Yamaha TDM900A User Manual
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.
WARNING
CAUTION:
NOTE:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
INSTRUMENT PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ELECTRICAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . 7
CABLE ROUTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SWINGARM AND DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
CHECKING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . 28
ANTI-LOCK BRAKE SYSTEM (ABS) . . . . . . . . . . . . . . . . . . . . . . . . 30
ABS OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
ABS COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
FRONT WHEEL SENSOR AND SENSOR ROTOR . . . . . . . . . . . 50
REAR WHEEL SENSOR AND SENSOR ROTOR . . . . . . . . . . . . 54
HYDRAULIC UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
HYDRAULIC ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
CHECKING THE RESERVOIR TANK FLUID LEVEL . . . . . . . . . . 73
TRIAL RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
ELECTRICAL
ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
CHECKING THE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
ELECTRIC STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
CIRCUIT DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION . . . . . . . 78
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
SIGNALING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
CIRCUIT DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
CHECKING THE SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 86
ANTI-LOCK BRAKE SYSTEM (ABS) . . . . . . . . . . . . . . . . . . . . . . . . 94
CIRCUIT DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
ABS COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
ABS CONNECTOR LOCATION CHART. . . . . . . . . . . . . . . . . . . . 97
ECU (ABS) AND FAIL-SAFE RELAY . . . . . . . . . . . . . . . . . . . . . . 98
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
CHECKING THE ANTI-LOCK BRAKE SYSTEM. . . . . . . . . . . . . . 104
TROUBLESHOOTING BY THE SELF DIAGNOSIS . . . . . . . . . . . 107
MALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS
(PAST MALFUNCTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
MALFUNCTION CHECK BY THE ABS SELF DIAGNOSIS
(PRESENT MALFUNCTION). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
DELETING THE MALFUNCTION CODE . . . . . . . . . . . . . . . . . . . 120
TROUBLESHOOTING
ANTI-LOCK BRAKE SYSTEM (ABS) . . . . . . . . . . . . . . . . . . . . . . . . 122
ABS TROUBLESHOOTING OUTLINE . . . . . . . . . . . . . . . . . . . . . 122
BASIC INSTRUCTION FOR TROUBLESHOOTING. . . . . . . . . . . 123
BASIC PROCESS FOR TROUBLESHOOTING . . . . . . . . . . . . . . 124
TROUBLESHOOTING AT THE ABS WARNING LIGHT . . . . . . . . . . 125
ONLY THE ABS WARNING LIGHT DOES NOT COME ON. . . . . 125
ALL INDICATORS DO NOT COME ON. . . . . . . . . . . . . . . . . . . . . 125
ABS WARNING LIGHT CONTINUES TO FLASHES. . . . . . . . . . . 125
ABS WARNING LIGHT FLASHES EVERY 0.5 SECONDS. . . . . . 125
ABS WARNING LIGHT CONTINUES TO COME ON. . . . . . . . . . 125
TDM900A(T) 2005 WIRING DIAGRAM
FEATURES
INSTRUMENT PANEL
FEATURES
GENERAL INFORMATION
GEN
INFO
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
CO ADJUSTMENT/DIAGNOSTIC
MONITORING SELECTION MODE
Speed meter
Fuel meter
(The symbol “ ” blinks when the gasoline is
almost empty)
Trip / odometer display
Clock display
Temporary selection display for CO/ DIAG.
CO:
DIAG:
1
FEATURES
GEN
INFO
CO ADJUSTMENT MODE
DIAGNOSTIC MONITORING MODE
WHEN THE COMMUNICATION ERROR
OCCURRED BETWEEN ECU AND METER:
Cylinder identification
For #1 For #2
CO data
Example:
lean rich
–128 0 128
Diagnostic monitoring code
Example: code “01”
Monitoring data
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
CO adjustment and diagnostic monitoring mode
Mode Selection
FEATURES
GEN
INFO
Normal mode
Turn “ON” the main switch
• The self-diagnostic function starts a system
check
System normal Malfunction detec-
Normal meter display
CO adjustment mode
Refer to “CO adjustment” in chapter 3.
(Manual No.: 5PS1-AE1)
tion fault number
appears on the
clock LCD.
The engine trouble warning light
illuminates.
CO/DIAG mode
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.
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.
Diagnosis monitoring mode
Refer to “TROUBLESHOOTING” in chapter
7.
(Manual No.: 5PS1-AE1)
(The engine cannot be started in this mode)
3
GEN
SPECIAL TOOLS
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 Illustration
Test coupler adaptor
90890-03149
This tool is used to check the ABS diagnosis.
INFO
4
GENERAL SPECIFICATIONS/
ENGINE SPECIFICATIONS/CHASSIS SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
Model code 2B01 (EUR) •
Weight
Wet (with oil and a full fuel tank) 224 kg (494 lb) •
Dry (without oil and fuel) 193 kg (426 lb) •
Maximum load (total of cargo, rider,
200 kg (441 lb) •
passenger, and accessories)
ENGINE SPECIFICATIONS
Item Standard Limit
Throttle bodies
Model (manufacturer) × quantity 38EIS (MIKUNI) × 2•
ID mark 5PS1 11 •
• •
• •
• •
• •
• •
• •
CHASSIS SPECIFICATIONS
Item Standard Limit
Front tire
Tire type Tubeless •
Size 120 / 70ZR 18M / C (59W) •
Model (manufacturer) D220FSTJ (DUNLOP) •
Tire pressure (cold)
0 ~ 90 kg 225 kPa (2.25 kgf/cm
90 ~ 200 kg 225 kPa (2.25 kgf/cm
High-speed riding 225 kPa (2.25 kgf/cm
Min. tire tread depth •
• • 1.6 mm
Rear tire
Tire type Tubeless •
Size 160 / 60ZR 17M / C (69W) •
Model (manufacturer) D220STJ (DUNLOP) •
Tire pressure (cold)
0 ~ 90 kg 250 kpa (2.5 kgf/cm
90 ~ 200 kg 290 kPa (2.9 kgf/cm
High-speed riding 250 kPa (2.5 kgf/cm
Min. tire tread depth •
• • 1.6 mm
Drive chain:
Type (manufacturer) DID525HV KAI (DAIDO) •
Link quantity 118 •
Drive chain slack 50 ~ 60 mm •
Maximum 15-link section •
• • 239.3 mm
2
, 2.25 bar, 32 psi) • • •
2
, 2.25 bar, 32 psi) • • •
2
, 2.25 bar, 32 psi) • • •
2
, 2.5 bar, 35.6 psi) • • •
2
, 2.9 bar, 41.3 psi) • • •
2
, 2.5 bar, 35.6 psi) • • •
• •
• •
• •
(0.06 in)
• •
• •
• •
(0.06 in)
• •
• •
• •
(9.42 in)
5
ELECTRICAL SPECIFICATIONS
SPEC
ELECTRICAL SPECIFICATIONS
Item Standard Limit
Ignition system
Ignition system type Transistorized coil ignition (digital) •
Ignition timing 10° BTDC at 1,150 r/min •
Advancer type Electric •
Pickup coil resistance/color 192 ~ 288 Ω/L/Y-G/W •
Transistorized coil ignition unit model
TBDF15 (DENSO) •
(manufacturer)
Indicator light
(voltage/ wattage × quantity)
Turn signal indicator light 14 V 1.2 W × 1•
ABS warning light 14 V 1.4 W × 1•
Starter relay
Model (manufacturer) MS5F-631 (JIDECO) •
Amperage 180 A •
Coil resistance 4.18 ~ 4.62 Ω •
Front wheel sensor
Model (manufacturer) OELABW (SUMITOMO) •
Resistance 1.2 ~ 1.6 kΩ at 20°C •
Rear wheel sensor
Model (manufacturer) OELABX (SUMITOMO) •
Resistance 1.2 ~ 1.6 kΩ at 20°C •
Fail-safe relay
Model (manufacturer) G8R-40Y (OMRON) •
Fuses (amperage × quantity)
Main fuse 40 A × 1•
Fuel injection system fuse 10 A × 1•
Headlight fuse 20 A × 1•
Signaling system fuse 10 A × 1•
Ignition fuse 10 A × 1•
Radiator fan motor fuse 20 A × 1•
Hazard light fuse 10 A × 1•
Backup fuse 10 A × 1•
ABS fuse 10 A × 1•
ABS motor fuse 30 A × 1•
Reserve fuse 20 A × 1•
10 A × 1•
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
6
TIGHTENING TORQUES
CHASSIS TIGHTENING TORQUES
TIGHTENING TORQUES
SPEC
Part to be tightened
Lower bracket pinch bolt M8 23 2.3 16.6
Upper bracket and wire guide M6 7 0.7 5.1
Throttle cable adjusting nut M6 5 0.5 3.6
Engine mounting:
Rear upper mounting bolt and nut M10 45 4.5 32.5
Rear lower mounting bolt and nut M10 45 4.5 32.5
Pinch bolt M8 26 2.6 18.8
Frame and rear frame M10 41 4.1 29.7
Sidestand and sidestand bracket M8 23 2.3 16.6
Sidestand bracket and frame M8 26 2.6 18.8
Rear footrest and footrest bracket M6 9 0.9 6.5
Front wheel sensor and sensor housing M8 30 3.0 22
Rear wheel sensor and sensor housing M8 30 3.0 22
Hydraulic unit and hydraulic unit bracket M8 16 1.6 12
Hydraulic unit bracket and frame M8 16 1.6 12
Hydraulic unit and brake hose M10 30 3.0 22
Front brake hose holder and front brake hose M6 10 1.0 7.2
Rear brake hose holder and rear brake hose M6 7 0.7 5.0
Frame and connector plate M5 7 0.7 5.0
Frame and brake hose holder M6 10 1.0 7.2
Thread
size
Tightening
torque
Nm m•kg ft•lb
Remarks
7
CABLE ROUTING
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
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
SPEC
8
CABLE ROUTING
SPEC
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.
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).
9
CABLE ROUTING
SPEC
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.
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.
10
Fasten the headlight sub-wire harness with the
clamp that is passed through the center hole of
stay 1.
CABLE ROUTING
SPEC
11
CABLE ROUTING
SPEC
Stay 3
Ignition coil assembly
Neutral switch lead
O
sensor lead
2
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
O
sensor
2
Cylinder identification sensor
lead
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
12
CABLE ROUTING
SPEC
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.
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.
13
CABLE ROUTING
SPEC
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 O
boss seat face to the outside of the vehicle.
Fasten the neutral switch lead, O
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.
sensor lead should not stick out from the
2
sensor lead,
2
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.
14
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.
CABLE ROUTING
SPEC
15
CABLE ROUTING
SPEC
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
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
16
CABLE ROUTING
SPEC
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.
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).
17
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.
CABLE ROUTING
SPEC
18
CABLE ROUTING
SPEC
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
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)
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CABLE ROUTING
SPEC
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
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
20
CABLE ROUTING
SPEC
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.
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.
21
CABLE ROUTING
SPEC
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.)
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.
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