RECEIVED 2008 APR 18 A 10:35 DEFECTS INVESTIGATION RECALL MGMT DIV.

08V-180 (22 pages)

MOTORCYCLE
2007 YAMAHA MOTOR CORPORATION, U.S.A.

RECALL

This modification has top priority. This bulletin must be performed immediately to ensure customer safety.
2006~2007 CP250 (Morphous); 2005~2007 YP400 (Majesty) FACTORY MODIFICATION CAMPAIGN Fuel Pump Harness
Yamaha Motor Corporation, U.S.A., has determined that a defect which relates to motor vehicle safety exists in all 2006 and certain 2007 CP250 (Morphous) and all 2005, 2006, and certain 2007 YP400 (Majesty) scooters. In affected scooters, the engine could stall and be difficult to restart because the wire terminals in the fuel pump wire coupler have corroded. This is because water can enter from the main wire harness end and run through the harness to the fuel pump coupler. If the water remains in the coupler for an extended period of time, the terminals can become corroded, which can prevent the fuel pump from operating properly. If this corrosion affects fuel pump operation while the scooter is being ridden, there could be an accident resulting in injury or death. To correct this defect, Yamaha is initiating a Factory Modification Campaign. Affected scooters must have a sub-harness installed which is designed to allow any water between the wire harness and the fuel pump to drain out before it reaches the fuel pump. If either the main wire harness connector or the fuel pump connector is already corroded, the corresponding assembly(ies) must also be replaced.
ion described in M2007-012A and the 90UA claim was filed, no additional action is necessary now. The previously described modification satisfies this recall. Effective immediately, Service-Per-Bulletin code 90UA is expired and is replaced by the recall campaign number 9900xx. Please make a note on Technical Bulletin M2007-012A to refer to this bulletin instead. NOTE: The service procedure involves use of a special terminal removal tool that was mailed with Technical Bulletin M2007-012A. Co

MAIN WIRE HARNESS

SUBHARNESS WATERPROOF COUPLER

NON-WATERPROOF COUPLER

FUEL PUMP COUPLER
ANY WATER IS DRAINED HERE
This is the same problem and correction procedure announced in Technical Bulletin M2007-012A. Due to the possibility of stalling as well as hard starting, the 90-code procedure is now a recall. If an affected unit already had the modication described in M2007-012A and the 90UA claim was led, no additional action is necessary now. The previously described modication satises this recall. Effective immediately, Service-PerBulletin code 90UA is expired and is replaced by the recall campaign number 9900xx. Please make a note on Technical Bulletin M2007-012A to refer to this bulletin instead. NOTE: The service procedure involves use of a special terminal removal tool that was mailed with Technical Bulletin M2007-012A. Contact your Regional Technical Advisor (RTA) if you do not have the special tool from the earlier mailing.

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Yamaha is notifying all registered owners of affected scooters by mail, except those with units already modied and claimed with the Service-Per-Bulletin 90UA. A copy of this letter is included in this bulletin. The customer should take the letter along with the affected scooter to an authorized Yamaha dealer for the modication. A computer report listing all affected scooters invoiced to your dealership is included with this bulletin. Use the list to help ensure all scooters are modied. All sold scooters that have been registered with Yamaha will show the customers name and address. Your dealership must notify the owner of any affected scooter that was actually sold but is listed as unsold in the report. You must modify all affected scooters in your inventory as well as all customer-owned scooters brought to you for this service. Any affected scooter that you purchase from Yamaha in the future will also require modication. If you purchase a scooter from another dealer, check to see if the procedures in this bulletin have already been performed before you sell the scooter. Scooters that are affected should not be operated until they are modied. It is a violation of Yamaha policy for your dealership to deliver any affected scooters to customers until the procedures in this bulletin are performed. When the modication on each scooter is performed, follow the Warranty Information section of this bulletin to receive reimbursement. Be sure to use the Factory Modication Campaign procedures in Chapter 8 of the Warranty and Y.E.S. Handbook (LIT-11790-00-05).

Modify:

All units in the affected range that were not already modified according to the procedures described in M2007-012A. Before modifying a unit, check for a punch mark on the VIN as shown in the Identification Procedure section of this bulletin which indicates that the required modification has already been performed.

Parts Required:

Yes, order one Fuel Pump Sub-harness Kit per unit.

Warranty:

Factory Modification Campaign. See the Warranty Information section of this bulletin. Units which had Service-Per-Bulletin 90UA claimed from M2007-012A will automatically be updated in Yamahas warranty records to show that this recall modification was performed.

Notify Customers: Yes. You must immediately contact any customer whose scooter shows as unregistered on the enclosed report. Yamaha has sent letters to customers whose scooters were registered for warranty as of xx/xx/08.

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2006 CP250V 2007 CP250W 2005 YP400T 2006 YP400V 2007 YP400W
SG18Y-0000009~0001188 SG18Y-0001189~0001706 SH03Y-0000009~0002523 SH03Y-0002524~0004573 SH03Y-0004574~0007611
NOTE: Units in the affected range already modied according to the instructions in Technical Bulletin M2007012A do not need any further modication. The modication this bulletin describes is identical to that earlier bulletin.
NOTE: A special terminal remover tool was mailed with Technical Bulletin M2007-012A. This tool is to be used when removing any terminals from the fuel pump wire connector during this service procedure. If this tool is lost or misplaced, contact your Regional Technical Advisor (RTA) for a replacement tool.

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YP400 SERVICE PROCEDURE 1. Open the seat. Remove the felt liner from the storage compartment. 2. Remove the upper rear panel by pushing in the center pin of the plastic reusable rivets that are located inside the under-seat storage at the back.
READY TO REMOVE READY TO INSTALL SECURED

REMOVE RIVETS

3. Grip the upper rear panel rmly and pull towards the rear and up until it unsnaps from the side panels.

PULL HERE

4. Remove the Allen screw (6mm) and then remove the passenger seat.

SEAT BOLT

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YP400 SERVICE PROCEDURE (CONTD) 5. Remove the 2 screws underneath the top panel and then remove the panel.

REMOVE SCREWS

6. Remove 4 Allen head bolts and then remove the grab rail.
23 Nm (2.3 m kg, 17 ft lb)

REMOVE ALLEN BOLTS

7. Remove screws from each side of the lower panel and then remove the panel.

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YP400 SERVICE PROCEDURE (CONTD) 8. To remove the middle side panel, rst remove the small cover and rubber oor mats on the panel.

COVER MATS

COVER AND MATS REMOVED
Remove the 4 screws and then pull up on the panel to remove it. Repeat on the other side.
REMOVE SCREWS ON EACH SIDE

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YP400 SERVICE PROCEDURE (CONTD) 9. To remove the lower oorboard panel, remove 3 screws from the top of the panel and the one on the bottom front. Remove the panel. Repeat for the other side.
10. To remove the fuel ller cover, rst open the cover. Remove the fuel cap. Remove the cover screws and then remove the cover.
11. To remove the seat assembly, rst remove the 4 Allen head bolts under the seat and remove the seat cushion.
Then, remove the 6 screws on the top of the seat base and remove the cover.

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YP400 SERVICE PROCEDURE (CONTD) Finally, remove the clip from the hydraulic seat prop and remove the prop from its post. Remove the two 8mm Allen bolts and remove the seat. IMPORTANT: Note how the seat bracket assembly is constructed. When reassembling, open the seat slightly more than the fully open position to allow installation of the hydraulic seat support. Also, make sure that the end of the hydraulic seat support is reinstalled as it was before.
30 Nm (3.0 m kg, 22 ft lb)
REMOVE ALLEN BOLTS REMOVE CLIP
12. To remove the middle side panels: 4 bolts (6mm): three the front Remove the r 6mm bolts, three onon the front oorboard one on on the rear. oorboard and and onethe rear. Remove 4 screws at thethe frontthe the oorfour screws at front of of oorboard and one on the top in in the middle. board and one on the top the middle. 2 screws on each of the fuel Remove two screwson each side of the fuel ller. ller. rear of the panel outward and then Pull the rear of the panel outward and then back to remove the panel. back to remove the panel.

REMOVE SCREWS BOLTS

13. To remove the storage compartment, rst remove the 2 bolts (8mm) that hold each grab rail mount, then remove the mounts.
REMOVE BOLTS AND BRACKET ON BOTH SIDES
Remove the 4 shouldered bolts (6mm) from the front and center of the compartment.
11 Nm (1.1 m kg, 8.0 ft lb)

REMOVE 6MM BOLTS

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YP400 SERVICE PROCEDURE (CONTD) Unplug the compartment light. Lift the compartment up and unhook the starter relay and fuse box from their holders. Slide a small straight blade screwdriver between the holder and the backside of the fuse box to release it. Remove the storage compartment.

UNPLUG LIGHT

UNHOOK FUSE BOX AND STARTER RELAY
14. Remove the main wire harness coupler from the fuel pump. 15. Inspect the terminals on the harness connector and on the fuel pump. If there is corrosion, replace the main wire harness and/or fuel pump as necessary. Refer to the Service Manual (LIT-11616-18-38) for wire-harness replacement. For tips on replacing the fuel pump, see the procedures given in Technical Bulletin M2007-011R which covers fuel pump seal replacement. If the coupler is wet, but not corroded, dry it with compressed air. NOTE: If the procedures in Technical Bulletin M2007-011R have not been performed, do them now.
PUSH THE RETAINING LATCH IN, THEN LIFT THE COUPLER UP AND OFF

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YP400 SERVICE PROCEDURE (CONTD) Sub-harness Installation 1. Using the wide end of the special terminal removal tool, remove the coupler inner cover and rear cap.

COUPLER REAR CAP

COUPLER INNER COVER
2. Using the narrow end of the terminal removal tool, remove the terminals from the fuel pump wire coupler of the main wire harness. 3. Remove the coupler inner cover from the new coupler as described in step 1 on the previous page.
TERMINAL LEAD WIRE COLORS: 1. FUEL SENDER: GREEN FUEL PUMP: RED/BLUE

3/4. GROUND: BLACK

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YP400 SERVICE PROCEDURE (CONTD) 4. Install the wire terminals into the new coupler in the position described below. Make sure to push the terminal into the terminal slot all the way until it clicks. If the terminal is inserted in the wrong direction, it cannot be inserted all the way. Reinstall the inner cover. NOTE: Either black lead wire terminal can be inserted into either black-labeled slot.
Terminal Lead Wire Color of Terminal Slot Label on New Coupler Green Red/Blue Black Black
TERMINAL HOOK DIRECTION COLOR LABEL
5. Install the fuel pump sub-harness. Plug one end of the fuel pump sub-harness into the coupler modied in step 4 above and the other into the fuel pump.

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YP400 SERVICE PROCEDURE (CONTD) 6. Secure the fuel pump sub-harness with the supplied plastic bands (zip ties) as shown.
CAUTION: Be sure to secure the fuel pump sub-harness as shown. This positions the wire harness coupler of the main wire harness in a position that will allow any water that enters the wire harness to drain out.
FASTEN THE SUB-HARNESS AND THE IGNITION COIL WIRE LEAD WITH A PLASTIC BAND
FASTEN THE SUB-HARNESS AND THE FUEL PUMP WIRE LEAD WITH A PLASTIC BAND
FASTEN THE SUB-HARNESS TO THE MAINFRAME WITH A PLASTIC BAND
FASTEN THE COUPLER TO THE MAIN FRAME WITH A PLASTIC BAND WIRE ROUTING OF SUB-HARNESS

COLOR LABEL FACES FORWARD
7. After starting the engine to conrm that the fuel pump operates correctly, reassemble the scooter in the reverse order (refer to step 11 on page 7 regarding the handling of the seat).

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CP250 SERVICE PROCEDURE 1. Open the seat. Remove the felt liner from the front storage compartment. Remove the 7 screws that secure the storage compartments, and then remove the storage compartments.
2. Remove the main wire harness coupler from the fuel pump.

COUPLER

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CP250 SERVICE PROCEDURE (CONTD) 3. Clean the area around the fuel pump thoroughly to prevent any dirt or debris from entering the fuel tank or fuel hose during removal. 4. Inspect the terminals on the harness connector and on the fuel pump. If there is corrosion, replace the main wire harness and/or fuel pump as necessary. Refer to the Service Manual (LIT-11616-19-48) for wire-harness replacement. For tips on replacing the fuel pump, see the procedures given in Technical Bulletin M2007-011R which covers fuel pump seal replacement. If the coupler is wet, but not corroded, dry it with compressed air. NOTE: If the procedures in Technical Bulletin M2007-011R have not been done, do them now.

FUEL HOSE CAP

FUEL HOSE
5. Using the wide end of the special terminal removal tool, remove the coupler inner cover and rear cap.

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CP250 SERVICE PROCEDURE (CONTD) 6. Using the narrow end of the terminal removal tool, remove the terminals from the fuel pump wire coupler of the main wire harness. 7. Remove the coupler inner cover from the new coupler as described in step 5 on the previous page.

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CP250 SERVICE PROCEDURE (CONTD) 8. Install the wire terminals into the new coupler in the position described below. Make sure to push the terminal into the terminal slot all the way until it clicks. If the terminal is inserted in the wrong direction, it cannot be inserted all the way. Reinstall the inner cover. NOTE: Either black lead wire terminal can be inserted into either black-labeled slot.
9. Install the fuel pump sub-harness. Plug one end of the fuel pump subharness into the coupler modied in step 8 above and the other into the fuel pump.

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CP250 SERVICE PROCEDURE (CONTD) 10. Secure the fuel pump sub-harness with the supplied plastic bands (zip ties) as shown.
CAUTION: Be sure to secure the fuel pump sub-harness as shown below. This positions the wire harness coupler of the main wire harness in a position that will allow any water that enters the wire harness to drain.

FASTEN THE SUB-HARNESS TO THE MAIN WIRE HARNESS WITH A PLASTIC BAND
FASTEN THE SUB-HARNESS TO THE BOX LIGHT SWITCH LEAD AND THE BOX LIGHT LEAD WITH A PLASTIC BAND
FASTEN THE SUB-HARNESS TO THE THROTTLE CABLE WITH A PLASTIC BAND
WIRE ROUTING OF SUB-HARNESS
FASTEN THE SUB-HARNESS TO THE PLASTIC HOLDER OF THE SIDE STAND SWITCH LEAD WITH A PLASTIC BAND
11. After starting the engine to conrm that the fuel pump operates correctly, reassemble the scooter in the reverse order (refer to step 11 on page 7 regarding the handling of the seat).

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Model YP400 CP250
Part Name Fuel Pump Sub-harness Kit Fuel Pump Sub-harness Kit
Part Number 90891-30049-00 90891-30050-00

Qty 1 1

Dealer Cost $9.63 $9.63

Kit Part Contents:

No. 3 Sub-harness Coupler Plastic Band Part Name Qty 4
When the modication is complete, put a punch mark next to the Primary ID as shown. Check for this punch mark if you encounter an unfamiliar unit. You can also check unit status on YDS or by contacting your Regional Technical Advisor.

PUNCH MARK HERE

* JYASG18YX6A000008
NOTE: Because the service procedure is the same, this punch mark is identical to the one made if the procedures in Technical Bulletin M2007-012A were completed prior to this recall announcement. If you already see this mark, the modication was performed previously.

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The owner of each warranty-registered unit will receive a letter announcing this campaign. The letter has a label that includes the Primary ID and Recall Number. The modification is authorized for all scooters, both sold and unsold, regardless of ownership or warranty status. You do not need the customers letter to perform the modification or to file for reimbursement. Submit a Recall Request for the fuel pump sub harness kit as described below using Recall Number 9900xx. Choose the status M. You will be reimbursed for the Fuel Pump Sub-harness Kit and your handling fee, plus labor. The labor allowance is 0.3 hour for CP250 and 1.0 hour for YP400. YDS: When signed on to YDS, click on the Service Tab, and then Recall Request-Add. This function will allow you to enter multiple Primary IDs for the same recall. Remember that YDS requires a 7-digit serial number, so use a 0 as the first digit. The system will check your submission instantly to make sure the Primary ID numbers youve entered are valid for the recall. You can check back the next day for your claim numbers to track your credit. MAIL Complete a recall Reimbursement Request (LIT-11790-00-03) as shown below:
If the main wire harness and/or fuel pump require replacement because of corrosion that has already occurred, submit a second standard warranty claim for the parts and labor. Reference the claim number of your 9900xx Recall Request in the Problem line of this second request. Put only the additional labor necessary for replacing the corroded parts under Extra Labor. If you have any questions about proper procedures for Factory Modification Campaigns, see Chapter 8 in your Warranty and Y.E.S. Handbook (LIT-11760-00-05).

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XX, XXXX Dear Yamaha Owner:

SAFETY RECALL NOTICE

This notice is sent to you in accordance with the requirements of the National Trafc and Motor Vehicle Safety Act. Yamaha Motor Corporation, U.S.A., has determined that a defect which relates to motor vehicle safety exists in all 2006 and certain 2007 CP250 (Morphous) and all 2005, 2006, and certain 2007 YP400 (Majesty) scooters. Our records show that you own the affected scooter shown on the label above. The reason for this recall: In affected scooters, the engine could stall and be difcult to restart because the wire terminals in the fuel pump wire coupler have corroded. This is because water can enter from the main wire harness end and run through the harness to the fuel pump coupler. If the water remains in the coupler for an extended period of time, the terminals can become corroded, which can prevent the fuel pump from operating properly. If this corrosion affects fuel pump operation while the scooter is being ridden, there could be an accident resulting in injury or death. To correct this defect, your authorized Yamaha dealer will install a sub-harness which is designed to allow any water between the wire harness and the fuel pump to drain out before it reaches the fuel pump. Your dealer will also inspect the connectors. If either the main wire harness connector or the fuel pump connector is already corroded, the corresponding assembly(ies) will also be replaced. There will be no charge to you for this procedure. Installing the sub-harness takes less than 30 minutes for the Morphous model and about 1 hour for the Majesty model, but your dealer may need to keep your scooter longer depending upon their schedule. Please call your Yamaha dealer to make a service appointment to have this procedure performed. Remember to take this letter with you when you take in your scooter. You should not ride your scooter until this modication is performed. If you are unable to return to the Yamaha dealer who sold you the scooter, this service will be performed by any authorized Yamaha Scooter dealer. For the name of a dealer near you, call 1-800-88-YAMAHA or visit the Yamaha web site at: www.yamaha-motor.com. Federal regulations require that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within 10 days. If you need help: If, after contacting your dealership, you have questions or concerns which the dealership is unable to answer, please write to: Yamaha Motor Corporation, U.S.A. Customer Relations Department P.O. Box 6555 Cypress CA 90630 or call 1-800-962-7926 If, after contacting Yamaha Customer Relations, you are still not satised that we have done our best to remedy the situation without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Trafc Safety Administration, 400 Seventh Street, SW., Washington, DC 20590; or call the Auto Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www. safercar.gov. If you no longer own this Yamaha: If you have sold your scooter to another party, please call us toll-free at 1-800-227-5963 with the name and address of the new owner, along with the serial number shown above your name on the address label above.

What Yamaha and your dealer will do:

What you should do now:

Were sorry to cause you any inconvenience, but we are sincerely concerned about your safety and continued satisfaction with our products. Thank you for giving your attention to this important matter. Sincerely, Customer Support Group Yamaha Motor Corporation, U.S.A. PAGE 20 of 20

2006~2007 CP250 (Morphous); 2005~2007 YP400 (Majesty) FACTORY MODIFICATION CAMPAIGN Fuel Pump Harness Yamaha Technical Bulletin M2008-002R
Yamaha Motor Corporation, U.S.A. posts this notice as a service to Yamaha customers and potential Yamaha customers. Yamaha Motor Corporation, U.S.A. has decided a defect relating to motor vehicle safety exists in certain models of the Morphous and Majesty scooters. Yamaha Technical Bulletin M2008-002R was originally released on May 6, 2008. Affected Models 2006 CP250V Morphous 2007 CP250W Morphous 2005 YP400T Majesty 2006 YP400V Majesty 2007 YP400W Majesty PID Range SG18Y-0000009~0001188 SG18Y-0001189~0001706 SH03Y-0000009~0002523 SH03Y-0002524~0004573 SH03Y-0004574~0007611
NOTE: Units in the affected range already modified according to the instructions in Technical Bulletin M2007-012A do not need any further modification. The modification this bulletin describes is identical to that earlier bulletin. The reason for this recall: In affected scooters, the engine could stall and be difficult to restart because the wire terminals in the fuel pump wire coupler have corroded. This is because water can enter from the main wire harness and run through the harness to the fuel pump coupler. If water remains in the coupler, the terminals can become corroded, which can prevent the fuel pump from operating properly. If this corrosion affects fuel pump operation while the scooter is being ridden, there could be an accident resulting in injury or death. What Yamaha and your dealer will do: To correct this defect, your authorized Yamaha dealer will install a sub-harness designed to allow water to drain before it reaches the fuel pump. If either the main wire harness connector or the fuel pump connector is corroded, it will also be replaced. What you should do now: You should not ride your scooter until this important modification is performed. If you are not the first owner of the scooter and are unsure if this modification has been done, contact any authorized Yamaha Motorcycle Dealer to check. Any authorized Yamaha Motorcycle Dealer can perform this service. For the name and location of a dealer near you, call 1-800-88-YAMAHA or visit the Dealer Locator section of this website.