Yamaha Mt 01 T 2005 Manual
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ISC (IDLE SPEED CONTROL) UNIT 6-13 ET5YU1015CHECKING THE ISC (IDLE SPEED CONTROL) SYSTEM 1. Check: Hoses Loose connections → Connect properly. Cracks/damage → Replace. 2. Check: Surge tank Cracks/damage → Replace. 3. Check: One-way valve Cracks/damage/faulty → Replace. NOTE: Check that air flows smoothly only in the direc- tion of the arrow shown in the illustration. 4. Check: Intake solenoid Damage → Replace.
7 ELECTRICAL SYSTEM IGNITION SYSTEM......................................................................................... 7-1 CIRCUIT DIAGRAM .................................................................................. 7-1 TROUBLESHOOTING .............................................................................. 7-3 ELECTRIC STARTING SYSTEM.................................................................... 7-5 CIRCUIT DIAGRAM .................................................................................. 7-5 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION .......................... 7-7 TROUBLESHOOTING .............................................................................. 7-9 CHARGING SYSTEM.................................................................................... 7-11 CIRCUIT DIAGRAM ................................................................................ 7-11 TROUBLESHOOTING ............................................................................ 7-13 LIGHTING SYSTEM...................................................................................... 7-15 CIRCUIT DIAGRAM ................................................................................ 7-15 TROUBLESHOOTING ............................................................................ 7-17 SIGNALING SYSTEM................................................................................... 7-19 CIRCUIT DIAGRAM ................................................................................ 7-19 TROUBLESHOOTING ............................................................................ 7-21 FUEL INJECTION SYSTEM.......................................................................... 7-25 CIRCUIT DIAGRAM ................................................................................ 7-25 ECU SELF-DIAGNOSTIC FUNCTION .................................................... 7-27 SELF-DIAGNOSTIC FUNCTION TABLE ................................................ 7-28 TROUBLESHOOTING METHOD ............................................................ 7-31 DIAGNOSTIC MODE .............................................................................. 7-31 TROUBLESHOOTING DETAILS ............................................................ 7-39 FUEL PUMP SYSTEM................................................................................... 7-67 CIRCUIT DIAGRAM ................................................................................ 7-67 TROUBLESHOOTING ............................................................................ 7-69 MUFFLER COOLING SYSTEM.................................................................... 7-71 CIRCUIT DIAGRAM ................................................................................ 7-71 TROUBLESHOOTING ............................................................................ 7-73 IMMOBILIZER SYSTEM................................................................................ 7-75 CIRCUIT DIAGRAM ................................................................................ 7-75 GENERAL INFORMATION ..................................................................... 7-77 PART REPLACEMENT AND KEY CODE REGISTRATION REQUIREMENTS ................................................................................... 7-77 TROUBLESHOOTING ............................................................................ 7-81 SELF-DIAGNOSIS FAULT CODE INDICATION ..................................... 7-81
ELECTRICAL COMPONENTS...................................................................... 7-85 CHECKING THE SWITCHES ................................................................. 7-89 CHECKING THE BULBS AND BULB SOCKETS ................................... 7-92 CHECKING THE FUSES ........................................................................ 7-93 CHECKING AND CHARGING THE BATTERY ....................................... 7-94 CHECKING THE RELAYS ...................................................................... 7-96 CHECKING THE TURN SIGNAL/HAZARD RELAY................................ 7-97 CHECKING THE RELAY UNIT (DIODE) ................................................ 7-98 CHECKING THE SPARK PLUG CAPS................................................... 7-99 CHECKING THE IGNITION COILS......................................................... 7-99 CHECKING THE IGNITION SPARK GAP............................................. 7-100 CHECKING THE CRANKSHAFT POSITION SENSOR........................ 7-100 CHECKING THE LEAN ANGLE CUT-OFF SWITCH ............................ 7-100 CHECKING THE STATOR COIL .......................................................... 7-101 CHECKING THE RECTIFIER/REGULATOR ........................................ 7-101 CHECKING THE HORN ........................................................................ 7-102 CHECKING THE ENGINE TEMPERATURE SENSOR ........................ 7-102 CHECKING THE FUEL SENDER ......................................................... 7-103 CHECKING THE SPEED SENSOR ...................................................... 7-103 CHECKING THE THROTTLE POSITION SENSOR ............................. 7-104 CHECKING THE FUEL PUMP .............................................................. 7-104 CHECKING THE EXUP SERVO MOTOR............................................. 7-105 CHECKING THE DECOMPRESSION SOLENOID ............................... 7-105 CHECKING THE INTAKE AIR PRESSURE SENSORS ....................... 7-106 CHECKING THE AIR TEMPERATURE SENSOR ................................ 7-107 CHECKING THE INTAKE SOLENOID .................................................. 7-107 CHECKING THE MUFFLER COOLING FAN MOTOR ......................... 7-107 CHECKING THE MUFFLER COOLING FAN TEMPERATURE SENSOR .............................................................................................. 7-108
IGNITION SYSTEM 7-1 EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM Br/W B L/B R/Y B/YPGY BDg Ch Br/W L/YG/L R/Y B/Y B G Y B Dg Ch Sb/W R/LL/W1 L/Y L/GSbL /R B /RB/YL R B1 B2 B1B2 BB2 LgR/WY/LR/GR/G B2 LgY/L R/W B B BL G G Sb/W R/GLg Dg R/WCh Y/L Y/L YLR/W R/G Lg B B ON OFF B B B R R B B Y L BG L/G L/G B(BLUE) L/G B (BLUE) (DARK GREEN)B B B3 B3 WL B LW/YB/LB/L Br/Y B B L B/L G/Y Br/B B/RY/B Gy Lg O OGy/R Gy/B Gy/WB/GB3 B3GG/R Y/GBr/LB/Y Y/L Gy1 L/RL/Y R/L R/W Y W/Y W/B W/R W/G R/B R/BR/G BrGy/GBr/Y P/WP/L P/Y Br/W B/Br B/BrB/L L/W L B GBR/L B Y B G B/LGy1 Gy B LB/L B/LBr/Y Br/W P/W P/W (BLACK) (BLACK)(BLACK)(BLACK) (BLACK)BrB LgBr/BBr/B R/B R/BR/G P/L W/G Br/L B/Br B/Br P/Y P/W P/L W/G W/R Br/L R/G P/L W/G Br/L R/G R/B B/L B/L P/Y L Y/GB/L Y/G L Gy/RB/R GG/RB/LG G/R B/L Gy/R W/R Gy/G Sb/W WG (GRAY) WGy(DARK GRAY) (BLACK) (BLACK) (BLACK) LgLGy/RLg BB GG G WB Y Y DB B B L L D Br Br Br B D (BLACK) (BLACK) (BLACK) (BLACK) B B/Y L/Y (BROWN) (BROWN)Y Br W/B L/W1 B/RR/WYBr(BLUE) (BLACK) (BLACK)R R (GRAY)(GRAY) R/WL/W R/B B B/YB(BLUE) L/W1 Y L B LY BL Y B Br L L B Br/L Br/L Br/L R/B G/YR/WBr/RBr/G RGy/R R R B R RR/B Br/W B BRR B BR /WR/WR LL B OOB/R OOB/RA WIRE HARNESS WIRE HARNESS WIRE HARNESS WIRE HARNESS SUB-WIRE-HARNESS1 SUB-WIRE-HARNESS2 SUB-WIRE-HARNESS2 SUB-WIRE-HARNESS3WG B Gy B Gy WG(BLACK) (BLACK)B ChB BDg ChBBDgCLL YY Br Br D Y Br B B B LL B G/YBr/WR/BL BB3 BB2 BB1 BB4BB BB Y YG GL/R L/RB B (GRAY) (GRAY)(BLACK) (BLACK) Dg B B L Ch BBCh B B Ch B Dg Dg (BLACK) (BLACK)BB Dg Dg G G Y/B R/Y G/L R/Y B1 BB4 BB3 BB2 BB1 Br/WB/L B/L L P/Y(BLACK)B/LLY(BLACK)LB SbBSbSbR L (BLACK) (BLACK)BR BB B RRBr/L Br/LBr/R Br/R R R/B R/B R/L L/R W/B G/Y Y/G R/WR/W Y Br/Y Br/W L Br B/L L/Y L/W Gy/R B/R Gy/W B/RB/R W/R B/GB/R B/LL Lg Dg ChLB GY/L R/G R/LB/L R/W Gy/G Gy/W SbDgCh Y BB WL R/LGy/W Gy/GB/L (GRAY) (GRAY)BChB Ch Br/G Br/W Br/W B/G B/RB/G B/R G/RY/L GO O O O Gy Y/B Y/B G/L G/L R/YR/Y R/Y B B (BLACK) B Ch DgB Br/WBr/G Y B L/R L B Br/WR/Y Br Gy Gy GyBW WB C C Gy1 W R/L B B B B/Y W/B B2 B/LGy1 R/B Gy/R B/Y Y B R /G R /GY /L R/W Lg B2 G/R Dg ChDg Ch Dg ChC CB/L O O A A O O A Br/BR/W Y BB B B B B Y Br L B/LW/Y B/R B/R Gy/B BBB R R B BYL BG L/GL/GB B3B3 LB/LL B/LB/L Br/YBr/W P/W LgBr/B Br/B B/BrB/Br P/YP/W P/LW/GW/RBr/LR/G P/LW/GBr/LR/G R/B B/L B/L P/Y Y/GL Gy/BB/R G/RB/LGy/RW/R Gy/G Sb/W LgL YYD BBBLLD BrBr Br B D B B/Y R R L/W1 B/RR/W LYB Br LLBBr/LBr/LBr/LR/BG/Y R/W Br/R Br/G R Gy/R R RRR R/BBr/W BBRR RBBR/WL B YBr DgB ChB GG B1BB4BB3BB2BB1 Sb R/LL/RL/YB/R L/W1 Sb/WSb R L R R/BR/BR/LL/RW/BG/YY/GR/W R/W W/YYBr/YBr/WLBrB/LL/YL/W Gy/RB/R Gy/W B/RB/R LgDgChL B G Y/L R/G R/L B/L R/W Gy/G Gy/W Br/GBr/WBr/W B/GB/R B/GB/R G/RY/LGOO OO GyY/B Y/BG/LG/L R/Y R/YR/Y B ChDg B B L/R LB Br/W R/Y Br GyGyGyBWWB C C Gy1 W R/LB BB B/Y W/B Br/RBr/L B2 B/LGy1 R/B Gy/R B/Y Y B R/G R/G Y/LR/WLgB2 Dg Ch Dg Ch Dg Ch B/L OOAOOA W GG GB Y Y L/Y
IGNITION SYSTEM 7-2 3. Main switch 4. Battery 8. Main fuse 10.ECU fuse 13.Relay unit 14.Starting circuit cut-off relay 16.Neutral switch 19.Sidestand switch 20.Crankshaft position sensor 24.Lean angle cut-off switch 29.ECU (electronic control unit) 32.Spark plug 33.Cylinder-#2 right ignition coil 34.Cylinder-#2 left ignition coil 35.Cylinder-#1 left ignition coil 36.Cylinder-#1 right ignition coil 56.Clutch switch 73.Engine stop switch 81.Ignition fuse
IGNITION SYSTEM 7-3 EAS27150TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). NOTE: Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank 3. Air filter case 4. Battery box 5. Engine NG → OK ↓ NG → OK ↓ NG → OK ↓ OK → NG ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ 1. Check the fuses. (Main, ignition, and ECU) Refer to “CHECKING THE FUSES” on page 7-93.Replace the fuse(s). 2. Check the battery. Refer to “CHECKING AND CHARGING THE BATTERY” on page 7-94.Clean the battery terminals. Recharge or replace the battery. 3. Check the spark plugs. Refer to “CHECKING THE SPARK PLUGS” on page 3-8.Re-gap or replace the spark plug(s). 4. Check the ignition spark gap. Refer to “CHECKING THE IGNITION SPARK GAP” on page 7-100.Ignition system is OK. 5. Check the spark plug caps. Refer to “CHECKING THE SPARK PLUG CAPS” on page 7-99.Replace the spark plug cap(s). 6. Check the ignition coils. Refer to “CHECKING THE IGNITION COILS” on page 7-99.Replace the ignition coil(s). 7. Check the crankshaft position sensor. Refer to “CHECKING THE CRANKSHAFT POSITION SENSOR” on page 7-100.Replace the crankshaft position sensor.
IGNITION SYSTEM 7-4 NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ NG → OK ↓ 8. Check the main switch. Refer to “CHECKING THE SWITCHES” on page 7-89.Replace the main switch/immobilizer unit. 9. Check the engine stop switch. Refer to “CHECKING THE SWITCHES” on page 7-89.Replace the right handlebar switch. 10.Check the neutral switch. Refer to “CHECKING THE SWITCHES” on page 7-89.Replace the neutral switch. 11.Check the sidestand switch. Refer to “CHECKING THE SWITCHES” on page 7-89.Replace the sidestand switch. 12.Check the clutch switch. Refer to “CHECKING THE SWITCHES” on page 7-89.Replace the clutch switch. 13.Check the relay unit (starting circuit cut-off relay). Refer to “CHECKING THE RELAYS” on page 7-96.Replace the relay unit. 14.Check the relay unit (diode). Refer to “CHECKING THE RELAY UNIT (DIODE)” on page 7-98.Replace the relay unit. 15.Check the lean angle cut-off switch. Refer to “CHECKING THE LEAN ANGLE CUT-OFF SWITCH” on page 7-100.Replace the lean angle cut-off switch. 16.Check the entire ignition system wiring. Refer to “CIRCUIT DIAGRAM” on page 7-1.Properly connect or repair the ignition system wiring. Replace the ECU.
ELECTRIC STARTING SYSTEM 7-5 EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM Br/W B L/B R/Y B/YPGY BDg Ch Br/W L/YG/L R/Y B/Y B G Y B Dg Ch Sb/WR/L L/W1 L/Y L/GSbL /R B /RB/YL R B1 B2 B1B2 R/GB2 LgY/L R/W B B BL G G Sb/W R/GLg Dg R/WCh Y/L Y/L YLR/W R/G Lg B B ON OFF BBB R R B BYL BG L/GL/GB(BLUE) L/G B (BLUE) (DARK GREEN)B B B3B3 WL B LW/YB/L B B LB/L B GBR/L B Y B G B/LGy1 Gy B LB/LW/Y L B/LB/L Br/YBr/W P/W P/W (BLACK) (BLACK)(BLACK)(BLACK) (BLACK)BrB LgBr/B Br/B R/B R/BR/G P/L W/G Br/L B/BrB/Br P/YP/W P/LW/GW/RBr/LR/G P/LW/GBr/LR/G R/B B/L B/L P/Y L Y/GB/L Y/GL Gy/BB/R GG/RB/LG G/RB/LGy/RW/R Gy/G Sb/W WG (GRAY)WGy(DARK GRAY) (BLACK) (BLACK) (BLACK) LgL Gy/RLg BB G G G W B YYD BBBLLD BrBr Br B D (BLACK) (BLACK) (BLACK) (BLACK) B B/YL/Y (BROWN) (BROWN)Y Br W/B L/W1 B/RR/WYBr(BLUE) (BLACK) (BLACK)R R (GRAY)(GRAY) R/WL/W R/B B B/YB(BLUE) Y L/W1 B/RR/W Br Y L B LY BLYB Br LLBBr/LBr/LBr/LR/BG/Y R/W Br/R Br/G R Gy/R R R BRR R/BBr/W BBRR RBBR/WR/WR LL B OOB/R OOB/RA WIRE HARNESS WIRE HARNESS WIRE HARNESS WIRE HARNESS SUB-WIRE-HARNESS1 SUB-WIRE-HARNESS2 SUB-WIRE-HARNESS2 SUB-WIRE-HARNESS3WG B Gy B Gy WG(BLACK) (BLACK)B ChB BDg ChBBDgCLL YY Br Br D YBr B B B LL B G/YBr/WR/BL BB3 BB2 BB1 BB4BB BB Y YG GL/R L/RB B (GRAY) (GRAY)(BLACK) (BLACK) DgB B L ChBBCh B B Ch B Dg Dg (BLACK) (BLACK)BBB Dg Dg GG Y/B R/Y G/L R/Y B1BB4BB3BB2BB1 Br/WB/L B/LL P/Y(BLACK)Y(BLACK)LB SbBSb R/LL/RL/YB/R L/W1 Sb/WSb R L (BLACK) (BLACK)BR BB B RRBr/L Br/LBr/R Br/R R R/BR/BR/LL/RW/BG/YY/GR/W R/W W/YYBr/YBr/WLBrB/LL/YL/W Gy/RB/R Gy/W B/RB/R W/R B/GB/R B/LL LgDgChL B G Y/L R/G R/L B/L R/W Gy/G Gy/W SbDgCh Y BB WL R/LGy/W Gy/GB/L (GRAY) (GRAY)BBChB Ch Br/GBr/WBr/W B/GB/R B/GB/R G/RY/LGOO OO GyY/B Y/BG/LG/L R/Y R/YR/Y B B (BLACK) B ChDg B Br/WBr/G Y B L/R LB Br/W R/Y Br GyGyGyBWWB C C Gy1 W R/LB BB B/Y W/B Br/RBr/L B2 B/LGy1 R/B Gy/BGy/R B/Y Y B R/G R/G Y/LR/WLgB2 G/R Dg Ch Dg Ch Dg Ch C C B B B B B/L O B/RB/R OA A OOA Br/BR/W Y BB2 LgR/WY/LR/G B/L Br/Y G/Y Br/B B/RY/B Gy Lg O OGy/R Gy/B Gy/WB/GB3 B3GG/R Y/GBr/LB/Y Y/L Gy1 L/RL/Y R/L R/W Y W/Y W/B W/R W/G R/B R/BR/G BrGy/GBr/Y P/WP/L P/Y Br/W B/Br B/BrB/L L/W L B/LL