Yamaha CYGNUS RAY ZR 2022 Supplementary Service Manual
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Yamaha CYGNUS RAY ZR 2022 Supplementary Service Manual

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2022
SUPPLEMENTARY
SERVICE MANUAL
LCG125
LCG125D
B2U-F8197-E1

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Summary of Contents for Yamaha CYGNUS RAY ZR 2022

  • Page 1 2022 SUPPLEMENTARY SERVICE MANUAL LCG125 LCG125D B2U-F8197-E1...
  • Page 2 Supplementary Service Manual together with the following manual. FASCINO (LCX125) 2020 SERVICE MANUAL: B7J-F8197-E0 RAY ZR (LCG125 & LCG125D) 2022 SUPPLEMENTARY SERVICE MANUAL ©2022 by India Yamaha Motor Pvt. Ltd. First edition, September 2021 All rights reserved. Any reproduction or unauthorized use without the written permission of India Yamaha Motor Pvt.
  • Page 3 EAS200071 IMPORTANT This manual was produced by the India Yamaha Motor Pvt. 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 man- ual. 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.
  • Page 4 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. •...
  • Page 5 EAS20101 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ELECTRICAL SYSTEM...

  • Page 9: General Information

    GENERAL INFORMATION FEATURES..................... 1-1 INDICATOR LIGHTS AND WARNING LIGHTS (for disc) ......1-1 INDICATOR LIGHTS AND WARNING LIGHTS (for drum) ...... 1-2 SPECIAL TOOLS ................... 1-3...

  • Page 10: Features

    ” This warning light comes on if a problem is de- FEATURES tected in the electrical circuit monitoring the en- gine. If this occurs, have a Yamaha dealer check EAU4939J the self-diagnostic system. INDICATOR LIGHTS AND WARNING LIGHTS The electrical circuit of the warning light can be (for disc) checked by turning the vehicle on.

  • Page 11: Indicator Lights And Warning Lights (For Drum)

    (for drum) This warning light comes on if a problem is de- tected in the electrical circuit monitoring the en- gine. If this occurs, have a Yamaha dealer check the self-diagnostic system. The electrical circuit of the warning light can be 0 0 0 0 checked by turning the vehicle on.

  • Page 12: Special Tools

    SPECIAL TOOLS INFO EAS00027 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. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
  • Page 13 SPECIAL TOOLS INFO Tool name/Tool No. Illustration Steering C-spanner S 1108 (90890-01268) This tool is used to loosen and tighten the steering ring nut. Magneto puller S 1109 (90890-01189) This tool is used to remove the AC magneto rotor with the help of magneto holder.
  • Page 14 SPECIAL TOOLS INFO Tool name/Tool No. Illustration Lower bearing inner race installer Ø30X40.5XØ48 S 1170 Ø48 Ø30 This tool is used to install the bearings. S 1170 Bearing punch with pilot driver (ø8mm) YSST-951 S 1122 This tool is used to install the bearings. Piston pin replacer YSST-207A (90890-01304)
  • Page 15 SPECIAL TOOLS INFO Tool name/Tool No. Illustration Piston base YSST-604 (90890-01067) This tool is used to support the piston. Small screw driver YSST-609 This tool is used to adjust throttle screw/retract tim- ming chain tensioner. Scraper YSST-612 This tool is used to scrap the sealant from crankcase surface.
  • Page 16 SPECIAL TOOLS INFO Tool name/Tool No. Illustration Bearing puller 6202 YSST-624 This tool is used to remove the bearings of main axle (transmission cover). Bearing puller 6203 YSST-624 A This tool is used to remove the bearing of drive axle (left crankcase).
  • Page 17 This tool is used to check efficiency of ignition at spark plug. Compression gauge INS-009 (90890-03081) This instrument is used to measure the engine com- pression. Yamaha bond No.1215 TG-1215 (90890-85505) This bond is used to seal two mating surfaces (e.g., crankcase mating surfaces). Yamaha diagnostic tool INS-018...
  • Page 18 SPECIAL TOOLS INFO Tool name/Tool No. Illustration Yamaha diagnostic tool (Ver.3) INS-019 (90890-03264) This tool is used to diagnose electrical fault in ad- vance fuel injection system. Sub harness 3 (90890-03266) This tool is used to connect FI YDT coupler to adapter interface (BS-VI models).

  • Page 19: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ............... 2-1 MAINTENANCE SPECIFICATION (ENGINE)..........2-2 MAINTENANCE SPECIFICATION (CHASSIS) ..........2-5 MAINTENANCE SPECIFICATION (ELECTRICAL)........2-7 TIGHTENING TORQUES ................2-9 GENERAL TIGHTENING TORQUE SPECIFICATIONS ......2-9 ENGINE TIGHTENING TORQUES ............2-10 CHASSIS TIGHTENING TORQUES ............2-12 CABLE ROUTING ..................2-17...

  • Page 20: General Specifications

    SPEC GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Model Model B2U8 (LCG125D_Street Rally) B2U9 (LCG125_Disc) B2UA (LCG125_Drum) B2UH (LCG125_Disc) Dimensions Overall length 1880 mm (74.0 in) Overall width 685 mm (27.0 in) (Drum, Disc) 750 mm (29.5 in) (Street Rally) Overall height 1190 mm (46.9 in) Wheelbase 1280 mm (50.4 in) Ground clearance...

  • Page 21: Maintenance Specification (Engine)

    SPEC MAINTENANCE SPECIFICATION (ENGINE) MAINTENANCE SPECIFICATION (ENGINE) Engine Combustion cycle 4-stroke Cooling system Air cooled Valve train SOHC Displacement 125 cm³ Number of cylinders Single cylinder 52.4  57.9 mm (2.06  2.28 in) Bore × stroke Compression ratio 10.2 : 1 Compression pressure 1522–1960 kPa/870 r/min (15.2–19.6 kgf/cm²/ 870 r/min, 216.5–278.8 psi/870 r/min)
  • Page 22 SPEC MAINTENANCE SPECIFICATION (ENGINE) Rocker arm/rocker arm shaft Rocker arm inside diameter limit 10.015 mm (0.3943 in) Rocker arm shaft outside diameter limit 9.935 mm (0.3911 in) Valve, valve seat, valve guide Valve clearance (cold) Intake 0.06–0.10 mm (0.0024–0.0039 in) Exhaust 0.22–0.26 mm (0.0087–0.0102 in) Valve dimensions...
  • Page 23 SPEC MAINTENANCE SPECIFICATION (ENGINE) Automatic centrifugal clutch Clutch shoe thickness limit 2.1 mm (0.08 in) Clutch housing inside diameter limit 125.5 mm (4.94 in) Clutch-in revolution 2200–2600 r/min Clutch-stall revolution 4200–4800 r/min V-belt V-belt width limit 19.0 mm (0.75 in) Drivetrain Transmission type V-belt automatic...

  • Page 24: Maintenance Specification (Chassis)

    SPEC MAINTENANCE SPECIFICATION (CHASSIS) MAINTENANCE SPECIFICATION (CHASSIS) Chassis Caster angle 26.4 ° Trail 91 mm (3.6 in) Front wheel Wheel type Cast wheel 12  1.85 Rim size Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit 0.5 mm (0.02 in) Wheel axle bending limit 0.25 mm (0.01 in)
  • Page 25 Fork spring free length limit 248.1 mm (9.77 in) Inner tube bending limit 0.2 mm (0.01 in) Recommended oil Yamaha Suspension Oil G10 Quantity (left) 54.0 cm³ (1.83 US oz, 1.90 Imp.oz) Quantity (right) 54.0 cm³ (1.83 US oz, 1.90 Imp.oz) Level (left) 85 mm (3.3 in)

  • Page 26: Maintenance Specification (Electrical)

    SPEC MAINTENANCE SPECIFICATION (ELECTRICAL) MAINTENANCE SPECIFICATION (ELECTRICAL) Voltage System voltage 12 V Ignition system Ignition timing (B.T.D.C.) 3.0–7.0 °/1300 r/min Engine control unit Model B7J1 (Disc, Street Rally) B7J2 (Drum) Ignition coil 2.34–2.86  Primary coil resistance Secondary coil resistance 9.45–11.55 k...
  • Page 27 SPEC MAINTENANCE SPECIFICATION (ELECTRICAL) Indicator light High beam indicator light LED (Disc, Street Rally) 1.7 W (Drum) Turn signal indicator light LED (Disc, Street Rally) 1.7 W (Drum) Engine trouble warning light LED (Disc, Street Rally) 1.7 W (Drum) ECO indicator light LED (Disc, Street Rally) 1.7 W (Drum) Stop and Start System indicator light...

  • Page 28: Tightening Torques

    SPEC TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the speci- fied tightening torque is reached.

  • Page 29: Engine Tightening Torques

    SPEC TIGHTENING TORQUES EAS20013 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Cylinder head nut (Initial torque) 10 N·m (1.0 kgf·m, 7.4 lb·ft) Cylinder head nut (Final torque) 27 N·m (2.7 kgf·m, 20 lb·ft) Spark plug 13 N·m (1.3 kgf·m, 9.6 lb·ft) Cylinder head bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Cylinder head stud bolt (for muffler)
  • Page 30 SPEC TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Contact closely Transmission oil filler plug spot face V-belt case cover bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Cover bolt (v- belt case cover) 10 N·m (1.0 kgf·m, 7.4 lb·ft) V-belt case air filter element cover 10 N·m (1.0 kgf·m, 7.4 lb·ft) bolt...

  • Page 31: Chassis Tightening Torques

    SPEC TIGHTENING TORQUES EAS30017 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine bracket and frame nut 50 N·m (5.0 kgf·m, 37 lb·ft) Engine bracket and engine nut 54 N·m (5.4 kgf·m, 40 lb·ft) Front fender and lower bracket bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft) Front wheel axle nut 26 N·m (2.6 kgf·m, 19 lb·ft)
  • Page 32 SPEC TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Wire harness ground lead bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) (at crank case) SGCU (starter generator control 9 N·m (0.9 kgf·m, 6.6 lb·ft) unit) assembly bolt Ignition coil assembly bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) Seat lock cable screw (at main 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
  • Page 33 SPEC TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Throttle cable plate and throttle 1.4 N·m (0.14 kgf·m, 1.0 lb·ft) cable housing screw Throttle cable free play adjusting 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) lock nut Speedometer assembly screw 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) Handlebar nut 53 N·m (5.3 kgf·m, 39 lb·ft)
  • Page 34 SPEC TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front brake light switch screw 1.2 N·m (0.12 kgf·m, 0.88 lb·ft) UBS brake cable lock nut at master 7 N·m (0.7 kgf·m, 5.2 lb·ft) cylinder (disc) Front brake lever bolt (disc) 6 N·m (0.6 kgf·m, 4.4 lb·ft) Brake pad pin 17 N·m (1.7 kgf·m, 13 lb·ft)
  • Page 35 SPEC TIGHTENING TORQUES 2-16...

  • Page 36: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING CABLE ROUTING (For Drum) - Chassis (Front left view) 2-17...
  • Page 37 SPEC CABLE ROUTING CABLE ROUTING (For drum) - Chassis (Front left view) È Rear brake cable shall pass through cable 1 Horn 2 Horn lead guide of frame. É Insert the sidestand switch lead clamp into 3 Wire harness (Headlight) 4 Wire harness front leg shield.
  • Page 38 SPEC CABLE ROUTING CABLE ROUTING - Engine (Rear left view) È Route the rear brake cable through cable 1 Canister purge hose (check valve to throttle body) guide. 2 Check valve 3 Canister purge hose (canister assembly to check valve) 4 Canister 5 Fuel tank breather hose (fuel tank to canister assembly)
  • Page 39 SPEC CABLE ROUTING 2-20...
  • Page 40 SPEC CABLE ROUTING CABLE ROUTING (Top view) Front Side 2-21...
  • Page 41 SPEC CABLE ROUTING CABLE ROUTING (Top view) È Route the spark plug lead above the damper 1 Wire harness (injector) 2 Wire harness (engine temperature sensor) as shown in figure. É Insert the wire harness clamp into rear fend- sensor lead 4 Spark plug lead Ê...
  • Page 42 SPEC CABLE ROUTING CABLE ROUTING - Engine (Rear left view) 2-23...
  • Page 43 SPEC CABLE ROUTING CABLE ROUTING - Engine (Rear left view) È Insert the clamp into rear fender. 1 SGCU (Starter generator control unit) É Insert the clamp into the hole of frame. 2 Wire harness (Ignition coil) Ê Contact the protector assembly to spark plug 3 Wire harness (Frame ground) lead and then attach the spark plug lead into 4 Main relay...
  • Page 44 SPEC CABLE ROUTING CABLE ROUTING (For Drum) - Chassis (Front view) 2-25...
  • Page 45 SPEC CABLE ROUTING CABLE ROUTING (For Drum) - Chassis (Front view) È Wire harness (Front turn signal light assem- 1 Turn signal relay 2 Wire harness (headlight assembly) bly) shall be attached with leg shield hook. É Wire harness shall not be slack in this area. 3 Main switch coupler Ê...
  • Page 46 SPEC CABLE ROUTING CABLE ROUTING (For drum) 1 Auxiliary light assembly 8 UBS brake cable 2 Front handlebar cover 9 Speedometer cable 3 Windshield 0 Rear brake cable 4 Meter assembly A Wire harness 5 Meter cover B Throttle cable 6 Rear handlebar cover C Handlebar assembly 7 Front brake cable...
  • Page 47 SPEC CABLE ROUTING 2-28...
  • Page 48 SPEC CABLE ROUTING CABLE ROUTING (For drum) - handlebar 2-29...
  • Page 49 SPEC CABLE ROUTING CABLE ROUTING (For drum) - handlebar Ó Grip end shall be properly installed till the end 1 Front brake lever 2 Grip end of throttle grip. Ô Align “ 3 Throttle grip ” mark of brake lever holder with 4 Front brake cable punch “...
  • Page 50 SPEC CABLE ROUTING CABLE ROUTING (For disc) - Chassis (Front left view) 2-31...
  • Page 51 SPEC CABLE ROUTING CABLE ROUTING (For disc) - Chassis (Front left view) È Rear brake cable shall pass through cable of 1 Horn 2 Horn lead guide of frame. É Insert the horn lead clamp into front fender. 3 Wire harness (Headlight) Ê...
  • Page 52 SPEC CABLE ROUTING CABLE ROUTING (For Disc) - Chassis (Front right view) È Route the seat lock cable through frame as- 1 Main switch 2 Seat lock cable sembly hole. É Insert the wire harness clamp into frame hole. 3 Horn Ê...
  • Page 53 SPEC CABLE ROUTING 2-34...
  • Page 54 SPEC CABLE ROUTING CABLE ROUTING (For Disc) - Chassis (Front view) 2-35...
  • Page 55 SPEC CABLE ROUTING CABLE ROUTING (For Disc) - Chassis (Front view) È Wire harness (Front turn signal light assem- 1 Turn signal relay 2 Wire harness (headlight assembly) bly) shall be attached with leg shield hook. É Wire harness shall not be slack in this area. 3 Main switch coupler Ê...
  • Page 56 SPEC CABLE ROUTING CABLE ROUTING (For disc) 1 Auxiliary light assembly 7 Speedometer cable 2 Front handlebar cover 8 Rear brake cable 3 Windshield 9 Throttle cable 4 Meter assembly 0 Wire harness 5 Meter cover A Handlebar assembly 6 Rear handlebar cover 2-37...
  • Page 57 SPEC CABLE ROUTING 2-38...
  • Page 58 SPEC CABLE ROUTING CABLE ROUTING (For disc) - handlebar 2-39...
  • Page 59 SPEC CABLE ROUTING CABLE ROUTING (For drum) - handlebar Ñ Connect turn signal light (left & right) with wire 1 Front brake lever 2 Grip end harness. Ò Route the wire harness (Front brake light 3 Throttle grip 4 UBS brake cable switch) from back side of handlebar assem- 5 Handlebar grip (left) bly and connect with front brake light switch.
  • Page 60 SPEC CABLE ROUTING 2-41...

  • Page 61: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 PERIODIC MAINTENANCE (For Drum) ..........3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION  CONTROL SYSTEM ................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ...... 3-1 PERIODIC MAINTENANCE (For Disc) ............ 3-4 INTRODUCTION ..................

  • Page 62: Periodic Maintenance

    EAUE0173 • From 19000 km (11800 mi), repeat the maintenance intervals starting from 4000 km (2400 mi). • Items marked with an asterisk (*) should be performed by a Yamaha dealer as they require special tools, data and technical skills.

  • Page 63: Periodic Maintenance (For Disc)

    PERIODIC MAINTENANCE ODOMETER READING ITEM CHECK OR MAINTENANCE JOB 1000 km 4000 km 7000 km 10000 km 13000 km 16000 km** (600 mi) (2400 mi) (4200 mi) (6000 mi) (7800 mi) (9600 mi) • Check operation and adjust brake  ...
  • Page 64 PERIODIC MAINTENANCE ODOMETER READING ITEM CHECK OR MAINTENANCE JOB 1000 km 4000 km 7000 km 10000 km 13000 km 16000 km** (600 mi) (2400 mi) (4200 mi) (6000 mi) (7800 mi) (9600 mi) • Check operation. • Check throttle grip free play, and 27 * Throttle grip adjust if necessary.

  • Page 65: Introduction

    EAUE0173 • From 19000 km (11800 mi), repeat the maintenance intervals starting from 4000 km (2400 mi). • Items marked with an asterisk (*) should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 66 PERIODIC MAINTENANCE ODOMETER READING ITEM CHECK OR MAINTENANCE JOB 1000 km 4000 km 7000 km 10000 km 13000 km 16000 km** (600 mi) (2400 mi) (4200 mi) (6000 mi) (7800 mi) (9600 mi) • Check operation, fluid level and  ...
  • Page 67 PERIODIC MAINTENANCE ODOMETER READING ITEM CHECK OR MAINTENANCE JOB 1000 km 4000 km 7000 km 10000 km 13000 km 16000 km** (600 mi) (2400 mi) (4200 mi) (6000 mi) (7800 mi) (9600 mi) Front and rear     ...

  • Page 68: Engine

    ENGINE ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at the Top Dead Center (TDC) on the compression b.

  • Page 69: Checking The Fuel Filter

    ENGINE 5. Adjust: 6. Install: • Valve clearance • Cylinder head cover gasket a. Loosen the locknut “1”. • Cylinder head cover b. Insert a feeler gauge “2” between the end Cylinder head cover bolt of the adjusting screw “3” and the valve tip. 11 N·m (1.1 kgf·m, 8.1 lb·ft) •...

  • Page 70: Checking The Canister

    ENGINE CHECKING THE CANISTER 1. Remove: • Seat/storage compartment • Center cover • Fuel tank cover • Grab bar 2. Disconnect: • Tail light coupler 3. Remove: • Rear side cover assembly along with tail light Refer to “GENERAL CHASSIS” on page 4-6. 4.

  • Page 71: Chassis

    CHASSIS CHASSIS Set the steering C-spanner at a right angle to the EAS30645 CHECKING AND ADJUSTING THE steering nut. STEERING HEAD 1. Stand the vehicle on a level surface. Steering C-spanner EWA13120 YSST-S1108 WARNING (90890-01268) Securely support the vehicle so that there is no danger of it falling over.

  • Page 72: Electrical

    ELECTRICAL ELECTRICAL EAS00162 REPLACING THE HEADLIGHT BULB 1. Remove: • Front cover assembly • Headlight cowling assembly Refer “GENERAL CHASSIS” on page 4-8. 2. Disconnect: • Headlight bulb coupler “1” 5. Install: • Headlight bulb Secure the new headlight bulb with the head- light bulb holder.

  • Page 73: Replacing License Plate Light Bulb

    ELECTRICAL Direction “a” License plate light screw Headlight beam is raised. 1.8N·m (0.18 kgf·m, 1.3 lb·ft) Direction “b” Headlight beam is lowered. 3. Install: • Front upper cover REPLACING LICENSE PLATE LIGHT BULB 1. Remove: • License plate light “1” by removing screw “2”. •...
  • Page 74 ELECTRICAL 3-13...
  • Page 75 CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE BATTERY COVER ............4-2 INSTALLING THE BATTERY COVER ............. 4-2 REMOVING THE SEAT/STORAGE COMPARTMENT......4-4 INSTALLING THE SEAT/STORAGE COMPARTMENT ......4-4 REMOVING THE CENTER COVER ............4-4 INSTALLING CENTER COVER ............... 4-4 REMOVING THE FUEL TANK COVER ........... 4-5 INSTALLING THE FUEL TANK COVER ..........
  • Page 76 CHAS GENERAL CHASSIS GENERAL CHASSIS Removing the battery and battery cover Order Job/Parts to remove Q’ty Remarks Battery box cover Battery cover Negative battery lead Disconnect. Positive battery lead Disconnect. Battery For installation, reverse the removal proce- dure.

  • Page 77: General Chassis

    CHAS GENERAL CHASSIS EAS31677 REMOVING THE BATTERY COVER Ensure battery cover is set properly on its origi- 1. Remove nal position before tighten the battery cover bolt. • Battery box cover “1” Battery cover bolt 4 N·m (0.4 kgf·m, 3.0 lb·ft) •...
  • Page 78 CHAS GENERAL CHASSIS Removing the center cover, seat/storage compartment, grab bar Order Job/Parts to remove Q’ty Remarks Seat/storage compartment Center cover • Open seat Fuel tank cover • Remove the fuel tank cap before removing the fuel tank cover. Grab bar For installation, reverse the removal proce- dure.

  • Page 79: Removing The Seat/Storage Compartment

    CHAS GENERAL CHASSIS REMOVING THE SEAT/STORAGE REMOVING THE CENTER COVER COMPARTMENT 1. Remove: 1. Place the vehicle on a center stand. • Seat/storage compartment Refer “REMOVING THE SEAT/STORAGE WARNING COMPARTMENT” on page 4-4. Securely support the vehicle so that there is •...

  • Page 80: Removing The Fuel Tank Cover

    CHAS GENERAL CHASSIS REMOVING THE FUEL TANK COVER REMOVING THE GRAB BAR 1. Place the vehicle on a center stand. 1. Remove: • Fuel tank cover WARNING Refer “REMOVING THE FUEL TANK COV- Securely support the vehicle so that there is ER”...
  • Page 81 CHAS GENERAL CHASSIS Removing the rear side covers and rear fender Order Job/Parts to remove Q’ty Remarks Seat/storage compartment, center cover, fuel Refer to “GENERAL CHASSIS” on page tank cover, grab bar 4-3. Tail/brake light coupler Disconnect. Rear side cover assembly Refer to “REAR SHOCK ABSORBER AS- Rear shock absorber assembly with cover SEMBLY”...

  • Page 82: Removing The Rear Side Cover Assembly

    CHAS GENERAL CHASSIS REMOVING THE REAR SIDE COVER • Remove the rear side cover assembly “1” by ASSEMBLY gently pulling to rearward. 1. Place the vehicle on a centerstand. WARNING Securely support the vehicle so that there is no danger of it falling over. 1.
  • Page 83 CHAS GENERAL CHASSIS Removing the front upper cover, front side covers and headlight cowling assembly For Disc For Drum Order Job/Parts to remove Q’ty Remarks Front upper cover Front side cover (right) Front side cover (left) Before removing headlight cowling discon- nect both wire harness holding clamps as Headlight cowling assembly shown.

  • Page 84: Removing The Front Side Cover Assembly And Headlight Cowling

    CHAS GENERAL CHASSIS REMOVING THE FRONT SIDE COVER ASSEMBLY AND HEADLIGHT COWLING 1. Place the vehicle on a center stand. WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove. • Front upper cover “1” by removing screws “2” and gently pull outward from its slots.

  • Page 85: Installing The Front Side Cover Assembly And Headlight Cowling

    CHAS GENERAL CHASSIS Headlight cowling bracket bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) 3. Install: • Front side covers (both side) • Carefully fix the side cover lugs and latches on its original projection. • Tighten the front side covers bolts to the spec- ified torque.
  • Page 86 CHAS GENERAL CHASSIS Removing the footboard and leg shield assembly Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Battery cover and battery 4-1. Refer to “GENERAL CHASSIS” on page Rear side cover assembly 4-6. Front upper cover, front side covers (right & left) Refer to “GENERAL CHASSIS”...
  • Page 87 CHAS GENERAL CHASSIS Removing the footboard and leg shield assembly Order Job/Parts to remove Q’ty Remarks Leg shield Foot board (upper) For installation, reverse the removal proce- dure. 4-12...

  • Page 88: Removing The Footboard And Legshield Assembly

    CHAS GENERAL CHASSIS REMOVING THE FOOTBOARD AND LEGSHIELD ASSEMBLY Remove the footboard (lower) and front inner 1. Place the vehicle on a center stand. fender assembly side from its projection from WARNING leftside, open the sidestand for smoothly remove the assembly. Securely support the vehicle so that there is no danger of it falling over.
  • Page 89 CHAS GENERAL CHASSIS 3. Remove: • Leg shield • Wire harness (fuse box and YDT coupler) “1”. • Footboard assembly by removing the bolts “1” from footboard (upper). For installation, reverse the removal procedure. 4-14...

  • Page 90: Handlebar

    CHAS HANDLEBAR HANDLEBAR Removing the handlebar Order Job/Parts to remove Q’ty Remarks Rear view mirror assy (left & right) Handlebar front cover assembly Disconnect. Auxiliary light coupler Disconnect. Front turn signal light connectors (left & right) Disconnect. Auxiliary light with front covers & windshield 1+1+1 Speedometer cable assy Disconnect.
  • Page 91 CHAS HANDLEBAR Removing the handlebar Order Job/Parts to remove Q’ty Remarks End Grip (right) Throttle cable housing Throttle cable Disconnect. Throttle grip Brake light switch (front) Disconnect. Front brake cable (For drum) Disconnect. Front brake lever Lever holder right (For drum) Refer to “REMOVING THE FRONT BRAKE Front brake master cylinder (For disc) MASTER CYLINDER”...
  • Page 92 CHAS HANDLEBAR Removing the handlebar Order Job/Parts to remove Q’ty Remarks Lever holder (left) Disconnect. End grip (left) Handle grip (left) Handlebar For installation, reverse the removal proce- dure. 4-17...
  • Page 93 CHAS HANDLEBAR Removing the brush gaurd (for B2U8) Order Job/Parts to remove Q’ty Remarks Rear view mirror assy Disconnect. End grip Brush guard assembly For installation, reverse the removal proce- dure. 4-18...

  • Page 94: Removing The Front Handlebar Cover Assembly

    CHAS HANDLEBAR REMOVING THE FRONT HANDLEBAR COVER ASSEMBLY Separate the auxiliary light “1” from light cover 1. Remove: and windshield “2” by removing screws “3” from • Rear view mirror assembly (left & right) its projection as shown. • Handlebar front cover assembly by removing screws “1”...

  • Page 95: Checking The Handlebar

    CHAS HANDLEBAR 4. Disconnect: CHECKING THE HANDLEBAR • Front brake light switch connector 1. Check: 5. Remove: • Handlebar “1” Bends/cracks/damage  Replace. • UBS brake cable (For disc) • Front brake lever assembly • Front brake master cylinder assembly (for disc) 6.
  • Page 96 CHAS HANDLEBAR 4. Install: 8. Install: • Rear brake cable • Throttle cable “1” • UBS brake cable • Throttle grip “2” • Throttle cable • Grip end “3” • Wire harness • Speedometer cable Refer to “CABLE ROUTING”. Align the cables properly before installing with handlebars as per cable routing guidelines.

  • Page 97: Installing The Front Handlebar Cover Assembly

    CHAS HANDLEBAR Auxiliary light cover screw • Install the brake master cylinder holder with the 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) “UP” mark “a” facing up. • Align the edge “b” of the brake master cylinder • Auxiliary light assembly “1” and tighten the holder with the edge “c”...

  • Page 98: Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY EAS06850 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job/Parts to remove Q’ty Remarks Seat/storage compartment, center cover, rear Refer to “GENERAL CHASSIS” on page side cover assembly, fuel tank cover assembly. 4-1.

  • Page 99: Removing The Rear Shock Absorber Assemblies

    CHAS REAR SHOCK ABSORBER ASSEMBLY REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on the suitable stand so that the rear wheel is elevated.

  • Page 100: Installing The Seat Lock Cable

    CHAS REAR SHOCK ABSORBER ASSEMBLY 3. Remove: INSTALLING THE SEAT LOCK CABLE • Main switch cap 1. Insert the seat lock cable into frame. Refer “REMOVING THE FOOTBOARD AND LEGSHIELD ASSEMBLY” on page 4-13. • Before inserting the seat lock cable into frame. •...

  • Page 101: Electrical System

    ELECTRICAL SYSTEM IGNITION SYSTEM ..................5-1 CIRCUIT DIAGRAM (For disc) ..............5-1 CIRCUIT DIAGRAM (For drum) ............... 5-3 TROUBLESHOOTING ................5-5 ELECTRIC STARTING SYSTEM ..............5-7 CIRCUIT DIAGRAM (For disc) ..............5-7 CIRCUIT DIAGRAM (For drum) ............... 5-9 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ....... 5-11 TROUBLESHOOTING ................

  • Page 103: Ignition System

    ELEC IGNITION SYSTEM IGNITION SYSTEM CIRCUIT DIAGRAM (For disc)
  • Page 104 ELEC IGNITION SYSTEM 1. Battery 2. Battery positive lead 3. Battery negative lead 4. Fuse box 5. Main fuse 6. Backup fuse 7. Sub fuse 10.Main switch 18.SGCU (Starter generator control unit) 19.Joint connection 2 20.Ignition coil 21.Spark plug 22.Crankshaft position sensor 30.Starter generator 31.Sidestand switch 35.Joint connection 4...

  • Page 105: Circuit Diagram (For Drum)

    ELEC IGNITION SYSTEM CIRCUIT DIAGRAM (For drum)
  • Page 106 ELEC IGNITION SYSTEM 1. Battery 2. Battery positive lead 3. Battery negative lead 4. Fuse box 5. Main fuse 6. Backup fuse 7. Sub fuse 10.Main switch 17.Joint connection 4 20.SGCU (Starter generator control unit) 21.Joint connection 2 22.Ignition coil 23.Spark plug 24.Crankshaft position sensor 32.Starter generator...

  • Page 107: Troubleshooting

    ELEC IGNITION SYSTEM EAS30492 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Battery cover 2. Fuel tank cover 3. Rear side cover assembly 4. Seat/storage compartment 1. Check the fuses. NG...
  • Page 108 ELEC IGNITION SYSTEM 8. Check the crankshaft position sen- NG sor. Refer to “CHECKING THE CRANK- Replace the sidestand switch. SHAFT POSITION SENSOR” on base manual page no. 7-103. OK 9. Check the entire ignition system NG wiring. Properly connect or replace the wire har- ness.

  • Page 109: Electric Starting System

    ELEC ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM (For disc)
  • Page 110 ELEC ELECTRIC STARTING SYSTEM 1. Battery 2. Battery positive lead 3. Battery negative lead 4. Fuse box 5. Main fuse 6. Backup fuse 7. Sub fuse 8. Signalling fuse 10.Main switch 11.Main relay 14.Front brake light switch 15.Joint connection 3 18.SGCU (Starter generator control unit) 22.Crankshaft position sensor 30.Starter generator...

  • Page 111: Circuit Diagram (For Drum)

    ELEC ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM (For drum)
  • Page 112 ELEC ELECTRIC STARTING SYSTEM 1. Battery 2. Battery positive lead 3. Battery negative lead 4. Fuse box 5. Main fuse 6. Backup fuse 7. Sub fuse 8. Signalling fuse 10. Main switch 11. Main relay 14. Joint connection 3 15. Rear brake light switch 16.

  • Page 113: Starting Circuit Cut-Off System Operation

    ELEC ELECTRIC STARTING SYSTEM EAS30494 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is turned to “ON” and the start switch “ ” is pushed, the starter generator can only operate if at least one of the following conditions is met: •...

  • Page 114: Troubleshooting

    ELEC ELECTRIC STARTING SYSTEM EAS30495 TROUBLESHOOTING The starter generator fails to turn. • Before troubleshooting, remove the following part(s): 1. Battery cover 2. Fuel tank cover 3. Seat/storage compartment 4. Rear side cover assembly 1. Check the fuses. NG Replace the fuse(s). Refer to “CHECKING THE FUSES”...
  • Page 115 ELEC ELECTRIC STARTING SYSTEM 8. Check the brake light switches. NG (Front and rear) Replace the brake light switch(es). Refer to “CHECKING THE SWITCHES” on base manual page no. 7-92. OK 9. Check the entire starting system NG wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM (For ness.
  • Page 116 ELEC ELECTRIC STARTING SYSTEM 5-14...

  • Page 117: Stop And Start System

    ELEC STOP AND START SYSTEM STOP AND START SYSTEM CIRCUIT DIAGRAM (For disc) 5-15...
  • Page 118 5. Main fuse 6. Backup fuse 7. Sub fuse 10.Main switch 11.Main relay 15.Joint connection 3 17.YDT (Yamaha diagnostic tool) coupler 18.SGCU (Starter generator control unit) 22.Crankshaft position sensor 23.Engine temperature sensor 25.MAQS (Modularized air quantity sensor) assembly 26.Intake air pressure sensor 27.Intake air temperature sensor...

  • Page 119: Circuit Diagram (For Drum)

    ELEC STOP AND START SYSTEM CIRCUIT DIAGRAM (For drum) 5-17...
  • Page 120 6. Backup fuse 7. Sub fuse 10.Main switch 11.Main relay 14.Joint connection 3 17.Joint connection 4 19.YDT (Yamaha diagnostic tool) coupler 20.SGCU (Starter generator control unit) 24.Crankshaft position sensor 25.Engine temperature sensor 27.MAQS (Modularized air quantity sensor) 28.Intake air pressure sensor 29.Intake air temperature sensor...

  • Page 121: Stop And Start System Operation

    • Throttle valve: opened 1. Battery 2. Main relay 3. Main fuse 4. Main switch 5. Multi-function meter 6. Yamaha diagnostic tool coupler 7. Start System indicator light 8. SGCU (starter generator control unit) 9. Starter generator 10.Crankshaft position sensor 11.Engine temperature sensor 12.Throttle position sensor...

  • Page 122: Troubleshooting

    ELEC STOP AND START SYSTEM EASB631006 TROUBLESHOOTING • The engine stop function does not operate. • The engine start function does not operate. • The Stop and Start System indicator light fails to come on. • Before troubleshooting, remove the following part(s): 1.
  • Page 123 ELEC STOP AND START SYSTEM Checking the Stop and Start System The engine stop function does not operate. 1. Check the engine temperature sen- NG sor. Replace the engine temperature sensor. Refer to “CHECKING THE ENGINE TEMPERATURE SENSOR” on base manual page no. 7-101. OK...
  • Page 124 ELEC STOP AND START SYSTEM NG The throttle position sensor is faulty. Re- 4. Check the throttle position sensor. place the throttle body assembly. OK 5. Check the entire Stop and Start NG System wiring. Properly connect or replace the wiring Refer to “CIRCUIT DIAGRAM (For harness.

  • Page 125: Charging System

    ELEC CHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM (For disc) 5-23...
  • Page 126 ELEC CHARGING SYSTEM 1. Battery 2. Battery positive lead 3. Battery negative lead 4. Fuse box 5. Main fuse 6. Backup fuse 7. Sub fuse 10.Main switch 11.Main relay 15.Joint connection 3 18.SGCU (Starter generator control unit) 22.Crankshaft position sensor 30.Starter generator 63.Engine ground 1 64.Engine ground 2...

  • Page 127: Circuit Diagram (For Drum)

    ELEC CHARGING SYSTEM CIRCUIT DIAGRAM (For drum) 5-25...
  • Page 128 ELEC CHARGING SYSTEM 1. Battery 2. Battery positive lead 3. Battery negative lead 4. Fuse box 5. Main fuse 6. Backup fuse 7. Sub fuse 10.Main switch 11.Main relay 14.Joint connection 3 20.SGCU (Starter generator control unit) 24.Crankshaft position sensor 32.Starter generator 67.Engine ground 2 68.Engine ground 1...

  • Page 129: Troubleshooting

    ELEC CHARGING SYSTEM EAS30497 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Battery cover 2. Seat/storage compartment 3. Fuel tank cover 4. Rear side cover assembly 1. Check the fuses. NG Replace the fuse(s). Refer to “CHECKING THE FUSES”...
  • Page 130 ELEC CHARGING SYSTEM 5-28...

  • Page 131: Lighting System

    ELEC LIGHTING SYSTEM EAS20075 LIGHTING SYSTEM CIRCUIT DIAGRAM (For disc) 5-29...
  • Page 132 ELEC LIGHTING SYSTEM 1. Battery 2. Battery positive lead 3. Battery negative lead 4. Fuse box 5. Main fuse 6. Backup fuse 7. Sub fuse 9. Terminal fuse 10.Main switch 18.SGCU (Starter generator control unit) 30.Starter generator 38.Auxiliary light 39.License plate light 40.Taillight assembly 42.Taillight 46.Dimmer/Pass switch...

  • Page 133: Circuit Diagram (For Drum)

    ELEC LIGHTING SYSTEM CIRCUIT DIAGRAM (For drum) 5-31...
  • Page 134 ELEC LIGHTING SYSTEM 1. Battery 2. Battery positive lead 3. Battery negative lead 4. Fuse box 5. Main fuse 6. Backup fuse 7. Sub fuse 9. Terminal fuse 10.Main switch 20.SGCU (Starter generator control unit) 32.Starter generator 39.Auxiliary light 40.License plate light 41.Taillight assembly 43.Taillight 46.Dimmer switch...

  • Page 135: Troubleshooting

    ELEC LIGHTING SYSTEM EAS30499 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, auxiliary lights, license light or meter light. • Before troubleshooting, remove the following part(s): 1. Battery cover 2. Front upper cover 3. Leg shield assembly bolt (left & right) 4.
  • Page 136 ELEC LIGHTING SYSTEM 7. Check the entire lighting system NG wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM (For ness. disc)” on page 5-29. OK Replace the SGCU, meter assembly, tail/brake light assembly or headlight unit. Refer to “REPLACING THE SGCU (Starter generator control unit)”...

  • Page 137: Signaling System

    ELEC SIGNALING SYSTEM SIGNALING SYSTEM CIRCUIT DIAGRAM (For disc) 5-35...
  • Page 138 ELEC SIGNALING SYSTEM 1. Battery 2. Battery positive lead 3. Battery negative lead 4. Fuse box 5. Main fuse 6. Backup fuse 7. Sub fuse 8. Signalling fuse 10.Main switch 12.Turn signal relay 13.Horn 14.Front brake light switch 18.SGCU (Starter generator control unit) 30.Starter generator 34.Fuel sender 40.Taillight assembly...

  • Page 139: Circuit Diagram (For Drum)

    ELEC SIGNALING SYSTEM CIRCUIT DIAGRAM (For drum) 5-37...
  • Page 140 ELEC SIGNALING SYSTEM 1. Battery 2. Battery positive lead 3. Battery negative lead 4. Fuse box 5. Main fuse 6. Backup fuse 7. Sub fuse 8. Signalling fuse 10.Main switch 12.Horn 13.Turn signal relay 15.Rear brake light switch 16.Front brake light switch 20.SGCU (Starter generator control unit) 32.Starter generator 35.Fuel sender...

  • Page 141: Troubleshooting

    ELEC SIGNALING SYSTEM EAS30501 TROUBLESHOOTING Any of the following fail to light: turn signal lights, brake light, warning lights or indicator lights. • The horn fails to sound. • The fuel meter fails to come on. • The speedometer fails to operate. •...
  • Page 142 ELEC SIGNALING SYSTEM Checking the signaling system The horn fails to sound. 1. Check the horn switch. NG The horn switch is faulty. Replace the left Refer to “CHECKING THE handlebar switch. SWITCHES” on base manual page no. 7-92. OK 2.
  • Page 143 ELEC SIGNALING SYSTEM 3. Check the turn signal relay. NG Refer to “CHECKING THE TURN Replace the turn signal relay. SIGNAL RELAY” on base manual page no. 7-99. OK 4. Check the entire signaling system NG wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM (For ness.
  • Page 144 ELEC SIGNALING SYSTEM 5-42...

  • Page 145: Fuel Injection System

    ELEC FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM CIRCUIT DIAGRAM (For disc) 5-43...
  • Page 146 4. Fuse box 5. Main fuse 6. Backup fuse 7. Sub fuse 8. Signalling fuse 10.Main switch 16.Injector 17.YDT (Yamaha diagnostic tool) coupler 18.SGCU (Starter generator control unit) 19.Joint connection 2 20.Ignition coil 21.Spark plug 22.Crankshaft position sensor 23.Engine temperature sensor 24.ISC (Idle speed control) unit...

  • Page 147: Circuit Diagram (For Drum)

    ELEC FUEL INJECTION SYSTEM CIRCUIT DIAGRAM (For drum) 5-45...
  • Page 148 5. Main fuse 6. Backup fuse 7. Sub fuse 8. Signalling fuse 10.Main switch 17.Joint connection 4 18.Injector 19.YDT (Yamaha diagnostic tool) coupler 20.SGCU (Starter generator control unit) 21.Joint connection 2 22.Ignition coil 23.Spark plug 24.Crankshaft position sensor 25.Engine temperature sensor 26.ISC (Idle speed control) unit...

  • Page 149: Ecu Self-Diagnostic Function

    ELEC FUEL INJECTION SYSTEM EAS30505 ECU SELF-DIAGNOSTIC FUNCTION The SGCU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
  • Page 150 ELEC FUEL INJECTION SYSTEM 5-48...

  • Page 151: Fuel Pump System

    ELEC FUEL PUMP SYSTEM FUEL PUMP SYSTEM CIRCUIT DIAGRAM (For disc) 5-49...
  • Page 152 ELEC FUEL PUMP SYSTEM 1. Battery 2. Battery positive lead 3. Battery negative lead 4. Fuse box 5. Main fuse 6. Backup fuse 7. Sub fuse 10.Main switch 18.SGCU (Starter generator control unit) 33.Fuel pump 63.Engine ground 1 64.Engine ground 2 5-50...

  • Page 153: Circuit Diagram (For Drum)

    ELEC FUEL PUMP SYSTEM CIRCUIT DIAGRAM (For drum) 5-51...
  • Page 154 ELEC FUEL PUMP SYSTEM 1. Battery 2. Battery positive lead 3. Battery negative lead 4. Fuse box 5. Main fuse 6. Backup fuse 7. Sub fuse 10.Main switch 20.SGCU (Starter generator control unit) 34.Fuel pump 67.Engine ground 2 68.Engine ground 1 5-52...

  • Page 155: Troubleshooting

    ELEC FUEL PUMP SYSTEM EAS30514 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Battery cover 2. Front side covers 3. Footrest board assemblies 4. Fuel tank 1. Check the fuses. NG (Main, ignition and fuel injection system) Replace the fuse(s).

  • Page 156: Electrical Components

    ELEC ELECTRICAL COMPONENTS EAS20089 ELECTRICAL COMPONENTS 10,11,12,13,14 16, 17 5-54...
  • Page 157 ELEC ELECTRICAL COMPONENTS 1. Turn signal relay 2. Rear brake light switch 3. Front brake light switch 4. Meter assembly 5. Main switch 6. Main relay 7. Ignition coil 8. SGCU (starter generator control unit) 9. Fuel pump 10.Intake air pressure sensor 11.Intake air temperature sensor 12.Throttle position sensor 13.ISC (idle speed control) unit...
  • Page 158 66. Body ground 14. Front brake light switch Black/White 15. Joint connection 3 Black/Yellow 16. Injector Br/B Brown/Black Br/L Brown/Blue 17. YDT (Yamaha diagnostic tool) Br/W Brown/White coupler Green/Blue 18. SGCU (Starter generator con- Green/Red trol unit) Green/Yellow 19. Joint connection 2...
  • Page 159 17. Joint connection 4 Br/L Brown/Blue 69. Engine ground 3 Br/W Brown/White 18. Injector 70. Body ground Green/Blue 19. YDT (Yamaha diagnostic tool) Green/Red coupler Green/Yellow 20. SGCU (Starter generator con- Gy/R Gray/Red trol unit) Blue/Black 21. Joint connection 2 Blue/Red 22.
  • Page 161 B2U-F8197-E1 1Y242(SSM-01)1573-09-21-E...
  • Page 162 LCG125D 2022 (B2U8) / LCG125 2022 (B2U9, B2UH) WIRING DIAGRAM...
  • Page 163 LCG125 2022 (B2UA) WIRING DIAGRAM...

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