw (aluminium) M5 4 0.4
Fuel cock fastening screw M6 7 0.7
Fuel sender fastening screw M6 7 0.7
NOTE:
1. First, tighten the ring nut approximately 52 Nm (5.2 m·kg) by using the torque wrench, then loosen the
ring nut completely.
2. Retighten the ring nut to specification.
17
MAINTENANCE SPECIFICATIONS
SPEC
ELECTRICAL
18
MAINTENANCE SPECIFICATIONS
SPEC
19
GENERAL TORQUE SPECIFICATIONS/
CONVERSION TABLE
SPEC
GENERAL TORQUE SPECIFICATIONS CONVERSION TABLE
This chart specifies torque for standard fasteners All specification data in this manual are listed in SI
with standard I.S.O. pitch threads. Torque specifi- and METRIC UNITS. Use this table to convert
cations for special components or assemblies are METRIC unit data to IMPERIAL unit data.
provided for each chapter of this manual. To avoid
Ex.
warpage, tighten multi-fastener assemblies in a
crisscross fashion, in progressive stages, until the METRIC MULTIPLIER IMP
specified torque is reached. Unless otherwise ** mm 0.03937 = ** in
specified, torque specifications require clean, dry 2 mm 0.03937 = 0.08 in
threads. Components should be at room tempera-
ture.
CONVERSION TABLE
METRIC TO IMP
Known Multiplier Result
m·kg 7.233 ft·lb
m·kg 86.794 in·lb
Torque
cm·kg 0.0723 ft·lb
cm·kg 0.8679 in·lb
kg 2.205 lb
Weight
g 0.03527 oz
km/hr 0.6214 mph
km 0.6214 mi
A: Distance between flats
m 3.281 ft
B: Outside thread diameter Distance
m 1.094 yd
cm 0.3937 in
General torque
A B mm 0.03937 in
specifications
(nut) (Bolt) cc (cm3) 0.03527 oz (IMP liq.)
N·m m·kg Volume/ cc (cm3) 0.06102 cu·in
10 mm 6 mm 6 0.6 Capacity lt (liter) 0.8799 qt (IMP liq.)
lt (liter) 0.2199 gal (IMP liq.)
12 mm 8 mm 15 1.5
kg/mm 55.997 lb/in
14 mm 10 mm 30 3.0 Miscel-
laneous kg/cm2 14.2234 psi (lb/in2)
17 mm 12 mm 55 5.5 Centigrade 9/5 (°C) + 32 Fahrenheit (°F)
19 mm 14 mm 85 8.5
22 mm 16 mm 130 13.0
20
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
21
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
CHASSIS
22
LUBRICATION DIAGRAMS
SPEC
EB205000
LUBRICATION DIAGRAMS
1 Rocker arm shaft (intake) 3 Oil filter 5 Drive axle
2 Rocker arm shaft (exhaust) 4 Oil pump 6 Middle drive shaft
23
LUBRICATION DIAGRAMS
SPEC
1 Oil pump 3 Oil filter
2 Releaf valve 4 Middle drive shaft
24
LUBRICATION DIAGRAMS
SPEC
1 Camshaft 4 Middle drive shaft
2 Crankshaft 5 Drive axle
3 Main axle 6 Connecting rod big end
25
CABLE ROUTING
SPEC
CABLE ROUTING
1 Relays group 9 Filler tank cap fuel drain pipe u Clutch cable
2 Flasher relay 0 Filler tank cap fuel drain pipe i Front brake cable (left)
3 Speed sensor q Fuel hose (carburetor-3 way) o Carburetor pipe vent
4 Sidestand switch w Handlebar switch leads (left) p Pipe drain
5 Fuel drain hose e Rectifier/regulator å Fix the wires of the left swicth
6 Engine earth r Spark plug cap (front cilinder) assy to the handlebar by means of
7 Neutral switch t Throttle cables no. 2 plastic clamps.
8 Carburetor heater y Wireharness ∫ Fix the headlight leads to the
clamp.
t q 0 9
o p 2 1
y∫
wå
e
8
u
i r
7 6 5 4 3
26
CABLE ROUTING
SPEC
a Rubber cap for front wiring ; Ignition coil (rear cylinder) . Throttle cables
connections z Starter relay assy / Brake cable
s Horn x Depression fuel cock (front master cylinder)
d Front brake hose (right) c Spark plug cap (rear cylinder) ! Thermo swicth
f A.I.S. pipe to the front cylinder v A.I.S. pipe to the rear cylinder
ç Check that the wires of the igni-
g Starter motor b A.I.S. system tion coil do not remain tensioned.
h Starter motor lead n Throttle position sensor (TPS) ∂ Fix the wires of the right switch
j Oil level gauge m Ignition coil (front cylinder) assy to the handlebar by means of
k Rear brake hose , Handlebar switch leads (right) no. 1 plastic clamp.
l Brake fluid reservoir hose
/
ç;
∂,
z x c !
çm
l v
n
f d
j h g
27
CABLE ROUTING
SPEC
@ Carburetor pipe vent ( Battery negative (-) terminal Y Rubber cap for front wiring
# Depression fuel cock ) Igniter unit connections
$ Battery Q Fuel filter U Spark plug lead (front)
% Fuel hose W Fuel pump I Throttle cable
^ Spark plug lead (rear) E Fuel sender ´ Position the spark plug wire of
& Battery positive (+) terminal R Air intake pipe (A.I.S. system) the rear cylinder below the fuel
hose.
* Fuse box T Anti-theft alarm connectors
U
R
E
#
W
%
Q
$
)
( &
^
´
28
INTRODUCTION/PERIODIC MAINTENANCE/ INSP
LUBRICATION INTERVALS ADJ
PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjustments.
These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a
longer service life. The need for costly overhaul work will be greatly reduced. This information applies to
vehicles already in service as well as to new vehicles that are being prepared for sale. All service techni-
cians should be familiar with this entire chapter.
• Check operation.
16 Sidestand • Lubricate. ✓ ✓ ✓ ✓ ✓
17 * Sidestand
Switch • Check operation and for oil leakage. ✓ ✓ ✓ ✓ ✓ ✓
29
INTRODUCTION/PERIODIC MAINTENANCE/ INSP
LUBRICATION INTERVALS ADJ
ODOMETER READING (x 1,000 km) Annual
N0. ITEM CHECK OR MAINTENANCE JOB
1 10 20 30 40 check
Rear
suspension relay • Check operation. ✓ ✓ ✓ ✓
20 * arm and
connecting
arm
pivoting • Lubricate with lithium-soap-based grease. ✓ ✓
points
• Check starter (choke) operation.
21 * Carburators • Adjust engine idling speed and ✓ ✓ ✓ ✓ ✓ ✓
• synchronization.
• Change.
22 Engine oil • Check oil level and vehicle for ✓ ✓ ✓ ✓ ✓ ✓
oil leakage.
Engine oil
23 filter element • Replace. ✓ ✓ ✓
* Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
NOTE:
• The annual checks must be performed every year, except if a kilometer-based maintenance is per-
formed instead.
• From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
• Hydraulic brake system:
• Check the brake fluid level regularly and fill as required.
• Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.
• Replace the brake hoses every four years or if cracked or damaged.
30
INSP
ADJUSTING THE FRONT BRAKE ADJ
EB304001
CHASSIS
ADJUSTING THE FRONT BRAKE
1. Adjust:
• brake lever position
(distance a between the brake lever and
the handlebar grip)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting dial 1 while holding the
lever pushed away from the handlebar grip
NOTE:
Align the setting on the adjusting dial with the
arrow mark 2
Position n. 1 Maximum a
distance
Position n. 5 Minimum a
distance
WARNING
After adjusting the brake lever position, make
sure the pin on the brake lever holder is firm-
ly inserted in the hole in the adjusting dial.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
WARNING
A soft or spongy feeling in the brake lever can
indicate the presence of air in the brake sys-
tem. Before the vehicle is operated, the air
must be removed by bleeding the brake sys-
tem. Air in the brake system will considerably
reduce braking performance and could result
in loss of control and possibly an accident.
Therefore, inspect and, if necessary, bleed the
brake system. After adjusting the brake lever
free play, make sure that there is no brake
drag.
31
INSP
CHECKING THE FUSES ADJ
EAS00181
1. Remove:
• seat
• storage compartment 1
2. Check:
• fuse
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester to the fuse and
check it for continuity.
NOTE:
Set the pocket tester selector to “Ω 1”.
Pocket tester
90890-03112
b. If the pocket tester indicates "∞", replace the
fuse.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Replace:
• blown fuse
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn off the ignition.
b. Install a new fuse of the correct amperage rat-
ing.
c. Turn on the switches to verify if the electrical
circuit is operational.
d. If the fuse immediately blows again, check the
electrical circuit.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
32
INSP
CHECKING THE FUSES ADJ
Amperage
Fuses Quantity
rating
1 Main fuse 30 A 1
2 Carburetor heater fuse 15 A 1
3 Headlight fuse 15 A 1
4 Signaling system fuse 10 A 1
5 Ignition fuse 10 A 1
6 Odometer fuse (backup) 10 A 1
7 Parking lighting fuse 10 A 1
8 Igniter fuse 5A 1
9 Reserve fuse 30 A 1
0 Reserve fuse 15 A 1
q Reserve fuse 10 A 1
w Reserve fuse 5A 1
WARNING
Never use a fuse with an amperage rating
other than that specified. Improvising or using
a fuse with the wrong amperage rating may
cause extensive damage to the electrical sys-
tem, cause the lighting and ignition systems
to malfunction and could possibly cause a fire.
4. Install:
• storage compartment
• seat
33
ENGINE REMOVAL
ENG
ENGINE
ENGINE REMOVAL
SEAT, STORAGE COMPARTMENT, SIDE COVERS, FUEL TANK,
AIR FILTER CASE ASSEMBLY, CARBURETOR ASSEMBLY AND EXHAUST SYSTEM
34
ENGINE REMOVAL
ENG
35
CARBURETOR
CARB
CARBURETION
CARBURETOR
36
FRONT BRAKE
CHAS
CHASSIS
FRONT BRAKE MASTER CYLINDER
37
FRONT BRAKE
CHAS
38
FRONT BRAKE
CHAS
FRONT BRAKE CALIPERS
39
FRONT BRAKE
CHAS
40
HANDLEBAR
CHAS
HANDLEBAR
41
HANDLEBAR
CHAS
42
HANDLEBAR
CHAS
EASB0025
2. Install:
• handlebar
• upper handlebar holders
23 Nm (2.3 m•kg)
CAUTION:
• First, tighten the bolts on the front side of
the handlebar holder, then on the rear side.
• Turn the handlebar all the way to the left and
right. If there is any contact with the fuel
tank, adjust the handlebar position.
NOTE:
Align the match marks on the handlebar with the
upper surface of the lower handlebar holders.
3. Install:
• throttle grip 1
• throttle cable
WARNING
Make sure that the pin a on the throttle cable
housing is aligned with the hole b in the han-
dlebar.
4. Install:
• master cylinder 1
Refer to “FRONT AND REAR BRAKES”.
NOTE:
Align the slit in the brake lever holder with the
punch mark a in the handlebar.
43
HANDLEBAR
CHAS
5. Install:
• master cylinder holder 2
10 Nm (1.0 m•kg)
NOTE:
Install the master cylinder holder 2 with the mark
"UP" facing up.
6. Install:
• clutch lever holder 1
NOTE:
Align the slit in the clutch lever a holder with the
punch mark in the handlebar.
7. Install:
• left handlebar switch 2
NOTE:
Aligh the matching surface on the handlebar
switches with the punch mark a on the handle-
bar.
8. Install:
• clutch cable
9. Connect:
• clutch switch coupler
NOTE:
Apply a thin coat of lithium soap base grease onto
the end of the clutch cable.
10. Adjust:
• clutch cable free play
Refer to “ADJUSTING THE CLUTCH
CABLE FREE PLAY” in Chapter 3.
11. Adjust:
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in Chapter 3.
44
STEERING HEAD
CHAS
STEERING HEAD
LOWER BRACKET
45
STEERING HEAD
CHAS
46
ELECTRICAL COMPONENTS
ELEC
ELECTRICAL
ELECTRICAL COMPONENTS
1 Main switch 6 Oil level gauge assembly
2 Igniter unit 7 Neutral switch
3 Ignition coil (rear cylinder) 8 Sidestand switch
4 Ignition coil (front cylinder) 9 Speed sensor
5 Horn 0 Immobilizer control unit
47
ELECTRICAL COMPONENTS
ELEC
q Fuel meter senser unit y Relay assembly
w Battery u Fuse assembly
e Starter relay i Rectifier/regulator
r Relay assembly o Thermo switch
t Flasher relay
48
SWITCHES
ELEC
EAS0010
SWITCHES
CHECKING SWITCH CONTINUITY
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.
CAUTION:
Never insert the tester probes into the coupler
terminal slots 1. Always insert the probes
from the opposite end of the coupler, taking
care not to loosen or damage the leads.
Pocket tester
90890-03112
NOTE:
• Before checking for continuity, set the pocket
tester to “0” and to the “Ω x 1” range.
• When checking for continuity, switch back and
forth between the switch positions a few times.
49
CHECKING THE SWITCHES
ELEC
EAS00731
50
CHECKING THE SWITCHES
ELEC
1 Clutch switch 8 Hazard switch
2 Pass switch 9 Engine stop switch
3 Horn switch 0 Start switch
4 Dimmer switch q Fuses
5 Turn switch w Rear brake switch
6 Main switch e Sidestand switch
7 Front brake switch r Neutral switch
51
CHECKING THE BULBS AND BULB SOCKETS
ELEC
EAS00732
TYPES OF BULBS
Le lampadine utilizzate su questo motociclo sono
illustrate nella figura a sinistra.
• The bulbs used on this motorcycle are shown in
the illustration on the left.
• Bulbs A and B are used for headlights and
usually use a bulb holder which must be de-
tached before removing the bulb. The majority of
these bulbs can be removed from their respec-
tive socket by turning them counterclockwise.
• Bulb C is used for turn signal and tail/brake
lights and can be removed from the socket by
pushing and turning the bulb counterclockwise.
• Bulbs D and E are used for meter and indicator
lights and can be removed from their respective
socket by turn D and pulling E them out.
52
CHECKING THE BULBS AND BULB SOCKETS
ELEC
WARNING
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
CAUTION:
• Be sure to hold the socket firmly when
removing the bulb. Never pull the lead, oth-
erwise it may be pulled out of the terminal in
the coupler.
• Avoid touching the glass part of the headlight
bulb to keep it free from oil, otherwise the
transparency of the glass, the life of the bulb
and the luminous flux will be adversely affect-
ed. If the headlight bulb gets soiled, thor-
oughly clean it with a cloth moistened with
alcohol or lacquer thinner.
2. Check:
• bult (for continuity)
(with the pocket tester)
No continuity → Replace.
Pocket tester
90890-03112
NOTE:
Before checking for continuity, set the pocket
tester to “0” and to the “Ω x 1” range.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the tester positive probe to terminal
1 and the tester negative probe to terminal
2, and check the continuity.
b. Connect the tester positive probe to terminal
1 and the tester negative probe to terminal
3, and check the continuity.
c. If either of the readings indicate no continuity,
replace the bulb.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
53
CHECKING THE BULBS AND BULB SOCKETS
ELEC
CHECKING THE CONDITION OF THE BULB
SOCKETS
The following procedure applies to all of the bulb
sockets.
1. Check:
• bulb socket (for continuity)
(with the pocket tester)
No continuity → Replace.
Pocket tester
90890-03112
NOTE:
Check each bulb socket for continuity in the same
manner as described in the bulb section; howev-
er, note the following.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the
respective leads of the bulb socket.
c. Check the bulb socket for continuity. If any of
the readings indicate no continuity, replace
the bulb socket.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
54
EB805000
B B2 RG RG B2 B 50
YL GL RW RW GL YL
B2
YL
GL
RG
RW
1 B R
W W
R
R
(BLACK)
Gy1
4
Gy BL B Gy
CIRCUIT DIAGRAM
BL
RB
SbW
L LB LR
L
SbW RB
W W R 5
W W L RW LG LY Sb BY LW
W W W W R
W W 2 B R RW
W W RB
YL
RB
RW
L Lg LR YB Y L Gy1 LY RB RW B Br Or
B
B
LB
YL WB Sb W RL BL G Gy2 Or
Sb
LY
LG
BY
LR
B
LW
11
B
Or
LB
B
7 8
BrR BrR B 9
B RB
BW 10
ON R B
R B LB LB B Gy2 Gy2
OFF LR
BrL BrL
(BLACK)
P (BLACK) PUMP
12
15
IMMOBILIZER SYSTEM
B2 B1 B1 B2
B
43 40 Gy1
PU
6
10A
BrL RW
Y L L Y L L VCC
B2 3 BL B Y Y Sb
TPS NS
B1 B BL Br G B
S.GND SL1 B G
13 G LR Y
40 SL2 Y LR
BB3 LY
SS
BB4 WB HD
48
RL +B
RB
RW
LW
BB2 MAIN HARNESS HEAD LIGHT
SP RPM GND
BB1
G
LG
Br
W
21
YB
GY RB
RB GY
17
RW Br Br RW HAZARD E/G STOP START
B B 10A OFF OFF FREE G Br
R 49
B B ON RUN PUSH B BrB BrB B
B
B B LG B 14
LW B B LW
(BLUE) (BLUE)
Dg BrW Ch Ch BrW Dg
BB3 BB2 16
BB4 BB1 MAIN HARNESS CARB.HEATER
Dg
Gy
Br
Ch
BrW
55
18
BrL 15A RY
B GW GW B
19 38
10A
BrL Br
B
BrG
RY
RY
42 RY
Br
LB Br
45 L
5A RY WB BrW
R RL
25 W
P BrG
B B BL
(BLACK)
LB
WB
GY
L W
47
BrW
W L 41
GY Br
BL B
10A BrG
46
BrR
P
24
RY
LY
BY
BrW
LB
Ch BrW Dg Dg BrW Ch
PASSING DIMMER HORN 23 TURN
15A
BrL BrY
20 OFF HI OFF L
ON LO ON N
R
G P B RY
BrY
RY B P G LY
Y BY LY LB LB LY BY Y 26
BY
34 51 (BLACK)
Y
Dg
G
Ch
B B
BrBBrY
22
Y B
)
%
#
h
a
t
0
5
3
HI BEAM
BrB
IMOBILIZER
IMMOBILIZER SYSTEM
LR
GL
Y
G
B B B
LR
BrB B BrB
44
A
A
G
Y
LR A
30 32 RG Br B GW Dg Ch GL
LR
GY
BrB
12V5W
BrB
31
Ch
33
Dg
Dg
Ch
B
LR B B LR W YB Y BW SbW
Ch
Ch
Dg
Dg
Battery
Y
LR
B
12V10W
12V10W
12V21/5W
Sb
12V10W
12V10W
LR B GY
12V5W
Igniter unit
12V60/55W
29 Ch Dg Ch Dg
Igniter fuse
B B B B
Main switch
GY B LR
Ignition fuse
B
B
Backup fuse
B
ELEC
B B
B
B
27
B
B
B
G
Sb
35 36 37
39 Y B Ch Dg Ch Dg
Sb
B B B
B A B
28
Multi-function display
The key with the red bow is used to register codes in each standard key. Do not use the key with the red
bow for driving. It should only be used for re-registering new codes in the standard keys. The immobiliz-
er system cannot be operated with a new key until the key registered with a code. If you lose the code re-
registering key, the igniter unit and main switch (included with an immobilizer unit) needs to be re-placed.
Therefore, always use a standard key for driving. (See caution below.)
NOTE:
Each standard key is registered during production, therefore re-registering at purchase is not necessary.
CAUTION:
• DO NOT LOSE THE CODE RE-REGISTERING KEY! If the code re-registering key is lost, registering
new codes in the standard keys is impossible. The standard keys can still be used to start the vehi-
cle, however if code re-registering is required (i.e., if a new standard key is made or all keys are lost)
the entire immobilizer system must be replaced. Therefore, it is highly recommended to use either
standard key after any code re-registering and keep the code re-registering key in a safe place.
• Do not submerse either of the keys in water.
• Do not expose the keys to excessively high temperatures.
• Do not place either of the keys close to magnets (this includes, but not limited to, products such as
speakers, etc.).
• Do not place heavy items on either key.
• Do not grind either key or alter their shape.
• Do not disassemble the plastic part of either key.
• Keep other immobilizer keys away for this unit’s code re-registering key and main switch.
56
IMMOBILIZER SYSTEM
ELEC
KEY CODES REGISTRATION METHOD
In the course of use, you may encounter the following case where replace these parts and registration
of code re-registering/ standard key is required.
NOTE:
Each standard key is registered during production, therefore re-registering at purchase is not neces-sary.
*1 Replaced as a set with the immobilizer unit. (Because attended to replace the code re-registering key)
*2 Accessory locks mean the seat lock, fuel tank cap or the helmet holder.
NOTE:
It is prohibited to start the engine with the standard key that is not registered.
If the main switch is turned “ON” with the standard key that is not registered, the immobilizer system indicator
light blinks and indicates the error code “52”.
(Refer to “SELF-DIAGNOSIS ERROR CODE INDICATION”).
57
IMMOBILIZER SYSTEM
ELEC
1. Check that the immobilizer system indicator light is flashing. It indicates the “standby mode”. To initiate
the standby mode, turn “OFF” the main switch and then it will be the standby mode when it passes 30
seconds. After 24 hours have passed, the indicator light stop flashing and the standby mode ends.
2. After the main switch is turned “ON” with the code re-registering key, before 5 seconds elapses, turn
“OFF” the main switch and then turn “ON” the main switch with the standard key (the first new key) that
you want to register.
3. It enters the key registration mode and the two standard key codes that have been stored in the mem-
ory are erased and the first new standard key code will be registered. At this time, the indicator light
rapidly blinks (“OFF” for 0.5 sec. and “ON” for 0.5 sec.).
4. In the condition as mentioned above (while the indicator light continues rapid flashing), after the main
switch is turned “ON” with the first new standard key, turn “OFF” the main switch before 5 seconds
elapses, and then turn “ON” the main switch with the standard key that you want to register (which is
the second new key or the standard key remained in hand).
5. When the registration is finished, the indicator light goes off.
6. Check that the engine can be started with the two registered standard keys.
NOTE:
The flashing stops when 5 seconds elapses and the registration mode is finished. In this case, the seccond stan-
dard key cannot be registered and only the first standard key is registered.
58
IMMOBILIZER SYSTEM
ELEC
EAS00781 EAS00739
TROUBLESHOOTING 2. Battery
The immobilizer system fail to operate. • Check the condition of the battery. Refer to
(The immobilizer system indicator light “CHECKING AND CHARGING THE BAT-
starts to blinking the self-diagnosis code se- TERY” in chapter 3.
quence.) Open-circuit voltage
12.8 V or more at 20 °C
Check:
1. Main, ignition and backup fuses • Is the battery OK?
2. Battery YES NO
3. Main switch
4. Wiring (of the entire immobilizer system) • Clean the battery
NOTE: terminals.
• Before troubleshooting, remove the following • Recharge or replace
part(-s). the battery.
1) Seat
2) Side covers
3) Fuel tank (lift) EAS00749
EAS00738
Replace the main
1. Main, ignition and backup fuses switch.
• Check the main, ignition and backup fuses
for continuity.
Refer to “CHECKING THE FUSES” in chap-
ter 3. EAS00787
YES NO
59
IMMOBILIZER SYSTEM
ELEC
CHECKING THE IMMOBILIZER SYSTEM
• Set the main switch to “ON”.
1. Immobilizer system indicator light does not go • Measure the voltage (12 V) between red/
on when the main switch is turned “ON”. green and black on the immobilizer unit.
• Are the voltage within specification?
1. Voltage
YES NO
• Connect the pocket tester (DC 20 V) to the
multi-function display couplers as shown.
The wiring circuit
Tester positive probe – green/blue 1 from the battery to
Tester negative probe – black 2 the immobilizer unit
is faulty and must be
repaired.
2 1
Dg Ch GL 3. Voltage
RG Br B GW
Y BW SbW • Connect the pocket tester (DC 20 V) to the
W YB
immobilizer unit couplers as shown.
Tester positive probe – red/white 1
Tester negative probe – black 2
• Set the main switch to “ON”.
• Measure the voltage (12 V) between green/
blue and black on the multi-function display. 2
• Are the voltage within specification?
B B2 RG RG B2 B
YES NO
YL GL RW RW GL YL
Replace the multi-
function display 1
B B2 RG RG B2 B
YL GL RW RW GL YL
60
IMMOBILIZER SYSTEM
ELEC
4. Voltage
• Connect the pocket tester (DC 20 V) to the
immobilizer unit couplers as shown.
Tester positive probe – green/blue 1
Tester negative probe – black 2
B B2 RG RG B2 B
YL GL RW RW GL YL
YES NO
61
IMMOBILIZER SYSTEM
ELEC
SELF-DIAGNOSIS ERROR CODE INDICATION
When the system failure occurred, the error code number is indicated in the immobilizer system indicator
light blinks at the same time. The pattern of blinking also shows the error code.
Error
Detection Symptoms Trouble Measures
code
51 IMMOBILIZER Cannot transmit code 1) Objects that may keep off radio 1) Keep clear of magnets,
UNIT between the key and waves exist around the keys and metals and other keys
immobilizer unit. antennas. from the surroundings of
2) Immobilizer unit failure. keys and antennas.
3) Key failure. 2) Replace the immobilizer
unit.
3) Replace the key.
52 IMMOBILIZER Codes do not match 1) Disturbed by other transponder. 1) Place the immobilizer
UNIT between the key and Failed to verify continually for ten unit away more than 50
immobilizer unit. times. mm from the transpon-
2) Unregistered sub key was used. der of other vehicle.
2) Register the standard
key.
53 IMMOBILIZER Cannot transmit code be- Noise interference or disconnected 1) Check the wire harness
UNIT tween the ignitor unit and lead/cable. and connector.
immobilizer unit. 1) Obstruction due to radio wave 2) Replace the immobilizer
noise. unit.
2) Error by disconnection of the 3) Replace the ignitor unit.
communication harness.
3) Immobilizer unit failure.
4) Ignitor unit failure.
54 IMMOBILIZER Codes do not match be- Noise interference or disconnected 1) Register the code re-
UNIT tween ignitor unit and im- lead/cable. registering key ID.
mobilizer unit. 1) Obstruction due to radio wave 2) Replace the immobilizer
noise. unit.
2) Immobilizer unit failure. 3) Replace the ignitor unit.
3) Ignitor unit failure (When the
used parts from other vehicles
are used, the code re-registering
key ID is not registered to the
ECU.)
55 IMMOBILIZER Key code registration error. Same standard key was attempted Prepare the new standard
UNIT to continuously two times register. key and register it.
56 ECU IGNITER Underfinition code is re- Noise interference or disconnected 1) Check the wire harness
UNIT ceived. lead/cable. and connector.
2) Replace the immobilizer
unit.
3) Replace the ignitor unit.
Light OFF
62
SELF-DIAGNOSIS DEVICE ELEC
SELF-DIAGNOSIS DEVICE
When the key is turned to "ON", the tachometer and
speedometer needles should move to the maximum, 0 / r/min (for 3 seconds)
then back to zero. In addition all the warning lights and
the indicator lights should come on for a few seconds,
then go off. If the tachometer or speedometer needle Indication of the r/min corresponding
does not move as described or either of the warning to the first figure of error code
lights or indicator lights do not come on, check their (for 2.5 seconds)
electrical circuits.
This model is equipped with a self-diagnosis device for
the following electrical circuits:
• speedometer 0 / r/min (for 0.5 second)
• tachometer
• throttle position sensor
• speed sensor
• ignition coil No. 1 Indication of the r/min corresponding
• ignition coil No. 2 to the second figure of error code
(for 2.5 seconds)
• fuel cut solenoid carburetor No. 1
• fuel cut solenoid carburetor No. 2.
If any of the above circuits are defective, the tachometer
needle will repeatedly signal a two digit error code (e.g., Current engine speed
(for 3 seconds)
15, 16, 23, 24, 33, 34, 42).
If the tachometer needle signal such an error code, note
the circuit-specific number of r/min and check the oper-
ation of the system according to the following procedure.
r/min Open circuit the Fuel is cut off only to the cylinder
3 3 Ignition coil No. 1
primary in which a malfunction is detected.
Disconnected
4 2 r/min Speed sensor
Short-circuit
63
SELF-DIAGNOSIS DEVICE ELEC
EASB0044
Lg LR YB Y L Gy1 LY RB RW B Br Or
RB
YL
LB
YL WB Sb W RL BL G Gy2
LR
Or
LB
9
B LB LB B
10
Gy2
LR
(BLACK) (BLACK) PUMP
B
Gy1
PU
Y L L Y L L VCC
BL B Y Y Sb
TPS NS
13 B BL
S.GND SL1
SL2
Br
G
LY
SS
WB HD
RL +B
SP RPM GND
YB
W
0 Ignitor unit
e Throttle position sensor
64
SELF-DIAGNOSIS DEVICE ELEC
1. Speed sensor
CIRCUIT DIAGRAM
RB
SbW RB L LB LR
LG LY Sb BY LW
RB
RW
RB
YL
Lg LR YB Y L Gy1 LY RB RW B Br Or
LB
11
YL WB Sb W RL BL G Gy2 Or
LG
LR
Or
LB
9
10 RB
12
B LB LB B Gy2 Gy2
LR
(BLACK) (BLACK) PUMP
B
Gy1
PU
Y L L Y L L VCC
BL B Y Y Sb
TPS NS
13 B BL
S.GND SL1
SL2
Br
G
B G
Y LR
G B
LR Y
LY
SS 48
WB
RL
HD
+B
MAIN HARNESS HEAD LIGHT
• Set the main switch to “ON”.
SP RPM GND
G
• Turn the rear wheel slowly.
LG
Br
YB
W
49 G Br
• Check the tester voltage (0 V ~ 5 V ~ 0 V).
14
B BrB BrB B
B
B B LG B
(BLUE) (BLUE)
YES NO
25 L
W
BL
41
BrW
L W W L
BL B
BrW
0 Ignitor unit
! Speed sensor
1. Wire harness
• Check the wire harness for continuity.
Refer to "CIRCUIT DIAGRAM".
• Is the wire harness OK?
YES NO
2. Speed sensor
• Place the motorcycle on a suitable stand so
that the rear wheel is elevated.
• Connect the pocket tester (DC 20 V) to the
speed sensor connector.
Tester (+) lead → White terminal 1
Tester (–) lead → Body earth
65
SELF-DIAGNOSIS DEVICE ELEC
3. Ignition coil N. 1 and 2
1. Wiring
• Check the entire ignition system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the ignition system’s wiring properly con-
nected and without defects?
YES NO
Secondary coil resistance
Repair or replace the 10.7 14.5 k at 20°C (68°F)
wire harness.
• Is the ignition coil OK?
YES NO
EAS00747
Replace the ignitor Replace the ignition
2. Ignition coil resistance unit. coil.
The following procedure applies to all of the
ignition coils.
• Disconnect the ignition coil connectors from
the ignition coil terminals.
• Connect the pocket tester ( 1) to the igni-
tion coil as shwon.
Tester positive probe → Red/Black
Tester negative probe → Orange (Gray)
66
SELF-DIAGNOSIS DEVICE ELEC
4. Fuel-cut solenoid (EUR)
CIRCUIT DIAGRAM
L LB LR
Sb BY LW
RB
RW
RB
YL
Lg LR YB Y L Gy1 LY RB RW B Br Or
L WB Sb W RL BL G Gy2 Or
11
Or
9 RB
LB
10
LB B Gy2 Gy2
CK) (BLACK)
LR
PUMP
12
Gy1
PU
Y L L Y L L VCC
BL B Y Y Sb
TPS NS
B BL Br
S.GND SL1
G
SL2
LY
WB
SS
HD
48
RL +B
SP RPM GND
G
Br
YB
W
49 G Br
B 14
UE)
0 Igniter unit
* Fuel-cut solenoid 1
( Fuel-cut solenoid 2
1. Wire harness
• Check the wire harness for continuity.
Refer to “CIRCUIT DIAGRAM”.
• Is the wire harness OK?
YES NO
67
B B2 RG RG B2 B 50
YL GL RW RW GL YL
B2
YL
GL
RG
RW
1 B R
W W
R
R
CIRCUIT DIAGRAM
(BLACK)
Gy1
4
Gy BL B Gy
BL
RB
SbW
L LB LR
L
SbW RB
W W R 5 LG LY Sb BY LW
30A
W W L RW
W W W W R
W W 2 B R RW
W W RB
YL
RB
RW
L Lg LR YB Y L Gy1 LY RB RW B Br Or
B
B
LB
IGNITION SYSTEM
YL WB Sb W RL BL G Gy2 Or
Sb
LY
LG
BY
LR
B
LW
11
B
Or
LB
B
7 8
BrR BrR B 9
B RB
BW 10
ON R B
R B LB LB B Gy2 Gy2
OFF LR
BrL BrL
(BLACK)
P (BLACK) PUMP
12
B2 B1 B1 B2
15
B
43 40 Gy1
PU
6
10A
BrL RW
Y L L Y L L VCC
B2 3 BL B Y Y Sb
TPS NS
B1 B BL Br G B
S.GND SL1 B G
13 G LR Y
40 SL2 Y LR
BB3 LY
SS
BB4 WB HD
48
RL +B
RB
RW
LW
BB2 MAIN HARNESS HEAD LIGHT
SP RPM GND
BB1
G
LG
Br
W
21
YB
GY RB
RB GY
17
RW Br Br RW HAZARD E/G STOP START
B B 10A OFF OFF FREE G Br
R 49
B B ON RUN PUSH B BrB BrB B
B
B B LG B 14
LW B B LW
(BLUE) (BLUE)
Dg BrW Ch Ch BrW Dg
BB3 BB2 16
BB4 BB1 MAIN HARNESS CARB.HEATER
Dg
Gy
Br
Ch
BrW
68
18
BrL 15A RY
B GW GW B
19 38
10A
BrL Br
B
BrG
RY
1 Pickup coil
RY
42 RY
Br
LB Br
45 L
3 Main switch 5A RY WB BrW
R RL
25 W
P BrG
B B BL
(BLACK)
LB
WB
GY
L W
47
BrW
4 Starter relay W L 41
GY Br
BL B
10A BrG
46
BrR
P
24
RY
LY
BY
BrW
LB
5 Battery Ch BrW Dg Dg BrW Ch
PASSING DIMMER HORN 23 TURN
15A
BrL BrY
20 OFF HI OFF L
6 Wire minus lead ON LO ON N
R
G P B RY
BrY
RY B P G LY
Y BY LY LB LB LY BY Y 26
8 Starting circuit cut-off relay BY
34 51 (BLACK)
B
Y
Dg
G
Ch
B B
BrBBrY
0 Igniter unit 22
Y HI BEAM B
BrB
IGNITION SYSTEM
LR
GL
Y
G
B B B
LR
BrB B BrB
44
A
A
G
Y
LR A
r Sidestand switch 30 32 RG Br B GW Dg Ch GL
LR
GY
BrB
12V5W
BrB
31
Ch
33
Dg
Dg
Ch
B
LR B B LR W YB Y BW SbW
Ch
Ch
Dg
Dg
G
Y
LR
t Ignition fuse
12V10W
12V10W
12V21/5W
Sb
12V10W
12V10W
LR B GY
12V5W
12V60/55W
B
GY B LR
ELEC
B
B
B
B B
B
B
27
B
B
B
G
Sb
B B B
B A B
k Neutral switch 28
# Alarm system (Option)
) Immobilizer control unit
IGNITION SYSTEM
ELEC
EASB0030 EAS00739
TROUBLESHOOTING 2. Battery
The ignition system fails to operate (no • Check the condition of the battery.
spark or intermittent spark). Refer to “CHECKING AND CHARGING THE
BATTERY” in Chapter 3.
Check:
Min. open-circuit voltage
1. Main and ignition fuses
12.8 V or more at 20 °C (68 °F)
2. Battery
3. Spark plugs • Is the battery OK?
4. Ignition spark gap
YES NO
5. Spark plug cap resistance
6. Ignition coil resistance
7. Pickup coil resistance • Clean the battery ter-
8. Main switch minals.
9. Engine stop switch • Recharge or replace
10. Neutral switch the battery.
11. Sidestand switch
12. Wiring (of the entire ignition system)
EAS00741
NOTE:
3. Spark plugs
• Before troubleshooting, remove the following
part(-s): The following procedure applies to all of the
1) Seat spark plugs.
2) Side covers • Check the condition of the spark plug.
3) Fuel tank (lift) • Check the spark plug type.
4) Cowling (lift forward) • Measure the spark plug gap.
5) Storage compartment/battery cover Refer to “CHECKING THE SPARK PLUGS”
6) Cylinder head covers in Chapter 3.
• Troubleshoot with the following special tool(-s).
Standard spark plug
BPR7ES
Ignition checker W22EPR-U
90890-06754 Spark plug gap
Pocket tester 0.7 0.8 mm
90890-03112 • Is the spark plug in good condition, is it of the
EAS00738
correct type, and its gap within specification?
YES NO
69
IGNITION SYSTEM
ELEC
EAS00743
NO YES
EAS00745
• Measure the primary coil resistance.
5. Spark plug cap resistance.
Primary coil resistance
The following procedure applies to all of the 3.57 4.83 at 20°C (68 °F)
spark plug caps.
• Disconnect the spark plug cap from the spark • Connect the pocket tester ( 1k) to the
plug. ignition coil as shown.
• Connect the pocket tester ( 1k) to the • Measure the secondary coil resistance.
spark plug cap as shown. Tester positive probe →
• Measure the spark plug cap resistance. spark plug lead 1
Tester negative probe →
Orange (gray) lead 2
70
IGNITION SYSTEM
ELEC
EAS00749
8. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
YES NO
EAS00748
Replace the right
7. Pickup coil resistance handlebar switch.
• Disconnect the pickup coil coupler from the
wire harness.
• Connect the pocket tester ( 100) to the
EAS00751
pickup coil terminal.
10. Neutral switch
Tester positive probe → Gray 1
Tester negative probe → Black 2 • Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the neutral switch OK?
YES NO
71
IGNITION SYSTEM
ELEC
✳
EAS00754
14. Wiring
• Check the entire ignition system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the ignition system’s wiring properly con-
nected and without defects?
NO YES
72
B B2 RG RG B2 B 50
YL GL RW RW GL YL
B2
YL
GL
RG
RW
1 B R
W W
CIRCUIT DIAGRAM
R
R
(BLACK)
Gy1
4
Gy BL B Gy
BL
RB
SbW
L LB LR
L
SbW RB
W W R 5 LG LY Sb BY LW
30A
W W L RW
W W W W R
W W 2 B R RW
W W RB
YL
RB
RW
L Lg LR YB Y L Gy1 LY RB RW B Br Or
B
B
LB
YL WB Sb W RL BL G Gy2 Or
Sb
LY
LG
BY
LR
B
LW
11
B
Or
LB
B
7 8
BrR BrR B 9
B RB
BW 10
ON R B
R B LB LB B Gy2 Gy2
OFF LR
BrL BrL
(BLACK)
P (BLACK) PUMP
12
B2 B1 B1 B2
15
B
43 40 Gy1
PU
6
10A
BrL RW
Y L L Y L L VCC
B2 3 BL B Y Y Sb
TPS NS
B1 B BL Br G B
S.GND SL1 B G
13 G LR Y
40 SL2 Y LR
BB3 LY
SS
BB4 WB HD
48
RL +B
RB
RW
LW
BB2 MAIN HARNESS HEAD LIGHT
SP RPM GND
BB1
G
LG
ELECTRIC STARTING SYSTEM
Br
W
21
YB
GY RB
RB GY
17
RW Br Br RW HAZARD E/G STOP START
B B 10A OFF OFF FREE G Br
R 49
B B ON RUN PUSH B BrB BrB B
B
B B LG B 14
LW B B LW
(BLUE) (BLUE)
Dg BrW Ch Ch BrW Dg
BB3 BB2 16
BB4 BB1 MAIN HARNESS CARB.HEATER
Dg
Gy
Br
Ch
BrW
73
18
BrL 15A RY
B GW GW B
19 38
10A
BrL Br
B
BrG
RY
RY
3 Main switch 42 RY
Br
LB Br
45 L
5A RY WB BrW
R RL
25 W
4 Starter relay P BrG
B B BL
(BLACK)
LB
WB
GY
L W
47
BrW
W L 41
GY Br
5 Battery BL B
10A BrG
46
BrR
P
24
RY
LY
BY
BrW
LB
6 Wire minus lead Ch BrW Dg Dg BrW Ch
PASSING DIMMER HORN 23 TURN
15A
BrL BrY
20 OFF HI OFF L
ON LO ON N
7 Starter motor R
G P B RY
BrY
RY B P G LY
Y BY LY LB LB LY BY Y 26
BY
8 Starting circuit cut-off relay 34 51 (BLACK)
B
Y
Dg
G
Ch
B B
BrBBrY
22
Y HI BEAM B
BrB
r Sidestand switch
ELECTRIC STARTING SYSTEM
IMOBILIZER
LR
t Ignition fuse GL
Y
G
B B B
LR
BrB B BrB
44
A
A
G
Y
LR A
LR
y
GY
BrB
12V5W
BrB
31
Ch
33
Dg
Dg
Ch
B
LR B B LR W YB Y BW SbW
Ch
Ch
Dg
Dg
G
Y
LR
B
d Clutch switch
12V10W
12V10W
12V21/5W
Sb
12V10W
12V10W
LR B GY
12V5W
12V60/55W
Ch Dg Ch Dg
ELEC
B
GY B LR
B
B
B
B B
B
B
27
B
B
B
G
Sb
Neutral switch 35 36 37
Y B
k 39 Ch Dg Ch Dg
Sb
B B B
B A B
1 Battery
2 Main fuse
3 Main switch
4 Ignition fuse
5 Engine stop switch
6 Starting circuit cut-off relay
7 Starter motor
8 Clutch switch
9 Sidestand switch
0 Neutral switch
q Start switch
w Starter relay
74
ELECTRIC STARTING SYSTEM
ELEC
EASB0031 EAS00739
TROUBLESHOOTING 2. Battery
The starter motor fails to turn. • Check the condition of the battery.
Refer to “CHECKING AND CHARGING THE
Check: BATTERY” in Chapter 3.
1. Main and ignition fuses
Min. open-circuit voltage:
2. Battery
12.8 V or more at 20 °C (68 °F)
3. Starter motor
4. Starting circuit cut-off relay • Is the battery OK?
5. Starter relay
YES NO
6. Main switch
7. Engine stop switch
8. Neutral switch • Clean the battery ter-
9. Sidestand switch minals.
10. Clutch switch • Recharge or replace
11. Start switch the battery.
12. Wiring (of the entire starting system)
EAS00758
NOTE:
• Before troubleshooting, remove the following 3. Starter motor
part(-s): • Connect the battery positive terminal 1 and
1) Seat starter motor lead 2 with a jumper lead 3.
2) Side covers
3) Fuel tank (lift)
4) Cowling (lift forward)
5) Storage compartment/battery cover
• Troubleshoot with the following special tool(-s).
Pocket tester
90890-03112
EAS00738
WARNING
1. Main and ignition fuses
• A wire that is used as a jumper lead must
• Check the main and ignition fuses for conti- have at least the same capacity of the
nuity. battery lead, otherwise the jumper lead
Refer to “CHECKING THE FUSES” in may burn.
Chapter 3 • This check is likely to produce sparks,
• Are the main and ignition fuses OK? therefore make sure that no flammable
gas or fluid is in the vicinity.
YES NO
• Does the starter motor turn?
Replace the fuse(-s).
YES NO
75
ELECTRIC STARTING SYSTEM
ELEC
EAS00739 EAS00761
• Does the starting circuit cut-off relay have • Does the starter relay have continuity
continuity between Black and Blue/White? between Red and Black?
YES NO YES NO
EAS00749
6. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
YES NO
76
ELECTRIC STARTING SYSTEM
ELEC
EAS00750 EAS00764
YES NO YES NO
EAS00751 EAS00766
9. Sidestand switch
• Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the sidestand switch OK?
YES NO
EAS00763
YES NO
77
ELECTRIC STARTING SYSTEM
ELEC
STARTER MOTOR
78
ELECTRIC STARTING SYSTEM
ELEC
8 Planetary gears 2
9 Armature assembly 1
0 Brush holder/brush 1/1
Refer to “Assembling the starter motor.”
q Starter motor yoke 1
For assembly, reverse the disassembly
procedure.
79
ELECTRIC STARTING SYSTEM
ELEC
EAS00769
3. Measure:
• mica undercut a
Out of specification → Scrape the mica to
the proper measurement with a hacksaw
blade which has been grounded to fit the
commutator.
Mica undercut
0.7 mm
NOTE:
The mica must be undercut to ensure proper
operation of the commutator.
4. Measure:
• armature assembly resistances (commuta-
tor and insulation)
Out of specification → Replace the starter
motor.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the armature assembly resistances
with the pocket tester.
Pocket tester
90890-03112
Armature assembly
Armature coil resistance 1
0.026 0.034 at 20°C (68 °F)
Insulation resistance 2
Above 1 M at 20°C (68 °F)
b. If any resistance is out of specification,
replace the starter motor.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
80
ELECTRIC STARTING SYSTEM
ELEC
5. Measure:
• brush length a
Out of specification → Replace the brushes
as a set.
6. Measure:
• brush spring force
Out of specification → Replace the brush
springs as a set.
7. Check:
• gear teeth
Damage/wear → Replace the gear.
8. Check:
• oil seal
Damage/wear → Replace the defective
part(-s).
EAS00772
2. Install:
• starter motor yoke 1
• end bracket 2
• starter motor front cover 3
NOTE:
Align the projection a on the front cover with the
slot b on the end cover and starter motor yoke.
81
ELECTRIC STARTING SYSTEM
ELEC
3. Install:
• starter motor rear cover 1
NOTE:
Align the match marks a on the rear cover with
the match marks b on the front cover.
82
CIRCUIT DIAGRAM
1 B R
W W
R
R
(BLACK)
Gy1
4
Gy BL B Gy
CHARGING SYSTEM
BL
W W R 5
30A
W W L RW
W W W W R
W W 2 B R RW
W W
L
B
B
B
B
BrR BrR B
B
7
ON R B
R
OFF
83
BrL BrL
P
43 B2 B1 B1 B2
15
6
10A
BrL RW
B2 3
B1
BB3
BB4
BB2
BB1
21 RB GY GY RB
17
RW Br Br RW HAZARD E/G STOP
CHARGING SYSTEM
6
5
4
2
1
B B ON RUN
LW B B LW
Dg BrW Ch Ch BrW Dg
BB3 BB2
BB4 BB1
Battery
ELEC
Dg
Gy
Br
Ch
BrW
Pickup coil
Starter relay
TROUBLESHOOTING 2. Battery
The battery is not being charged. • Check the condition of the battery.
Refer to “CHECKING AND CHARGING THE
Check: BATTERY” in Chapter 3.
1. Main fuse Min. open-circuit voltage
2. Battery 12.8 V or more at 20 °C (68 °F)
3. Charging voltage
4. Startor coil assembly resistance • Is the battery OK?
5. Wiring (of the entire charging system) YES NO
NOTE:
• Before troubleshooting, remove the following • Clean the battery ter-
part(-s): minals.
1) Seat • Recharge or replace
2) Side covers the battery.
3) Storage compartment/battery cover
• Troubleshoot with the following special tool(-s).
EAS00775
Engine tachometer
90890-03113 3. Charging voltage
Pocket tester • Connect the engine tachometer to the spark
90890-03112 plug lead of cylinder #1.
• Connect the pocket tester (DC 20 V) to the
EAS00738
battery as shown.
YES NO
84
CHARGING SYSTEM ELEC
EAS00779
NOTE:
5. Wiring
Make sure that the battery is fully charged.
• Check the wiring connections of the entire
• Is the charging voltage within specification? charging system.
Refer to “CIRCUIT DIAGRAM”.
NO YES • Is the charging system’s wiring properly
conected and without defects?
The charging circuit
is OK. NO YES
YES NO
85
B B2 RG RG B2 B
YL GL RW RW GL YL
50
B2
YL
GL
RG
RW
1 B R
W W
R
R
Gy1 (BLACK) 4
Gy BL B Gy
BL
RB
SbW
L LB LR
L
SbW RB
W W R
CIRCUIT DIAGRAM
W W
5 L RW LG LY Sb BY LW
W W W W R
W W 2 B R RW
W W RB
YL
RB
RW
L Lg LR YB Y L Gy1 LY RB RW B Br Or
B
B
LB
YL WB Sb W RL BL G Gy2 Or
Sb
LY
LG
BY
LR
B
LW
B
11
Or
LB
LIGHTING SYSTEM
B
8
B
BrR BrR B
7 9 RB
BW 10
ON R B
R B LB LB B Gy2 Gy2
OFF LR
BrL BrL
(BLACK)
P (BLACK) PUMP
12
B2 B1 B1 B2
15
B
43 40 Gy1
PU
6
10A
BrL RW
Y L L Y L L VCC
B2 3 BL B Y Y Sb
TPS NS
B1 B BL Br G B
S.GND SL1 B G
13 G LR Y
40 SL2 Y LR
BB3 LY
SS
BB4 WB HD
48
RL +B
RB
RW
LW
BB2 MAIN HARNESS HEAD LIGHT
SP RPM GND
BB1
G
LG
Br
W
21
YB
GY RB
RB GY
17
RW Br Br RW HAZARD E/G STOP START
B B 10A OFF OFF FREE G Br
R 49
B B ON RUN PUSH B BrB BrB B
B
B B LG B 14
LW B B LW
(BLUE) (BLUE)
Dg BrW Ch Ch BrW Dg
BB3 BB2 16
BB4 BB1 MAIN HARNESS CARB.HEATER
Dg
Gy
Br
Ch
BrW
86
18
BrL 15A RY
B GW GW B
19 38
10A
BrL Br
B
BrG
RY
RY
42 RY
Br
LB Br
45 L
5A RY WB BrW
R RL
25 W
P BrG
B B BL
(BLACK)
LB
WB
GY
L W
BrW
47 W L 41
GY Br
BL B
10A BrG
46
BrR
P
24
RY
LY
BY
BrW
LB
3 Main switch
Ch BrW Dg Dg BrW Ch
PASSING DIMMER HORN 23 TURN
Starter relay BrL 15A 20 HI
4 BrY OFF
LO
OFF
ON
L
ON N
R
G P B RY
BrY
5 Battery RY B P G LY
Y BY LY LB LB LY BY Y 26
BY
34 51 (BLACK)
B
Y
Dg
G
Ch
BrB
0 Igniter unit
IMOBILIZER
LR
GL
Y
G
B B B
LR
LIGHTING SYSTEM
BrB B BrB
y Right handlebar switch 44 A
Y
A
G
LR A
30 RG Br B GW Dg Ch GL
LR
32
GY
BrB
12V5W
BrB
31
Ch
Dg
Dg
33
Ch
B
i Headlight fuse LR B B LR W YB Y BW SbW
Ch
Ch
Dg
Dg
G
Y
LR
B
12V10W
12V10W
12V21/5W
Sb
s LR B GY
12V5W
12V60/55W
29 Ch Dg Ch Dg
B B B B
B
GY B LR
B
B
Speedometer
B
h
B B
B
B
27
B
B
B
G
Sb
35 36 37
B
ELEC
39 Y Ch Dg Ch Dg
Sb
l Headligh B B B
B A B
28
. Tail/brake light
$ License plate light
& Dimmer switch relay
LIGHTING SYSTEM
ELEC
EASB0033 EAS00739
TROUBLESHOOTING 2. Battery
Any of the following fail to light: headlight, • Check the condition of the battery.
high beam indicator light, license plate light Refer to “CHECKING AND CHARGING THE
or meter light. BATTERY” in Chapter 3.
Min. open-circuit voltage
Check: 12.8 V or more at 20 °C (68 °F)
1. Main and headlight fuses
2. Battery • Is the battery OK?
3. Main switch
YES NO
4. Dimmer switch
5. Pass switch
• Clean the battery ter-
6. Dimmer switch relay
minals.
7. Igniter unit
• Recharge or replace
8. Wiring (of the entire charging system)
the battery.
NOTE:
• Before troubleshooting, remove the following
part(-s). EAS00749
EAS00738 EAS00784
YES NO
The dimmer switch
is faulty. Replace the
Replace the fuse(-s). right handlebar
switch.
87
LIGHTING SYSTEM
ELEC
EAS00786
7. Igniter unit
5. Pass switch
• Disconnect the igniter unit from the coupler
• Check the pass switch for continuity. and connect a new one.
Refer to “CHECKING THE SWITCHES”. • Is the lighting system’s OK ?
• Is the pass switch OK?
YES NO
YES NO
Replace the igniter The igniter unit is OK.
The pass switch is unit.
faulty. Replace the
right handlebar
switch. EAS00787
8. Wiring
• Check the entire lighting system’s wiring.
6. Dimmer switch relay Refer to “CIRCUIT DIAGRAM”.
• Is the lighting system’s wiring properly con-
• Disconnect the dimmer switch relay from the
nected and without defects?
coupler.
• Connect the pocket tester ( 1) and bat-
YES NO
tery (12V) to the dimmer switch relay coupler.
Battery positive terminal → White/Black 1 Check the condition of Properly connect or
Battery negative terminal → Red/Yellow 2 each of the lighting repair the lighting sys-
Tester positive probe → Blue/Black 3 system’s circuits. tem’s wiring.
Tester negative probe → Red/Yellow 4 Refer to “CHECKING
THE LIGHTING SYS-
2 TEM”.
RY 3
LB EAS00788
YES NO
88
LIGHTING SYSTEM
ELEC
EAS00789
2. Voltage
• Connect the pocket tester (20 V) to the meter
assembly coupler (wire harness side) as
shown.
Tester positive probe → Brown 1
Tester negative probe → Black 2
89
LIGHTING SYSTEM
ELEC
EAS00790 EASB0034
3. A tail/brake light fails to come on. 4. The license plate light fails to come on.
YES NO YES NO
2. Voltage 2. Voltage
• Connect the pocket tester (DC 20 V) to the • Connect the pocket tester (DC 20 V) to the
tail/brake light coupler (wire harness side) as license plate light coupler (wire harness side)
shown. as shown.
Tester positive probe → Blue/Red 1 Tester positive probe → Blue/Red 1
Tester negative probe → Black 2 Tester negative probe → Black 2
• Set the main switch to “ON”. • Set the main switch to “ON”.
• Measure the voltage (12 V) of Blue/Red 1 • Measure the voltage (12 V) of Blue/Red 1
on the tail/brake light coupler (wire harness on the license plate light coupler (wire har-
side). ness side).
• Is the voltage within specification? • Is the voltage within specification?
YES NO YES
NO
This circuit is OK. The wiring circuit This circuit is OK. The wiring circuit
from the main switch from the main switch
to the tail/brake light to the license plate
coupler is faulty and light coupler is faulty
must be repaired. and must be re-
paired.
90
B B2 RG RG B2 B
YL GL RW RW GL YL
50
B2
YL
GL
RG
RW
1 B R
W W
R
R
CIRCUIT DIAGRAM
Gy1 (BLACK) 4
Gy BL B Gy
BL
RB
SbW
L LB LR
L
SbW RB
W W R 5 LG LY Sb BY LW
30A
W W L RW
W W W W R
W W 2 B R RW
W W RB
YL
RB
RW
L Lg LR YB Y L Gy1 LY RB RW B Br Or
B
B
LB
YL WB Sb W RL BL G Gy2 Or
Sb
LY
LG
BY
LR
B
LW
B
11
Or
LB
SIGNALING SYSTEM
B
8
B
BrR BrR B
7 9 RB
BW 10
ON R B
R B LB LB B Gy2 Gy2
OFF LR
BrL BrL
(BLACK)
P (BLACK) PUMP
12
B2 B1 B1 B2
15
B
43 40 Gy1
PU
6
10A
BrL RW
Y L L Y L L VCC
B2 3 BL B Y Y Sb
TPS NS
B1 B BL Br G B
S.GND SL1 B G
13 G LR Y
14 SL2 Y LR
BB3 LY
SS
BB4 WB HD
48
RL +B
RB
RW
LW
BB2 MAIN HARNESS HEAD LIGHT
SP RPM GND
BB1
G
LG
Br
W
21
YB
GY RB
RB GY
17
RW Br Br RW HAZARD E/G STOP START
B B 10A OFF OFF FREE G Br
R 49
B B ON RUN PUSH B BrB BrB B
B
B B LG B 14
LW B B LW
(BLUE) (BLUE)
Dg BrW Ch Ch BrW Dg
BB3 BB2 16
BB4 BB1 MAIN HARNESS CARB.HEATER
Dg
Gy
Br
Ch
BrW
91
18
BrL 15A RY
B GW GW B
19 38
10A
BrL Br
B
BrG
RY
RY
RY
Br
42 Br
LB
45 L
5A RY WB BrW
R RL
25 W
P BrG
B B BL
(BLACK)
LB
WB
GY
L W
BrW
47 W L 41
GY Br
BL B
10A BrG
46
BrR
P
24
RY
LY
BY
BrW
LB
Ch BrW Dg Dg BrW Ch
PASSING DIMMER HORN 23 TURN
BrL 15A 20
BrY OFF HI OFF L
ON LO ON N
R
G P B RY
BrY
RY B P G LY
Y BY LY LB LB LY BY Y 26
BY
34 51 (BLACK)
Y
Dg
G
Ch
B B
BrBBrY
22
Y HI BEAM B
BrB
SIGNALING SYSTEM
IMOBILIZER
LR
GL
Y
G
B B B
LR
BrB B BrB
44
A
A
G
Y
LR A
30 RG Br B GW Dg Ch GL
LR
32
GY
BrB
12V5W
BrB
31
Ch
Dg
Dg
33
Ch
B
LR B B LR W YB Y BW SbW
Ch
Ch
Dg
Dg
G
Y
LR
B
12V10W
12V10W
12V21/5W
Sb
12V10W
12V10W
LR B GY
12V5W
12V60/55W
29 Ch Dg Ch Dg
B B B B
B
GY B LR
B
B
B
ELEC
B B
B
B
27
B
B
B
G
Sb
35 36 37
39 Y B Ch Dg Ch Dg
Sb
B B B B
B A B
28
SIGNALING SYSTEM
ELEC
3 Main switch
4 Starter relay
5 Battery
6 Wire minus lead
t Ignition fuse
y Right handlebar switch
u Front brake switch
o Signal fuse
s Left handlebar switch
f Horn
g Flasher relay
h Multi-function display
j Neutral switch lead
k Neutral switch
; Front turn signal light (L)
z Front turn signal light (R)
x Rear turn signal light (L)
c Rear turn signal light (R)
. Tail/brake light
/ Oil level gauge
@ Rear brake switch
92
SIGNALING SYSTEM
ELEC
EASB0035 EAS00739
TROUBLESHOOTING 2. Battery
• Any of the following fail to light: turn signal • Check the condition of the battery.
light, brake light or an indicator light. Refer to “CHECKING AND CHARGING THE
• The horn fails to sound. BATTERY” in Chapter 3.
Min. open-circuit voltage
Check: 12.8 V or more at 20 °C (68 °F)
1. Main and signaling system fuses
2. Battery • Is the battery OK?
3. Main switch YES NO
4. Hazard switch
5. Wiring (of the entrire signaling system)
• Clean the battery ter-
NOTE: minals.
• Before troubleshooting, remove the following • Recharge or replace
part(-s): the battery.
1) Seat
2) Side covers EAS00749
3) Fuel tank (lift)
4) Cowling (lift forward) 3. Main switch
5) Storage compartment/battery cover • Check the main switch for continuity.
• Troubleshoot with the following special tool(-s). Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
Pocket tester
90890-03112 YES NO
93
SIGNALING SYSTEM
ELEC
EAS00795
2. Voltage
5. Wiring
• Connect the pocket tester (DC 20 V) to the
• Check the entire signaling system’s wiring. horn connector at the horn terminal as
Refer to “CIRCUIT DIAGRAM”. shown.
• Is the signaling system’s wiring properly con-
Tester positive probe → Brown 1
nected and without defects?
Tester negative probe → Ground
YES NO
NO YES
94
SIGNALING SYSTEM
ELEC
3. Voltage
• Connect the pocket tester (DC 20 V) to the
tail/brake light coupler (wire harness side) as
shown.
• Set the main switch to “ON”. Tester positive probe → Green/Yellow 1
• Measure the voltage (12 V) of Black 1 at the Tester negative probe → Black 2
horn terminal.
• Is the voltage within specification?
YES NO
EAS00797
• Set the main switch to “ON”.
2. A tail/brake light fails to come on. • Pull in the brake lever or push down on the
brake pedal.
• Measure the voltage (12 V) of Yellow at the
1. Tail/brake light bulb and socket
tail/brake light coupler (wire harness side).
• Check the tail/brake light bulb and socket for • Is the voltage within specification?
continuity.
Refer to “CHECKING THE BULBS AND YES NO
BULB SOCKETS”.
• Are the tail/brake light bulb and socket OK? This circuit is OK. The wiring circuit
from the main switch
YES NO to the tail/brake light
coupler is faulty and
must be repaired.
Replace the tail/
brake lightbulb,
socket or both.
95
SIGNALING SYSTEM
ELEC
EAS00799
YES NO
4. Voltage
• Connect the pocket tester (DC 20 V) to the
flasher relay coupler (wire harness side) as
shown.
96
SIGNALING SYSTEM
ELEC
YES NO
YES NO
EAS00800
The flasher relay is 4. The neutral indicator light fails to come on.
faulty and must be
replaced. 1. Neutral indicator light bulb and socket
• Check the neutral indicator light bulb and
socket for continuity.
5. Voltage Refer to “CHECKING THE BULBS AND
• Connect the pocket tester (DC 20 V) to the BULB SOCKETS”.
turn signal light connectors or the meter • Are the neutral indicator light bulb and sock-
assembly coupler (wire harness side) as et OK?
shown.
YES NO
å Turn signal light
∫ Turn signal indicator light
Replace the neutral
Left turn signal light indicator light bulb,
Tester positive probe → Chocolate 1 socket or both.
Tester negative probe → Ground
Right turn signal light
Tester positive probe → Dark green 2
Tester negative probe → Ground 2. Neutral switch
• Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the neutral switch OK?
YES NO
97
SIGNALING SYSTEM
ELEC
YES NO
3. Voltage
• Connect the pocket tester (DC 20 V) to the
• Set the main switch to “ON”.
meter assembly coupler (wire harness side)
• Measure the voltage (12 V) of Brown 1 and
as shown.
Sky blue/White 2 at the meter assembly
coupler. Tester positive probe → Red/White 1
• Is the voltage within specification? Tester negative probe → Black/White 2
YES NO
EASB0036
• Set the main switch to “ON”.
5. The oil level warning light fails to come on. • Measure the voltage (12 V) of Brown 1 and
Black/White 2 at the meter assembly coupler.
1. Oil level warning light bulb and socket • Is the voltage within specification?
• Check the oil level warning light bulb and YES NO
socket for continuity.
Refer to “CHECKING THE BULBS AND This circuit is OK. The wiring circuit
BULB SOCKETS” from the main switch
• Are the oil level warning light bulb and sock- to the meter assem-
et OK? bly coupler is faulty
and must be re-
YES NO
paired.
Replace the oil level
warning light bulb,
socket or both.
98
B R
W W
R
R
(BLACK) 4
RB
SbW
L LB LR
L
SbW RB
W R 5
W L RW LG LY Sb BY LW
R
W B R RW
CIRCUIT DIAGRAM
2 RB
YL
RB
RW
L Lg LR YB Y L Gy1 LY RB RW B Br Or
B
B
LB
YL WB Sb W RL BL G Gy2 Or
Sb
LY
LG
BY
LR
B
LW
B
Or
LB
B
8
FUEL PUMP SYSTEM
B
BrR BrR B
7 9 RB
BW 10
ON R B
R B LB LB B Gy2 Gy2
OFF LR
BrL BrL
P (BLACK) (BLACK) PUMP
15
B
40 Gy1
PU
6
10A
BrL RW
Y L L Y L L VCC
3 BL B Y Y Sb
TPS NS
B BL Br
S.GND SL1
13 G
40 SL2
LY
SS
WB HD
RL +B
RB
RW
LW
SP RPM GND
LG
99
B
21
YB
GY RB
RB GY
17
RW Br Br RW HAZARD E/G STOP START
10A OFF OFF FREE G
R 49
ON RUN PUSH
B
B B LG B 14
LW B B LW
(BLUE) (BLUE)
Dg BrW Ch Ch BrW Dg
16
B
Dg
Gy
Br
Ch
BrW
3 Main switch
18 4 Starter relay
BrL 15A RY
FUEL PUMP SYSTEM
5 Battery
19 10A
6 Wire minus lead
BrL Br
8 Starting circuit cut-off relay
BrG
RY
RY
42 RY 9 Fuel pump
Br
LB Br
ELEC
5A
45 RY WB BrW 0 Igniter unit
R RL
25
P BrG
B B
(BLACK) Ignition fuse
LB
WB t
GY
BrW
47
GY Br y Right handlebar switch
10A BrG
46
BrR
P
24
RY
LY
BY
BrW
LB
FUEL PUMP SYSTEM
ELEC
EB808010
100
FUEL PUMP SYSTEM
ELEC
EASB0037 EAS00739
TROUBLESHOOTING 2. Battery
The fuel pump fails to operate. • Check the condition of the battery.
Refer to "CHECKING AND CHARGING THE
Check: BATTERY" in Chapter 3.
1. Main, and ignition fuses
Open-circuit voltage
2. Battery
12.8 V or more at 20 °C (68 °F)
3. Main switch
4. Engine stop switch • Is the battery OK?
5. Starting circuit cutoff relay (fuel pump relay)
YES NO
6. Fuel pump
7. Wiring (of the entire charging system)
• Clean the battery ter-
NOTE: minals.
• Before troubleshooting, remove the following • Recharge or replace
part(-s): the battery.
1) Seat
2) Side covers
EAS00749
3) Fuel tank (lift)
4) Storage compartment/battery cover 3. Main switch
• Troubleshoot with the following special tool(-s). • Check the main switch for continuity.
Refer to "CHECKING THE SWITCHES".
Pocket tester • Is the main switch OK?
90890-03112
YES NO
101
FUEL PUMP SYSTEM
ELEC
EB803023 EB808021
5. Starting circuit cutoff relay (fuel pump relay) 6. Fuel pump resistance
• Remove the relay unit from the wire harness. • Disconnect the fuel pump coupler from the
• Connect the pocket tester ( 1) and bat- wire harness.
tery (12 V) to the relay unit terminals. • Connect the pocket tester ( 1) to the fuel
pump coupler terminals.
Battery (+) terminal →
Red/Black terminal 1 Tester (+) lead → Blue/Black terminal 1
Battery (–) terminal → Tester (–) lead → Black terminal 2
Blue/Red terminal 2
Tester (+) lead → Red/Black terminal 1
Tester (–) lead → Blue/Black terminal 3
7. Wiring
• Check the entire fuel pump system’s wiring.
Refer to "CIRCUIT DIAGRAM".
• Is the fuel pump system’s wiring properly
connected and without defects?
NO YES
102
FUEL PUMP SYSTEM
ELEC
EASB0038
1. Check:
• Fuel pump operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill up the fuel tank.
b. Put the end of the fuel hose into an open con-
tainer.
c. Connect the battery (12 V) to the fuel pump
coupler terminals.
103
Q
m
n
b
v
p
6
5
4
3
B R
1
W W
R
R
Gy1 (BLACK) 4
Gy BL B Gy
BL
RB
SbW
L LB LR
L
SbW RB
W W R
Battery
5 LG LY Sb BY LW
30A
W W L RW
W W W W R
W W 2 B R RW
W W RB
YL
RB
RW
L Lg LR YB Y L Gy1 LY RB RW B Br Or
B
B
LB
YL WB Sb W RL BL G Gy2
Main switch
Or
Starter relay
Sb
LY
LG
BY
LR
B
LW
B
11
Or
LB
Thermo switch
B
8
BW
Carburetor heater
Carburetor heater
Carburetor heater
Carburetor heater
Carburetor heater
ON R R
B
B LB LB B
10
Gy2 Gy2
OFF LR
2
1
BrL BrL
(BLACK) PUMP
P (BLACK)
12
15
3/4
B2 B1 B1 B2
B
43 40
fuse
Gy1
PU
6
earth
10A
BrL RW
Y L L Y L L VCC
B2 BL B Y Y Sb
NS
3 TPS
B1 B BL Br G B
S.GND SL1 B G
13 G LR Y
40 SL2 Y LR
BB3 LY
SS
BB4 WB HD
48
RL +B
RB
RW
LW
BB2 MAIN HARNESS HEAD LIGHT
SP RPM GND
BB1
LG
G
Br
W
21
YB
RB GY GY RB 17
RW Br Br RW HAZARD E/G STOP START
B B 10A OFF OFF FREE G Br
R 49
B B ON RUN PUSH B BrB BrB B
B
B B LG B 14
LW B B LW
(BLUE) (BLUE)
Dg BrW Ch Ch BrW Dg
BB3 BB2 16
BB4 BB1 MAIN HARNESS CARB.HEATER
Dg
Gy
Br
Ch
BrW
CARBURETOR HEATER SYSTEM
104
18
BrL 15A RY
B GW GW B
19 BrL
10A
Br
B
BrG
RY
RY
42 RY
Br
LB Br
45 L
5A RY WB BrW
R RL 25 W
P BrG
B B BL
(BLACK)
LB
WB
GY
L
BrW
W W L
47
GY Br
BL B
10A BrG
46
P
BrR
RY
LY
24
BY
BrW
LB
Ch BrW Dg Dg BrW Ch
PASSING DIMMER HORN 23 TURN
15A
BrL BrY
20 OFF HI OFF L
ON LO ON N
R
G P B RY
BrY
RY B P G LY
Y BY LY LB LB LY BY Y BY
26
34 51 (BLACK)
Y
Dg
G
Ch
B B
BrBBrY
CARBURETOR HEATER SYSTEM
22
Y HI BEAM B
BrB
IMOBILIZER
LR
GL
Y
G
B B B
LR
BrB B BrB
44 A
A
G
Y
LR A
Dg Ch GL
LR
RG Br B GW
30
GY
BrB
32
12V5W
BrB
Ch
Dg
Dg
31 33
Ch
B
LR B B LR W YB Y BW SbW
Ch
Ch
Dg
Dg
ELEC
G
Y
LR
B
12V10W
12V10W
12V21/5W
Sb
12V10W
12V10W
LR B GY
12V5W
12V60/55W
29 Ch Dg Ch Dg
B B B B
B
GY B LR
B
B
B
B B
B
B
B
B
G
27
Sb
35 36 37
39 Y B Ch Dg Ch Dg
Sb
B B B B
A B
28
CARBURETOR HEATER SYSTEM
ELEC
EASB0039 EAS00739
TROUBLESHOOTING 2. Battery
The carburetor heater fails to operate. • Check the condition of the battery.
Refer to "CHECKING AND CHARGING THE
Check: BATTERY" in Chapter 3.
1. Main and carburetor heater fuses
Open-circuit voltage
2. Battery
12.8 V or more at 20 °C (68 °F)
3. Main switch
4. Thermo • Is the battery OK?
5. Carburetor heater
YES NO
6. Wiring (of the entire charging system)
NOTE: • Clean the battery ter-
• Before troubleshooting, remove the following minals.
part(-s): • Recharge or replace
1) Seat the battery.
2) Side covers
3) Fuel tank (lift)
EAS00749
4) Storage compartment/battery cover
• Troubleshoot with the following special tool(-s). 3. Main switch
• Check the main switch for continuity.
Pocket tester Refer to "CHECKING THE SWITCHES".
90890-03112 • Is the main switch OK?
YES NO
EAS00738
105
CARBURETOR HEATER SYSTEM
ELEC
EASB0041
5. Carburetor heater
• Remove the carburetor heater from the car-
buretor body.
• Connect the pocket tester to the carburetor
heater.
Tester (+) lead → Heater terminal 1
Tester (–) lead → Heater body 2
6. Wiring
OFF
• Check the entire carburetor heater system’s
wiring.
Refer to "CIRCUIT DIAGRAM".
ON • Is the carburetor heater system’s wiring
properly connected and without defects?
Thermoswitch Thermoswitch
12 ± 4 °C 23 ± 3 °C NO YES
106
TRBL
STARTING FAILURE/HARD STARTING SHTG ?
TROUBLESHOOTING
NOTE:
The following guide for troubleshooting does not cover all the possible causes of problems. It should be
helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspec-
tion, adjustment and replacement of parts.
ELECTRICAL SYSTEM
Immobilizer system Switch and wiring
• Refer to “TROUBLESHOOTING” of immobilizer • Faulty main switch
system in chapter “ELECTRICAL” of this manual. • Faulty engine stop switch
Spark plug • Broken or shorted wiring
• Improper plug gap • Faulty neutral switch
• Worn electrodes • Faulty start switch
• Wire between terminals severed • Faulty sidestand switch
• Improper heat range • Faulty clutch switch
• Faulty spark plug cap Starter motor
Ignition coil • Faulty starter motor
• Broken or shorted primary/secondary • Faulty starter relay
• Faulty spark plug lead • Faulty relay unit (starting circuit cut-off relay)
• Broken body • Faulty starter clutch
Full-transistor system
• Faulty ignitor unit
• Faulty pickup coil
107
YAMAHA MOTOR ITALIA S.P.A. PRINTED IN ITALY
WIRING DIAGRAM
BT1100 WIRING DIAGRAM
1 Pickup coil
2 Rectifier/regulator
B B2 RG RG B2 B 50
YL GL RW RW GL YL
3 Main switch
4
RW
RG
Starter relay
GL
B2
YL
B
5 Battery
6 Wire minus lead
7 Starter motor
1 8 Starting circuit cut-off relay
B R
W W
9 Fuel pump
(BLACK)
4
R
Gy1
Gy BL B Gy
0 Igniter unit
BL
5
SbW
RB
R SbW RB L LB LR
W W
L
LG LY Sb BY LW
W W W W
W
W
W
W 2 B
R
R RW
L RW
q Ignition coil 1
W W RB
w Ignition coil 2
RW
Lg LR YB Y L Gy1 LY RB RW B Br Or
RB
YL
L
11
LB
YL WB Sb W RL BL G Gy2
B
B
Or
Sb
LG
BY
LR
LW
LY
B
B
Or
LB
7 9 r Sidestand switch
B
B
10
BrR BrR B RB
BW
ON B
t Ignition fuse
12
R R B LB LB B Gy2 Gy2
OFF
15
BrL BrL LR
P (BLACK) (BLACK) PUMP
B
40 Gy1
BrL
10A
RW
PU
u Front brake switch
B2 3 Y L
BL
L
B
Y L
Y Y
L VCC
TPS NS Sb
i Headlight fuse
B1
40 13 B BL
S.GND SL1
Br
G
B G G B
LR Y
48 o
SL2 Y LR
BB3
BB4
LY
SS Signal fuse
WB HD
RL +B
p Carburetor heater fuse
RW
RB
LW
BB2 MAIN HARNESS HEAD LIGHT
SP RPM GND
21
BB1
17 G
a Backup fuse
LG
Br
GY RB
YB
W
RB GY
B
49
Br RW HAZARD E/G STOP START
B B R 10A
RW Br
OFF OFF FREE G Br s Left handlebar switch
B B
LW B B LW
ON RUN PUSH
B B
B LG B 14 B BrB BrB B
d Clutch switch
16
(BLUE) (BLUE)
Dg BrW Ch Ch BrW Dg
f
BB3 BB2
B
Dg
BrW
Gy
Ch
Br
B
g Flasher relay
h Multi-function display
j Neutral switch lead
k Neutral switch
18
15A
l Headlight
BrL RY
B
BrG
42 x
RY
RY Rear turn signal light (left)
45
RY
Br
Br
25 c
LB
R 5A RL
RY WB BrW
L
W
Rear turn signal light (right)
P BrG
B B BL
v Thermo switch
47
(BLACK)
41
WB
LB
BrW
GY
L W W L
10A 46 GY Br
24 BL B b Carburetor heater earth
BrW
BrR BrG
RY
BY
LY
LB
P
n Carburetor heater 1
20 Ch BrW Dg Dg BrW Ch
PASSING DIMMER HORN 23 TURN
m Carburetor heater 2
BrL 15A
BrY OFF HI OFF L
ON LO ON N
R , Fuel sender
RY B P G G P B RY
26
BrY
34
LY
. Tail/brake light
51
Y BY LY LB LB LY BY Y BY
(BLACK)
Dg
Ch
B
Y
22
G
B B
BrBBrY
LR
44 GL
# Anti-theft alarm (option)
LR
G
Y
30 31 32 33 $
A
A
G
Y
BrB
BrB
LR
GY
RG Br B GW Dg Ch GL
Dg
Dg
Ch
Ch
LR B B LR Y BW SbW
% Igniter fuse
B
W YB
Dg
Dg
Ch
Ch
LR
G
Y
12V21/5W
^
12V10W
12V10W
B
12V10W
12V60/55W
Sb
LR B GY
12V5W
29 Ch
B
Dg
B
Ch
B
Dg & Dimmer switch relay
B
27
GY B LR
*
B
B B
39 G
B
B
B
B
Sb
Y B Ch
B
Dg Ch Dg ( Fuel cut solenoid carburetor No. 2
Sb
B B B
B A B
COLOR CODE
B ...........Black Gy .........Gray R ...........Red B/W .......Black/White Br/Y.......Brown/Yellow
Br ..........Brown L............Blue Sb .........Sky blue B/Y ........Black/Yellow L/B ........Blue/Black R/B........Red/Black
Ch .........Chocolate Lg..........Light green W ..........White Br/B.......Brown/Black L/R ........Blue/Red R/G .......Red/Green
Dg .........Dark green O ...........Orange Y ...........Yellow Br/L .......Brown/Blue L/W .......Blue/White R/W.......Red/White
G ...........Green P ...........Pink B/L ........Black/Blue Br/W......Brown/White L/Y ........Blue/Yellow R/Y........Red/Yellow