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2005
TDM900A(T)
5PS1-AE4
SUPPLEMENTARY
SERVICE MANUAL
FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
TDM900A(T) 2005. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual.
TDM900(N) 2001 SERVICE MANUAL: 5PS1-AE1
TDM900(R) 2003 SUPPLEMENTARY SERVICE MANUAL: 5PS1-AE2
TDM900(S) 2004 SUPPLEMENTARY SERVICE MANUAL: 5PS1-AE3
TDM900A(T) 2005
SUPPLEMENTARY
SERVICE MANUAL
©2004 by Yamaha Motor Co., Ltd.
First Edition, December 2004
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
EAS00002
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one
manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha
vehicles should have a basic understanding of mechanics and the techniques to repair these types
of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to
render the vehicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. 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 appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
EAS00004
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
WARNING
CAUTION:
NOTE:
Failure to follow WARNING instructions could result in severe injury or death
to the motorcycle operator, a bystander or a person checking or repairing the
motorcycle.
A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle.
A NOTE provides key information to make procedures easier or clearer.
EAS00007
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are
laid out with the individual steps in sequential order.
The manual is divided into chapters. An abbreviation and symbol in the upper right corner of
each page indicate the current chapter.
Refer to “SYMBOLS”.
Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s)
appears.
Sub-section titles appear in smaller print than the section title.
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section.
Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
Jobs requiring more information (such as special tools and technical data) are described
sequentially.
EAS00008
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols
to
indicate the subject of each
chapter.
General information
Specifications
Periodic checks and adjustments
Chassis
Engine
Cooling system
Fuel injection system
Electrical system
Troubleshooting
Symbols
to
indicate the following.
Serviceable with engine mounted
Filling fluid
Lubricant
Special tool
Tightening torque
Wear limit, clearance
Engine speed
Electrical data
Symbols
to
in the exploded diagrams
indicate the types of lubricants and lubrication
points.
Engine oil
Gear oil
Molybdenum-disulfide oil
Wheel-bearing grease
Lithium-soap- based grease
Molybdenum-disulfide grease
Symbols
to
in the exploded diagrams
indicate the following.
Apply locking agent (LOCTITE®)
Replace the part
CONTENTS
GENERAL INFORMATION
FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUMENT PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
4
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . .
CABLE ROUTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWINGARM AND DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . .
ANTI-LOCK BRAKE SYSTEM (ABS) . . . . . . . . . . . . . . . . . . . . . . . .
ABS OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ABS COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT WHEEL SENSOR AND SENSOR ROTOR . . . . . . . . . . .
REAR WHEEL SENSOR AND SENSOR ROTOR . . . . . . . . . . . .
HYDRAULIC UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE RESERVOIR TANK FLUID LEVEL . . . . . . . . . .
TRIAL RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
5
6
7
7
8
28
28
30
30
31
49
50
54
57
64
73
73
ELECTRICAL
ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRIC STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION . . . . . . .
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIGNALING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . .
74
76
77
77
78
79
83
83
85
86
ANTI-LOCK BRAKE SYSTEM (ABS) . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ABS COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ABS CONNECTOR LOCATION CHART. . . . . . . . . . . . . . . . . . . .
ECU (ABS) AND FAIL-SAFE RELAY . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE ANTI-LOCK BRAKE SYSTEM. . . . . . . . . . . . . .
TROUBLESHOOTING BY THE SELF DIAGNOSIS . . . . . . . . . . .
MALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS
(PAST MALFUNCTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS
(PRESENT MALFUNCTION). . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DELETING THE MALFUNCTION CODE . . . . . . . . . . . . . . . . . . .
94
94
96
97
98
103
104
107
107
108
120
TROUBLESHOOTING
ANTI-LOCK BRAKE SYSTEM (ABS) . . . . . . . . . . . . . . . . . . . . . . . .
ABS TROUBLESHOOTING OUTLINE . . . . . . . . . . . . . . . . . . . . .
BASIC INSTRUCTION FOR TROUBLESHOOTING . . . . . . . . . . .
BASIC PROCESS FOR TROUBLESHOOTING . . . . . . . . . . . . . .
TROUBLESHOOTING AT THE ABS WARNING LIGHT . . . . . . . . . .
ONLY THE ABS WARNING LIGHT DOES NOT COME ON. . . . .
ALL INDICATORS DO NOT COME ON. . . . . . . . . . . . . . . . . . . . .
ABS WARNING LIGHT CONTINUES TO FLASHES. . . . . . . . . . .
ABS WARNING LIGHT FLASHES EVERY 0.5 SECONDS. . . . . .
ABS WARNING LIGHT CONTINUES TO COME ON. . . . . . . . . .
TDM900A(T) 2005 WIRING DIAGRAM
122
122
123
124
125
125
125
125
125
125
FEATURES
GEN
INFO
GENERAL INFORMATION
FEATURES
INSTRUMENT PANEL
Clock
TRIP/ODO meter
SELECT button
RESET button
Engine trouble warning light
Function indication
The indications of the self-diagnosis function can be checked and inspection operations can be performed through the use of the multi-function meter on the instrument panel.
Based on the signals received from the sensors, the ECU inputs the signals into the multi-function
meter. Then, the conditions of the sensors appear on the clock and trip/odometer display of the
multi-function meter.
NORMAL MODE
Speed meter
Fuel meter
(The symbol “ ” blinks when the gasoline is
almost empty)
Trip/odometer display
Clock display
CO ADJUSTMENT/DIAGNOSTIC
MONITORING SELECTION MODE
Temporary selection display for CO/DIAG.
CO:
DIAG:
1
GEN
INFO
FEATURES
CO ADJUSTMENT MODE
Cylinder identification
For #1
For #2
CO data
Example:
lean
–128
DIAGNOSTIC MONITORING MODE
0
rich
128
Diagnostic monitoring code
Example: code “01”
Monitoring data
WHEN THE COMMUNICATION ERROR
OCCURRED BETWEEN ECU AND METER:
Error code
Example: When the error code is “Er-1”
For details of error codes, refer to
“FAIL-SAFE ACTION TABLE” in chapter 7.
(Manual No.: 5PS1-AE1)
CAUTION:
If the display
shown in the illustration to
the left appears, the multi-function display
is malfunctioning. Replace the meter
assembly.
CAUTION:
If the fuel meter does not display the fuel
level, but repeatedly flashes as shown in
the illustration, the fuel level monitoring
system is malfunctioning. Check the fuel
sender and the electrical circuit.
2
FEATURES
GEN
INFO
CO adjustment and diagnostic monitoring mode
Mode Selection
Normal mode
CO/DIAG mode
Turn “ON” the main switch
• The self-diagnostic function starts a system
check
1. While keeping both the SELECT and
RESET buttons pressed, turn “ON” the
main switch. Keep the buttons pressed for
8 seconds or more.
• All the segments are “OFF” expect the clock
and the trip LCD.
• “DIAG” appears on the clock LCD.
System normal
Normal meter display
Malfunction detection fault number
appears on the
clock LCD.
The engine trouble warning light
illuminates.
Switching between CO adjustment mode and
DIAG mode
1. Press the SELECT button in order to
switch the display to “CO” or “DIAG”.
2. Simultaneously press the SELECT and
RESET buttons for 2 seconds or more to
select an item.
CO adjustment mode
Refer to “CO adjustment” in chapter 3.
(Manual No.: 5PS1-AE1)
Diagnosis monitoring mode
Refer to “TROUBLESHOOTING” in chapter
7.
(Manual No.: 5PS1-AE1)
(The engine cannot be started in this mode)
3
SPECIAL TOOLS
GEN
INFO
EB104000
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly.
Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No.
Tool name/Function
Test coupler adaptor
90890-03149
This tool is used to check the ABS diagnosis.
4
Illustration
GENERAL SPECIFICATIONS/
ENGINE SPECIFICATIONS/CHASSIS SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item
Model code
Weight
Wet (with oil and a full fuel tank)
Dry (without oil and fuel)
Maximum load (total of cargo, rider,
passenger, and accessories)
Standard
Limit
2B01 (EUR)
•••
224 kg (494 lb)
193 kg (426 lb)
200 kg (441 lb)
•••
•••
•••
ENGINE SPECIFICATIONS
Item
Throttle bodies
Model (manufacturer) × quantity
ID mark
Standard
38EIS (MIKUNI) × 2
5PS1 11
Limit
•••
•••
CHASSIS SPECIFICATIONS
Item
Front tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0 ~ 90 kg
90 ~ 200 kg
High-speed riding
Min. tire tread depth
Rear tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
0 ~ 90 kg
90 ~ 200 kg
High-speed riding
Min. tire tread depth
Drive chain:
Type (manufacturer)
Link quantity
Drive chain slack
Maximum 15-link section
Standard
Limit
Tubeless
120/70ZR 18M/C (59W)
D220FSTJ (DUNLOP)
•••
•••
•••
225 kPa (2.25 kgf/cm2, 2.25 bar, 32 psi)
225 kPa (2.25 kgf/cm2, 2.25 bar, 32 psi)
225 kPa (2.25 kgf/cm2, 2.25 bar, 32 psi)
•••
•••
•••
•••
1.6 mm
(0.06 in)
Tubeless
160/60ZR 17M/C (69W)
D220STJ (DUNLOP)
•••
•••
•••
250 kpa (2.5 kgf/cm2, 2.5 bar, 35.6 psi)
290 kPa (2.9 kgf/cm2, 2.9 bar, 41.3 psi)
250 kPa (2.5 kgf/cm2, 2.5 bar, 35.6 psi)
•••
•••
•••
•••
1.6 mm
(0.06 in)
DID525HV KAI (DAIDO)
118
50 ~ 60 mm
•••
•••
•••
•••
239.3 mm
(9.42 in)
5
ELECTRICAL SPECIFICATIONS
SPEC
ELECTRICAL SPECIFICATIONS
Item
Ignition system
Ignition system type
Ignition timing
Advancer type
Pickup coil resistance/color
Transistorized coil ignition unit model
(manufacturer)
Indicator light
(voltage/wattage × quantity)
Turn signal indicator light
ABS warning light
Starter relay
Model (manufacturer)
Amperage
Coil resistance
Front wheel sensor
Model (manufacturer)
Resistance
Rear wheel sensor
Model (manufacturer)
Resistance
Fail-safe relay
Model (manufacturer)
Fuses (amperage × quantity)
Main fuse
Fuel injection system fuse
Headlight fuse
Signaling system fuse
Ignition fuse
Radiator fan motor fuse
Hazard light fuse
Backup fuse
ABS fuse
ABS motor fuse
Reserve fuse
Standard
Limit
Transistorized coil ignition (digital)
10° BTDC at 1,150 r/min
Electric
192 ~ 288 Ω/L/Y-G/W
TBDF15 (DENSO)
•••
•••
•••
•••
•••
14 V 1.2 W × 1
14 V 1.4 W × 1
•••
•••
MS5F-631 (JIDECO)
180 A
4.18 ~ 4.62 Ω
•••
•••
•••
OELABW (SUMITOMO)
1.2 ~ 1.6 kΩ at 20°C
•••
•••
OELABX (SUMITOMO)
1.2 ~ 1.6 kΩ at 20°C
•••
•••
G8R-40Y (OMRON)
•••
40 A × 1
10 A × 1
20 A × 1
10 A × 1
10 A × 1
20 A × 1
10 A × 1
10 A × 1
10 A × 1
30 A × 1
20 A × 1
10 A × 1
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
6
SPEC
TIGHTENING TORQUES
TIGHTENING TORQUES
CHASSIS TIGHTENING TORQUES
Thread
size
Part to be tightened
Lower bracket pinch bolt
Upper bracket and wire guide
Throttle cable adjusting nut
Engine mounting:
Rear upper mounting bolt and nut
Rear lower mounting bolt and nut
Pinch bolt
Frame and rear frame
Sidestand and sidestand bracket
Sidestand bracket and frame
Rear footrest and footrest bracket
Front wheel sensor and sensor housing
Rear wheel sensor and sensor housing
Hydraulic unit and hydraulic unit bracket
Hydraulic unit bracket and frame
Hydraulic unit and brake hose
Front brake hose holder and front brake hose
Rear brake hose holder and rear brake hose
Frame and connector plate
Frame and brake hose holder
7
Tightening
torque
M8
M6
M6
Nm
23
7
5
m•kg
2.3
0.7
0.5
ft•lb
16.6
5.1
3.6
M10
M10
M8
M10
M8
M8
M6
M8
M8
M8
M8
M10
M6
M6
M5
M6
45
45
26
41
23
26
9
30
30
16
16
30
10
7
7
10
4.5
4.5
2.6
4.1
2.3
2.6
0.9
3.0
3.0
1.6
1.6
3.0
1.0
0.7
0.7
1.0
32.5
32.5
18.8
29.7
16.6
18.8
6.5
22
22
12
12
22
7.2
5.0
5.0
7.2
Remarks
CABLE ROUTING
CABLE ROUTING
Clamp
Front turn signal light (right)
Headlight sub-wire harness
Indicator light lead
Stay 3
Front turn signal light (left)
Meter lead
Indicator light
Meter
Stay 1
Headlight coupler
Headlight adjusting knob
Throttle cables
Clutch cable
Left handlebar switch lead
Main switch lead and immobilizer lead
Cover 7
Horn lead
Horn
Front wheel sensor lead
Front brake hose (OUT)
Cover 8
Front brake hose (IN)
Right handlebar switch lead
Front fork
8
SPEC
CABLE ROUTING
Fasten the left handlebar switch lead to the handlebar with a band.
Through the left handlebar switch lead and clutch
cable to the wire guide on the upper bracket.
Fasten the main switch lead and immobilizer lead
to the wire guide with a clamp. There should be no
slack between main switch and wire guide. Cut the
clamp tip leaving 3 ~ 8 mm (0.12 ~ 0.31 in).
Route the main switch lead through the cover 7 so
that it route beneath the left handlebar switch lead.
Route the clutch cable through the hole in front of
the head pipe on the frame.
Route the front wheel sensor lead along the brake
hose and clamp it at the position shown the drawing.
9
SPEC
It should be 30 ~ 40 mm (1.18 ~ 1.57 in) from the
lower end of the grommet of the brake hose.
Route the right handlebar switch lead, front brake
hose (IN, OUT), front wheel sensor lead and throttle cables through the cover 8.
Route the right handlebar switch lead, front brake
hose (IN) and throttle cables (2 cables) through the
wire guide of the upper bracket.
Fasten the right handlebar switch lead to the handlebar with a band.
Fasten the main switch lead and immobilizer lead
with a clamp so that it faces the front side of the
vehicle.
Fasten the horn lead to the front fork (left side) with
a clamp as shown in the drawing. Cut the clamp tip
leaving 3 ~ 8 mm (0.12 ~ 0.31 in).
CABLE ROUTING
Fasten the horn lead to the upper side of the under
bracket as shown in the drawing. Cut the clamp tip
leaving 3 ~ 8 mm (0.12 ~ 0.31 in).
10 mm (0.39 in)
Fasten the turn signal light lead (right) together
with the coupler to the stay 1.
Clamp the white tape of headlight sub-wire harness to the stay 1. (For detail of the clamp, refer to
section BB.)
Fasten the wire harness and turn signal light lead
(left) together with the coupler to the stay 1.
And locate the turn signal light lead, under the wire
harness.
Route the wire harness through the outside of the
bolt.
To the headlight relay.
10
SPEC
To the ECU.
After the clamping, direct the band point to the
front.
Clamp the headlight sub-wire harness to the stay 1
with a band.
Clamp the headlight sub-wire harness to the dent
in the stay 1.
Route the all leads through inside of the headlight
adjusting knob. Because of the protruding of the
wire harness, it does not have to become the disturbance of operation of the headlight adjusting
knob.
Clamp the meter lead, indicator light lead, headlight sub-wire harness to the stay 1 with a band.
CABLE ROUTING
Fasten the headlight sub-wire harness with the
clamp that is passed through the center hole of
stay 1.
11
SPEC
CABLE ROUTING
Stay 3
Ignition coil assembly
Neutral switch lead
O2 sensor lead
Speed sensor lead
Sidestand switch lead
Pickup coil lead
Fuel tank drain hose
Air filter drain hose
Coolant reservoir tank drain
hose
Battery negative lead
Seat lock cable
Immobilizer coupler
Joint coupler
Tail/brake light lead
Rear turn signal light
Rear turn signal light lead
Rectifier/regulator lead
Coolant reservoir tank
Rear shock absorber
Swingarm
Sidestand switch
O2 sensor
Cylinder identification sensor
lead
12
SPEC
Turn signal light relay
Headlight relay
Main relay
Front wheel sensor
ECU
ECU lead
Stay 1
6 poles water proof coupler
Boss
Starter motor lead
Frame
Engine
Oil pipe
CABLE ROUTING
To the headlight.
Route the 6 poles water proof coupler through
inside of the ECU lead, and the 12 poles coupler
through outside of the ECU lead.
Connect the headlight sub-wire harness coupler in
front of ECU and make it not to route above the
ECU lead.
Fasten the wire harness to the stay 1 with a clamp.
Clamp position shall be at the position shown in
the drawing 1. The knot should be faced to the outside of the vehicle.
Insert the terminal (black) of the ignition coil lead
as shown in the drawing.
Pass the cylinder identification sensor lead above
the left radiator hose.
13
SPEC
Pass the rectifier/regulator lead above the frame
cross tube.
Route the tail/brake light lead through the guides
(3 places) of the tail/brake lgiht bracket.
Fasten the tail/brake light lead at outside of the
frame with a clamp. After connecting the tail/brake
light lead coupler, insert the surplus wiring
between frame, and positioning without routing
above the frame.
Fasten the rectifier/regulator lead with the clamp
installed with the rear fender. The clamp tip should
face the inner side of the vehicle.
CABLE ROUTING
Route the fuel drain hoses (2 hoses), air filter drain
hose, and coolant reservoir tank drain hose trough
the clamp. For the fuel drain hose, the white paint
mark should be under the clamp. The position is
regardless of ranks. Arrange the end of coolant
reservoir tank drain hose, air filter case drain hose
and fuel drain hose from the clamp.
The O2 sensor lead should not stick out from the
boss seat face to the outside of the vehicle.
Fasten the neutral switch lead, O2 sensor lead,
speed sensor lead, sidestand switch lead and
rectifier/regulator lead with the clamp as shown in
the drawing. Cut the clamp tip leaving 3 ~ 8 mm
(0.12 ~ 0.31 in) and make if face to the outside of
the vehicle.
14
SPEC
Less than 20 mm (0.79 in)
Route the spark plug lead for the right cylinder
below the water pipe and behind the hose for the
air cut-off valve.
Route the front wheel sensor lead inside the vehicle and secure it to the front brake hose with a
clamp.
Pass the front wheel sensor lead through the cable
holder tightened together with the front brake caliper.
Fasten the cylinder identification sensor lead to the
inner side of the frame with a clamp.
Pass the front wheel sensor lead between the front
brake caliper and front brake hose.
CABLE ROUTING
Pass the harness for the relay between ECU and
the main relay.
Fasten the ECU lead with the clamp installed to
the plate of front side hole. Align the positioning
tape and the clamp. Install the clamp to the out
side of plate.
Insert the terminal (white) of the spark plug lead as
shown in the drawing.
Pass the fuel drain hose coolant reservoir tankdrain hose and air filter drain hose behind the battery negative lead.
Route the fuel drain hoses (2 hoses), air filter drain
hose and coolant reservoir tank drain hose
through the guide located behind the swingarm
head pipe. Do not make hoses to cross in the area
between D and E.
15
SPEC
CABLE ROUTING
Rear brake light switch lead
Rear brake light switch
Rear wheel sensor lead
Brake fluid reservoir hose
Clamp
Rear brake hose (OUT)
Rear brake hose (IN)
Fuel tank return hose
Fuel hose
Fuel tank drain hose
Clamp
Clamp
Brake hose holder
Rear wheel sensor lead
Clamp
Seat bracket
Front wheel sensor lead
ECU (ABS) sub-wire harness
ECU (ABS)
Radiator fan motor relay
ABS check coupler
Brake hose holder
Stay 2
Radiator
Clutch cable
Thermo wax hose
Coolant reservoir tank hose
Rear brake hose
Starter motor lead
Hydraulic unit drain hose
16
SPEC
CABLE ROUTING
The right and left positions for the starter motor
lead and rear wheel sensor lead can be accepted
in random oder.
Pass the brake fluid reservoir hose and the rearbrake light switch lead through the gap between
the rear fender and rear frame and route it behind
the seat bracket.
Clamp the coolant reservoir tank hose and brake
hose.
Clamping position should be behind the protector
and of the coolant reservoir tank hose.
Route the throttle cables and right handlebar
switch lead inside of the brake hose holder.
Route the clutch cable through the guide of brake
hose holder.
Route the clutch cable through the guide of stay 2.
17
SPEC
Route the rear brake hose and starter motor lead
over the frame cross tube.
Route the hydraulic unit drain hose behind the
cross tube, front of the oil hose and also front of
the pivot shaft.
Direct the rear brake light switch lead to the front.
Clamp the grommet parts of the rear brake hose
and rear wheel sensor lead.
Clamp the ABS check coupler lead. Either upward
or downward direction of pawl is acceptable.
Pass the fuel hose between the fuel tank drain
hoses
Route by the outside of the brake hose.
Ensure that the leads are not folded.
Point the tip of the clamp downward and cut the
surplus part leaving 0 ~ 5 mm (0 ~ 0.20 in).
CABLE ROUTING
Route inside the brake hose holder.
Attach the clamp so that its opening section faces
in the direction indicated in the drawing.
Clamp the grommet which is attached to the sensor lead.
Make sure to insert it to the deepest point.
Make sure to catch more than 3 notches. Install
the pawl so that it points to the outside of the vehicle.
18
SPEC
CABLE ROUTING
SPEC
Battery
Rectifier/regulator
Rear wheel sensor lead
Starter motor lead
Battery band
Battery positive lead
Lean angle cut-off switch
Atmospheric pressure sensor
Fuse (main)
Starter relay
Rear turn signal light lead (right)
Rear turn signal light (right)
Tail/brake light lead
Tail/brake light
Rear turn signal light lead (left)
Throttle cables
Handlebar switch lead (right)
Front brake hose
Stay
Front wheel sensor lead
Thermo wax hose
Intake vacuum hose
Sub-wire harness (air filter case)
Oil level switch lead
Hydraulic unit lead
Coolant reservoir tank hose
Hydraulic unit assembly
Fail-safe relay
Rear brake light switch lead
19
CABLE ROUTING
SPEC
Bracket 1
Air induction system lead
Coolant temperature sensor lead
Cover 2
Main switch lead and immobilizer lead
Left handlebar switch lead
Boot
Frame
Wire harness
Intake vacuum hose (Joint section)
Front brake hose (IN)
Front brake hose (OUT)
Clamp
Rear turn signal light (left)
Joint coupler
Immobilizer coupler
Seat lock cable
Fuse box
Battery negative lead
Hydraulic unit motor coupler
Coolant reservoir tank drain hose
Fuel pump lead 2
Fuel pump lead 1
Sub-wire harness (throttle body)
Radiator fan motor lead
Cylinder identification sensor lead
Hose 1
20
CABLE ROUTING
Put the cover on the coupler for the immobilizer
lead and wire harness.
Install the projection part of the coupler pointing to
the connector housing 2.
Align the projection part of the connector housing
2 with the hole of the locking bracket.
Attach the boot over the immobilizer coupler.
To the air induction system.
To the ECU (ABS).
To the air filter case.
Route the sub-wire harness (air filter case) and
intake vacuum hose over or side by the brake
hose.
To the oil tank.
Route the starter motor lead and rear wheel sensor
lead under the rear frame attaching boss section.
21
SPEC
Route the starter motor lead and rear wheel sensor lead by the right of the battery. The upper and
lower positions of the leads can be accepted in
random order.
Route the battery positive lead under the battery
band. (secure with a band)
Pass the rear turn signal light lead (right) through
the right hole of the fender.
Pass the rear turn signal light leads (right and left)
through the clamp installed to the rear fender.
Adjust the length of the rear turn signal light lead
(left) by folding and then bundle it.
Pass the rear turn signal light lead (left) through
the left hole of the fender.
Pass the rear turn signal light leads (right and left)
between the ribs of the rear fender.
CABLE ROUTING
Pass the seat locking cable through the hole section of the seat bracket of the rear frame. Either
direction of the seat locking cable can be
accepted.
Set the immobilizer coupler and joint coupler
between the ribs of the rear fender.
Route the battery negative lead (black lead) above
the seat locking cable.
Route the battery positive lead (red lead) below
the seat locking cable.
Route the battery positive lead together with the
rear wheel sensor lead and starter motor lead as
shown in the illustration.
Route the battery negative lead above the battery.
Route the rear brake light switch lead below the
battery band. (secure with a band.)
22
SPEC
Clamp the coolant reservoir tank hose to the
hydraulic unit bracket.
To the fuel pump.
Fasten the wire harness to the inner side of the
frame with the harness wrapping clamp.
Arrange to route the throttle cable so that its
upper side is the return cable and lower side for
the pulling cable.
To the throttle body.
Route the wire harness, cylinder identification
sensor lead and radiator fan motor lead under
the bracket 1.
Route the cylinder identification sensor lead and
radiator fan motor lead above the radiator hose.
To the radiator.
CABLE ROUTING
Bundle the coolant temperature sensor lead and
air induction system lead with the clamp. Cut the
clamp tip leaving 3 ~ 8 mm (0.12 ~ 0.31 in).
To the headlight.
Secure the wire harness to the holes at the internal left side and right side of the cover 2 with the
harness wrapping clamp.
Bundle the main switch lead, immobilizer lead,
left handlebar switch lead and right handlebar
switch lead with the clamp. Point the tip of the
clamp to the front side and set it between cover
and wire harness. Place the clamp at the right
side of the vehicle from the coupler as shown in
the illustration.
23
SPEC
Fasten the cylinder identification sensor lead
and radiator fan motor lead to the frame with the
clamp as shown in the illustration. Point the tip of
the clamp to the downside.
Clamp it pointing the coolant reservoir tank hose
to the outside and the throttle body hose to the
inside. Position the clamp opening at the inside.
After binding a clamp, make sure to insert the
excessive part to the gap with the frame.
Clamp the coolant reservoir tank hose and brake
hose.
CABLE ROUTING
SPEC
Hose clamp (carburetor joint upper side)
Connect the intake vacuum hose joint of the air filter system assembly side and the pipe of the throttle body side.
Make sure to match the white paint mark to the
position right overhead.
Insert the hose until its end contacts the component. Point the pawl of the clip downward.
Install the clip so that its pawl is oriented within the
rangeshown in the drawing.
To assemble to the throttle body assembly, it is
allowed to apply the silicon liquid.
Intake vacuum hose joint
Clip
Intake vacuum hose
Clamp (fuel pump side)
Clamp (injector side)
Air filter case
Air filter drain hose
Fuel pump
Fuel hose
Fuel tank return hose
Hose
Filter
Stay
Throttle body
Hose clamp (carburetor joint lowerside)
Carburetor joint
24
CABLE ROUTING
SPEC
Insert the fuel tank return hose until its end con- 2. After the procedure item 1 as above is finished,
insert the clamp of the fuel pump side from the
tacts the component.
lower side of the engine and check that the
,
To assemble to the carburetor joint 1, it is allowed
and
parts are completely equipped.
to apply the engine oil.
3. After the procedure item 1 as above is finished, lay
Attach the hose clamp in this direction.
over the
part of the injector side clamp from the
This part works as a stopper against drop-off.
engine left side and insert the
part from the
Fuel piping connector attachment directions.
engine upper side while turning.
1. Insert the connector until the click sound is heard
Check that the
and
parts are completely
and check that the connector does not come off.
equipped.
Care should be taken so that the foreign matter is
not caught. (It is prohibited to wear cotton work
gloves during the operation.)
Always use hands to connect/disconnect the connector without using tools.
25
CABLE ROUTING
SPEC
Clamp
Drain plug
Hydraulic unit drain hose
Hydraulic unit motor coupler
Hydraulic unit assembly
Clamp (to the coolant reservoir tank hose)
Union bolt
Fail-safe relay
Brake hose holder
Fuel tank mold
Rear brake hose (OUT)
Rear brake hose (IN)
Bracket 2
Frame
Bracket 1
Coolant reservoir tank
Wire harness assembly
Relay stay
Protector
Oil level sensor coupler
Hydraulic unit coupler
Front brake hose assembly (IN)
Front brake hose assembly (OUT)
26
CABLE ROUTING
Insert the pin of the bracket 1 to the hydraulic unit
assembly.
Press front brake hose (IN) to the front brake hose
assembly (out) and tighten.
Insert the pin of the bracket 2 to the hydraulic unit
assembly.
Press brake hose to the detent pin of the hydraulic
unit assembly and tighten.
Clamp the wire harness assembly (for the fail-safe
relay) to the bracket 1.
Clamp the wire harness assembly. Clamp position
should be at the white taping section of the wire
harness assembly.
Insert brake hose holder projection to the hole.
To the rear brake master cylinder.
27
SPEC
To the rear brake caliper.
Insert hydraulic unit drain hose to the deepest
point.
Fit the fuel tank mold in the bracket 1.
Keep approximately 7 ~ 10 mm (0.28 ~ 0.39 in)
away from the bolt position.
Upper and lower excessive parts should be
appressed. Appearance such as containing bubbles is no object.
SWINGARM AND DRIVE CHAIN
CHAS
EAS00709
SWINGARM AND DRIVE CHAIN
CHECKING THE DRIVE CHAIN
1. Measure:
• Measure the dimension between 15-links
on the inner side
and outer side
of the
roller and calculate the dimension between
pin centers.
• Dimension
between pin centers = (Inner
dimension
+ Outer dimension )/2
• 15-link section
of the drive chain
Out of specification → Replace the drive
chain, front drive sprocket and rear drive
sprocket as a set.
15-link drive chain section limit
(maximum)
239.3 mm (9.42 in)
NOTE:
• While measuring the 15-link section, push
down on the drive chain to increase its tension.
• Perform this measurement at two or three different places.
2. Check:
• drive chain
Stiffness → Clean and lubricate or replace.
3. Clean:
• drive chain
a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosene and remove
any remaining dirt.
c. Remove the drive chain from the kerosene
and completely dry it.
28
SWINGARM AND DRIVE CHAIN
CHAS
CAUTION:
This motorcycle has a drive chain with
small rubber O-rings
between the drive
chain side plates. Never use high-pressure
water or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to
clean the drive chain. High-pressure methods could force dirt or water into the drive
chain’s internals, and solvents will deteriorate the O-rings. A coarse brush can also
damage the O-rings. Therefore, use only
kerosine to clean the drive chain.
4. Check:
• O-rings
Damage → Replace the drive chain.
• drive chain rollers
Damage/wear → Replace the drive chain.
• drive chain side plates
Damage/wear → Replace the drive chain.
Cracks → Replace the drive chain and
make sure that the battery breather hose is
properly routed away from the drive chain
and below the swingarm.
5. Lubricate:
• drive chain
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
6. Check:
• drive sprocket
• rear wheel sprocket
More than 1/4 tooth
wear → Replace the
drive chain sprockets as a set.
Bent teeth → Replace the drive chain
sprockets as a set.
Correct
Drive chain roller
Drive chain sprocket
29
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
ANTI-LOCK BRAKE SYSTEM (ABS)
ABS OUTLINE
Yamaha ABS features
1. The Yamaha ABS (Anti-Lock Brake System) features a dual electronic control system, which acts
on the front and rear brakes independently.
2. The ABS features a compact and lightweight design to help maintain the basic maneuverability of
the motorcycle.
3. The hydraulic unit, which is the main component of the ABS, is centrally located on the motorcycle to increase mass centralization.
ABS layout
ABS warning light
Electronic control unit (ECU)
Fail-safe relay
Hydraulic unit
Rear brake caliper
Rear wheel sensor
Rear disc rotor
Front brake caliper
30
Front wheel sensor
Front disc rotor
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
EAS00872
ABS
The operation of the Yamaha ABS brakes is
the same as conventional motorcycles, with a
brake lever for operating the front wheel brake
and a brake pedal for operating the rear wheel
brake.
When wheel lockup is detected during emergency braking, hydraulic control is performed
by the hydraulic system independently.
EAS00873
Useful terms
• Wheel speed:
The rotation speed of the front and rear
wheels.
• Chassis speed:
The speed of the chassis.
When the brakes are applied, wheel speed
and chassis speed are reduced. However,
the chassis travels forward by its inertia
even though the wheel speed is reduced.
• Brake force:
The force applied by braking to reduce the
wheel speed.
• Wheel lock:
A condition that occurs when the rotation of
one or both of the wheels has stopped but
the motorcycle continues to travel.
• Side force:
The force on the tires which supports the
motorcycle when cornering.
31
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
• Slip ratio:
When the brakes are applied, slipping
occurs between the tires and the road surface. This causes a difference between the
wheel speed and the chassis speed.
Slip ratio is the value that shows the rate of
wheel slippage and is defined by the following formula.
Slip ratio =
Chassis speed – Wheel speed
× 100 (%)
Chassis speed
0%:
There is no slip between the wheel
and the road surface. The chassis speed is
equal to the wheel speed.
100%: The wheel speed is “0”, but the
chassis is moving (i.e., wheel lock).
EAS00874
Brake force and motorcycle stability
When the brake pressure is increased, wheel
speed is reduced. Slip occurs between the tire
and the road surface and brake force is generated. The limit of this brake force is determined
by the friction force between the tire and the
road surface and is closely related to wheel
slippage. Wheel slippage is represented by the
slip ratio.
Therefore, side force is also closely related to
wheel slippage. See figure . If the brakes are
applied while keeping the proper slip ratio, it is
possible to obtain the maximum brake force
without losing much side force.
ABS allows full use of the tire capabilities even
on slippery road surfaces or less slippery road
surfaces. See figure .
Friction force between the
tire and road surface
Brake force
Side force
Friction force between the
tire and road surface
Slip ratio (%)
Less slippery
road surface
Controlling zone
Slippery road surface
Slip ratio (%)
32
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
EAS00875
Wheel slip and hydraulic control
The ECU (ABS) calculates the wheel speed of
each wheel according to the rotation signal
received from the front and rear wheel sensors. In addition, the ECU (ABS) calculates the
motorcycle chassis speed and the rate of
speed reduction based on the wheel speed
values.
The difference between the chassis speed and
the wheel speed calculated in the slip ratio formula is equal to the wheel slip. When the
wheel has a tendency to lock, the wheel speed
is suddenly reduced. When the wheel slip and
the wheel speed reduction rate exceed the
preset values, the ECU (ABS) determines that
the wheel has a tendency to lock.
If the slip is large and the wheel has a tendency to lock (point A in the figure), the ECU
(ABS) reduces the brake fluid pressure in the
brake caliper and increases the pressure of the
brake fluid in the brake caliper when the tendency to lock has diminished (point B in the figure).
Motorcycle speed
Wheel speed
Pressurized
Depressurized
Brake force
EAS00876
ABS operation and motorcycle control
If the ABS starts operating, there is a tendency
of the wheel to lock, and the motorcycle is
approaching the limit of control. To make the
rider aware of this condition, the ABS has been
designed to generate a reaction-force pulsating action in the brake lever or brake pedal.
NOTE:
When the ABS is activated, a pulsating action
may be felt at the brake lever or brake pedal,
but this does not indicate a malfunction.
33
ANTI-LOCK BRAKE SYSTEM (ABS)
The higher the cornering force on a tire, the
less traction there is available for braking. This
is true whether the motorcycle is equipped with
an ABS or not. Therefore, sudden braking
while cornering is not recommended. Excessive cornering force, which an ABS cannot prevent, could cause the tire to slip sideways.
Brake force
Friction force between the
tire and road surface
CHAS
Side force
WARNING
Slip ratio (%)
The braking of the motorcycle, even in the
worst case, is principally executed when
the motorcycle is advancing straight ahead.
During a turn, sudden braking is liable to
cause a loss of traction of the tires. Even in
motorcycles equipped with an ABS, overturning of the motorcycle cannot be prevented if it is braked suddenly.
The ABS functions to prevent the tendency of
the wheel to lock by controlling the brake
hydraulic pressure. But, if there is a tendency
of the wheel to lock on a slippery road surface,
due to engine braking, the ABS may not be
able to prevent the wheel from locking.
WARNING
The ABS controls only the tendency of the
wheel to lock caused by applying the
brakes. The ABS cannot prevent wheel lock
on slippery surfaces, such as ice, when it is
caused by engine braking, even if the ABS
is operating.
34
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
EAS00877
Electronic ABS features
The Yamaha ABS (Anti-lock Brake System) has been developed with the most advanced electronic
technology.
The ABS control is processed with good response providing various travel conditions for motorcycles.
The ABS also includes a highly developed self-diagnostic function. The ABS detects any problem
conditions and allows normal braking even if the ABS is not operating properly.
When this occurs, the ABS warning light on the meter assembly comes on.
The ABS stores the malfunction codes in the memory of the ECU (ABS) for easy problem identification and troubleshooting.
ABS block diagram
Rear brake master cylinder
Hydraulic unit
Hydraulic pump
ABS motor
Buffer chamber
Hydraulic control valve
Front brake master cylinder
Rear brake caliper
Front brake caliper
ECU (ABS)
35
Rear wheel sensor
Front wheel sensor
ABS warning light
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
EAS000878
ABS component functions
• Wheel sensors and sensor rotors
Wheel sensors
detect the wheel rotation
speed and transmit the wheel rotation signal to
the ECU (ABS).
Each wheel sensor is composed of a permanent magnet and a coil. The wheel sensors are
installed in the sensor housing for each wheel.
Sensor rotors
are pressed in the inner side
of the front and rear wheel hubs and rotate
with the wheels. The sensor rotors have 44
serrations inside and are installed close to the
wheel sensors. As the distance changes
between the top and bottom of the serrations
with the rotation of the wheels, inductive electromotive force is generated in the wheel sensors. Wheel rotation speed is detected based
on the frequency of this alternating voltage.
At high speed
At low speed
Wheel sensor
Sensor rotor
• ABS warning light
The ABS warning light comes on to warn the
rider if a malfunction in the ABS occurs.
When the main switch is set to “ON”, the ABS
warning light comes on for 2 seconds to check
if the ABS warning light is disconnected and to
check if the ABS is operating properly, then
goes off.
CAUTION:
If the rear wheel is raced with the motorcycle on the centerstand, the ABS warning
light may flash or come on. If this occurs,
set the main switch to “OFF”, then back to
“ON”. The ABS operation is normal if the
ABS warning light comes on for 2 seconds,
then goes off.
ABS warning light
36
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
EAS00879
• Hydraulic unit
The hydraulic unit
is composed of a hydraulic control valve (solenoid valve, flow control
valve), a buffer chamber, and a hydraulic pump
for each brake and an ABS motor. The hydraulic unit adjusts the front and rear wheel brake
fluid pressure to control the wheel rotation
speed according to signals transmitted from
the ECU (ABS).
To front brake master cylinder
To the rear brake caliper
To the ECU (ABS)
To the front brake caliper
To rear brake master cylinder
Hydraulic pump
ABS motor
Buffer chamber
Hydraulic control valve
37
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
• Hydraulic control valve
The hydraulic control valve is composed of
a flow control valve and solenoid valve.
When the ABS is activated, the flow control
valve regulates the flow of brake fluid to
each brake and the solenoid valve
decreases and increases the brake fluid
pressure.
1) When the brakes are operated normally, the
solenoid valve
is closed, the spool
of
the flow control valve does not move, and
the hydraulic line between the brake master
cylinder and brake caliper is open.
2) When the ABS is activated, the solenoid
valve
is opened by the power supplied
from the ECU (ABS) signals to decrease
the brake fluid pressure and the spool
of
the flow control valve is moved toward the
solenoid valve.
3) When the ECU (ABS) stops transmitting
signals to decrease the brake fluid pressure, the solenoid valve
closes and the
brake fluid is pressurized again. Pressurizing the brake fluid again, while the ABS is
activated, limits the flow of the brake fluid
with the movement of the flow control valve
spool
and provides a gradual pressure
increase.
Orifice
Solenoid valve
Spool
Flow control valve
38
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
• Electronic control unit (ECU)
The ECU (ABS)
controls the ABS and is
installed inside the right cowling. To protect the
ECU (ABS) from water damage, it is protected
by a cover .
39
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
As shown in the block diagram below, the ECU (ABS) receives wheel sensor signals from the front
and rear wheels and also receives signals from other monitor circuits. Both a main microcomputer
and a sub microcomputer are installed in the ECU (ABS) to provide mutual monitoring.
Battery
Engine stop switch
Starting circuit cut-off relay
Sidestand switch
Starter relay
Starter motor
Start switch
Front wheel sensor
Rear wheel sensor
Main fuse
Main switch
Generator
Rectifier/regulator
ABS fuse
ABS motor fuse
ABS test coupler
ECU (ABS)
Rear brake light switch
Front brake light switch
Tail/brake light
Meter assembly
ABS warning light
Fail-safe relay
ABS motor relay
Solenoid relay
Hydraulic unit
ABS motor
Front solenoid
Rear solenoid
The necessary actions are confirmed by the motor monitor circuit and control signals are transmitted to the hydraulic unit and fail-safe relay.
40
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
• ABS control operation
The ABS control operation performed in the
ECU (ABS) is divided into the following two
parts.
• Hydraulic control
• Self-diagnosis
These operations are performed once every
8/1,000 of a second. When a failure is
detected in the ABS, a malfunction code is
stored in the memory of the ECU (ABS) for
easy problem identification and troubleshooting.
NOTE:
Some types of failures are not recorded in the
memory of the ECU (ABS) (e.g., a drop in battery voltage).
Software operation flow
Set the main switch to “ON”.
Initialize
Self-diagnosis (when static)
Self-diagnosis (when riding)
Receive signals
Control operation
Depressurize/pressurize
8/1,000 of a second
41
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
• Fail-safe relay
The fail-safe relay controls the power supply of
the hydraulic unit and is located beside the
hydraulic unit.
Fail-safe relay
Composition and operation
The fail-safe relay is composed of the solenoid relay
and ABS motor relay . The solenoid relay
is activated (continuous) by signals transmitted from the ECU (ABS). As a result, the solenoid valve
can be operated.
If a malfunction occurs in the circuit, the solenoid relay is deactivated and it becomes impossible for
the solenoid valve to reduce the hydraulic pressure of the brake fluid and normal braking is
resumed.
The ABS motor relay is also activated by signals transmitted from the ECU (ABS) and operates
simultaneously when the ABS starts to reduce the hydraulic pressure of the brake fluid.
If the solenoid relay is turned off, the motor relay is also deactivated and the motor stops operating if
there is a malfunction.
Solenoid relay
ABS motor relay
Solenoid valve
Electric control unit (ECU)
Pump motor relay coil
Pump motor monitor
ABS warning light
Fail-safe relay coil
Rear solenoid
Front solenoid
42
Power
Fail-safe relay
Hydraulic unit
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
ABS operation
The ABS hydraulic circuit consists of two systems: the front wheel and rear wheel. The following
describes the front system only.
• Normal braking (ABS not activated)
When the ABS is not activated port D
of the solenoid valve is closed because a control signal has
not been transmitted from the ECU (ABS) and port A
and port B
of the flow control valve are
open. Therefore, when the brake lever is squeezed, the hydraulic pressure in the brake master cylinder increases and the brake fluid is sent to the brake caliper via port A and port B.
At this time, the inlet and outlet check valves of the pump close the lines and brake fluid is not sent.
As a result, the brake master cylinder directly pressurizes the brake caliper during normal braking.
When the brake lever is released, the brake fluid in the brake caliper returns to the brake master cylinder via port A and port B.
Brake master cylinder
Brake light switch
ABS motor
Pump
Buffer chamber
Flow control valve
Port A
Spool
Port B
Orifice
43
Port D
Solenoid valve
Port C
Brake caliper
ECU (ABS)
ABS warning light
Brake fluid pressure
Time
Repressurizing
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
• Emergency braking (ABS activated)
1) Depressurized state
When the front wheel is about to lockup, port D
of the solenoid valve is opened by the
“depres-surization” signal transmitted from the ECU (ABS). When this occurs, the spool of the
flow control valve compresses the return spring to close port B . Brake fluid that has entered
through port A
is restricted by the orifice
and the brake fluid is sent to the brake caliper via
port C
and port D , and the buffer chamber. As a result, the hydraulic pressure in the brake
caliper is reduced.
The brake fluid stored in the buffer chamber is pumped back to the brake master cylinder by the
fluid pressure pump linked to the pump motor.
Brake master cylinder
Brake light switch
ABS motor
Pump
Buffer chamber
Flow control valve
Port A
Spool
Port B
Orifice
44
Port D
Solenoid valve
Port C
Brake caliper
ECU (ABS)
ABS warning light
Brake fluid pressure
Time
Repressurizing
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
2) Pressurized state
Port D
is closed by the “pressurization” signal transmitted from the ECU (ABS). Before this
occurs, the spool of the flow control valve has compressed the return spring to close port B .
Brake fluid that has entered through port A
is further restricted by the orifice
and the brake
fluid is sent to the brake calipers via port A
and port C . At this time, the brake is pressurized at a constant speed regardless of the brake fluid pressure level since restriction of port A
changes so that a constant pressure difference is maintained between chamber A
and chamber B
of the flow control valve.
Brake master cylinder
Brake light switch
ABS motor
Pump
Buffer chamber
Flow control valve
Port A
Spool
Port B
Orifice
Port D
45
Solenoid valve
Port C
Brake caliper
ECU (ABS)
ABS warning light
Brake fluid pressure
Time
Repressurizing
Chamber A
Chamber B
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
EAS00880
Self-diagnosis function
• ABS warning light
The ABS warning light
comes on when a
malfunction is detected by the ABS self-diagnosis. It is located in the meter assembly.
Main switch
OFF
ABS warning
light
• Instances when the ABS warning light
comes on
1) The ABS warning light comes on when the
main switch is set to “ON”.
The ABS warning light comes on for 2 seconds while the ABS is performing a selfdiagnosis, then goes off if there are no
problems.
2) The ABS warning light comes on while
riding.
If the ABS warning light comes on while
riding, a malfunction has been detected in
the ABS. The ABS hydraulic control will not
be performed. The ABS will have recourse
to manual braking if this occurs.
3) The ABS warning light flashes while riding.
If the ABS warning light flashes while riding,
there is no problem with the function of the
ABS. However, the ECU (ABS) input has
unstable factors. (For details, refer to
“TROUBLESHOOTING”.)
NOTE:
The ABS warning light comes on or flashes if
the motorcycle is ridden with the test coupler
adaptor connected to the test coupler.
Main switch
ON
Goes off
Comes on for
2 seconds.
Goes off
Preparation
ABS warning
light
Comes on
Comes on
Goes off
ABS warning
light
Preparation
46
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
4) The ABS warning light
flashes and maltifunction code
is indicated on the multifunction display when a test coupler adaptor
is connected to the 4-pin test coupler
for
troubleshooting the ABS.
The 4-pin test coupler can be accessed by
removing the side cowling (right).
When the test coupler adaptor is connected to
the 4-pin test coupler, the ABS warning light
starts flashing and the multifunction display
indicates all the maltifunction codes recorded
in the ECU (ABS).
Test coupler adaptor
90890-03149
NOTE:
The ABS warning light comes on or flashes if
the motorcycle is ridden with the test coupler
adaptor connected to the test coupler.
47
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
Cautions for operation
ABS warning light:
• When the main switch is set to “ON”, the ABS warning light comes on for 2 seconds, then goes
off.
• If the ABS warning light comes on while riding, stop the motorcycle, and then set the main switch
to “OFF”, then set the main switch to “ON”. The ABS operation is normal if the ABS warning light
comes on for 2 seconds, then off.
• If the rear wheel is raced with the motorcycle on the centerstand, the ABS warning light may flash
or come on. If this occurs, set the main switch to “OFF”, then back to “ON”. The ABS operation is
normal if the ABS warning light comes on for 2 seconds, then goes off.
• The ABS operation is normal if the ABS warning light flashes.
• Even if the ABS warning light remains on and does not go off or if it comes on after riding, conventional braking performance of the motorcycle is maintained.
ABS function:
• A brake system in which the hydraulic control has been performed by the ABS alerts a rider that
the wheels had a tendency to lock by generating a reaction-force pulsating action in the brake
lever or brake pedal. When the ABS is activated, the grip between the road surface and tires is
close to the limit. The ABS cannot prevent wheel lock* on slippery surfaces such as ice, when it is
caused by engine braking, even if the ABS is activated.
• The ABS is not designed to shorten the braking distance or improve the cornering performance.
• Depending on the road conditions, the braking distance may be longer compared to that of vehicles not equipped with an ABS. Therefore, ride at a safe speed and keep a safe distance between
yourself and other vehicles.
• The braking of the motorcycle, even in the worst case, is principally executed when the motorcycle is advancing straight ahead. During a turn, sudden braking is liable to cause a loss of traction
of the tires. Even motorcycles equipped with an ABS cannot be prevented from falling over if
braked suddenly.
• The ABS does not work when the main switch is set to “OFF”. The conventional braking function
can be used.
* Wheel lock: A condition that occurs when the rotation of one or both of the wheels has stopped
but the motorcycle continues to travel.
48
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
EAS00882
ABS COMPONENTS
Front brake hose (front brake master cylinder to
hydraulic unit)
ABS test coupler
ABS warning light
Front brake hose (hydraulic unit to front brake caliper)
Front wheel sensor
Front wheel sensor rotor
Electronic control unit (ECU)
49
Rear brake hose (hydraulic unit to rear brake caliper)
Rear brake hose (rear brake master cylinder to
hydraulic unit)
Hydraulic unit
Rear wheel sensor rotor
Rear wheel sensor
Fuse box
Fail-safe relay
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
EAS00889
FRONT WHEEL SENSOR AND SENSOR ROTOR
40 Nm (4.0 m•kg, 29 ft•lb)
40 Nm (4.0 m•kg, 29 ft•lb)
40 Nm (4.0 m•kg, 29 ft•lb)
72 Nm (7.2 m•kg, 52 ft•lb)
20 Nm (2.0 m•kg, 14 ft•lb)
40 Nm (4.0 m•kg, 29 ft•lb)
18 Nm (1.8 m•kg, 13 ft•lb)
18 Nm (1.8 m•kg, 13 ft•lb)
30 Nm (3.0 m•kg, 22 ft•lb)
Order
1
2
3
4
5
6
7
8
Job/Part
Removing the front wheel sensor
and sensor rotor
Q’ty
Brake caliper (left and right)
Front wheel sensor
Wheel axle pinch bolt
Front wheel axle
Collar (right)
Sensor housing
Brake disc (left and right)
Front wheel
2
1
1
1
1
1
2
1
Remarks
Remove the parts in the order listed.
NOTE:
Place the motorcycle on a suitable stand
so that the front wheel is elevated.
Loosen.
For installation, reverse the removal
procedure.
50
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
Maintenance of the front wheel sensor and
sensor rotor
• ABS wheel sensor and sensor rotor
CAUTION:
• Handle the ABS components with care
since they have been accurately adjusted.
Keep them away from dirt and do not subject them to shocks.
• The ABS wheel sensor cannot be disassembled. Do not attempt to disassemble
it. If faulty, replace with a new one.
• Removing the front wheel sensor
1. Remove:
• brake hose holder
• front wheel sensor lead holder
• brake caliper
• front wheel sensor
CAUTION:
• Be sure not to contact the sensor electrode to any metal part when removing the
front wheel sensor from the sensor housing.
• Do not operate the brake lever when
removing the brake caliper.
• Checking the front wheel sensor and sensor rotor
1. Check:
• front wheel sensor
Cracks/bends/distortion → Replace.
Iron powder/dust → Clean.
51
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
2. Measure:
• front wheel sensor resistance
Connect the pocket tester (Ω × 1k) to the
terminals of the front wheel sensor coupler.
Tester positive probe → Terminal
Tester negative probe → Terminal
Regulated resistance
1.2 ~ 1.6 kΩ at 20 °C
Out of specification → Replace.
3. Check:
• front wheel sensor rotor
Cracks/damage → Replace the front wheel
assembly.
NOTE:
The wheel sensor rotor of the motorcycle is
inserted under pressure by a special process
and cannot be replaced as a single unit. To
replace the sensor rotor, replace the wheel
assembly.
• Installing the front wheel sensor
1. Install:
• front wheel
NOTE:
Align the slot in the sensor housing with the
projection of the front fork before assembly.
CAUTION:
Make sure there are no foreign materials in
the wheel hub. Foreign materials cause
damage to the inner sensor rotor and front
wheel sensor.
52
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
2. Install:
• front wheel sensor
30 Nm (3.0 m•kg, 22 ft•lb)
• front wheel sensor lead holder
• brake caliper
40 Nm (4.0 m•kg, 29 ft•lb)
• brake hose holder
NOTE:
When installing the front wheel sensor, check
the wheel sensor lead for twists and the sensor
electrode for foreign materials.
CAUTION:
To route the front wheel sensor lead, refer
to “CABLE ROUTING”.
3. Check:
• front wheel sensor installation
Check if the wheel sensor housing is
installed properly. Refer to “P51 Maintenance of the front wheel sensor and sensor
rotor”.
53
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
EAS00890
REAR WHEEL SENSOR AND SENSOR ROTOR
40 Nm (4.0 m•kg, 29 ft•lb)
27 Nm (2.7 m•kg, 20 ft•lb)
30 Nm (3.0 m•kg, 22 ft•lb)
150 Nm (15.0 m•kg, 108 ft•lb)
Order
1
2
3
4
5
6
7
8
9
10
11
Job/Part
Q’ty
Remarks
Removing the rear wheel sensor and
Remove the parts in the order listed.
sensor rotor
NOTE:
Place the motorcycle on a suitable stand
so that the rear wheel is elevated.
Brake caliper
Brake caliper bracket bolt
Lock nut
Adjusting bolt
Rear wheel sensor
Wheel axle nut
Washer
Wheel axle
Adjusting block
Rear wheel
Sensor housing
1
1
2
2
1
1
2
1
2
1
1
For installation, reverse the removal
procedure.
54
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
Maintenance of the rear wheel sensor and
sensor rotor
CAUTION:
• Be sure not to contact the sensor electrode to any metal part when removing the
front wheel sensor from the sensor housing.
• Do not operate the brake lever when
removing the brake caliper.
• Removing the rear wheel sensor
1. Disconnect:
• rear wheel sensor
2. Remove:
• clamp
• rear wheel sensor lead holder
3. Remove:
• rear wheel sensor
CAUTION:
Be sure not to contact the sensor electrode
to any metal part when removing the rear
wheel sensor from the sensor housing.
• Checking the rear wheel sensor and sensor rotor
Refer to “Checking the front wheel sensor and
sensor rotor”.
55
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
• Installing the rear wheel sensor
1. Install:
• rear wheel
NOTE:
• Align the slot
of the sensor housing
with the projection
of the rear brake caliper
bracket , and then assemble them.
• After installation, check that the projection
of the rear brake caliper bracket is inserted
into the projection
of the sensor housing.
CAUTION:
Make sure there are no foreign materials in
the wheel hub. Foreign materials cause
damage to the inner sensor rotor and rear
wheel sensor.
2. Install:
• rear wheel sensor
30 Nm (3.0 m•kg, 22 ft•lb)
NOTE:
When installing the rear wheel sensor, check
the rear wheel sensor lead for twists and the
sensor electrode for foreign materials.
CAUTION:
To route the rear wheel sensor lead, refer to
“CABLE ROUTING”.
3. Connect:
• rear wheel sensor coupler
• rear wheel sensor lead holder
• clamp
CAUTION:
To route the rear wheel sensor lead, refer to
“CABLE ROUTING”.
4. Check:
• rear wheel sensor installation
Check if the wheel sensor housing is
installed properly. Refer to “P55 Maintenance of the rear wheel sensor and sensor
rotor”.
56
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
EAS00891
HYDRAULIC UNIT
30 Nm (3.0 m•kg, 22 ft•lb)
30 Nm (3.0 m•kg, 22 ft•lb)
16 Nm (1.6 m•kg, 12 ft•lb)
16 Nm (1.6 m•kg, 12 ft•lb)
Order
Job/Part
Q’ty
Removing the hydraulic unit
Seat
Fuel tank
ABS motor coupler/Hydraulic unit sole- 1/1
noid coupler
Fail-safe relay/Fail-safe relay coupler
1/1
1
2
Brake fluid
Union bolt/copper washers
Front brake hose
3
4
5
Union bolt/copper washers
Front brake hose
Union bolt/copper washers
Remarks
Remove the parts in the order listed.
Refer to “SEAT” in chapter 3.
(Manual No.: 5PS1-AE1)
Refer to “FUEL TANK” in chapter 3.
(Manual No.: 5PS1-AE1)
Refer to “ECU (ABS) AND FAIL-SAFE
RELAY”.
Drain.
1/2
1 (front brake master cylinder to hydraulic
unit)
1/2
1 (hydraulic unit to front brake caliper)
1/2
57
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
30 Nm (3.0 m•kg, 22 ft•lb)
30 Nm (3.0 m•kg, 22 ft•lb)
16 Nm (1.6 m•kg, 12 ft•lb)
16 Nm (1.6 m•kg, 12 ft•lb)
Order
6
7
8
9
10
11
Job/Part
Rear brake hose
Union bolt/copper washers
Rear brake hose
Nut
Hydraulic unit
Hydraulic unit bracket 2
Q’ty
Remarks
1 (rear brake master cylinder to hydraulic
unit)
1/2
1 (hydraulic unit to rear brake caliper)
2
1
1
For assembly, reverse the disassembly
procedure.
58
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
Maintenance of the hydraulic unit
CAUTION:
Do not remove the hydraulic unit to check
the resistance of the solenoid valves and
the ABS motor for continuity.
WARNING
Refill with the same type of brake fluid that
is already in the system. Mixing fluids may
result in a harmful chemical reaction, leading to poor braking performance.
CAUTION:
• Handle the ABS components with care
since they have been accurately adjusted.
Keep them away from dirt and do not subject them to shocks.
• The ABS wheel sensor cannot be disassembled. Do not attempt to disassemble
it. If faulty, replace with a new one.
• Do not set the main switch to “ON” when
removing the hydraulic unit.
• Do not clean with compressed air.
• Do not reuse the brake fluid.
• Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
• Do not allow any brake fluid to contact the
couplers. Brake fluid may damage the
couplers and cause bad contacts.
• If the union bolts for the hydraulic unit
have been removed, be sure to tighten
them to the specified torque and bleed the
brake system.
59
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
• Checking the resistance of the solenoid
valves and ABS motor for continuity
CAUTION:
When check the hydraulic unit solenoid
relay and ABS motor, do not remove the
brake hoses.
1. Measure:.
• resistance of the solenoid valve (front)
Connect a pocket tester (Ω × 1) to the terminals of the solenoid valve (front).
Tester positive probe → Terminal
Tester negative probe → Terminal
Solenoid valve resistance
2.96 ~ 3.20 Ω at 20 °C
Out of specification → Replace the hydraulic unit.
2. Measure:
• resistance of the solenoid valve (rear)
Connect the pocket tester (Ω × 1) to the terminals of solenoid valve (rear).
Tester positive probe → Terminal
Tester negative probe → Terminal
Solenoid valve resistance
2.96 ~ 3.20 Ω at 20 °C
Out of specification → Replace the hydraulic unit.
3. Check:
• ABS motor for continuity
Connect the pocket tester (Ω × 1) to the terminals of the ABS motor coupler.
Tester positive probe → Terminal
Tester negative probe → Terminal
There is continuity.
No continuity → Replace the hydraulic unit.
60
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
• Removing the hydraulic unit
1. Remove:
• brake hose
(from the front brake master
cylinder)
• brake hose
(to the front brake caliper)
• brake hose
(from the rear brake master
cylinder)
• brake hose
(to the rear brake caliper)
NOTE:
Do not operate the brake lever and brake pedal
while removing the brake hoses.
CAUTION:
When removing the brake hoses, cover the
area around the hydraulic unit to catch any
spilt brake fluid. Do not allow the brake
fluid to contact other parts.
2. Remove:
• hydraulic unit bracket 2
NOTE:
Loosen the nuts in the proper sequence.
3. Remove:
• hydraulic unit
NOTE:
To avoid brake fluid leakage and to prevent foreign materials from entering the hydraulic unit,
insert a rubber plug
or a bolt (M10 × 1.25)
into each union bolt hole.
• Checking the hydraulic unit
1. Check:
• hydraulic unit
Cracks/damage → Replace the hydraulic
unit.
61
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
• Installing the hydraulic unit
Proceed in the reverse order of disassembly.
Pay attention to the following items.
1. Install:
• hydraulic unit bracket 2
16 Nm (1.6 m•kg, 12 ft•lb)
NOTE:
Tighten the nuts in the proper sequence.
2. Install:
• hydraulic unit
NOTE:
Do not allow any foreign materials to enter the
hydraulic unit or the brake hoses when installing the hydraulic unit.
CAUTION:
Do not remove the rubber plugs or bolts
(M10 × 1.25) installed in the union bolt
holes before installing the hydraulic unit.
3. Remove:
• rubber plugs or bolts (M10 × 1.25)
4. Install:
• copper washer
• brake hose
(to the rear brake caliper)
• brake hose
(from the rear brake master
cylinder)
• brake hose
(to the front brake caliper)
• brake hose
(from the front brake master
cylinder)
• union bolt
30 Nm (3.0 m•kg, 22 ft•lb)
WARNING
The brake hoses to the front and rear brake
calipers can be distinguished by the rubber
at the end of each hose. Be sure to connect
each brake hose to the correct union bolt
hole.
CAUTION:
To route the front and rear brake hoses,
refer to “CABLE ROUTING”.
62
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
5. Fill:
• brake master cylinder reservoirs
Recommended brake fluid
DOT 4
6. Bleed the brake system.
7. Check the operation of the hydraulic unit
according to the brake lever and the brake
pedal response. (Refer to “P68 Hydraulic
unit operation test 1”.)
CAUTION:
Always check the operation of the hydraulic unit according to the brake lever and the
brake pedal response.
8. Delete the malfunction codes. (Refer to
“P120 Deleting the malfunction codes”.)
9. Perform a trial run. (Refer to “P73 Trial
run”.)
63
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
HYDRAULIC ABS
EAS00892
Bleeding the ABS system
WARNING
Always bleed the brake system when the
brake related parts are removed.
CAUTION:
Bleed the brake system in the following
order.
1st: Front brake caliper
2nd: Rear brake caliper
• Brake lever
• Brake pedal
• Front brake hose
master cylinder)
• Rear brake hose
master cylinder)
64
(from the front brake
(from the rear brake
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
Bleeding instruction
Hydraulic unit
Brake caliper
Solenoid valve
Buffer chamber
Hydraulic pump
Brake master cylinder pressure
Hydraulic pump pressure
EAS00134
Bleeding the ABS brake
WARNING
Bleed the ABS whenever:
• the system is disassembled.
• a brake hose is loosened, disconnected or
replaced.
• the brake fluid level is very low.
• brake operation is faulty.
NOTE:
• Be careful not to spill any brake fluid or allow
the brake master cylinder reservoir or brake
fluid reservoir to overflow.
• When bleeding the ABS, make sure there is
always enough brake fluid before applying the
brake. Ignoring this precaution could allow air
to enter the ABS, considerably lengthening
the bleeding procedure.
• If bleeding is difficult, it may be necessary to
let the brake fluid settle for a few hours.
• Repeat the bleeding procedure when the tiny
bubbles in the hose have disappeared.
65
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
1. Remove:
• seat
Refer to “SEAT” in chapter 3.
(Manual No.: 5PS1-AE1)
2. Bleed:
• ABS
a. Fill the brake fluid reservoir to the proper
level with the recommended brake fluid.
b. Install the diaphragm (brake master cylinder reservoir or brake fluid reservoir).
c. Connect a clear plastic hose
tightly to
the bleed screw .
Front
Rear
d. Place the other end of the hose into a container.
e. Slowly apply the brake several times.
f. Fully squeeze the brake lever or fully
depress the brake pedal and hold it in position.
g. Loosen the bleed screw.
NOTE:
Loosening the bleed screw will release the
pressure and cause the brake lever to contact
the throttle grip or the brake pedal to fully
extend.
h. Tighten the bleed screw, and then release
the brake lever or brake pedal.
i. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the brake
fluid in the plastic hose.
j. Check the operation of the hydraulic unit.
Refer to “P68 Hydraulic unit operation test
1”.
CAUTION:
Make sure that the main switch is set to
“OFF” before checking the operation of the
hydraulic unit.
k. After operating the ABS, repeat steps (e) to
(i), and then fill the primary circuit with the
recommended brake fluid.
66
ANTI-LOCK BRAKE SYSTEM (ABS)
l.
CHAS
Tighten the bleed screw to the specified
torque.
Bleed screw
6 Nm (0.6 m•kg, 4.3 ft•lb)
m. Fill the brake fluid reservoir to the proper
level with the recommended brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
(Manual No.: 5PS1-AE1)
WARNING
After bleeding the ABS, check the brake
operation.
• Final check
Checking procedures
1. Check the brake fluid level in the brake
master cylinder reservoirs.
2. Check the wheel sensors for proper installation.
3. Perform hydraulic unit operation test 1 or 2.
4. Delete the malfunction codes.
5. Perform a trial run.
• Checking the brake fluid level of the brake
master cylinder reservoirs
1. Check:
• brake fluid level
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
(Manual No.: 5PS1-AE1)
• Checking the wheel sensors for proper
installation
1. Check if the front wheel sensor housing and
the rear wheel sensor housing are installed
correctly. (Refer to “P51 Maintenance of the
front wheel sensor and sensor rotor” and
“P55 Maintenance of the rear wheel sensor
and sensor rotor”.)
67
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
2. Check:
• installation of the wheel sensors to the sensor housings (Refer to “P51 Maintenance of
the front wheel sensor and sensor rotor”
and “P55 Maintenance of the rear wheel
sensor and sensor rotor”.)
Wheel sensor
30 Nm (3.0 m•kg, 22 ft•lb)
Hydraulic unit operation test
The reaction-force pulsating action generated
in the brake lever and brake pedal when the
ABS is activated can be tested when the
motorcycle is stopped.
The hydraulic unit operation can be tested by
the following two methods.
• Hydraulic unit operation test 1: this test generates the same reaction-force pulsating
action that is generated in the brake lever
and brake pedal when the ABS is activated.
• Hydraulic unit operation test 2: this test
checks the function of the ABS after the
system was disassembled, adjusted, or serviced.
• Hydraulic unit operation test 1
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
1. Place the motorcycle on the sidestand.
2. Set the main switch to “OFF”.
3. Remove:
• seat
Refer to “SEAT”.
(Manual No.: 5PS1-AE1)
• right side cowling
Refer to “FRONT COWLINGS”.
(Manual No.: 5PS1-AE1)
68
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
4. Check:
• battery voltage
Battery voltage
Higher than 12.8 V
Lower than 12.8 V → Charge or replace the
battery.
NOTE:
• If the battery voltage is lower than 12.8 V,
charge the battery and perform hydraulic unit
operation test 1.
• If the battery voltage is lower than 10 V, the
ABS warning light comes on and the ABS
does not operate.
5. Connect the test coupler adaptor
test coupler .
to the
Test coupler adaptor
90890-03149
6. Set the engine stop switch
to “ ”.
7. Set the main switch to “ON”.
NOTE:
After setting the main switch to “ON”, wait
(approximately 2 seconds) until the ABS warning light goes off.
8. Push the start switch
onds.
for at least 4 sec-
CAUTION:
Do not operate the brake lever or the brake
pedal.
69
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
9. After releasing the start switch, operate the
brake lever and the brake pedal simultaneously.
NOTE:
• A reaction-force pulsating action is generated
in the brake lever
0.5 second after the
brake lever and the brake pedal are operated
simultaneously and continues for approximately 1 second.
• Be sure to continue to operate the brake lever
and brake pedal even after the pulsating
action has stopped.
10.After the pulsating action has stopped in
the brake lever, it is generated in the brake
pedal
0.5 second after and continues for
approximately 1 second.
NOTE:
Be sure to continue to operate the brake lever
and brake pedal even after the pulsating action
has stopped.
11.After the pulsating action has stopped in
the brake pedal, it is generated in the brake
lever 0.5 second after and continues for
approximately 1 second.
CAUTION:
• Check that the pulsating action is felt in
the brake lever, brake pedal, and again in
the brake lever, in this order.
• If the pulsating action is felt in the brake
pedal before it is felt in the brake lever,
check that the brake hoses are connected
correctly to the hydraulic unit.
• If the pulsating action is hardly felt in
either the brake lever or brake pedal,
check that the brake hoses are connected
correctly to the hydraulic unit.
70
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
12.Set the main switch to “OFF”.
13.Remove the test coupler adaptor from the
test coupler.
14.Set the main switch to “ON”.
15.Set the engine stop switch to “ ”.
• Hydraulic unit operation test 2
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
1. Place the motorcycle on the centerstand.
2. Set the main switch to “OFF”.
3. Remove:
• seat
Refer to “SEAT”.
(Manual No.: 5PS1-AE1)
• right side cowling
Refer to “FRONT COWLINGS”.
(Manual No.: 5PS1-AE1)
4. Check:
• battery voltage
Battery voltage
Higher than 12.8 V
Lower than 12.8 V → Charge or replace the
battery.
NOTE:
• If the battery voltage is lower than 12.8 V,
charge the battery and perform hydraulic unit
operation test 2.
• If the battery voltage is lower than 10 V, the
ABS warning light comes on and the ABS
does not operate.
5. Connect the test coupler adaptor
test coupler .
Test coupler adaptor
90890-03149
71
to the
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
6. Set the main switch to “ON” while operating
the brake lever and the brake pedal simultaneously.
CAUTION:
When the main switch is set to “ON”, be
sure to operate both the brake levers and
the brake pedal simultaneously. If only the
brake levers or brake pedal are operated,
set the main switch to “OFF” and start the
procedure again.
Main switch
On
ABS
warning
light
7. Check:
• Hydraulic unit operation
When the main switch is set to “ON”, the
ABS warning light comes on for 2 seconds,
goes off for 3 seconds, then starts flashing.
When the ABS warning light starts flashing,
the brake lever
will return to its home
position. The brake pedal
will then return
to its home position, then the brake lever
will return to its home position again.
ON
OFF
Flashing
2.0
seconds
3.0
seconds
0.5
second
0.5
second
0.5
second
ABS motor
CAUTION:
• Check that the brake lever returns to its
home position before the brake pedal
returns to its home position.
• If the brake pedal returns to its home position before the brake lever does, check
that the brake hoses are connected correctly to the hydraulic unit.
• If either the brake lever or brake pedal
returns to its home position slowly, check
that the brake hoses are connected correctly to the hydraulic unit.
• If the operation of the hydraulic unit is normal, delete all of the malfunction codes.
72
ANTI-LOCK BRAKE SYSTEM (ABS)
CHAS
CHECKING THE RESERVOIR TANK FLUID
LEVEL
1. Check:
• brake fluid level
Keep the reservoir cap horizontal and check
the level.
Less than the low level → Add the brake
fluid more than low level .
Recommended brake fluid
DOT #4
CAUTION:
• Do not mix the brake fluids of different
brands.
• If the brake fluid is attached to the coated
surface, plastics or rubbers, it may cause
the damage. Do not allow it to attach. Wipe
off the attached brake fluid immediately.
TRIAL RUN
After all checks and services are completed,
always ensure the motorcycle has no problems
by performing the trial running at a speed of
faster than 10 km/h.
73
ELECTRICAL COMPONENTS
‘
EAS00729
ELECTRICAL
ELECTRICAL COMPONENTS
Rear brake light switch
Oil level switch
Radiator fan motor
ECU (ABS)
Horn
Wire harness
Ignition coil
Front brake light switch
Clutch switch
Fail safe relay
Starter relay
Fuse box
Battery
Neutral switch
Sidestand switch
74
ELEC
ELECTRICAL COMPONENTS
Coolant temperature sensor
Atomospheric pressure sensor
Intake air tempreture sensor
Intake air pressure sensor
Lean angle cut-off switch
Turn signal relay
Fuel injection system relay
Radiator fan motor relay
Rear wheel sensor
Starting circuit cut-off relay
Speed sensor
O2 sensor
Crankshaft position sensor
Front wheel sensor
Cylinder identification sensor
ECU
75
ELEC
CHECKING THE SWITCHES
ELEC
EAS00731
CHECKING THE SWITCHES
Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage/wear Repair or replace.
Improperly connected Properly connect.
Incorrect continuity reading Replace the switch.
Main switch
Horn switch
Pass switch
Dimmer switch
Hazard switch
Turn signal switch
Clutch switch
Engine stop switch
Start switch
Front brake light switch
76
Neutral switch
Rear brake light switch
Fuses
Sidestand switch
W W W
R/W
P
Br
10
OFF
ON
G/Y
MAIN
B
W
R
R
80
W
W
W
B
B
B
B
Br/L
Br/L
Br/L
R
Br/R
Br/L
R
Br/R
2
B
W
Br/L
Br/R
77
76
79
78
B B
B B
11
R
B
B
R
B
B
B
B
B
B
B L/R
Br
75
BrG
R/B B Br
55
5
G/Y W/L R/W
R/Y
R/W
B
B
R
R
R
Br B R/B
R/W L/W G/Y
R
B/W
R
R
R
B
B
Br/L
Br/W
B
B
B/W
56
B B
73
Y/L G/L R/W
B B R/G
R/W Lg Y/L
R/G B
B
9
7
B/W
R
G/L
Y L/R B
Y/L
R/W
L/W R/W
L/W
R/W
RUN
OFF
57
Br Y
12
8
6
B
Br/R
B
G/Y
B
L
B
L
L
81
82
B L
74
Y
R
R/G
3
R/G
R/W
R/W
Y
R/Y
B
L/B
R/Y
PUSH
FREE
58
13
Y/B
R/B W/L R/L
72
71
L/B
B
Lg
B/Y
B/W B/R L/W L/R R/W L/G L/Y Sb
Br/R L/W G/R
R/B
B/Y
4
L/R
Br/L
B
L/W
R/W
W/L
Lg
Sb
Sb
L/Y
L/G
16
B
L/G
59
L/G B
B B
15
14
Br/R
ON
OFF
60
R/L
Br/L
L/W
HEADLIGHT SUB-WIRE HARNESS 2
R/W
B/L
B/L P/W L
HI
LO
ON
62
G/R B/L
Br/W B/L
B/L P L
W/B
L
L
21
20
B/L
Y B/L
Gy G/W
E
B/L
B/L
B/L
P
L
B/L
Gy
54
P/W
G/W
B
Ch
67
B
N
L
R
64
L Y/G B/L
G/R
L
Y
B/L
ON
Ch
A
B
B
Br/W
L
Y
B/L
OFF
63
BrG
Br/W
23
22
B
L
Y
B/L
18
WIRE HARNESS SUB-WIRE HARNESS 2
P/W P/W
L
G/W L/Y
19
HEADLIGHT SUB-WIRE
HARNESS 1
OFF
61
B/L
L W/B
B/L
W L/Y
17
66
Br
A
B/L Br/W
L R/L
L
24
Ch D Ch
B
Dg
68
B
Dg
Gy/G
65
L/Y
B/Y
L/Y
B/Y
Gy/G
R/W
Y/G
G/R
Br/W
P
P/W
Y
L
B/L
W/B
G/W
Gy
L/W
L/Y
B/Y
R/W
L/R
R/L
E
L G/Y
Br/W
B/L
D
B
Ch
69
B
Ch
Dg D Dg
Ch L/Y B B/Y Br
Dg Y L/B Br/W R/Y
Br B/Y B L/Y Ch
R/Y Br/W L/B Y Dg
25
W L
26
Br/W
Gy/G B/L
B
Dg
70
B
Dg
F
R/W Br
G/Y L
W/Y
Y/L
G/Y
Y/B
Br/B
Br/R
A
A
R/B R/B
G/B G/B
Br/B R/W
D
53
W B
R/L
R/L
48
45
52
51
50
49
47
46
G/R
D
G/R
W/Y G/R G L Br/W Y
Br/R Y/B
R/W
44
R/L B
W Y/L B/W L/R G/L Lg Br R/G
G/R
L
Br/W
Y
G/L
W
G
R/G
Br
B/L
B/L
G B/W
L W/Y
R/W
W L/Y
31
R/L R/B
R/L G/B
R/W L/R
Br Br/R
30
29
Br/B
Br/R
43
L
B/L
B W
L
L
W/Y
27
28
Br/W P/W Y Y/L Gy B/L
ABS SUB-WIRE HARNESS 1
L/W B/Y L/Y R/W Br/B G/Y
WIRE HARNESS
B B/W
L/W P/W W/B W/R
Br/W Y
B/W B Y Br/W
G
W/R W/B P/W L/W
Y/G P G/R R/L W/B G/W B/W
Br/R R/W
R/B R/B
G/B G/B
O
GyR
Gy/G W/Y
L
RADIATOR FAN MOTOR
WIRE HARNESS RELAY SUB-WIREHARNESS
Br R/W
R/W Br/B
Br/W B/L
WIRE HARNESS SUB-WIRE HARNESS 3
Br/B R/W
G/B R/B
WIRE HARNESS SUB-WIRE HARNESS 1
R/L L
Ch
WIRE HARNESS
Br/W
E
Br/W
WIRE HARNESS
BrG
R/B G/B
B/W
P/W
B/W
B/L
B/W
Y
G D G
B
R/G
B/L
B/W
R/L A R/L
P/W Y
B/L
Br/W
Br/B
E
Br/B
R/W
E
R/W
G/L R/G Y/L
B/Y
36
R/L
B
W/Y W B/W
L/Y
B W/L W/Y
W R/W W/G
B/W
B/W
W/Y
Y/L
Lg
R/B
R/B
O
W/G R/W W
W/Y W/L B
W/Y
35
C
W/Y
B Sb
W/R Lg
Lg W/R
Sb B
Lg
W/Y
Lg
W/R
W/Y W/L B
W/G R/W W
Br/W Y B B/W
L/W P/W W/B W/R
Y
Br/W
L/W
Sb
L/W W/B P/W W/R
W/R
Br/W
Lg
34
33
Sb
34
32
ABS SUB-WIRE HARNESS 2
H
GyR
B/W
R/B G/B O GyR B/W
WIRE HARNESS
G
B/W
C
B
Y/L R/G G/L
L/R
B
Br
Br
Y/L
B/W W W/Y
Br/W
Br
D
Br
Lg
D
Lg
C
Y/L
B/W
C
B/W
Dg Lg Br
B/Y
B/W W/Y
W/L
W/G
37
B
W
L/W
L/W
B Y G/R Br/W Ch G L
P/W
P/W
L/R L/B
W/B
W/B
B
W/R
W/R
B
Br/W
Br/W
W
R/W
B
W/G
W/L
P/W
W/B
R/W
B
W
B/W
W/Y
B/Y
W/Y
B Sb
Y
Y
1
R
Br
L
L
G/Y
G/Y
F
G/Y
F
L
L
B
B
Br/R
R/W
Br
Br
F
Br
F
R/W
L/R
D
L/R
L/R
B
R/W
Y
B/W
B/W
D
R/Y
L/B
Y
Y
B
R/Y
L/B
W/L
R/Y
Y/B
L/B
D
B/W
B/W
W/G
W/G
L/B L/R
B
R/W
R/W
38
B W/L W/Y
W R/W W/G
B/W B Y Br/W
W/RW/BP/W L/W
W/G W/L
W W
W G
R R
39
Br/W
B
B
W
B/Y
W/Y
P/W
L G Ch Br/W G/R Y B
W/B
R/W
42
41
40
B W
B W
W
W/L
L/R
B
B
W
W
W/R
W
W
W/G
R/W
R/W
B/W
Br Lg Dg
L/B
B
L/B
Y
Y D Y
Ch
B
W/L
W/L
Y/G
Dg
Dg
B
R/B
Fuse (main)
Starter relay
Starter motor
Battery
Main switch
Starting circuit cut-off relay
Sidestand switch
Neutral switch
Engine stop switch
Start switch
Clutch switch
Fuse (ignition)
B
Ch
B
B
Y
B
B
D
Dg
B
G/L
C
G/L
W/Y
W/Y
C
R/G
W
C
W
W
B
B
B
77
B
W
B R/W W/B
W B
W/Y B/Y
B/W R/W
R/W B
P/W Br/W W/R R/W
ELECTRIC STARTING SYSTEM
ELEC
EAS00755
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM
ELECTRIC STARTING SYSTEM
ELEC
EAS00756
STARTING CIRCUIT CUT-OFF SYSTEM
OPERATION
If the engine stop switch is set to “ ” and the
main switch is set to “ON” (both switches are
closed), the starter motor can only operate if at
least one of the following conditions is met:
• The transmission is in neutral (the neutral
switch is closed).
• The clutch lever is pulled to the handlebar
(the clutch switch is closed) and the sidestand is up (the sidestand switch is closed).
The starting circuit cut-off relay prevents the
starter motor from operating when neither of
these conditions has been met. In this
instance, the starting circuit cut-off relay is
open so current cannot reach the starter
motor. When at least one of the above conditions has been met the starting circuit cut-off
relay is closed and the engine can be started
by pressing the starter switch.
WHEN THE TRANSMISSION IS IN
NEUTRAL
WHEN THE SIDESTAND IS UP AND
THE CLUTCH LEVER IS PULLED
TO THE HANDLEBAR
Battery
Main fuse
Main switch
Ignition fuse
Engine stop switch
Starting circuit cut-off relay
Diode (starting circuit cut-off relay)
Clutch switch
Sidestand switch
Neutral switch
Start switch
Starter relay
Starter motor
78
ELECTRIC STARTING SYSTEM
ELEC
EAS00739
EAS00757
TROUBLESHOOTING
The starter motor fails to turn.
Check:
1.main and ignition fuses
2.battery
3.starter motor
4.starting circuit cut-off relay
5.diode (starting circuit cut-off relay)
6.starter relay
7.main switch
8.engine stop switch
9.neutral switch
10.sidestand switch
11.clutch switch
12.start switch
13.wiring connections
(of the entire starting system)
NOTE:
• Before troubleshooting, remove the following
part(s):
1) seat
2) fuel tank
3) air filter case
4) side cowlings
• Troubleshoot with the following special
tool(s).
2. Battery
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3. (Manual No.:
5PS1-AE1)
Minimum open-circuit voltage
12.8 V or more at 20°C
• Is the battery OK?
NO
YES
• Clean the battery
terminals.
• Recharge or replace the battery.
EAS00758
3. Starter motor
• Connect the positive battery terminal
and starter motor lead
with a jumper
lead .
Pocket tester
90890-03132
EAS00738
1. Main and ignition fuses
• Check the main and ignition fuses for continuity.
Refer to “CHECKING THE FUSES” in chapter 3. (Manual No.: 5PS1-AE1)
• Are the main and ignition fuses OK?
YES
WARNING
• A wire that is used as a jumper lead
must have at least the same capacity or
more as that of the battery lead, otherwise the jumper lead may burn.
• This check is likely to produce sparks,
therefore make sure nothing flammable
is in the vicinity.
NO
Replace the fuse(s).
• Does the starter motor turn?
YES
NO
Repair or replace
the starter motor.
79
ELECTRIC STARTING SYSTEM
EAS00759
ELEC
Tester positive probe →
black/yellow
Tester negative probe →
sky blue
4. Starting circuit cut-off relay
• Disconnect the starting circuit cut-off relay
from the wire harness.
• Connect the pocket tester (Ω × 1) and battery (12 V) to the starting circuit cut-off relay
terminals as shown.
Tester positive probe →
blue/yellow
Tester negative probe →
sky blue
Battery positive terminal →
red/black
Battery negative terminal →
black/yellow
Tester positive probe →
blue/yellow
Tester negative probe →
blue/green
Tester positive prove → blue/white
Tester negative prove → white/blue
Tester positive probe →
sky blue
Tester negative probe →
black/yellow
Tester positive probe →
sky blue
Tester negative probe →
blue/yellow
No
continuity
Tester positive probe →
blue/green
Tester negative probe →
blue/yellow
• Does the starting circuit cut-off relay have
continuity between blue/white and black?
YES
Continuity
NO
Replace the starting
circuit cut-off relay.
EAS00760
5. Starting circuit cut-off relay (diode)
• Disconnect the starting circuit cut-off relay
from the wire harness.
• Connect the pocket tester (Ω × 1) to the
starting circuit cut-off relay terminals as
shown.
• Measure the starting circuit cut-off relay for
continuity as follows.
NOTE:
When you switch the tester’s positive and
negative probes, the readings in the above
chart will be reversed.
• Are the testing readings correct?
YES
NO
Replace the starting
circuit cut-off relay.
80
ELECTRIC STARTING SYSTEM
EAS00761
ELEC
EAS00750
6. Starter relay
8. Engine stop switch
• Disconnect the starter relay from the coupler.
• Connect the pocket tester (Ω × 1) and battery (12 V) to the starter relay terminals as
shown.
• Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the engine stop switch OK?
YES
Battery positive terminal →
red/white
Battery negative terminal →
blue/white
NO
Replace the right
handlebar switch.
Tester positive probe → red
Tester negative probe → black
EAS00751
9. Neutral switch
• Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the neutral switch OK?
YES
NO
Replace the neutral
switch.
EAS00752
• Does the starter relay have continuity
between red and black?
YES
10. Sidestand switch
• Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the sidestand switch OK?
NO
Replace the starter
relay.
YES
Replace the sidestand switch.
EAS00749
7. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
YES
NO
EAS00763
11. Clutch switch
• Check the clutch switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the clutch switch OK?
NO
Replace the main
switch.
YES
NO
Replace the clutch
switch.
81
ELECTRIC STARTING SYSTEM
EAS00764
12. Start switch
• Check the start switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the start switch OK?
YES
NO
Replace the right
handlebar switch.
EAS00766
13. Wiring
• Check the entire starting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the starting system’s wiring properly connected and without defects?
YES
The starting system
circuit is OK.
NO
Properly connect or
repair the starting
system’s wiring.
82
ELEC
W W W
1
R/W
P
B
L
L
G/Y
R
B
L
Br
10
OFF
ON
MAIN
B
W
R
Br/R
80
W
Br/L
81
82
B
B
B
B
Br/L
Br/L
Br/L
R
Br/R
Br/L
R
Br/R
2
B
W
Br/L
Br/R
77
76
79
78
B
B
B
B
11
B
B
R
B
B
B
B
B
B
B
B L/R
Br
75
BrG
R/B B Br
55
5
G/Y W/L R/W
R/Y
R/W
B
R
R
R
Br B R/B
R/W L/W G/Y
R
R
R
R
B
B
W
R
B/W
W
B
B/W
B
56
G/L
B L
6
Y
Y/L
L/W
R/W
RUN
OFF
57
Br Y
12
8
Y L/R B
74
B B
73
Y/L G/L R/W
B B R/G
R/W Lg Y/L
R/G B
B
9
7
B/W
R
R/W
L/W R/W
B
Br/W
R
R/G
Br/R
Y
R/Y
B
L/B
R/Y
PUSH
FREE
58
13
Y/B
72
71
L/B
B
Lg
B/Y
16
L/G
59
L/G B
B B
15
14
ON
OFF
60
L
B/L
B/L P/W L
HI
LO
ON
62
G/R B/L
Br/W B/L
B/L P L
W/B
L
21
20
B/L
Y B/L
Gy G/W
OFF
61
B/L
L W/B
B/L
W L/Y
17
66
Br
R/B
R/W
W/Y W B/W
R/B W/L R/L
B/W B/R L/W L/R R/W L/G L/Y Sb
Br/R L/W G/R
L/W
3
B
G/Y
R/B
B/Y
4
R/G
Br/L
B
Br/R
R/L
Br/L
L/R
R/W
R/W
L/W
R/W
W/L
Lg
Sb
Sb
L/Y
L/G
B
E
B/L
B/L
B/L
P
L
B/L
B/L
B/L
ON
OFF
63
BrG
Br/W
23
22
B
54
P/W
B
G/R
L
Y
B/L
L
N
R
64
L Y/G B/L
Ch
67
B
Ch
A
B
B
Br/W
Y
L
B/L
L
G/W
Gy
Y
B/L
18
WIRE HARNESS SUB-WIRE HARNESS 2
P/W P/W
L
G/W L/Y
19
HEADLIGHT SUB-WIRE
HARNESS 1
Br/W
E
Br/W
B/W W W/Y
BrG
WIRE HARNESS
L R/L
R/L L
L
24
Ch D Ch
B
Dg
68
B
Dg
Gy/G
65
L/Y
B/Y
L/Y
B/Y
Gy/G
R/W
Y/G
G/R
Br/W
P
P/W
Y
L
B/L
W/B
G/W
Gy
L/W
L/Y
B/Y
R/W
L/R
R/L
WIRE HARNESS SUB-WIRE HARNESS 1
B/L Br/W
Br/W B/L
Br/W
B/L
D
B
Ch
69
B
Ch
Dg D Dg
Ch L/Y B B/Y Br
Dg Y L/B Br/W R/Y
Br B/Y B L/Y Ch
R/Y Br/W L/B Y Dg
25
W L
26
Br/W
Gy/G B/L
B
Dg
70
B
Dg
WIRE HARNESS SUB-WIRE HARNESS 3
B/W
B Y G/R Br/W Ch G L
B/W
HEADLIGHT SUB-WIRE HARNESS 2
B/W
WIRE HARNESS
Ch
R/W Br/B
G/Y L
L G/Y
W/Y
Y/L
G/Y
Y/B
Br/B
Br/R
A
A
R/B R/B
G/B G/B
Br/B R/W
D
L
53
W B
R/L
R/L
Br
48
52
51
50
49
47
46
45
G/R
D
G/R
W/Y G/R G L Br/W Y
B/W
W/Y
Y/L
Lg
R/B
R/B
O
W/G R/W W
W/Y W/L B
Sb B
W/Y
35
C
W/Y
Lg
W/Y
B
B
W/Y
W/Y W/L B
W/G R/W W
Br/W Y B B/W
L/W P/W W/B W/R
W/L
Y
W/G
P/W
Br/W
38
W/RW/BP/W L/W
B W/L W/Y
W R/W W/G
B/W B Y Br/W
W G
W/G W/L
W W
R R
B
Y
W/B
R/W
39
R/W
W
L/W
B/Y
W/R Lg
B/W
W/Y
W/R
B Sb
Lg
37
W/L
W/G
W
Sb
B/Y
B/W W/Y
W/R
L/W W/B P/W W/R
Lg
Br/W
Sb
34
33
B Sb
Lg W/R
34
32
ABS SUB-WIRE HARNESS 2
H
GyR
B/W
R/B G/B O GyR B/W
B/W
36
B W/L W/Y
W R/W W/G
WIRE HARNESS
Br/R Y/B
R/W
44
R/L B
G B/W
B/L
W Y/L B/W L/R G/L Lg Br R/G
G/R
L
Br/W
Y
G/L
W
G
R/G
B/L
W L/Y
31
R/W
L W/Y
Br Br/R
R/L R/B
R/L G/B
R/W L/R
L/W B/Y L/Y R/W Br/B G/Y
30
29
Br/B
Br/R
43
B W
L
B/L
W/Y
L
27
28
Br/W P/W Y Y/L Gy B/L
ABS SUB-WIRE HARNESS 1
B B/W
Br/W Y
B/W B Y Br/W
WIRE HARNESS
L/W P/W W/B W/R
G
W/R W/B P/W L/W
Y/G P G/R R/L W/B G/W B/W
Br/R R/W
R/B R/B
G/B G/B
O
GyR
Gy/G W/Y
L
RADIATOR FAN MOTOR
WIRE HARNESS RELAY SUB-WIREHARNESS
R/W Br
F
Br R/W
R/G
E
B/W
R/L A R/L
Br/B R/W
G D G
L G Ch Br/W G/R Y B
B/L
Br/W
Br/B
E
Br/B
R/W
E
R/W
G/B R/B
B
A
B/Y
R/L
L/R
R/B G/B
B
P/W
Y/L
Y
L/Y
G
B/W
B
Br
Br
Lg
D
Lg
C
Y/L
B/W
C
B/W
B
L/W
L/W
P/W Y
P/W
P/W
G/L R/G Y/L
W/B
W/B
C
Br/W
B
W/R
W/R
Y/L R/G G/L
Y
Br
D
Br
B
Br/W
Br/W
Dg Lg Br
B
B
Y
W
R
Br
Br
F
R/W
F
R/W
R/W
L/R
D
L/R
L/R
B
B/W
B/W
L/R L/B
R/Y
L/B
Y
Y
B
R/Y
L/B
W/L
R/Y
Y/B
L/B
D
B/W
B/W
W/G
W/G
D
B
W
W
Br/W
B
B
W
B/Y
W/Y
P/W
L/B L/R
W/B
R/W
42
41
40
B W
B W
W
W/L
L/R
B
B
R/W
R/W
W/R
W
W
W/G
R/W
R/W
B/W
Br Lg Dg
L/B
B
L/B
Y
Y D Y
Ch
B
B
B
Y/G
Dg
Dg
B
Br
Br
L
L
G/Y
G/Y
F
G/Y
F
L
L
B
Ch
B
B
Y
B
B
D
Dg
B
G/L
C
G/L
W/L
W/L
C
R/G
W
C
W
W
B
W/Y
W/Y
83
B
W
B R/W W/B
W B
W/Y B/Y
B/W R/W
R/W B
P/W Br/W W/R R/W
SIGNALING SYSTEM
ELEC
EAS00780
SIGNALING SYSTEM
CIRCUIT DIAGRAM
SIGNALING SYSTEM
Fuse (main)
Battery
Main switch
Fuse (backup)
Starting circuit cut-off relay
Neutral switch
ECU
Fuel pump
Oil level warning light
Neutral indicator light
Multi-function meter
Engine trouble warning light
Turn signal indicator light
Oil level switch
Turn signal relay
Front brake light switch
Horn switch
Hazard switch
Turn signal switch
Horn
Rear turn signal light (left)
Rear turn signal light (right)
Front turn signal light (left)
Front turn signal light (right)
Rear brake light switch
Tail/brake light
Fuse (hazard)
Fuse (signal)
84
ELEC
SIGNALING SYSTEM
EAS00794
ELEC
EAS00739
TROUBLESHOOTING
2. Battery
• Any of the following fail to light: turn signal light, brake light or an indicator light.
• The horn fails to sound.
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3. (Manual No.:
5PS1-AE1)
Check:
1. main, signaling, hazard light and back up
fuses
2. battery
3. main switch
4. wiring connections
(of the entire signaling system)
NOTE:
• Before troubleshooting, remove the following
part(s):
1) fuel tank
2) front cowling
3) air filter case
• Troubleshoot with the following special
tool(s).
Minimum open-circuit voltage
12.8 V or more at 20°C
• Is the battery OK?
YES
NO
• Clean the battery
terminals.
• Recharge or replace the battery.
EAS00749
3. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
Pocket tester
90890-03132
YES
NO
EAS00738
Replace the main
switch.
1. Main, signaling system, hazard lighting
and backup fuses
• Check the main, signaling system, hazard
lighting and backup fuses for continuity.
Refer to “CHECKING THE FUSES” in chapter 3.
• Are the main, signaling system, hazard
lighting and backup fuses OK?
YES
EAS00795
4. Wiring
• Check the entire signal system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the signaling system’s wiring properly
connected and without defects?
NO
YES
NO
Replace the fuse(s).
Check the condition
of each of the signaling system’s circuits.
Refer to “CHECKING THE SIGNALING SYSTEM”.
85
Properly connect or
repair the signaling
system’s wiring.
SIGNALING SYSTEM
ELEC
EAS00796
3. Horn
CHECKING THE SIGNAL SYSTEM
1. The horn fails to sound.
• Disconnect the black connector at the horn
terminal.
• Connect a jumper lead
to the horn terminal and ground the jumper lead.
• Set the main switch to “ON”.
• Push the horn switch.
• Does the horn sound?
1. Horn switch
• Check the horn switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the horn switch OK?
YES
NO
Replace the left handlebar switch.
2. Voltage
• Connect the pocket tester (DC 20 V) to the
horn connector at the horn terminal as
shown.
Positive tester probe → black/white
Negative tester probe → ground
YES
The horn is OK.
• Set the main switch to “ON”.
• Push the horn switch.
• Measure the voltage (DC 12 V) of black/
white at the horn terminal.
• Is the voltage within specification?
YES
NO
The wiring circuit
from the main switch
to the horn connector is faulty and must
be repaired.
86
NO
Replace the horn.
SIGNALING SYSTEM
ELEC
EAS00797
2. The tail/brake light fails to come on.
3. Voltage
• Connect the pocket tester (DC 20 V) to the
tail/brake light coupler (wire harness side)
as shown.
1. Tail/brake light bulb and socket
• Check the tail/brake light bulb and socket
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS” in chapter 3. (Manual
No.: 5PS1-AE1)
• Are the tail/ brake light bulb and socket OK?
YES
NO
Replace the tail/
brake light bulb,
socket or both.
Positive tester probe → yellow
Negative tester probe → black
• Set the main switch to “ON”.
• Pull in the brake lever or push down on the
brake pedal.
• Measure the voltage (DC 12 V) of yellow
on the tail/brake light coupler (wire harness
side).
• Is the voltage within specification?
2. Brake light switches
• Check the brake light switches for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the brake light switch OK?
YES
NO
Replace the brake
light switch.
YES
This circuit is OK.
87
NO
The wiring circuit
from the main switch
to the tail/brake light
coupler is faulty and
must be repaired.
SIGNALING SYSTEM
ELEC
EAS00799
3. The turn signal light, turn signal indicator
light or both fail to blink.
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) on brown/
green
at the turn signal relay coupler
(wire harness side).
• Is the voltage within specification?
1. Turn signal indicator light bulb and socket
• Check the turn signal light bulb and socket
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS” in chapter 3. (Manual
No.: 5PS1-AE1)
• Are the turn signal light bulb and socket
OK?
YES
YES
The wiring circuit
from the main switch
to the turn signal
relay
coupler
is
faulty and must be
repaired.
NO
Replace the turn signal light bulb, socket
or both.
4. Voltage
• Connect the pocket tester (DC 20 V) to the
turn signal relay coupler (wire harness side)
as shown.
2. Turn signal switch
• Check the turn signal switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the turn signal switch OK?
YES
NO
Positive tester probe → brown/white
Negative tester probe → ground
NO
Replace the left handlebar switch.
3. Voltage
• Connect the pocket tester (DC 20 V) to the
turn signal relay coupler (wire harness side)
as shown.
• Set the main switch to “ON”.
• Set the turn signal switch to “ ” or “ ”.
• Measure the voltage (DC 12 V) on brown/
white
at the turn signal relay coupler
(wire harness side).
• Is the voltage within specification?
Positive tester probe → brown/green
Negative tester probe → ground
YES
NO
The turn signal relay
is faulty and must be
replaced.
88
SIGNALING SYSTEM
ELEC
EAS00800
4. The neutral indicator light fails to come on.
5. Voltage
• Connect the pocket tester (DC 20 V) to the
turn signal light coupler or meter assembly
coupler (wire harness side) as shown.
1. Neutral indicator light bulb and socket
• Check the neutral indicator light bulb and
socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS” in chapter 3. (Manual
No.: 5PS1-AE1)
• Are the neutral indicator light bulb and socket OK?
Turn signal light
Turn signal indicator light
Left turn signal light
Positive tester probe → chocolate
Negative tester probe → ground
Right turn signal light
Positive tester probe → dark green
Negative tester probe → ground
YES
NO
Replace the neutral
indicator light bulb,
socket or both.
2. Neutral switch
• Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the neutral switch OK?
YES
NO
Replace the neutral
switch.
• Set the main switch to “ON”.
• Set the turn signal switch to “ ” or “ ”.
• Measure the voltage (DC 12 V) of the
brown/white
or blue/red
at the turn
signal light coupler (wire harness side).
• Is the voltage within specification?
YES
This circuit is OK.
NO
The wiring circuit
from the turn signal
switch to the turn
signal light coupler
(meter
assembly
coupler) is faulty and
must be repaired.
89
SIGNALING SYSTEM
ELEC
EAS00753
3. Starting circuit cut-off relay (diode)
4. Voltage
• Disconnect the starting circuit cut-off relay
from the wire harness.
• Connect the pocket tester (Ω × 1) to the
starting circuit cut-off relay terminals as
shown.
• Check the starting circuit cut-off relay for
continuity.
• Connect the pocket tester (DC 20 V) to the
meter assembly coupler (wire harness side)
as shown.
Tester positive probe →
light green
Tester negative probe →
sky blue
Continuity
Tester positive probe →
sky blue
Tester negative probe →
light green
No
continuity
Positive tester probe → brown
Negative tester probe → light green
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V).
• Is the voltage within specification?
YES
This circuit is OK.
NOTE:
When you switch the positive and negative
tester probes, the readings in the above
chart will be reversed.
The wiring circuit
from the main switch
to the meter assembly coupler is faulty
and
must
be
repaired.
EAS00802
5. The oil level warning light fails to come on.
• Are the tester readings correct?
YES
NO
1. Oil level warning light bulb and socket
• Check the oil level warning light bulb and
socket for continuity.
Refer to “CHECKING THE LEDs” in chapter
8. (Manual No.: 5PS1-AE1)
• Are the oil level warning light bulb and
socket OK?
NO
Replace the starting
circuit cut-off relay.
YES
NO
Replace the oil level
warning light bulb,
socket or both.
90
SIGNALING SYSTEM
ELEC
2. Engine oil level switch
4. Voltage
• Drain the engine oil and remove the engine
oil level switch from the oil tank.
• Check the engine oil level switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the engine oil level switch OK?
• Connect the pocket tester (DC 20 V) to the
engine oil level switch coupler as shown.
YES
Tester positive probe → white
Tester negative probe → black
NO
Replace the engine
oil level switch.
3. Voltage
• Connect the pocket tester (DC 20 V) to the
meter assembly coupler (wire harness side)
as shown.
• Set the main switch to “ON”.
• Measure the voltage (5 V) of white
and
black
at the oil level switch coupler.
• Is the voltage within specification?
Positive tester probe → brown
Negative tester probe → black/white
YES
This circuit is OK.
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) of brown
and black/white
at the meter assembly
coupler.
• Is the voltage within specification?
YES
NO
The wiring circuit
from the main switch
to the meter assembly coupler is faulty
and must be repaired.
91
NO
The wiring circuit
from
the
meter
assembly to the oil
level switch coupler
is faulty and must be
repaired.
SIGNALING SYSTEM
ELEC
EAS00803
6. The fuel level gauge fails to operate.
1. Fuel sender
• Drain the fuel from the fuel tank and remove
the fuel pump assembly from the fuel tank.
• Connect the pocket tester (Ω × 1) to the fuel
sender as shown.
Positive tester probe → green
Negative tester probe → black/white
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) of green
and black/white
at the meter assembly
coupler.
• Is the voltage within specification?
YES
NO
The wiring circuit
from the fuel sender
to the meter assembly coupler is faulty
and
must
be
repaired.
• Measure the fuel sender resistances.
NOTE:
Measure the resistances when the float arm
is in contact with the full position and empty
position of the stopper.
Fuel sender resistance
Full position of the float
19 ~ 21 Ω at 20°C
Empty position of the float
139 ~ 141 Ω at 20°C
3. Voltage
• Connect the pocket tester (DC 20 V) to the
meter assembly coupler as shown.
Tester positive probe → brown
Tester negative probe → black/white
• Is the fuel sender OK?
NO
YES
Replace
pump.
the
fuel
2. Voltage
• Connect the pocket tester (DC V 20) to the
meter assembly (wire harness side) as
shown.
• Set the main switch to “ON”.
• Measure the voltage (12 V) of brown
and
black/white
at the meter assembly coupler.
• Is the voltage within specification?
Positive tester probe → green
Negative tester probe → black/white
YES
This circuit is OK.
92
NO
Replace the meter
assembly.
SIGNALING SYSTEM
EAS00805
7. The clock fails to operate.
1. Voltage
• Connect the pocket tester (DC V 20) to the
meter assembly (wire harness side) as
shown.
Positive tester probe → brown
Negative tester probe → black/white
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V).
• Is the voltage within specification?
YES
Replace the meter
assembly.
NO
The wiring circuit
from the main switch
to the meter assembly coupler is faulty
and must be repaired.
93
ELEC
W W W
R/W
P
B
L
L
G/Y
R
B
L
Br
10
OFF
ON
MAIN
B
W
R
80
W
W
W
Br/L
81
82
B
B
B
B
Br/L
Br/L
Br/L
R
Br/R
Br/L
R
Br/R
2
B
W
Br/R
Br/L
Br/R
77
76
B
B
79
78
B
B
11
R
B
B
R
B
B
B
B
B
B
B L/R
Br
75
BrG
R/B B Br
55
5
G/Y W/L R/W
R/Y
R/W
B
B
R
R
Br/W
R
Br B R/B
R/W L/W G/Y
R
B/W
R
R
R
B
B
4
B
B
B/W
56
G/L
B L
6
Y
Y/L
R/W
L/W R/W
L/W
R/W
RUN
OFF
57
Br Y
12
8
Y L/R B
74
B B
73
Y/L G/L R/W
B B R/G
R/W Lg Y/L
R/G B
B
9
7
B/W
R
B
W
Br/L
B
G/Y
R
R/G
Y
R/Y
B
L/B
R/Y
PUSH
FREE
58
13
Y/B
72
71
L/B
B
Lg
B/Y
16
L/G
59
L/G B
B B
15
14
HEADLIGHT SUB-WIRE HARNESS 2
R/B W/L R/L
B/W B/R L/W L/R R/W L/G L/Y Sb
Br/R L/W G/R
WIRE HARNESS
L/W
Br/R
R/G
R/W
R/W
R/B
B/Y
3
L/R
Br/R
ON
OFF
60
R/L
Br/L
B
L/W
R/W
W/L
Lg
Sb
Sb
L/Y
L/G
B
Br
66
B/L
B/L P/W L
HI
LO
ON
62
G/R B/L
Br/W B/L
B/L P L
W/B
OFF
61
B/L
L W/B
B/L
W L/Y
17
L
L
21
20
B/L
Y B/L
Gy G/W
E
B/L
B/L
B/L
P
L
B/L
ON
OFF
63
BrG
Br/W
23
22
B
Gy
G/W
54
P/W
L
Y
B/L
18
B
G/R
L
Y
B/L
L
N
R
64
L Y/G B/L
Ch
67
B
Ch
A
B
B
Br/W
L
Y
B/L
WIRE HARNESS SUB-WIRE HARNESS 2
P/W P/W
L
G/W L/Y
19
HEADLIGHT SUB-WIRE
WIRE HARNESS
HARNESS 1
BrG
R/B
R/W
L
24
Ch
Ch D Ch
B
Dg
68
B
Dg
Gy/G
65
L/Y
B/Y
L/Y
B/Y
Gy/G
R/W
Y/G
G/R
Br/W
P
P/W
Y
L
B/L
W/B
G/W
Gy
L/W
L/Y
B/Y
R/W
L/R
R/L
WIRE HARNESS SUB-WIRE HARNESS 1
L R/L
E
L G/Y
Br/W
B/L
D
B
Ch
69
B
Ch
Dg D Dg
Ch L/Y B B/Y Br
Dg Y L/B Br/W R/Y
Br B/Y B L/Y Ch
R/Y Br/W L/B Y Dg
25
W L
26
Br/W
Gy/G B/L
B
Dg
70
B
Dg
F
R/W Br
G/Y L
W/Y
Y/L
G/Y
Y/B
Br/B
Br/R
A
A
R/B R/B
G/B G/B
Br/B R/W
D
53
W B
R/L
R/L
B/L
48
45
52
51
50
49
47
46
G/R
D
G/R
W/Y G/R G L Br/W Y
Br/R Y/B
R/W
44
R/L B
G B/W
B/L
L W/Y
R/W
W Y/L B/W L/R G/L Lg Br R/G
G/R
L
Br/W
Y
G/L
W
G
R/G
Br
31
W L/Y
R/L R/B
R/L G/B
R/W L/R
Br Br/R
30
29
Br/B
Br/R
43
L
B/L
B W
L
L
W/Y
27
28
Br/W P/W Y Y/L Gy B/L
ABS SUB-WIRE HARNESS 1
L/W B/Y L/Y R/W Br/B G/Y
WIRE HARNESS
B B/W
L/W P/W W/B W/R
Br/W Y
B/W B Y Br/W
G
W/R W/B P/W L/W
Y/G P G/R R/L W/B G/W B/W
Br/R R/W
R/B R/B
G/B G/B
O
GyR
Gy/G W/Y
L
RADIATOR FAN MOTOR
WIRE HARNESS RELAY SUB-WIREHARNESS
Br R/W
R/W Br/B
Br/W B/L
WIRE HARNESS SUB-WIRE HARNESS 3
B/L Br/W
Br/B R/W
B/W
G/B R/B
B/W
A
B/W
R/L L
B/W
R/B G/B
G D G
P/W
R/G
B/L
Br/W
E
Br/W
E
R/L A R/L
Y
B/L
Br/W
Br/B
Br/B
R/W
E
R/W
B
L/Y
36
R/L
B
B/L
B/Y
B W/L W/Y
W R/W W/G
B/W
B/W
W/Y
Y/L
Lg
R/B
R/B
O
W/G R/W W
W/Y W/L B
W/Y
35
C
W/Y
Lg
W/Y
B
B Sb
W/L
W/G
W/Y
B
B B/W
W/Y W/L B
W/G R/W W
Br/W Y
L/W P/W W/B W/R
Y
Br/W
W
W/G
W/L
P/W
W/B
R/W
W/R Lg
L/W
B/Y
W/R
B/W
W/Y
Lg
37
B
W
Sb
B/Y
B/W W/Y
W/R
L/W W/B P/W W/R
Lg
Br/W
Sb
34
33
B Sb
Lg W/R
Sb B
34
32
ABS SUB-WIRE HARNESS 2
H
GyR
B/W
R/B G/B O GyR B/W
WIRE HARNESS
G
B/W
P/W Y
B
G/L R/G Y/L
Y/L
W/Y W B/W
L/R
B
Br
Br
Lg
D
Lg
C
Y/L
B/W
C
B/W
C
L/W
L/W
Y/L R/G G/L
P/W
P/W
B/W W W/Y
W/B
Dg Lg Br
Br/W
Br
D
Br
B
W/R
W/B
B
Br/W
Br/W
W/R
B Y G/R Br/W Ch G L
Y
Y
L/R L/B
B
B
1
R
Br
Br
F
R/W
F
R/W
R/W
L/R
D
L/R
L/R
B
R/W
Y
B/W
D
R/Y
L/B
Y
Y
B
R/Y
L/B
W/L
R/Y
Y/B
L/B
D
B/W
B/W
W/G
W/G
B/W
L/B L/R
B
R/W
R/W
38
B W/L W/Y
W R/W W/G
B/W B Y Br/W
W/RW/BP/W L/W
W/G W/L
W W
W G
R R
39
Br/W
B
B
W
B/Y
W/Y
P/W
L G Ch Br/W G/R Y B
W/B
R/W
42
41
40
B W
B W
W
W/L
L/R
B
B
W
W
W/R
W
W
W/G
R/W
R/W
B/W
Br Lg Dg
L/B
B
L/B
Y
Y D Y
Ch
B
B
B
Y/G
Dg
Dg
B
Br
Br
L
L
G/Y
G/Y
F
G/Y
F
L
L
B
D
Ch
B
B
Y
B
B
B
Dg
B
G/L
C
G/L
W/L
W/L
C
R/G
W
C
W
W
W/Y
W/Y
94
B
W
B R/W W/B
W B
W/Y B/Y
B/W R/W
R/W B
P/W Br/W W/R R/W
ANTI-LOCK BRAKE SYSTEM (ABS)
ELEC
EAS00884
ANTI-LOCK BRAKE SYSTEM (ABS)
CIRCUIT DIAGRAM
ANTI-LOCK BRAKE SYSTEM (ABS)
Fuse (ABS)
Fuse (main)
Fuse (ABS motor)
Battery
Main switch
ABS test terminal
ECU (ABS)
ABS wire lead
Fail safe relay
Hydraulic unit
Front wheel sensor
Rear wheel sensor
Multi-function meter
ABS indicator light
Front brake light switch
Start switch
Rear brake light switch
95
ELEC
ANTI-LOCK BRAKE SYSTEM (ABS)
SPEC
EAS00882
ABS COMPONENTS
Front brake hose (front brake master cylinder to
hydraulic unit)
ABS test coupler
ABS warning light
Front brake hose (hydraulic unit to front brake caliper)
Front wheel sensor
Front wheel sensor rotor
Electronic control unit (ECU)
Rear brake hose (hydraulic unit to rear brake caliper)
96
Rear brake hose (rear brake master cylinder to
hydraulic unit)
Hydraulic unit
Rear wheel sensor rotor
Rear wheel sensor
Fuse box
Fail-safe relay
ANTI-LOCK BRAKE SYSTEM (ABS)
ELEC
EAS00883
ABS CONNECTOR LOCATION CHART
Wire harness end
Wire harness end
Wire harness end
ECU (ABS) coupler
ABS wire lead coupler
Wire harness end
Wire harness end
ABS test terminal
coupler
Wire harness end
Wire harness end
Wire harness end
Front wheel sensor
coupler
Fail-safe relay coupler
Wire harness end
Rear wheel sensor
coupler
Multi-function coupler
97
Wire harness end
Hydraulic unit coupler
ANTI-LOCK BRAKE SYSTEM (ABS)
ELEC
EAS00888
ECU (ABS) AND FAIL-SAFE RELAY
10 Nm (1.0 m•kg, 7.2 ft•lb)
Order
Job/Part
Removing the ECU (ABS) and failsafe relay
Side cowling (right)
Q’ty
Refer to “FRONT COWLINGS” in chapter
3. (Manual No.: 5PS1-AE1)
Refer to “SEAT” in chapter 3. (Manual No.:
5PS1-AE1)
Refer to “FUEL TANK” in chapter 3.
(Manual No.: 5PS1-AE1)
Seat
Fuel tank
1
2
3
4
5
6
7
8
Remarks
Remove the parts in the order listed.
Fail-safe relay
Fail-safe relay coupler
ABS motor coupler
Relay stay
Hydraulic unit solenoid coupler
Band
ECU (ABS)
Front wheel sensor coupler
1
1
1
1
1
1
1
1
98
Disconnect.
Disconnect.
Disconnect.
Disconnect.
ANTI-LOCK BRAKE SYSTEM (ABS)
ELEC
10 Nm (1.0 m•kg, 7.2 ft•lb)
Order
9
Job/Part
ECU (ABS) coupler
Q’ty
Remarks
3 Disconnect.
For installation, reverse the removal
procedure.
99
ANTI-LOCK BRAKE SYSTEM (ABS)
ELEC
Maintenance of the ECU (ABS)
• Removing the ECU (ABS)
1. Remove:
• ECU (ABS)
NOTE:
When removing the ECU (ABS), take care not
to damage the ECU (ABS) or ECU (ABS) couplers.
2. Remove:
• ECU (ABS) coupler
• ECU (ABS) coupler
NOTE:
Do not pull the ECU (ABS) leads to remove the
ECU (ABS) couplers.
Always press on the locks
to disconnect the
ECU (ABS) couplers from the ECU (ABS).
• Checking the ECU (ABS)
1. Check:
• ECU (ABS) terminals
Cracks/damage → Replace the ECU (ABS).
• ECU (ABS) coupler terminals
Defective connections/contamination/disconnections → Repair or clean.
NOTE:
If the ECU (ABS) coupler terminals are
clogged with mud or dirt, clean with compressed air.
Maintenance of the ABS fail-safe relay
• Removing the fail-safe relay
1. Remove:
• ABS fail-safe relay coupler
NOTE:
Do not pull the ABS fail-safe relay leads to
remove the ABS fail-safe relay coupler.
Always press on the lock
to disconnect the
ABS fail-safe relay coupler from the ABS failsafe relay.
100
ANTI-LOCK BRAKE SYSTEM (ABS)
ELEC

Operation of solenoid relay
• Checking the fail-safe relay
1. Check:
• solenoid relay for continuity
Connect the pocket tester (Ω × 1) to the terminals.
Check for continuity between terminals
and
of the solenoid relay.
Tester positive probe → Terminal
Tester negative probe → Terminal
Tester reading is “ ”. → Replace the failsafe relay.
• Check for continuity between terminals
and
of the solenoid relay.
Tester positive probe → Terminal
Tester negative probe → Terminal
Continuity
Terminal number
Normal
condition
Solenoid relay resistance
150 ~ 450 Ω
Connect the
battery to
terminals
and
Tester reading is “ ”. → Replace the failsafe relay.
• Connect the positive battery terminal to terminal
and the negative battery terminal
to terminal , and then check for continuity
between terminals
and
of the solenoid relay.
Tester positive probe → Terminal
Tester negative probe → Terminal
Tester reading is “ ”. → Replace the failsafe relay.
CAUTION:
When connecting the solenoid relay and
battery terminals, be careful not to shortcircuit the positive and negative battery terminals.
Fail-safe relay
ABS motor relay
Solenoid relay
101
ANTI-LOCK BRAKE SYSTEM (ABS)
ELEC
2. Check:
• ABS motor relay for continuity
Connect the pocket tester (Ω × 1) to the terminals of the ABS motor relay.
Check for continuity between terminals
and
of the ABS motor relay.
Tester positive probe → Terminal
Tester negative probe → Terminal
ABS motor relay resistance
50 ~ 150 Ω
Operation of motor relay
Tester reading is “ ”. → Replace the failsafe relay.
Continuity
Terminal number
Normal
condition
CAUTION:
Do not reverse the connections. If the
pocket tester leads are connected in
reverse to terminals
and
, a correct
pocket tester reading cannot be obtained.
Connect the
battery to
and
terminal
• Connect the positive battery terminal to terminal
and the negative battery terminal
to terminal , and then check for continuity
between terminals
and
of the ABS
motor relay.
Tester positive probe → Terminal
Tester negative probe → Terminal
Tester reading is “ ”. → Replace the failsafe relay.
CAUTION:
• Be sure to connect the pocket tester positive and negative probes correctly. If the
pocket tester probes are connected in
reverse, the diode of the fail-safe relay will
be broken.
• When connecting the battery and the ABS
motor relay terminals, be careful not to
short-circuit the positive and negative battery terminals.
102
ANTI-LOCK BRAKE SYSTEM (ABS)
TROUBLESHOOTING
EB802401
2. Battery
• ABS warning light fail to come on.
• All ABS warning and other indicator lights
fail to come on.
• ABS warning light continues to come on.
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3. (Manual No.:
5PS1-AE1)
Check:
1. ABS motor, ABS, main and signal fuses.
2. Battery.
3. Main switch.
4. Wiring (of the entire anti-lock brake system).
NOTE:
• Before troubleshooting, remove the following
part(-s):
1) side cowlings (left and right)
2) front cowling
3) seat
4) fuel tank
5) meter assembly
• Troubleshoot with the following special
tool(-s).
Open-circuit voltage
12.8 V or more at 20°C
• Is the battery OK?
YES
NO
• Clean the battery
terminals.
• Recharge or replace the battery.
EB802411
3. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
Pocket tester
90890-03112
YES
EB802400
NO
Replace the main
switch.
1. ABS motor, ABS, main and signal fuses
• Check the ABS motor, ABS, main and signal fuses for continuity.
Refer to “CHECKING THE FUSES” in chapter 3. (Manual No.: 5PS1-AE1)
• Are the ABS motor, ABS, main and signal
fuses OK?
YES
ELEC
EAS00795
4. Wiring
• Check the entire anti-lock brake system’s
wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the anti-lock brake system’s wiring properly connected and without defects?
NO
Replace the fuse(-s).
YES
Check the condition
of each of the antilock brake system’s
circuits. Refer to
“CHECKING
THE
ANTI-LOCK BRAKE
SYSTEM”.
103
NO
Properly connect or
repair the anti-lock
brake system’s wiring.
ANTI-LOCK BRAKE SYSTEM (ABS)
CHECKING THE ANTI-LOCK BRAKE
SYSTEM
1. Only the ABS warning light fail to come on
when the main switch is turned ON.
3. ABS warning light circuit.
• Remove the ECU coupler and check the
continuity at the white/red terminal on the
ECU side and the test coupler adapter side
of the wire harness.
• Is the ECU continuity OK?
1. ABS coupler and wire harness.
• Check the ABS coupler and wire harness
for continuity.
• Check the ECU and ABS wire harness for
continuity.
Refer to “CIRCUIT DIAGRAM”.
• Is the anti-lock brake system’s wiring properly connected and without defects?
OK
ELEC
NO
YES
Replace the ECU.
NO
Properly connect or
replace the ABS
coupler and wire
harness.
2. All ABS warning and other indicator lights
fail to come on.
• Properly connect or
replace the ABS
coupler and wire
harness.
• Properly connect or
replace the ECU
and fail-safe relay
and wire harness.
1. Main switch.
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
NO
YES
Replace the main
switch.
2. ABS warning light
• Connect the ABS test coupler and ABS test
coupler adapter.
2. Battery.
ABS test coupler adapter warning light
terminal (white/red)
→ Battery Negative lead
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3. (Manual No.:
5PS1-AE1)
Open-circuit voltage
12.8 V or more at 20°C
• Is the battery OK?
YES
• Clean the battery
terminals.
• Recharge or replace the battery.
• Does the ABS warning light come on?
OK
NO
Replace the
warning light.
NO
ABS
104
ANTI-LOCK BRAKE SYSTEM (ABS)
3. Main fuse.
• Check the main fuse for continuity.
Refer to “CHECKING THE FUSES” in chapter 3. (Manual No.: 5PS1-AE1)
• Is the main fuse OK?
YES
NO
Replace the fuse.
4. Wiring
• Check the entire anti-lock brake system’s
wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the anti-lock brake system’s wiring properly connected and without defects?
YES
Check the condition
of each of the antilock brake system
circuits.
Refer to “CHECKING THE ANTILOCK BRAKE SYSTEM”.
NO
Properly connect or
repair the anti-lock
brake system’s wiring.
105
ELEC
ANTI-LOCK BRAKE SYSTEM (ABS)
ELEC
3. ABS warning light continues to come on.
1) Check the ABS fuse
• Blown fuse → Replace
2) Check the battery voltage
The voltage should be always higher than the regulated voltage in order to operate the ABS correctly. If the power voltage goes lower than 10 V, the ABS warning light comes on and ABS operation stops. When the power voltage recovers to be higher than 10 V, the system resumes its
operation.
The fact that the voltage lowered less than 10 V means that something is defective with the magnet, battery or rectifier regulator.
Correct the malfunction following the normal instructions and regulate the system to operate in
the normal condition.
3) Check the Electronic Control Unit (ECU) in the side cowling.
Refer to “FRONT COWLINGS” in chapter 3. (Manual No.: 5PS-AE1)
Is the coupler securely connected?
• Connected → Inspect the malfunction by the ABS self diagnosis
• Not connected → Connect the ABS coupler again.
4. ABS warning light flashes
1) Slipping of one wheel (Flash pattern: Lighting ON for 0.75 sec./OFF for 0.25 sec.)
Causes to those cases in which the ABS warning light flashed while driving, but “it turned to be
normal”, or “the ABS warning light flashed but flashing stopped when the main switch was turned
OFF and then turned ON again” could be thought as follows:
(1) Rear wheel slipped. → The system is normal.
(2) Demonstrated wheelie. → The system is normal.
(3) The vehicle in question ran continually on the extremely bumpy road. → The system is normal.
2) ABS stops by the Electronic Control Unit (ECU)
This is the case when the Electronic Control Unit (ECU) judged that the system should stop
because it has been exposed to the extremely strong radio wave, static electricity or radioactivity.
3) Defective condition of the brake light switch section (Flash pattern: Lighting ON for 0.25 sec./
OFF for 0.75 sec.)
Check the brake light switch (front and rear) without starting the engine.
Check whether the brake lights up or not when the front and rear brakes are engaged respectively.
(1) It reacts only to one brake.
→ The coupler of brake switch has come off. (Refer to “WIRING DIAGRAM”.)
→ The brake light switch on the side that the brake light does not react is out of order.
(2) It does not react to either of brakes.
→ It could be thought that the wire harness is disconnected or the fuse is blown. (Refer to
“WIRING DIAGRAM”.)
(3) Brake light comes on.
→ It could be thought that the coupler between the ABS harness and wire harness is not connected. (Refer to “ABS CONNECTOR LOCATION CHART”.)
(4) Possible causes other than these cases.
→ Disconnection or short-circuit between the meter and ECU (ABS).
4) ABS continual control while braking
• It may flash if the ABS operation time became longer while braking. (Flash pattern: Lighting ON
for 0.25 sec./OFF for 0.75 sec.)
106
ANTI-LOCK BRAKE SYSTEM (ABS)
ELEC
TROUBLESHOOTING BY THE SELF DIAGNOSIS
Arrangement and the function of test couplers
• ECU becomes the malfunction diagnostic mode when the T/C terminal is grounded.
• Malfunction code which the ECU generated in the malfunction diagnostic mode (rise and fall of
voltage) is output at the T/F terminal.
• ABS warning light terminal is used when checking the ABS warning light circuit.
• To ground the T/C terminal, connect the test coupler adapter with the test coupler. Before connecting, check if the battery is sufficiently charged.
(sky-blue) T/C
(light green) T/F
Grounding (black)
ABS warning light (white/red)
Test coupler adapter
MALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS (PAST MALFUNCTION)
Remove the side cowling (right) and check the location of test coupler . Remove the protective
cap and connect the ABS test coupler adapter
to the test coupler. The T/C terminal (sky-blue)
is now connected to the ground.
1) Indicate the malfunction code (Example: malfunction code 11)
Multifunction display
2) ABS warning light flashes every 0.5 second for more than 6 seconds.
→ P108, 109
If the ABS warning light flashes every 0.5 second, the malfunction code of a past malfunction has
not been stored in the memory of the ECU (ABS). If a malfunction code is displayed on the multifunction display, the ABS warning light flashes. Make sure that the customer understands the
possible conditions when the ABS warning light comes on.
107
ANTI-LOCK BRAKE SYSTEM (ABS)
ELEC
MALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS (PRESENT MALFUNCTION)
NOTE:
Before proceeding to read the part of “Arrangement and the function of test coupler”.
Remove the battery cover and check the location of test coupler. Connect the test coupler adapter
with the test coupler in order to ground the T/C terminal (sky-blue). (Figure- )
Protective cap
Test coupler
Lock plate
Grounding
(black)
(white/red)
T/C terminal
T/F terminal Light terminal
(white/red)
(light green)
Test coupler
adapter
(light green)
(white/red)
Set the range of pocket tester to DC20V. Connect the negative (–) terminal of tester to the T/F terminal (light green) and positive (+) terminal to the positive (+) terminal of battery. (Figure- )
Read the tester indication. (Figure- )
As an example, “10 digits/1 digit pattern” of tester reading is shown below.
This example is the pattern which
shows malfunction code 21.
This example is the pattern which
shows malfunction code 12.
12 V
10
0V
Time
(second)
10
1 1
10
1
0.5 0.5 0.5
1
1.5
0.5
3
1
108
1.5
1
1.5
3
ANTI-LOCK BRAKE SYSTEM (ABS)
ELEC
• Diagnosis by the malfunction code
Malfunction codes are used to determine the malfunctions that have occurred. (Refer to “P107 ABS
malfunction check by the ABS self-diagnosis (past malfunction)” and “P108 ABS malfunction check
by the ABS self-diagnosis (present malfunction)”.) The malfunction codes are explained in the following table.
NOTE:
Record all of the malfunction codes displayed and check the check points.
Malfunction
code
Problem
Check point
Reference
Front wheel sensor signal is not received properly.
•
•
•
•
Installation of the front wheel sensor Malfunction
Front wheel sensor lead and coupler code 11
ABS wire harness circuit
(P111)
Front wheel sensor rotor
Rear wheel sensor signal is not received properly.
•
•
•
•
Installation of the rear wheel sensor Malfunction
Rear wheel sensor lead and coupler code 12
ABS wire harness circuit
(P111)
Rear wheel sensor rotor
Incorrect signal is detected by the front (13) or
rear (14) wheel sensor.
• Wheel sensor installation
• Wheel sensor housings
• Wheel sensor rotors
Malfunction
codes 13
(front wheel)
and 14
(rear wheel)
(P112)
• Continuity of sensor circuits
• ABS wire harness circuit
• Connection of sensor coupler
Malfunction
codes 15
(front wheel
sensor) and
16 (rear wheel
sensor)
(P112)
Malfunction
code 21
(P112)
11
*1
12
13 (front)
14 (rear)
13
14
No continuity in the front or rear wheel sensor
circuits
15 (front)
16 (rear)
15
16
21
Hydraulic unit solenoid circuit is broken or short- • ABS wire harness circuit
circuited.
• Hydraulic unit solenoid coupler
• Hydraulic unit solenoid
Disconnection is detected on the system of failsafe relay and hydraulic unit solenoid coupler.
• ABS wire harness circuit
• Fail-safe relay circuit
• Hydraulic unit solenoid coupler
Malfunction
code 31
(P113)
Defective operation of the fail-safe relay is
detected.
• Fail-safe relay
• ABS wire harness circuit
Malfunction
code 32
(P113)
Defective operation of the ABS motor is
detected. (ABS motor stops and will not rotate.)
•
•
•
•
Malfunction
code 33
(P114)
31
32
33
109
ABS wire harness circuit
ABS motor coupler
Fail-safe relay
ABS motor circuit
ANTI-LOCK BRAKE SYSTEM (ABS)
Malfunction
code
Problem
ELEC
Check point
Reference
Defective operation of the ABS motor is
• Fail-safe relay
detected. (ABS motor keeps running and will not • ABS wire harness circuit
stop.)
• ABS motor circuit
Malfunction
code 34
(P114)
Malfunction
code 41
(P115)
41
Front wheel will not recover from the locking ten- • Brake dragging
dency even though the signal is continuously
• Hydraulic unit operation test 2
transmitted from the ECU (ABS) to release the
(Refer to P71.)
hydraulic state (when the battery voltage is nor- • Front wheel brake line
mal).
Malfunction
code 42
(P116)
42
Rear wheel will not recover from the locking ten- • Brake dragging
• Hydraulic unit operation test 2
dency even though the signal is continuously
(Refer to P71.)
transmitted from the ECU (ABS) to release the
hydraulic state (when the battery voltage is nor- • Rear wheel brake line
mal).
Front wheel will not recover from the locking ten- • Brake dragging
dency even though the signal is continuously
• Hydraulic unit operation test 2
transmitted from the ECU (ABS) to release the
(Refer to P71)
hydraulic state (when the battery voltage is low). • Front wheel brake line
• Battery voltage
Malfunction
code 51
(P118)
Rear wheel will not recover from the locking ten- • Brake dragging
dency even though the signal is continuously
• Hydraulic unit operation test 2
transmitted from the ECU (ABS) to release the
(Refer to P71.)
hydraulic state (when the battery voltage is low). • Rear wheel brake line
• Battery voltage
Malfunction
code 52
(P119)
34
51
52
Present mal- ECU (ABS) may be malfunctioning
function (test
always indicates 12 V)
• ABS wire harness circuit (test coupler circuits)
• ECU (ABS) (Replace)
Maintenance
of the ECU
(ABS) (P100)
*1 Malfunction code 11 is indicated if the rear wheel rotates for more than 20 seconds with the front
wheel stopped.
NOTE:
Malfunction code 15 (front wheel sensor) or 16 (rear wheel sensor) is displayed if a defective connection to either the front or rear sensor is detected whether or not the motorcycle is ridden.
110
ANTI-LOCK BRAKE SYSTEM (ABS)
ELEC
• Malfunction code 11 (Front wheel sensor signal is not received correctly.)
Set the main switch to “OFF”, then back to “ON” after removing the test coupler adaptor.
1) ABS warning light remains on.
→ Defective connection in the front wheel sensor circuit.
• Front wheel sensor coupler is disconnected.
→ P51
• Front wheel sensor lead or coil is broken.
→ P51
• Sub-wire harness (ABS) sensor circuit is broken. → (Refer to “CIRCUIT DIAGRAM”.)
• ECU (ABS) coupler terminal is disconnected.
→ P100
2) ABS warning light comes on for 2 seconds, then goes off.
With the front wheel stopped, the rear wheel was rotated for more than 20 seconds. This is not a
malfunction.
A signal is not generated at the front wheel sensor.
• Front wheel sensor is not installed properly.
→ P51
• Front wheel sensor rotor is defective.
→ P51
Front wheel sensor circuit is short-circuited.
• Front wheel sensor or lead is short-circuited.
→ P51
• Sub-wire harness (ABS) sensor circuit is short-circuited. → (Refer to “CIRCUIT DIAGRAM”.)
Front wheel sensor output drops.
• Sensor signal output may drop due to failure of the bearings, wheel axle, wheel or sensor housing of the front wheel. Check these components when installed for looseness, distortion, and
bends.
• Malfunction code 12 (Rear wheel sensor signal is not received correctly.)
Set the main switch to “OFF”, then back to “ON”.
1) ABS warning light remains on.
→ Defective connection in the rear wheel sensor circuit.
• Rear wheel sensor coupler is disconnected.
→ P55
• Rear wheel sensor lead or coil is broken.
→ P55
• Sub-wire harness (ABS) sensor circuit is disconnected. → (Refer to “CIRCUIT DIAGRAM”.)
• ECU (ABS) coupler terminal is disconnected.
→ P100
2) ABS warning light comes on for 2 seconds, then goes off.
With the rear wheel stopped, the front wheel was rotated at a speed faster than 11 km/h. This is
not a malfunction.
A signal is not generated at the rear wheel sensor.
• Rear wheel sensor is not installed properly.
→ P55
• Rear wheel sensor rotor is defective.
→ P55
Rear wheel sensor circuit is short-circuited.
• Rear sensor or lead is short-circuited.
→ P55
• Sub-wire harness (ABS) sensor circuit is short-circuited. → (Refer to “CIRCUIT DIAGRAM”.)
Rear wheel sensor output drops
• Sensor signal output may drop due to failure of the bearings, wheel, or sensor housing of the rear
wheel. Check these components when installed for looseness, distortion, and bends.
NOTE:
If the motorcycle is ridden on extremely uneven roads continuously, the ABS warning light may flash
and malfunction code 11 or 12 may be recorded depending on the condition.
111
ANTI-LOCK BRAKE SYSTEM (ABS)
ELEC
• Malfunction codes 13 (front wheel) and 14 (rear wheel) (Incorrect signal is detected from
either the front or rear wheel.)
1) The wheel sensors or sensor rotors are not properly installed.
Installation of the front or rear wheel sensor
• Check that the wheel sensor is properly installed in the housing.
→ P51, 55
• Check if there is looseness between the housing and the wheel.
→ P51, 55
Installation of the front or rear wheel sensor rotor
• Check that the sensor rotor is correctly pressed in the wheel.
→ P51, 55
• Check the rotor and inside the rotor housing for foreign materials.
→ P51, 55
2) Teeth surfaces of the sensor rotors are defective.
• Check for flaws on the teeth surfaces of the front or rear wheel sensor rotors.
Also, check for any foreign materials.
→ P51, 55
3) Sensor output has dropped.
• Sensor signal output may drop due to failure of the bearings, wheel axle, wheel or sensor housing of the front or rear wheel. Check these components when installed for looseness, distortion,
and bends.
• Malfunction codes 15 (front wheel sensor) and 16 (rear wheel sensor) (No continuity in the
sensor circuits.)
Broken front or rear wheel sensor circuit is detected.
• Front or rear wheel sensor coupler is broken.
→ P51, 55
• Front or rear wheel sensor or lead is broken.
→ P51, 55
• Sub-wire harness (ABS) sensor circuit is broken.→ (Refer to “CIRCUIT DIAGRAM”.)
• Sub-wire harness (ABS) is disconnected from the ECU (ABS) coupler terminal. → P100
NOTE:
• Check that both the front and rear wheel sensor couplers are connected securely.
• If the motorcycle is ridden after malfunction code 15 (front wheel sensor) or 16 (rear wheel sensor)
is displayed, the malfunction code will be overwritten from 15 to 11 (front wheel sensor signal) or
from 16 to 12 (rear wheel sensor signal).
• Malfunction code 21 (Hydraulic unit solenoid circuit is broken or short-circuited.)
Check the following:
1) Hydraulic unit solenoid coupler
• Check if the hydraulic unit solenoid coupler terminal is disconnected. (Refer to “ABS COUPLERS”.)
2) Hydraulic unit solenoid
• Check the front and rear wheel solenoids for continuity
→ P59
• Check the insulation of all solenoid terminals and the negative battery terminal. → P59
3) Sub-wire harness (ABS)
• Check the hydraulic unit solenoid circuits for continuity. (See the illustration below.)
Fail-safe
relay
ECU
Front
solenoid
white
white
white
Rear
solenoid
Continuity
between:
white/
green
white/
blue
• Check the insulation of the hydraulic unit solenoid circuits and the negative battery terminal.
112
ANTI-LOCK BRAKE SYSTEM (ABS)
ELEC
• Malfunction code 31 (Disconnection is detected between the fail-safe relay and the hydraulic unit solenoid.)
Check the following:
1) ABS motor fuse
• Check if the ABS motor fuse beside the battery is blown.
2) Hydraulic unit solenoid coupler
• Check if the hydraulic unit solenoid coupler located in the right side cover is connected properly.
(Refer to “ABS CONNECTOR LOCATION CHART”.)
3) Sub-wire harness (ABS)
• Check the pink/white leads between the ECU (ABS) and the fail-safe relay for continuity. (Refer to
“CIRCUIT DIAGRAM”.)
• ECU (ABS) coupler terminal (pink/white) is disconnected.
→ P100
• Check the white leads between
and , and between
and
of the hydraulic unit solenoid
circuits for continuity.
Fail-safe
relay
Front
solenoid
white
white
white
Rear
solenoid
4) Fail-safe relay
• Check if the fail-safe relay operates correctly.
→ P100
5) Wire harness
• Check for continuity between the red/white terminal of the fail-safe relay coupler and the positive
battery terminal.
• Remove the ABS fuse and check for continuity between the brown/white lead of the fail-safe relay
coupler and the ABS fuse. (See the illustration below.)
Check for continuity between these two points .
• Malfunction code 32 (Fail-safe relay malfunction is detected.)
Check the following:
1) Fail-safe relay
• Check if the fail-safe relay operates correctly.
→ P100
2) Sub-wire harness (ABS)
• Disconnect the sub-wire harness (ABS) from the fail-safe relay and the ECU (ABS), and then
check the insulation of the fail-safe relay coupler between the red/white
and white
terminals.
113
ANTI-LOCK BRAKE SYSTEM (ABS)
ELEC
• Malfunction code 33 (ABS motor operation malfunction is detected. [ABS motor stops and
does not rotate.])
Check the following:
1) ABS motor fuse
• Check if the ABS motor fuse beside the battery is blown.
2) Fail-safe relay
• Check if the fail-safe relay operates correctly.
→ P100
3) Wire harness and sub-wire harness (ABS)
• Remove the fail-safe relay and the ABS motor fuse, and then check for continuity between the
red/white
(Refer to “P113–5) wire harness drawing”.) terminal of the sub-wire harness (ABS)
and the sub-wire harness (ABS) end (terminal A shown in the illustration) of the ABS motor fuse
terminal beside the battery. (Refer to “CIRCUIT DIAGRAM”.)
Terminal A
Terminal B
• Check for continuity between the positive battery terminal and the battery end of the ABS motor
fuse terminal (terminal B shown in the above illustration).
• Remove the ECU (ABS) and the fail-safe relay from the sub-wire harness (ABS), and then check
for continuity between the white/black lead terminals and the red/white lead terminals.
• Malfunction code 34 (ABS motor operation malfunction is detected. [ABS motor keeps
rotating and does not stop.])
Check the following:
1) ABS motor
• Check if the ABS motor coupler located under the fuel tank is connected properly.
• Check the ABS motor for continuity.
→ P59
2) Sub-wire harness (ABS)
• Remove the ABS motor coupler and check for continuity between the black terminal of the ABS
motor coupler of the sub-wire harness (ABS) and the negative battery terminal.
• Remove the ECU (ABS) coupler and check for continuity between the red/white terminal of the
ECU (ABS) coupler and the red/white terminal of the ABS motor coupler.
→ P100
• Remove the fail-safe relay and check for continuity between the red/white terminal of the ABS
motor coupler of the sub-wire harness (ABS) and the positive battery terminal.
3) Fail-safe relay
• Check if the fail-safe relay operates correctly.
→ P100
114
ANTI-LOCK BRAKE SYSTEM (ABS)
ELEC
• Malfunction code 41 (Front wheel does not recover from the locking tendency even though
the signal is continuously transmitted from the ECU (ABS) to release the hydraulic pressure
[when the battery voltage is normal].)
Check the following:
1) Rotation of the front wheel
• Check that there is no brake disc drag on the front wheel and make sure it rotates smoothly.
• Check the front wheel axle for loose bearings and bends, and the brake disc for distortion.
2) Brake master cylinder and brake caliper
• Check that the brake fluid pressure is correctly transmitted to the brake caliper when the brake
lever is operated and that the pressure decreases when the lever is released.
3) Brake fluid
• Visually check the brake fluid in the brake master cylinder reservoir and the fluid for water, foreign
materials, solidification and contamination.
• Check for air in the brake hose lines.
4) Brake hose lines
• Check the brake hose lines for kinks and deterioration.
WARNING
Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close
the brake hose lines.
• Check that the connections of the brake hose lines from the brake master cylinder to the hydraulic unit and to the front brake caliper from the hydraulic unit are correct.
WARNING
The front brake will not function properly if the connections are reversed.
• Front brake hose
inlet: from the front brake master cylinder
• Front brake hose
outlet: to the front brake caliper
NOTE:
• If the front brake hose inlet and outlet connections are reversed on the hydraulic unit, the brake
lever is pulled to full stroke without responding and will be pushed back slowly without pulsating
when the final check in P67 is performed.
• If the front and rear brake hose connections are reversed on the hydraulic unit, the pulsating action
in the brake lever and brake pedal will be performed in the reverse order when the final check in
P66 is performed.
115
ANTI-LOCK BRAKE SYSTEM (ABS)
ELEC
5) Hydraulic unit solenoid coupler terminal
• Check if the front and rear hydraulic unit solenoid coupler terminals (hydraulic unit and sub-wire
harness [ABS]) are reversed.
Front
Rear
Solenoid
red, white
red, green
Terminal color
Sub-wire harness (ABS)
white, white/blue
white, white/green
6) Hydraulic unit
If the malfunction is not corrected after performing steps 1) to 5), replace the hydraulic unit. Be sure
to connect the brake hoses and couplers correctly and securely. Check the hydraulic unit operation.
(Refer to “P67 Final check”.)
• Malfunction code 42 (Rear wheel does not recover from the locking tendency even though
the signal is continuously transmitted from the ECU (ABS) to release the hydraulic pressure
[when the battery voltage is normal].)
Check the following:
1) Rotation of the rear wheel
• Check that there is no brake drag on the rear wheel and make sure it rotates smoothly.
• Check for brake disc distortion.
2) Brake master cylinder and brake caliper
• Check that the brake fluid pressure is correctly transmitted to the brake disc when the brake
pedal is operated and that the pressure decreases when the pedal is released.
3) Brake fluid
• Visually check the brake fluid in the brake master cylinder reservoir and check the fluid for water,
foreign materials, solidification and contamination.
• Check for air in the brake hose lines.
4) Brake hose lines
• Check the brake hose lines for kinks and deterioration (particularly between the hydraulic unit
and the rear brake caliper).
WARNING
Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close
the brake hose lines.
116
ANTI-LOCK BRAKE SYSTEM (ABS)
ELEC
• Check that the connections of the brake hose lines from the brake master cylinder to the hydraulic unit and to the rear brake caliper from the hydraulic unit are correct.
WARNING
The rear brake will not function properly if the connections are reversed.
• Rear brake hose
inlet: from the rear brake master cylinder
• Rear brake hose
outlet: to the rear brake caliper
NOTE:
• If the rear brake hose inlet and outlet connections are reversed on the hydraulic unit, the brake
pedal is pressed down to full stroke without responding and will be pushed back slowly without pulsating when the final check is performed.
• If the front and rear brake hose connections are reversed on the hydraulic unit, the pulsating action
in the brake lever and brake pedal will be performed in the reverse order when the final check is
performed.
5) Hydraulic unit solenoid coupler terminal
• Check if the front and rear hydraulic unit solenoid coupler terminals (hydraulic unit and sub-wire
harness [ABS]) are reversed.
Front
Rear
Solenoid
red, white
red, green
Terminal color
Sub-wire harness (ABS)
white, white/blue
white, white/green
6) Hydraulic unit
If the malfunction is not corrected after performing steps 1) to 5), replace the hydraulic unit. Be sure
to connect the brake hose lines and couplers correctly and securely. Check the hydraulic unit operation. (Refer to “P67 Final check”.)
117
ANTI-LOCK BRAKE SYSTEM (ABS)
ELEC
• Malfunction code 51 (Front wheel does not recover from the locking tendency even though
the signal is continuously transmitted from the ECU (ABS) to release the hydraulic pressure
[when the battery voltage is low].)
Check the following:
1) Rotation of the front wheel
Refer to “P115 Malfunction code 41”.
2) Brake master cylinder and brake caliper
Refer to “P115 Malfunction code 41”.
3) Brake fluid
Refer to “P115 Malfunction code 41”.
4) Brake hose lines
Refer to “P115 Malfunction code 41”.
5) Hydraulic unit solenoid coupler terminals
Refer to “P115 Malfunction code 41”.
6) Hydraulic unit
Refer to “P115 Malfunction code 41”.
7) Battery voltage
Measure the battery voltage.
118
ANTI-LOCK BRAKE SYSTEM (ABS)
ELEC
• Malfunction code 52 (Rear wheel does not recover from the locking tendency even though
the signal is continuously transmitted from the ECU (ABS) to release the hydraulic pressure
[when the battery voltage is low].)
Check the following:
1) Rotation of the rear wheel
Refer to “P116 Malfunction code 42”.
2) Brake master cylinder and brake caliper
Refer to “P116 Malfunction code 42”.
3) Brake fluid
Refer to “P116 Malfunction code 42”.
4) Brake hose lines
Refer to “P116 Malfunction code 42”.
5) Hydraulic unit solenoid coupler terminals
Refer to “P116 Malfunction code 42”.
6) Hydraulic unit
Refer to “P116 Malfunction code 42”.
7) Battery voltage
Measure the battery voltage.
119
ANTI-LOCK BRAKE SYSTEM (ABS)
ELEC
DELETING THE MALFUNCTION CODE
1. Connect the test coupler adapter
to the
test coupler . Refer to “P109”.
2. Turn the main switch on.
The multifunction display indicates previously recorded mulfunction codes.
NOTE:
The ABS error code is not displayed during the
diagnosis of the fuel injection.
3. Turn the engine stop switch
off.
CAUTION:
If the starter switch is pushed without turning the engine stop switch off, it may damage the starting motor gears or other parts,
therefore be sure to turn it off.
4. Push the starter switch
more than 10
times in 4 seconds to delete the mulfunction
codes.
NOTE:
If the multifunction codes cannot be cleared,
the disconnection of the starter switch monitor
leads could be a cause.
5. Turn the main switch off.
120
ANTI-LOCK BRAKE SYSTEM (ABS)
ON
ABS
waening light
6. Turn the main switch on again.
Check that the ABS warning light goes on
for 2 seconds, then goes out for 3 seconds
and starts flashing.
7. Turn the main switch off.
8. Disconnect the test coupler adapter from
the test coupler, and install the protective
cap with the test coupler adapter. Deleting
the malfunction code is now finished.
NOTE:
Do not forget to install the protective cap.
ON
OFF
Main switch
2.0
3.0
seseconds
conds
ELEC
Flashing
0.5
0.5
0.5
0.5
seseseseconds conds conds conds
CAUTION:
Since the ECU remains in the memory until
the malfunction code is deleted, always
delete the malfunction code when the service work is finished.
121
ANTI-LOCK BRAKE SYSTEM (ABS)
ELEC
TROUBLESHOOTING
ANTI-LOCK BRAKE SYSTEM (ABS)
ABS TROUBLESHOOTING OUTLINE
This section describes the troubleshooting about ABS in details. Read carefully this service manual
before repairing various malfunctions, understand and perform the service.
Electronic control unit (ECU) has the self diagnostic function. When failures occur in the system, the
ABS warning light on the meter assembly indicates a mulfunction.
Troubleshooting mentioned below describes the cause pursuing and service method according to
the indication by the multifunction display. For troubleshooting other than these items, perform by following the normal service method.
WARNING
When the maintenance or check has been performed on related parts to ABS, be sure to execute the “final check” before delivering the motorcycle to the customer. Refer to “P67 ~ 73”.
ABS Warning Light Goes On and the ABS Condition
1) When the ABS warning light keeps going on → It works as a normal brake.
• Detecting the malfunction by means of the ABS self diagnostic function.
2) Light goes on and off at the time of starting → ABS operation is normal.
• ABS warning light goes on for 2 seconds every time the main switch is turned on and goes off
afterward.
3) When the ABS warning light flashes → ABS operation is normal.
• Brake switch is defective or improperly adjusted.
• Rear wheel is racing.
• Continuous riding on extremely uneven roads.
• Disconnection or short-circuit between the meter and ECU (ABS).
Self Diagnosis and Services
ECU has the self diagnostic function. By utilizing this function, quick and secure services are possible.
Previously occurred error phenomenon can be checked since it also installs the memory for storing
malfunction history.
“In case malfunctions are detected”
It is disabled to call the malfunction code by using the ABS warning light since the ABS warning light
already goes on. Connect the test coupler adapter to the test coupler, connect a pocket tester to the
terminal of light green lead and check by its pointing needle movement. (Refer to “P108”)
“In case any malfunctions are not detected”
The multifunction display indicates all the malfunction codes recorded in the ECU (ABS). You can
check it by using a pocket tester. Note everything if more than two items of malfunction codes are
recorded.
122
ANTI-LOCK BRAKE SYSTEM (ABS)
TRBL
SHTG
“Deleting the malfunction code”
When the malfunction service is finished, check the normal operation of motorcycle then delete the
malfunction code (Refer to “P120”). By deleting the malfunction code memory, it is possible to pursue the cause correctly if the next defective phenomenon occurred.
Self diagnosis by ECU
ECU performs the static check for whole system when the main switch is turned on. It is also possible to check the malfunction while riding. It is possible to check the recorded malfunction data by
using a pocket tester or the multifunction display of meter by setting the ECU to the self diagnostic
mode since all malfunctions which has been once detected are recorded.
Differences Between the Normal Handling and Services On a Vehicle
• Care should be taken not to damage components by shocks and pulling too much since the ABS
components are precisely adjusted.
• ECU, HU, Wheel sensors and fail-safe relay cannot be disassembled.
• Malfunction history in ECU is recorded. Delete it when the service is finished. (This is because
the past malfunction contents will be redundantly displayed when the same malfunction occurred
again.)
BASIC INSTRUCTION FOR TROUBLESHOOTING
WARNING
• Execute the troubleshooting on each malfunction from [A] to [D] in sequence.
• Use the sufficiently charged regular batteries only.
[A] Malfunction check by the ABS warning light
[B]Detail check of malfunction
Results by self diagnosis are displayed by the multifunction display or a pocket tester according
to the ECU’s operation.
[C]Supposing the malfunction cause and position
Find the malfunction cause by reasoning the place and situation where it occurred.
[D]ABS system services
Execute the final check after disassembly and assembly.
WARNING
Perform the troubleshooting [A] → [B] → [C] → [D] in order. Be sure to follow the order since
it results in the wrong diagnosis if the order is differently taken or omitted.
123
ANTI-LOCK BRAKE SYSTEM (ABS)
TRBL
SHTG
BASIC PROCESS FOR TROUBLESHOOTING
It does not go on.
“P104”
Warning light
does not
come on.
[A]
Goes on for 2 seconds and goes off afterward.
Check the ABS
warning light.
Flashing
Keeps coming on.
“P106”
Warning light
keeps flashing.
“P108”
Present
malfunction
“P106”
Warning light
keeps coming on.
“P107”
Past malfunction
NO
YES
YES
NO
NOTE: Display the
malfunction code
number and record it.
“P104”
Only ABS
warning light
does not
come on.
“P104”
All indicator lights
do not come on.
Check
the fuse.
Check the
connecting parts.
“P109”
Diagnoses by
malfunction codes.
“P106”
Warning light
keeps flashing.
Check the
wire harnesses.
Check the
ECU connector.
Check the
brake switch
circuit.
Check the
Check the disconnection
test coupler or short-circuit between
adaptor.
the meter and ECU (ABS).
“P106”
ABS warning light
flashes every
0.5 second.
To investigate, use
the diagnosis table
(from “P111” to “P119”).
Explain to the
customer.
Check the
wire harness.
ECU
“P100”
Fail-safe
relay
“P100”
Sensor
“P51, 55”
ECU
“P100”
HU
“P59”
Check
NG HU test
the
“P71”
piping.
OK
Are all defective phenomena corrected?
NO
Return to [A]
OK
Delete the malfunction
code record. “P120”
End
NOTE:
Do not delete the malfunction code during the troubleshooting procedures. Be sure to delete it when
the service is finished.
WARNING
Always execute the “final check” when the components related to ABS are checked and serviced.
124
TROUBLESHOOTING AT THE ABS WARNING LIGHT
TRBL
SHTG
TROUBLESHOOTING AT THE ABS WARNING LIGHT
When the main switch is turned “ON”. (Engine does not start.)
ONLY THE ABS WARNING LIGHT DOES NOT COME ON.
• Blown, damaged, or incorrect fuse (ABS fuse)
• Defective connection of the ABS harness and the wire harness
• Defective connection of the ABS harness and the electronic control unit (ECU)
• ABS harness is disconnected
• ABS warning light bulb is burnt out or the bulb contact is defective
• ECU defective
ALL INDICATORS DO NOT COME ON.
• Battery defective
• Blown, damaged, or incorrect fuse (Main fuse)
• Defective connection of the main fuse coupler
• Defective connection of the wire harness and the ABS harness
• Defective connection of the main switch coupler
• Defective connection of the meter coupler
ABS WARNING LIGHT CONTINUES TO FLASHES.
• Brake light switch (Front or rear) is defective
• Brake light switch coupler has come off
• Wire harness is disconnected
• Blown, damaged, or incorrect fuse (Main fuse)
• Defective connection of the ABS harness and the wire harness couplers
• Disconnection or short-circuit between the meter and ECU (ABS).
ABS WARNING LIGHT FLASHES EVERY 0.5 SECONDS.
• Voltage drop (Less than 10 V)
Battery
Rectifier/regulator
AC magneto
• Strong radio waves or static electricity
ABS WARNING LIGHT CONTINUES TO COME ON.
• Defective connection of the wheel sensor (Front or rear) circuit
• Wheel sensor lead (Front or rear) coupler has come off
• Wheel sensor lead (Front or rear) or the coil is disconnected
• Sensor circuit of the ABS harness is disconnected
• ECU coupler terminal has come off
125
TDM900A(T) 2005 WIRING DIAGRAM
A.C. magneto
Rectifier/regulator
Fuse (fuel injection system)
Fuse (ABS)
Fuse (main)
Fuse (ABS motor)
Starter relay
Starter motor
Battery
Main switch
Alarm
Immobilizer unit
Fuse (backup)
Starting circuit cut-off relay
Sidestand switch
Neutral switch
Cylinder identification sensor
Crankshaft position sensor
Throttle position sensor
Intake air pressure sensor
Atmospheric pressure sensor
Intake air temperature sensor
Coolant temperature sensor
Lean angle cut-off switch
O2 sensor
ECU
Injector #1
Injector #2
Air cut-off valve
Intake solenoid
Speed sensor
Ignition coil #1
Ignition coil #2
Spark plug
ABS test terminal
Fuel pump
ECU (ABS)
ABS wire lead
Fail safe relay
Hydraulic unit
Front wheel sensor
Rear wheel sensor
Meter assembly
Oil level warning light
Neutral indicator light
Multi-function meter
Engine trouble warning light
Immobilizer system indicator light
High beam indicator light
Turn signal indicator light
Meter light
ABS warning light
Oil level switch
Turn signal relay
Right handlebar switch
Front brake light switch
Engine stop switch
Start switch
Left handlebar switch
Horn switch
Pass switch
Dimmer switch
Hazard switch
Turn signal switch
Clutch switch
Horn
Rear turn signal light (left)
Rear turn signal light (right)
Front turn signal light (left)
Front turn signal light (right)
Headlight relay
Headlight
Rear brake light switch
Tail/brake light
Auxiliary light
Fuse (ignition)
Fuse (head)
Fuse (hazard)
Fuse (signal)
Fuse (radiator fan motor)
Radiator fan motor relay
Radiator fan motor
COLOR CODE
B ......
Br. . . . . .
Ch . . . . .
Dg . . . . .
G......
Gy . . . . .
L ......
Lg . . . . .
O......
P ......
R......
Sb . . . . .
W. . . . . .
Y ......
B/L . . . .
B/W. . . .
B/Y . . . .
Br/B. . . .
Br/G . . . .
Br/L . . . .
Br/R . . .
Br/W. . . .
G/B . . . .
G/L . . . .
Black
Brown
Chocolate
Dark green
Green
Gray
Blue
Light green
Orange
Pink
Red
Sky blue
White
Yellow
Black/Blue
Black/White
Black/Yellow
Brown/Black
Brown/Green
Brown/Blue
Brown/Red
Brown/White
Green/Black
Green/Blue
G/R. . . .
G/W . . .
G/Y. . . . .
Gy/G. . .
Gy/R . . .
L/B . . . .
L/G . . . .
L/R . . . .
L/W. . . .
L/ Y. . . .
P/W . . .
R/B . . . .
R/G . . . .
R/L . . . .
R/W . . .
R/Y . . . .
W/B . . .
W/G . . .
W/L . . . .
W/R . . .
W/Y . . .
Y/B . . . .
Y/G. . . . .
Y/L . . . .
Green/Red
Green/White
Green/Yellow
Gray/Green
Gray/Red
Blue/Black
Blue/Green
Blue/Red
Blue/White
Blue/Yellow
Pink/White
Red/Black
Red/Green
Red/Blue
Red/White
Red/Yellow
White/Black
White/Green
White/Blue
White/Red
White/Yellow
Yellow/Black
Yellow/Green
Yellow/Blue
YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
TDM900A(T) 2005 WIRING DIAGRAM
D
Br Lg Dg
3
Br/L
5
R
L/R L/B
Y/L R/G G/L
G/L R/G Y/L
B Y G/R Br/W Ch G L
B/W W W/Y
W/Y W B/W
WIRE HARNESS
HEADLIGHT SUB-WIRE HARNESS 2
WIRE HARNESS
HEADLIGHT SUB-WIRE
HARNESS 1
P/W Y
Y
P/W
B/L
B/L
WIRE HARNESS SUB-WIRE HARNESS 2
F
G
R/B G/B
G/B R/B
Br/B R/W
R/W Br/B
Br R/W
R/W Br
R/L L
L R/L
B/L Br/W
Br/W B/L
L G/Y
G/Y L
WIRE HARNESS SUB-WIRE HARNESS 1
RADIATOR FAN MOTOR
WIRE HARNESS RELAY SUB-WIREHARNESS
WIRE HARNESS SUB-WIRE HARNESS 3
H
W/R W/B P/W L/W
L/W P/W W/B W/R
B/W B Y Br/W
Br/W Y
WIRE HARNESS
B B/W
ABS SUB-WIRE HARNESS 1
W R/W W/G
W/G R/W W
B W/L W/Y
W/Y W/L B
WIRE HARNESS
ABS SUB-WIRE HARNESS 2
R
R/W
W
R
W
W
R
W
W
2
Br/R L/W G/R
L/W R/W
R/W
R
1
Dg Lg Br
L G Ch Br/W G/R Y B
E
Br/W
R
W
L/B L/R
A
B
Br/R
4
Br/L
C
R/B W/L R/L
B/W B/R L/W L/R R/W L/G L/Y Sb
B/Y
Lg
L
Y/G P G/R R/L W/B G/W B/W
Gy/G W/Y
R/B G/B O GyR B/W
L/W B/Y L/Y R/W Br/B G/Y
Br/W P/W Y Y/L Gy B/L
R/W L/R
Br/R Y/B
B/W
B/W
6
R
R/B
O
B
R
7
R
R/W
32
34
33
34
L/R
Gy
B/Y
G/W
L/Y
R/L
L/G
L/Y
Sb
R/W
W/L
B/Y
L/W
B/L
L/G
B
17
15
B
R/G B
B
L
L A L
P/W
P
B/L
Br/W
26
20
R/W Lg Y/L
L
Br/B
R/W
B/L
B
Sb
W/L
B
B
W/G
B Sb
30
35
L
21
Sb
W/Y
Lg
Lg
B/Y
W/R
W/R
W/Y
R/W
B Sb
W
G/Y
W/R Lg
B
W/Y
37
L
P
W/Y
B/L
B/L
31
B/L E B/L
Br/W
B/W
B/W
B/W
22
W L/Y
B/W
16
Br/W E Br/W
R/W
Br/W B/L
R/W
R R
W/B
W G
L W/Y
B/L
Br/W
P/W
Y
W/L
57
25
L
24
Gy/G
B
L/W P/W W/B W/R
W/RW/BP/W L/W
38
Br/W Y B B/W
Y/L
Y/B
L/B
Br Y
61
62
63
W/Y W/L B
G/L
48
HI
OFF
R
ON
ON
LO
ON
N
B/Y
L
L/Y
49
Y
B
B/W
65
Y
R/Y Br/W L/B Y Dg
L D L
Dg
Y
Ch
W/Y G/R G L Br/W Y
Dg D Dg
Dg
G/R D G/R
W
B
Dg
B D B
Dg
W B
69
70
Dg
B
Ch
B
53
B
68
B
B
67
B
B
B
B
Ch
L
Ch
B
B
B
B
L
L F L
Ch
72
B
B
52
W/Y
B
W/L
W
R/W
W/G
B/W
B
Y
Br/W
W/R
W/B
B
Dg
B
L/R
W Y/L B/W L/R G/L Lg Br R/G
Ch D Ch
B
Ch
L/B
Y
66
L/B
Dg
B
B W
G/Y
41
B W
W/Y B/Y
42
B W
W B
51
L
G/R
Ch L/Y B B/Y Br
Ch
Y
B
B/W
B
Y
L/B D L/B
L/R
74
G/Y
G/Y F G/Y
B/Y
50
Br/W
Dg Y L/B Br/W R/Y
Y D Y
F Br
Y
B
Y L/R B
L
82
W/Y C W/Y
W/Y
OFF
Br B/Y B L/Y Ch
B L
L
B W/L W/Y
W
Br
B
W R/W W/G
47
L/Y
OFF
Br
Br
R/W F R/W
R/W
75
B L/R
W/G R/W W
B/W
W C W
L/Y
B/Y
64
W
Br
B
Br/W
B/Y
60
46
G
P/W
G/L C G/L
Br/W
Y/B
73
B
Br/W D Br/W
L/B
R/Y
R/Y
59
71
L/B
R/Y
L/R
80
Br
L/R D L/R
R/Y
Br
R
R/Y
Br
W/Y
L/W
R/G
BrG
79
B/W B Y Br/W
Br
54
Br/W
L
R/W
W/Y
W
W/L
R/W
B
W/G
B/W
Y
Br/W
W/R
W/B
Lg
45
P/W
B/W C B/W
G D G
44
L/W
D Br
Br
BrG
R/G C R/G
BrG
Y/L C Y/L
B
B/L
43
78
B
B
R/L B
L Y/G B/L
PUSH
Br
G/Y
Gy/G B/L
W L
FREE
B/W
Br B R/B
Lg D Lg
R/W L/W G/Y
B
G/Y W/L R/W
R/B B Br
36
B/L
G/R
G/R B/L
58
56
G
R/L
G B/W
Y/G
W/L
R/B
R/W
B/L
23
RUN
B
B/W R/W
W/G W/L
L/W
B/L
R/Y
OFF
81
R/W B
W/G
77
55
R/W
W/B
40
W W
76
Br/L
Br/L
W/R
B/W
Y/B
W/L
B/L P L
Y
R/W
Sb
Y/L
B/L
Y/L G/L R/W
Br/R
W
B/Y
B
Y/L
B
R/W
G/L
R/G
B
L W/B
B B R/G
Br/L
B/W W/Y
Br Br/R
Br/B R/W
Gy/G
L/G B
W/Y
L/W W/B P/W W/R
R/W
29
Y/G
P/W P/W B P/W
B/L P/W L
Br/R
Br/R R/W
G/R
B/L
Lg
Br/W
Sb B
Lg W/R
Y
W/B
W L/Y
B B
12
B
Br/B
L
Y B Y
L
B
B/L
Y
R/W
Y B/L
19
R
Br/L
B B
R/L R/B
R/L
B/W
L
B
Br/R
W
B/W
B/L B B/L
W/B
W/G
B
B
B B
B R/W W/B
P/W Br/W W/R R/W
W
B
Br/R
B B
27
R/B R/B A R/B R/B
Gy
W
39
R/L
R/W E R/W
B/W
B
B B
28
GyR
G/W
11
Br/R
Br/L
10
G/B G/B A G/B G/B
Br/B E Br/B
Br/L
B/W
B
R
P
B
B
R/G
B
B
OFF
R/W
R/B
R/L G/B
R/W
18
Br/R
ON
G/W L/Y
O
W
Gy G/W
GyR
L/R
B
B
8
R/L
Br/W
Br/R
Lg
R/B
14
P/W
R
13
R/L A R/L
B
9
MAIN
L/W
R
R
L/W
L/W
B
R
W W W