yamaha roadliner wiring diagrams

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SUZUKI SV 1000 RADIATOR (COOLING SYSTEM) SERVICE MANUAL

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Filed Under (Suzuki) by admin on 26-02-2011

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FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION MALFUNCTION CODE DETECTED ITEM DETECTED FAILURE CONDITION CHECK FOR COO NO FAULT C11 Camshaft position sen- sor The signal does not reach ECM for more than 3 sec . after receiving the starter signal . The camshaft position sensor wiring and mechanical parts (Camshaft position sensor, intake cam pin, wiring/coupler con- nection) C12 Crankshaft position sensor The signal does not reach ECM for more than 2 sec . after receiving the starter signal . The crankshaft position sensor wiring and mechanical parts (Crankshaft position sensor, wiring/coupler connection) C13 Intake air pressure sensor The sensor should produce following voltage . (0.50 V < sensor voltage < 4 .85 V) Without the above range, C13 is indicated. Intake air pressure sensor, wiring/coupler connection C14 Throttle position sen- sor The sensor should produce following voltage . (0.20 V < sensor voltage < 4 .80 V) Without the above range, C14 is indicated. Throttle position sensor, wiring/coupler connection C15 Engine coolant temperature sensor The sensor voltage should be the following. (0.15 V <_ sensor voltage < 4 .5 V) Without the above range, C15 is indicated. Engine coolant temperature sensor, wiring/coupler connection C21 Intake air temperature sensor The sensor voltage should be the following. (0.15 V < sensor voltage < 4 .5 V) Without the above range, C21 is indicated. Intake air temperature sensor, wiring/coupler connection C22 Atmospheric pressure sensor The sensor voltage should be the following. (0.50 V < sensor voltage < 4 .5 V) Without the above range, C22 is indicated. Atm. pressure sensor, wiring/coupler connection C23 Tip over sensor The sensor voltage should be the following for more than 2 sec . after ignition switch turns ON . (0 .20 V < sensor voltage < 4 .80 V) Without the above value, C23 is indicated. Tip over sensor, wiring/coupler connection C24 or C25 Ignition signalCrankshaft position sensor signal is produced and ECM determines the ignition signal but signal from ignition coil is interrupted continuous by 4 times or more. In this case, the code C24 or C25 is indicated. Ignition coil, wiring/coupler connection, power supply from the battery SERVICING INFORMATION 8 .3 C28 Secondary throttle valve actuator No operating voltage is supplied from the ECM, C28 is indicated. STVA can not operate. STVA lead wire/coupler, STVA C29 Secondary throttle valve position sensor The sensor should produce following voltage . (0.10 V < sensor voltage < 4 .90 V) Without the above range, C29 is indicated . Secondary throttle position sensor, wiring/coupler connection C31 Gear position signalGear position signal voltage should be higher than the following for more than 2 seconds. (Gear position switch voltage >_ 0 .6 V) Without the above value, C31 is indicated. Gear position sensor, wiring/coupler connection, gearshift cam, etc. C32 or C33 Fuel injector Crankshaft position sensor signal is produced and ECM determines the injection signal but fuel injection signal is interrupted continuous by 4 times or more. In this case, the code C32 or C33 is indicated. Injector, wiring/coupler connection, power supply to the injector C41 Fuel pump relay No voltage is applied to fuel pump although fuel pump relay is turned ON, or voltage is applied to fuel pump although fuel pump relay is turned OFF . Fuel pump relay, connecting lead, power source to fuel pump relay C42 Ignition switchIgnition switch signal is not input in the ECM . Ignition switch, lead wire/coupler C44 Heated oxygen sensor (HO2S) [For E-02, 19] During 02 feedback control, 02 sensor voltage is higher or lower than the specification . No signal is detected during engine operation or no electrical power is supplied from the battery . HO2S lead wire/coupler connection Battery voltage supply to the HO2S C49 PAIR control solenoid valve (PAIR valve) When no operating voltage is supplied from the ECM, C49 is indicated. PAIR valve can not operate. PAIR valve lead wire/coupler

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YAMAHA ROADLINER / STRATOLINER Fuel Injected INSTALLATION INSTRUCTIONS

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Filed Under (Yamaha) by admin on 28-10-2010

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1. Be sure the main switch is in the off position during the installation process. Failure to do this will cause the “check engine” light to be set. 2. Remove seat exposing the Electronic Control Unit (ECU) and battery. 3. Remove the right side coil cover by removing two allen screws and gently pulling. 4. Disconnect the 6 pin factory connector behind the ignition coils. (Fig 1) 5. Connect Fuelpak 6 pin connectors in-line with factory connectors. 6. Disconnect 3 pin factory connectors behind the ignition coils and connect Fuelpak 3 pin connectors in-line with factory connectors. 7. Route Fuelpak harness up to battery area and reinstall coil side cover. 8. Connect Fuelpak black wire to negative ground wire. (Fig 2) 9. Locate factory 2 pin connector with brown and black wires. Disconnect empty connector and attach Fuelpak red wire connector. 10. Connect Fuelpak 10 pin connector to Fuelpak harness. 11. You are now ready to set-up your Fuelpak. INSTALLATION INSTRUCTIONS FOR P/N 65001 READ ALL INSTRUCTIONS BEFORE BEGINNING INSTALLATION FUEL INJECTION MANAGEMENT SYSTEM ROADLINER / STRATOLINER NOTICE: Fuelpak is intended for racing or off-highway use only, and is not legal for sale or use in California on pollution-controlled vehicles. PLEASE NOTE: FUELPAK USE REQUIRES A HIGH PERFORMANCE AIR FILTER. HOW IT WORKS ENTERING VALUES 1. Remove Fuelpak clear case cover by removing all four screws, save hardware . 2. Turn on main power with key, but do not start engine. Fuelpak display should light up, if not, turn power off and verify the connectors are fully seated. 3. Refer to Fuelpak Setting Reference to locate the Setting Values specific to your bike and exhaust system. If you do not find your setting, visit fuelpakfi.com or call tech support at (562) 921-0071. 4. Starting with mode 1 selected, press the value (+) or the value (-) buttons to input the correct value as indicated in your Setting Value. After entering your first value, press the mode select button to move to mode 2 and enter the value. Continue until you have entered the value for each of the first 18 mode positions. Each time the value (+) is pressed, the value increases by one number. Each time the value (-) is pressed, the value decreases by one number. (Please refer to the “How It Works” section directly above if you have questions about this step. 5. As the next procedure, after you have entered in your values for the first 18 modes, press the mode select button to move to mode 19. Fully twist open the throttle and return to idle position to calibrate the Fuelpak to your bike. 6. By pressing the mode select button twice, move to mode 21 and verify that it reads “0″ with the throttle closed, “50″ at approximately half-throttle and “99″ when fully opened; if not, repeat step 5. Do not proceed to step 7 until mode 21 is verified.

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YAMAHA MOTOR CORPORATION, U.S.A. STREET & ENDURO MOTORCYCLE LIMITED WARRANTY

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Filed Under (Yamaha) by admin on 27-12-2011

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GENERALEXCLUSIONS from this warranty shall include any failures caused by: a. Competition or racing use. b. Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts. c. Abnormal strain, neglect, or abuse. d. Lack of proper maintenance. e. Accident or collision damage. f. Modification to original parts. g. Damage due to improper transportation. SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance. THE CUSTOMER’S RESPONSIBILITY under this warranty shall be to: 1. Operate and maintain the motorcycle as specified in the appropriate Owner’s Manual. 2. Give notice to an authorized Yamaha motorcycle dealer of any and all apparent defects within ten (10) days after discovery, and make the machine available at that time for inspection and repairs at such dealer’s place of business. You may locate your nearest authorized Yamaha dealer through your local telephone directory. WARRANTY TRANSFER: To transfer any remaining warranty from the original purchaser to any subsequent purchaser, it is imperative that the machine be inspected and registered for warranty by an authorized Yamaha motorcycle dealer. In order for this warranty to remain in effect, this inspection and registration must take place within ten (10) days after transfer. Areasonable dealer imposed fee may be charged for the inspection. In no case will warranty be extended beyond the original period. EMISSIONS CONTROLSYSTEM WARRANTY Yamaha Motor Corporation, U.S.A. also warrants to the ultimate purchaser and each subsequent purchaser of each Yamaha motorcycle covered by this warranty with a displacement of 50cc or greater, that the vehicle is designed, built, and equipped so as to conform at the time of sale with all U.S. emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards within the periods listed immediately below. Failures other than those resulting from defects in material or workmanship which arise solely as a result of owner abuse and/or lack of proper maintenance are not covered by this warranty.

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YAMAHA ROADLINER AND STRATOLINER LAY DOWN LICENSEPLATE/ TAIL LIGHT INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 29-01-2011

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1. Remove the license plate. Remove the license plate holder assembly from the rear fender (three 8mm Allen bolts 5mm wrench). Remove the five 4mm Allen screws underneath the rear fender which secure the taillight/turn signal assembly to the rear fender (3mm wrench). As shown in photo #2, pull the taillight assembly out away from the fender, turn it over, place a towel or rag between the light and fender and allow it to rest on the fender. 2. Locate the supplied triangular license plate mounting block, two 8 x 20mm Allen screws with holes driiled thru and three rubber washers. Place the two Allen screws thru the upper holes in the block and the rubber washers over the screws on the backside of the block. Start the screws into the upper holes on the fender. Use one of the three screws removed earlier from the original mount in the remaining lower hole of the new block sliding the remaining rubber washer between the block and fender. Tighten all three Allen screws secure enough to compress the rubber washers (4-6 ft lbs.). 3. Locate the supplied license plate mounting plate and LED lights. Cut off the excess red and black wires at the end of the black loom or tube. Referring to photo (1) thread the wires of the LED lights thru the small holes in the mounting plate, peel the cover from the adhesive backing on the lights and press them firmly into place as shown. 4. Locate the three supplied ¼” x ½” flat head Allen screws. Hold the plate up to the mounting block installed earlier with the wires at the bottom of the plate. Thread the wires from the LED lights thru the holes in the upper bolts of the block. Install the plate onto the block using the three flat head screws being sure to keep the exposed wire behind he plate as short as possible and fitting into the slot or cut out at the edge of the block. Snug the screws and again check to see tat the wires are in the slot or cut out in the block and do not become pinched as the screws are tightened. Tighten the screws securely. 5. Where the wires from the taillight go thru the fender there is a grommet, pull this grommet out from the fender. Thread the wires from the LED lights thru the grommet with the other wires. Replace the grommet into the fender and remove any slack from the wires under the fender. Cut the LED wires off at 6″ past the grommet. 6. Referring to photo (2) remove 2″ of the black tubing exposing the red and black wires on the LEDs. Locate the supplied brake/tail light dual function element (a red wire at one end with a red and orange wire at the other) and wire connectors. Cut all three wires on the dual element to 3″ long. Strip the end of the single red wire on the element and both of the red wires from the LEDs then connect them using one of the blue butt connectors. Connect the two black wires from the LEDs to any one of the black wires on the tail light or signals using one of the supplied splice connectors (place both black wires into one of the holes on the connector). Using the remaining splice connectors attach the red wire from the dual element to the yellow wire on the tail light and the orange wire to the blue wire on the tail light. Turn on the ignition and check that the LEDs are working both as tail and brake lights when the brakes are applied.

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YAMAHA ROADLINER 1854cc exhaust system Installation Manual

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Filed Under (Yamaha) by admin on 10-11-2010

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1. Loosen and move the right side floorboard out of the way to ease installation of the exhaust. 2. Perform the following to remove the stock exhaust system. NOTE : You must disconnect and remove the power valve cables as well as unplug the oxygen sensor connector first, then remove the exhaust system and mounting bracket, see Figure 1 for power valve. Loosening the jam nuts on each cable, and disengaging the cable barrels from the power valve pulley disconnect the power valve cables. The power valve, and cables are not needed with the new Cobra exhaust system, leave the solenoid box under the seat in place without the cables. To disconnect the O 2 sensor remove the right rear footpeg and remove the steel plate with hook securing O 2 sensor harness behind it, retain plate for later reinstallation. Remove the socket head screw securing the O 2 sensor harness and bracket to engine case on the right side of the motorcycle, see Figure 2 , unplug the stock male and female connectors, and remove entire exhaust system. Disengage the female O 2 connector from the small bracket, (which was unbolted from engine case), to gain extra harness length, upon reassembly of new Cobra exhaust, the small bracket, (from engine case), will not be reused, unless a closed loop Fi2000 ® (92-1773CL /92-1773CL-50), is to be used, then please refer to those specific instructions. Next remove the oxygen sensor from the stock exhaust and retain for later reinstallation. 3. Install new exhaust-mounting bracket using the stock M10 bolts; tighten to factory specifications, Figure 3. 4. Install the front and rear headpipes on to the motorcycle using the supplied flanges, stock bolts and nuts. NOTE: On the rear headpipe be sure to install the stock flange cover as shown in Figure 4. Make sure the pipes are parallel to each other. DO NOT TIGHTEN. 5. Remove the muffler assembly from the box and slide two supplied 27-61MSC clamps onto the muffler inlets, refer to Figure 5 for alignment. Do not install oxygen sensor at this time, as it will not clear the frame rail during installation of the muffler assembly. 6. Slide the muffler assembly on to the headpipes by tapping on the headpipes by hand as you push the muffler forward making sure the assembly slides as far forward as possible. Secure the muffler assembly to the mounting bracket using the supplied 5/16-18 bolts but DO NOT TIGHTEN. Install the oxygen sensor at this time, by inserting it between the right frame rail, and engine case, tighten securely once installed. 7. Reconnect the oxygen sensor connectors, then reposition behind the frame rail and reinstall the M6 x 50 mm bolt removed from engine case and tighten to proper factory torque specification.

YAMAHA ROADLINER AND STRATOLINER PASSENGER FLOOBOARDS

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Filed Under (Yamaha) by admin on 26-12-2010

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1. Remove the passenger foot pegs pivot bolts and nuts. Remove the pegs, springs, detent ball and shims. 2. Locate the black mounting blocks supplied, notice they are marked “L” and “R” on their outer face. Install the blocks into the slots or clevises where you removed the foot pegs the tapered end should be facing down and the “L” and “R” to the outside. Install the original bolts and nuts removed earlier and tighten the bolts securely

YAMAHA ROADLINER / STRATOLINER REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 04-01-2012

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1. Cover the right frame tube in front of the exhaust with duct tape or any suitable material to protect frame during exhaust removal. 2. Remove the three capscrews holding the muffl er assembly to the support bar, loosen the muffl er clamp and carefully remove the muffl er from the motorcycle. 3. Remove and save the two 12mm bolts from the right side fl oorboard assembly (Figure 1) and carefully lower the fl oorboard out of the way. NOTE: Support the fl oorboard with a block of wood or other appropriate material, do not let it “hang” by the brake switch wire. 4. Remove the chrome cover over the power valve pulley. Using a 10mm wrench, remove both cables attached to the power valve pulley (Figure 2). 5. Remove and save the 5mm capscrew on the rear side cover to gain access to the O2 sensor harness plug and unplug O2 sensor from harness (Figure 3). 6. Remove the 4 nuts holding the exhaust system and carefully remove the exhaust system from the motorcycle (may require assistance). NOTE: It may be necessary to loosen the heatshield clamps to access the nuts on the front cylinder. 7. Trace the power valve cables to the drive motor (just under the rear fender on the right side). Remove the power valve cables and mounting clips from the motorcycle. 8. Using a 22mm wrench, carefully remove the O2 sensor from stock exhaust system and save for reuse with the new system. 9. Remove the plastic cover over the clutch banjo bolt (Figure 4). 10. Check the stock exhaust gaskets to be sure they are in good shape. If you have any doubts as to their condition, replace them

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Yamaha Roadliner And Stratoliners Brake Pedal Relocation Kit

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Filed Under (Yamaha) by admin on 27-12-2010

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1. This kit replaces the original rear brake actuating rod that connects the pedal to the master cylinder (see photo 1A) and the brake light switch spring (see photo 1B). Remove the two allen screws which attach the switches mounting plate to the frame (1C). Remove the spring. 2. Remove the cotter pin and washer from the forward end of the rod where it connects to the brake pedal (photo2A). Slide the rod over off of the brake pedal. Unscrew the rod from the threaded stud on the master cylinder. 3. Thread the new rod onto the stud until the end of the stud appears in the middle of the small sight hole that is cross drilled thru the rod (1D). Place the forward end of the rod back onto the brake pedal. Next check the distance between the bottom of the brake pedal and the top of the floorboard, this should be approximately 1 ¾”. If not, slide the rod off the pedal and thread it in or out to adjust the pedal height. With the rod on the pedal re-install the washer and cotter pin (Note: the cotter pin should go into the hole from the top down) then bend the cotter pin open. 4. Replace the brake light spring with the new one supplied. (Pushing down on the switches rubber cover will push the pin out). Re-install the switch bracket. Turn on the ignition and adjust the threaded collar on the brake switch so that the brake light comes on just as you feel some resistance when pushing on the pedal (when the brakes begin to drag).

YAMAHA ROADLINER AND STRATOLINER PASSENGER FLOOBOARD RELOCATION ARMS

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Filed Under (Yamaha) by admin on 23-12-2010

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1. When installing floorboards at the same time first refer to their instructions and using the longer right side black floorboards mounting block supplied with this set of relocation arms. Leave the final floorboards mounting bolt installed loosely at this time. 2. If installing the relocation arms after installing the floorboards at an earlier date proceed as follows. 3. On the left side remove the Allen screw below the floorboards pivot and remove the floorboard from the black mounting block. Remove the dowel pins from their holes on the block. Locate the left relocation arm (stamped “L” and “R” on their backsides). On the end with the clearance hole (not threaded) Place the two dowel pins into one of the two sets of holes which are directly across from each other (180 degrees apart). Hold the arm with the dowel pins up to the mounting block. Align the dowel pins with each of the three sets of holes in the block one at a time noting the height of the opposite end of the arm where the floorboard will mount. Move the dowel pins to the other set of holes on the arm and again hold the arm with the dowel pins up to the blocks three sets of holes. Choose the set of holes in both the block and arm which will set the floorboard to the desired height and place the arm with the dowel pins onto the block. Using one of the button head Allen screws supplied bolt the arm to the block and tighten securely. 4. Locate two of the dowel pins supplied and one of the Allen screw removed earlier. Place the dowel pins into the holes of the arm which allow the floorboard to be level or parallel to the ground. Place a drop of loctite on the threads of the screw and tighten securely. Install the right floorboard in the same manner. 5. On the right side remove the floorboard from the mounting block. Remove the mounting block and replace it with the longer one supplied. Install the right arm in the same manner as the left using the set of dowel pin holes to match the height or angle of the left arm. Install the right floorboard and tighten securely. Recheck all fasteners for tightness.

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YAMAHA ROADLINER AND STRATOLINER LAY DOWN LICENSEPLATE/ TAIL INSTALLATION INSTRUCTIONS

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Filed Under (Yamaha) by admin on 29-01-2011

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1. Remove the license plate. Remove the license plate holder assembly from the rear fender (three 8mm Allen bolts 5mm wrench). Remove the five 4mm Allen screws underneath the rear fender which secure the taillight/turn signal assembly to the rear fender (3mm wrench). As shown in photo #2, pull the taillight assembly out away from the fender, turn it over, place a towel or rag between the light and fender and allow it to rest on the fender. 2. Locate the supplied triangular license plate mounting block, two 8 x 20mm Allen screws with holes driiled thru and three rubber washers. Place the two Allen screws thru the upper holes in the block and the rubber washers over the screws on the backside of the block. Start the screws into the upper holes on the fender. Use one of the three screws removed earlier from the original mount in the remaining lower hole of the new block sliding the remaining rubber washer between the block and fender. Tighten all three Allen screws secure enough to compress the rubber washers (4-6 ft lbs.). 3. Locate the supplied license plate mounting plate and LED lights. Cut off the excess red and black wires at the end of the black loom or tube. Referring to photo (1) thread the wires of the LED lights thru the small holes in the mounting plate, peel the cover from the adhesive backing on the lights and press them firmly into place as shown. 4. Locate the three supplied ¼” x ½” flat head Allen screws. Hold the plate up to the mounting block installed earlier with the wires at the bottom of the plate. Thread the wires from the LED lights thru the holes in the upper bolts of the block. Install the plate onto the block using the three flat head screws being sure to keep the exposed wire behind he plate as short as possible and fitting into the slot or cut out at the edge of the block. Snug the screws and again check to see tat the wires are in the slot or cut out in the block and do not become pinched as the screws are tightened. Tighten the screws securely. 5. Where the wires from the taillight go thru the fender there is a grommet, pull this grommet out from the fender. Thread the wires from the LED lights thru the grommet with the other wires. Replace the grommet into the fender and remove any slack from the wires under the fender. Cut the LED wires off at 6″ past the grommet.

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